Service Manual PSI 4X LPG Engine
For use with the GC35K - FGC70K STC Chassis Service Manuals.
99739-7C100
FOREWORD This service manual describes the specifications, maintenance, and service procedures for 4X LPG Engine of Mitsubishi Forklift Trucks. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair, and assembly of the engine and engine parts. Read this manual carefully and understand the work procedures fully before disassembling, inspecting, repairing, or assembling the engine. The contents of this manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may differ partially from the one described in this manual.
Engine Mechanical - 4.3L Specifications Fastener Tightening Specifications Torque Specifications Fastener
Specification (SAE)
Specification (Metric)
Lube/Sealant
Main Cap
15 ft-lbf + 73°
20.3 N-m + 73°
ARP Ultra-Torque
Rod Bolts
20 ft-lbf + 70°
27.1 N-m + 70°
ARP Ultra-Torque
Cam Retainer Bolts
106 in-lbf
12 N-m
-
Cam Gear Bolts
18 ft-lbf
24.4 N-m
Oil Pump Bolt
66 ft-lbf
89.5 N-m
Oil Pan
18 ft-lbf
24.4 N-m
Oil Filter Adapter
41 ft-lbf
55.6 N-m
-
Timing Cover
106 in-lbf
12 N-m
-
Balancer Bolt
15 ft-lbf + 35°
20.3 N-m + 35°
-
Cylinder Head Bolts - Long
22 ft-lbf + 75°
29.8 N-m + 75°
PTFE Thread Sealant
Cylinder Head Bolts - Medium
22 ft-lbf + 65°
29.8 N-m + 65°
PTFE Thread Sealant
Cylinder Head Bolts - Short
22 ft-lbf + 55°
29.8 N-m + 55°
PTFE Thread Sealant
Lifter Hold Down Bolts
12 ft-lbf (144 in-lbf)
16.3 N-m
Blue Thread Sealant
Intake Bolts
27 in-lbf + 106 in-lbf + 132 in-lbf
3.1 N-m + 12 N-m + 14.9 Nm
Oil
Rocker Arm Bolts
30 ft-lbf
40.70 N-m
Assembly Lube
Valve Cover Bolts
106 in-lbf
12 N-m
-
Crank Sensor Bolt
106 in-lbf
12 N-m
-
Water Pump
35 ft-lbf
47.5 N-m
Red Thread Sealant Blue Thread Sealant
Flywheel
74 ft-lbf
100.3 N-m
Flex Plate
74 ft-lbf
100.3 N-m
Bell Housing
35 ft-lbf
47.5 N-m
Exhaust Manifold
35 ft-lbf
47.5 N-m
-
Blue Thread Sealant
NPT Plugs Iron 1/4" - 3/4"
150 in-lbs + 3/4 turn
17 N-m + 3/4 turn
PTFE Thread Sealant
Oil Pan Baffle
92 in-lbf
10.4 N-m
-
Oil Pan Drain Bolt
18 ft-lbf
24.4 N-m
Dry
Starter Bolts
40 ft-lbf
54.2 N-m
-
Block Drain Plug
22 ft-lbf + 1/2 turn
29.8 N-m + 1/2 turn
PTFE Thread Sealant
Balancer Shaft Retainer Bolt
106 in-lbf
12 N-m
-
Bolt, Rear Oil Crossover Cover
8 ft-lbs (96 in-lbf)
10.9 N-m
-
106 in-lbf
12 N-m
-
106 in-lbf
12 N-m
-
Long R Cr Shf Oil Seal Hsg Bolt Short R Cr Shf Oil Seal Hsg Bolt
3
Red Thread Sealant Blue Thread Sealant
Fastener
Specification (SAE)
Specification (Metric)
Lube/Sealant
Nut, R Cr Shf Oil Seal Hsg
106 in-lbf
12 N-m
-
106 in-lbf
12 N-m
-
53 in-lbf
6 N-m
-
NPT Plugs Iron 1/4-3/4
150 in-lbf
17 N-m
PTFE Thread Sealant
Spark Plug
22 ft-lbf
29.8 N-m
Dry
Stud and Nut, R Cr Shf Oil Seal Hsg Retainer, R Cr Shf Oil Seal Hsg
4
Engine Mechanical Specifications Clearance Specification (SAE)
Specification (Metric)
Bore, Cylinder
4.0016 - 4.0008
101.641 - 101.620
Stroke
3.4799
88.389
Out-of-Round,Cylinder Bore
0.002
0.05
Taper, Cylinder Bore
0.0138
0.35
Application
0.002
0.05
0.0020 Across 5.906 in 0.0010 Between bolts 0.0010 Across 0.984 in
0.051 Across 150 mm 0.025 Between Bolts
Diameter, Main Bores
2.6411 ± 0.0005
67.084 ± 0.013
Diameter, Camshaft Bearing Bore (1)
2.0200 ± 0.0005
51.308 ± 0.013
Diameter, Camshaft Bearing Bore (2)
2.0100 ± 0.0005
51.054 ± 0.013
Diameter, Camshaft Bearing Bore (3)
2.0000 ± 0.0005
50.800 ± 0.013
Diameter, Camshaft Bearing Bore (4)
2.0200 ± 0.0005
51.308 ± 0.013
Freeze Plug Press (Steel)
0.0140 - 0.0240
0.356 - 0.610
Freeze Plug Press, Cam Tunnel (Steel)
0.0075 - 0.0135
0.191 - 0.343
Crank to Camshaft Centerline
4.6409 ± 0.0100
117.879 ± 0.254
Height, Deck
9.0270 - 9.0250
229.286 - 229.235
Height, China Rail
9.9350 - 9.9150
252.349 - 251.841
Clearance, Piston Dome to Block Deck
0.015
0.38
Connecting Rod
Piston & Accessories
Block
Flatness, Head Deck Surface
5
0.025 Across 25 mm
Diameter, Skirt
3.9993 - 3.9999
101.582 - 101.597
Gap, Top Ring (@4.0010 Gage Diameter)
0.0100 - 0.0160
0.254 - 0.406
Gap, 2nd Ring (@4.0010 Gage Diameter)
0.0180 - 0.0260
0.457 - 0.660
Gap, Oil Control Ring (@4.0000 Gage Diameter)
0.0100 - 0.030 0
0.254 - 0.762
Bore, Wrist Pin
0.9281 - 0.9287
23.574 - 23.589
Diameter, Pin
0.9280 - 0.9274
23.571 - 23.556
Tension, Oil Ring
7.5 lbf - 12.5 lbf
33.4 N - 55.6 N
Clearance, Piston to Bore
0.0009 - 0.0023
0.023 - 0.058
Weight, Piston
1.1288 lbf ± 0.0110 lbf
5.021 N ± 0.049 N
Diameter (Dial) , Piston Gage
3.9940 ± 0.0118
101.448 ± 0.300
Clearance, Small End (Bearing to Wrist Pin)
0.0005 - 0.0011
0.013 - 0.028
Clearance, Big End (Crank Pin to Bearing)
0.0015 - 0.0031
0.038 - 0.079
Rod Side Clearance, Big End Side
0.0059 - 0.0138
0.150 - 0.351
Diameter, Big End (No Bearing)
2.3752 ± 0.0004
60.330 ± 0.010
Width, Big End
0.8925 ± 0.0019
22.670 ± 0.048
Crankshaft Camshaft
Weight, Connecting Rod
1.1288 ± 0.0110
28.672 ± 0.280
Distance, Big to Small End Centerline
5.7000 ± 0.0030
144.780 ± 0.076
Diameter, Connecting Rod (PIN) Journal
2.2493 ± 0.0006
57.132 ± 0.015
Out-of-Round, Connecting Rod (PIN) Journal
0.0003
0.008
Cylindricity, Connecting Rod (PIN) Journal
0.0003
0.008
Width, Connecting Rod (PIN)
0.9043 - 0.9004
22.970 - 22.870
Diameter, Main Journal (#1 - #3)
2.4489 ± 0.0005
62.202 ± 0.013
Diameter, Main Journal (#4 ONLY)
2.4489 ± 0.0006
62.202 ± 0.015
Runout, Main Journal
0.0004
0.01
Cylindricity, Main Bearing (#4)
0.0002
0.005
Width, Main Bearing (#4)
1.7205 - 1.7197
43.701 - 43.680
Clearance, Main Bearing (#1-3)
0.0011 - .0023
0.028 - 0.058
Clearance, Main Bearing (#4)
0.0011 - .0028
0.028 - 0.071
End Play (Fully Assembled)
0.0020 - .0079
0.051 - 0.203
Crank Sprocket Interference
0.0090 - 0.0129
0.229 - 0.330
Harmonic Damper Interference
0.0049 - 0.0075
0.124 - 0.191
Diameter, Snout
1.2400 - 1.2379
31.496 - 31.445
Diameter, Journal
1.8697 - 1.8677
47.490 - 47.440
Runout, Journal
Max = 0.002
Max = 0.05
Bearing Clearance, #1-4
0.0010 - 0.0052
0.025 - 0.132
End float (Fully Assembled)
0.0010 - 0.0089
0.025 - 0.226
Diameter, Base Circle
1.2594 - 1.2554
31.989 - 31.887
Lobe Lift, Exhaust
0.243
6.74
Lobe Lift, Intake
0.265
6.16
0.0020 Across 5.906
0.051 Across 150 mm
Cylinder Head
Flatness, Head Deck Surface
0.0012 Between Bolts
0.03 Between Bolts
0.0001 Across 0.984
0.025 Across 25 mm
Surface Finish Rz, Head Deck
0.787 μin
0.020 μm
Surface Finish Rmax, Head Deck
0.984 μin
0.025 μm
Leakage Rate, Combustion Chamber
1 inch Hg/3 sec @ 34 inch Hg
3.4 kPa/3 sec @ 115.1 kpa
Volume, Combustion Chamber
3.8354 in³
62.851 cc
Valves
Ratio, Compression
6
9.6:1 - 10:1
Valve Seat Runout, Intake
Max = 0.002
Max = 0.05
Valve Seat Runout, Exhaust
Max = 0.002
Max = 0.05
Diameter, Valve Stem, Intake
0.3413 ± 0.0004
8.669 ± 0.010
Valve Stem to Guide Clearance, Intake
0.0005 - 0.0019
0.013 - 0.048
Valve Guide Cylindricity, Intake
0.0005
0.013
Valve Seat Runout, Intake
Max = 0.002
Max = 0.05
Valve Seat Face Angle, Intake
45˚ ± 0.25˚
Head Deck to Valve Seat Gage Point, Intake
0.6630 - 0.6430
16.840 - 16.332
Diameter, Valve Stem, Exhaust
0.3409 ± 0.0004
8.659 ± 0.102
Valve Stem to Guide Clearance, Exhaust
0.0009 - 0.0023
0.023 - 0.058
Application
Specification (SAE)
Specification (Metric)
Valve Guide Cylindricity, Exhaust
0.0005
0.013
Valve Seat Runout, Exhaust
Max = 0.002
Max = 0.05
Push Rod
Hydraulic Lifter
Valve Spring
Valve Seat Face Angle, Exhaust
IGN
Head Deck to Valve Seat Gage Point, Exhaust
0.6071
15.42
Valve Guide Cylindricity, Exhaust
Max = 0.0005
Max = 0.013
Valve Spring Load, Installed Height, Intake
100 lbf - 110 lbf
445 N - 489 N
Valve Spring Load, Installed Height, Exhaust
100 lbf - 110 lbf
445 N - 489 N
I.D. (Minimum), Valve Spring
0.605 ± 0.010
15.37 ± 0.25
Valve Spring Installed Height, Intake
1.8
45.72
Valve Spring Installed Height, Exhaust
1.8
45.72
Preload, Lifter
0.0300 - 0.0701
0.762 - 1.781
Clearance, Lifter to Bore
0.0024 - 0.0011
0.061 - 0.028
Diameter, Lifter
0.8424 ± 0.0004
21.397 ± 0.010
Length, Intake
7.7125 - 7.4125
195.898 - 188.520
Length, Exhaust
7.2449 - 7.2252
184.020 - 183.520
Diameter, Oiling Hole
0.0750 - 0.0810
1.905 - 2.057
Diameter, Ball
0.3070 - 0.3170
7.798 - 8.052
Gap, Spark Plug
0.03
0.76
Dry Fill (Naturally Aspirated)
5.0 qt
4.73 L
Drain and Fill (Naturally Aspirated)
4.5 qt
Rocker
Rocker Ratio
Harmonic Balancer
Diameter, Damper I.D.
7
45˚ ± 0.25˚
4.26 L 1.7
1.2447 - 1.2459
31.615 - 31.646
Diagnostic Information and Procedures Base Engine Misfire Diagnosis Checks
Action
Engine Performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any Drivability, Emissions or Malfunctioning Indicator Lamp (MIL) concerns. The following diagnosis covers common concerns and possible causes. When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required. Refer to the appropriate section of the service manual for each specific procedure. This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft, worn or damaged bearings or bent valve pushrod. This table will not isolate a crossed fuel injector wire, faulty fuel injector or any other drivability component failure that may cause a misfire. The Powertrain On-Board Diagnostic System checks must be performed first. When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then proceed to the specific category. Preliminary
1. Perform DTC P0300 before proceeding with Base Engine Misfire Diagnosis information. DTC P0300 will assist in determining which cylinder or cylinders are misfiring. 2. Perform a visual inspection of the following: A loose or improperly installed engine flywheel or crankshaft balancer Worn, damaged or misaligned accessory drive system components 3. Listen to the engine for any abnormal internal engine noises. 4. Inspect the engine for acceptable oil pressure. 5. Verify if the engine has excessive oil consumption. 6. Verify if the engine has excessive coolant consumption. 7. Perform a compression test on the engine.
Intake Manifold Leaks
An intake manifold that has a vacuum leak may cause a misfire. Inspect for the following: Improperly installed or damaged vacuum hoses Faulty or improperly installed lower intake manifold and/or gaskets Cracked or damaged lower intake manifold Improperly installed MAP sensor The sealing grommet of the MAP sensor should not be torn or damaged Improperly installed throttle body or damaged gasket Warped intake manifold Warped or damaged cylinder head sealing surface
Coolant Consumption
Coolant consumption may or may not cause the engine to overheat. Inspect for the following: External coolant leaks Faulty cylinder head gasket Warped cylinder head Cracked cylinder head Damaged engine block
Oil Consumption
Oil consumption may or may not cause the engine to misfire. 1. Remove the spark plugs and inspect for an oil fouled spark plug. 2. Perform a cylinder compression test. 3. If the compression test indicates worn valves or valve guides, inspect the following: Worn, brittle or improperly installed valve stem oil seals Worn valve guides Worn valve stems Worn or burnt valves or valve seats 4. If the compression test indicates worn or damaged piston rings, inspect the following: Broken or improperly seated piston rings Excessive piston ring end gap Excessive cylinder bore wear or taper Cylinder damage Piston damage
8
Base Engine Misfire Diagnosis (cont’d) Checks
Action
Abnormal Internal Engine Noises
1. Start the engine and determine if the noise is timed to the engine camshaft speed or the crankshaft speed. 2. Using a timing light, two knocks per flash is the crankshaft speed and one knock per flash is the engine camshaft speed. 3. If the noise is timed to the engine camshaft speed, inspect the following: Missing or loose valve train components Worn or loose valve rocker arms Worn or bent valve pushrods Faulty valve springs Bent or burnt valves Worn engine camshaft lobes Worn or damaged camshaft timing chain and/or sprockets Important: A slight COLD knock or piston slapping noise could be considered normal if not present after the engine has reached normal operating temperatures. If the knock is timed to the crankshaft speed, inspect the following: Worn crankshaft or connecting rod bearings Piston to cylinder damage Worn piston or piston pin Faulty connecting rod Excessive carbon build-up on the top of the piston
No Abnormal Internal Engine Noise
1. Inspect for a worn or improperly installed camshaft timing chain and/or sprockets. 2. Remove the valve rocker arm cover on the side of the engine with the cylinder that is misfiring. 3. Inspect for the following: Loose valve rocker arm studs Bent valve push rods Faulty valve springs Faulty valve lifters (bleeding down) Worn or improperly seated valves Worn engine camshaft lobes
Engine Compression Test 1. Disconnect the positive ignition coil wire plug from ignition coil. 2. Disconnect the fuel injector electrical connector. 3. Remove all the spark plugs. 4. Block the throttle plate wide open. 5. Charge the battery if the battery is not fully charged. 6. Start with the compression gauge at zero. Then crank the engine through four compression strokes (four puffs). 7. Make the compression check the same for each cylinder. Record the reading. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). 8. If some cylinders have low compression, inject
9
approximately 15 ml (one tablespoon) of engine
oil into the combustion chamber through the spark plug hole. •
Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. • Piston Rings Leaking - Compression is low on the first stroke. Then compression builds up with the following strokes but does not reach normal. Compression improves considerably when you add oil. • Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. • If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the two cylinders. 9. Install the removed parts. 10. Connect the disconnected components.
10
Engine Noise Diagnosis Symptoms
Cause
When diagnosing engine noise complaints, use the following steps to isolate the source of the engine noise: Determine the type of noise For example, is the noise a light rattle/tapping or a low rumble/knocking? The exact operating condition under which the noise exists Note factors such as ambient temperature, the amount of engine warm-up time, the engine temperature, the engine RPM and other specifics. At what rate the noise occurs, and at what location on the engine Engine noises are generally synchronized to either engine speed (crankshaft, engine flywheel, connecting rods, crankshaft balancer or pistons and related components) or one-half engine speed (valve train noise such as valve rocker arms, valve lifters and camshaft timing chain). Determine the rate at which the noise is occurring. Compare the engine sounds to other engines, and make sure you are not trying to correct a normal condition. Noise on Start-Up but Only Lasts a Few seconds
Improper oil viscosity. Install the recommended oil viscosity for the expected temperatures. Worn or dirty valve lifters Excessive piston-to-cylinder bore clearance Excessive piston pin-to-bore clearance Excessive crankshaft bearing clearance
Knocks Cold and Continues for 1 to 2 Minutes
Loose or broken crankshaft balancer or accessory drive components Excessive piston-to-bore clearance A cold piston knock which appears in 1.5 minutes should be considered acceptable. A cold engine knock usually disappears when the specific cylinders secondary ignition circuit is grounded out.
Intermittent Noise on Idle, Disappearing When Engine Speed is Increased
Improper oil viscosity. Install the recommended oil viscosity for the expected temperatures. Lower than specified oil pressure Install an oil pressure gauge and measure the engine oil pressure. Dirty or worn valve lifter
Valve Train Noise (Rattle/Tapping)
The following conditions may cause valve train noise: Lower than specified oil pressure Worn or faulty oil pump Loose oil pump-to-engine block bolt Loose valve rocker arm attachments Worn valve rocker arms and/or valve pushrods Broken valve spring Sticking valves Worn, dirty or faulty valve lifters Worn engine camshaft lobes Worn valve guides or valve stems Bent, broken or damaged timing chain sprocket teeth
Knocks Hot at Idle (Rumble/Knocking)
The following conditions may cause a knocking noise: Malfunctioning accessory drive system components Loose or broken crankshaft balancer Detonation or spark knock Check for proper operation of the cooling, knock and ignition control components. Refer to diagnostic information in Engine Controls Excessive connecting rod bearing clearance Excessive piston pin-to-bore clearance Bent connecting rod Excessive crankshaft bearing clearance Loose torque converter bolts (if equipped) Cracked or damaged engine flywheel Exhaust leak at the exhaust manifold Combustion chamber deposits
11
Exhaust System Noise and/or Leakage
12
Exhaust system noise and/or leakage may be caused by the following conditions: Improperly installed or misaligned exhaust system components A cracked or broken exhaust manifold Damaged or worn exhaust manifold gaskets and/or seals Burnt or rusted out exhaust system components Broken or loose exhaust clamps and/or brackets
Valve Train Diagnosis General Information Symptoms
Cause
A light tapping noise at 1/2 engine speed, or any varying frequency, may indicate a valve train problem. Tapping noises will typically increase with increased engine speed. Before attempting to diagnose a valve train noise, check for the proper engine oil level and then allow the engine to obtain normal operating temperature. Following this procedure will bring all engine components to a normal state of expansion. Sit in the driver’s seat, then operate the engine at various speeds and listen for any abnormal engine noise. Valve Train Noise
Low engine oil pressure A worn or faulty oil pump A loose or plugged oil pump screen Loose valve rocker arm attachments (causing excessive valve lash) A worn or damaged valve rocker arm ball A worn valve rocker arm and/or valve pushrod A broken valve spring Sticking valves Valve lifters worn, dirty or faulty A broken valve lifter guide Engine camshaft lobes worn Worn valve guides or valve stems Bent valve pushrods Excessive free play in the camshaft timing chain Bent, broken or damaged camshaft sprocket teeth
Diagnostic Table Step
Action
Value(s)
Yes
No
—
Go to Step 2
System OK
—
Go to Step 3
Go to Step 4
Is the tapping noise gone?
—
System OK
Go to Step 6
Check for a low engine oil level. An engine with the engine oil level below the ADD mark on the oil level indicator may allow the oil pump to pump air at high engine RPM. Is the engine oil level below the ADD mark on the oil level indicator?
—
Go to Step 5
Go to Step 6
—
System OK
Go to Step 6
DEFINITION: A light tapping noise at 1/2 engine speed, or any varying frequency. 1
Is there valve train noise? Check for a high engine oil level. An engine with the engine oil level above the FULL mark on the oil level indicator allows the crankshaft counterweights to churn the engine oil into foam. When the foamy engine oil is pumped into the
2
valve lifters, the valve lifters become noisy. A solid column of engine oil ensures proper valve lifter operation. Is the engine oil level too high? Drain the engine oil to the proper level.
3
4
Add the engine oil as required.
5
Is the tapping noise gone?
13
Check for the proper engine oil pressure. Refer to Engine Mechanical Specifications and Oil Pressure Diagnosis and
6
Testing. Is the engine oil pressure within specifications?
14
41.4 kPa (6 psi) Go to Step 11
Go to Step 7
Diagnostic Table (cont’d) Step
Action
Value(s)
Yes
No
—
Go to Step 8
Go to Step 9
—
System OK
Go to Step 9
Is the oil pump damaged or are the bolts loose?
—
Go to Step 10
Go to Step 11
Repair as required. Is the tapping noise gone?
—
System OK
Go to Step 11
—
Go to Step 12
Go to Step 13
Is the tapping noise gone?
—
System OK
Go to Step 13
Perform an engine camshaft lobe lift test. Refer to Camshaft and Bearings Clean and Inspect. Is the engine camshaft lobes within specifications?
—
Go to Step 15
Go to Step 14
14
Replace the engine camshaft and valve lifters. Is the tapping noise gone?
—
System OK
Go to Step 13
15
Remove the engine front cover and inspect the camshaft timing chain and sprockets for excessive wear or damage. Refer to Timing Chain and Sprockets Clean and Inspect. Are the components worn or damaged?
—
Go to Step 17
Go to Step 16
16
Replace the components as required. Is the tapping noise gone?
—
System OK
Go to Step 17
17
Perform a complete disassembly of the engine and inspect all components. Are the components worn or damaged?
—
System OK
Go to Step 11
Replace the components as required. Did you complete the worn or damaged component replacement?
—
System OK
—
Check the oil pump screen for damage or a loose fit to the oil pump.
7
Is the oil pump screen loose or is the oil pump screen damaged? Repair as required.
8
Is the tapping noise gone? Check for a damaged oil pump or loose bolts. Refer to Oil Pump Clean and Inspect.
9
10
Remove and inspect the valve lifters, the valve rocker arms and the valve pushrods. Refer to Valve Rocker Arm 11
and Pushrods Clean and Inspect and Valve Lifters and Guides Clean and Inspect. Are the components worn or damaged?
12
13
18
15
Replace the components as required.
Oil Consumption Excessive oil consumption (not due to leaks) is the use 1.9 liters (2 quarts) of engine oil within 3,200 kilometers (2,000 miles). However, during initial engine break-in periods 4,828-6,437 kilometers (3,000-4,000 miles) oil consumption may exceed 1.9 liters (2 quarts) or more. The causes of excessive oil consumption include the following conditions: • External oil leaks. Tighten the bolts and/or replace gaskets and oil seals as necessary. • Incorrect oil level or improper reading of oil level indicator. With the vehicle on a level surface, allow adequate drain down time and check for the correct oil level. • Improper oil viscosity. Use a recommended SAE viscosity for the prevailing temperatures. • Continuous high speed operation and/or severe usage. • Crankcase ventilation system restrictions or malfunctioning components. Possible improper PCV valve. • Valve guides and/or valve stem oil seals worn, damaged or the seal omitted. Ream the valve guides and install oversize service valves and/ or new valve stem oil seals. • Piston rings broken, improperly installed, worn or not seated properly. Allow adequate time for the piston rings to seat. Replace broken or worn piston rings as necessary. • Piston improperly installed or miss-fitted.
Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time (2-3 minutes) and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gauge or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: • Engine oil diluted by moisture or unburned fuel mixtures • Improper engine oil viscosity for the expected temperature • Incorrect or faulty oil pressure gauge sensor • Incorrect or faulty oil pressure gauge • Plugged oil filter • Malfunctioning oil filter bypass valve
16
4. Remove the oil pressure gauge sensor or another engine block oil gallery plug. 5. Install an oil pressure gauge. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6psig) (minimum) at 1,000 RPM 7.2. 125 kPa (18 psig) (minimum) at 2,000 RPM 7.3. 166 kPa (24 psig) (minimum) at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: • Oil pump worn or dirty • • • • • •
Malfunctioning oil pump pressure relief valve Oil pump screen loose, plugged or damaged Excessive bearing clearance Cracked, porous or restricted oil galleries Engine block oil gallery plugs missing or incorrectly installed Broken valve lifters
Oil Leak Diagnosis Step
Action
Value(s)
Yes
No
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as well as the leak itself. 1. Operate the vehicle until it reaches normal operating temperature.
1
2. Park the vehicle on a level surface, over a large —
Go to Step 2
System OK
—
Go to Step 10
Go to Step 3
location of the leak?
—
Go to Step 10
Go to Step 4
1. Completely clean the entire engine and surrounding components. 2. Operate the vehicle for several kilometers (miles) at normal operating temperature and at varying speeds. 3. Park the vehicle on a level surface, over a large sheet of paper or other clean surface. 4. Wait (15 minutes). 5. Identify the type of fluid and the approximate location of the leak. Can you identify the type of fluid and the approximate location of the leak?
—
Go to Step 10
Go to Step 5
—
Go to Step 10
Go to Step 6
sheet of paper or other clean surface. Can you identify the type of fluid and the approximate
2
location of the leak? 1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. 2. Check for leaks at the following locations: • Sealing surfaces
3
• Fittings • Cracked or damaged components Can you identify the type of fluid and the approximate
4
1. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. 2. Check for leaks at the following locations: • Sealing surfaces
5
• Fittings • Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak?
17
1. Completely clean the entire engine and surrounding components. 2. Apply an aerosol-type powder (baby powder, foot powder,
etc.) to the suspected area. 3. Operate the vehicle for several kilometers (miles) at
6
normal operating temperature and at varying speeds. 5. Identify the type of fluid and the approximate location of the leak, from the discolorations in the powder surface.
18
Oil Leak Diagnosis (cont’d) Step
Action
Value(s)
Yes
No
—
Go to Step 10
Go to Step 4
—
Go to Step 10
Go to Step 8
—
Go to Step 10
Go to Step 9
—
Go to Step 10
System OK
• Improperly tightened or damaged fasteners • Cracked or porous components • Improper sealants or gaskets where required • Improper sealant or gasket installation • Damaged or worn gaskets or seals • Damaged or worn sealing surfaces 2. Inspect the engine for customer modifications. Is there mechanical damage, or customer modifications to the engine?
—
Go to Step 11
System OK
Repair or replace all damaged or modified components. Does the engine still leak oil?
—
Go to Step 1
—
Can you identify the type of fluid and the approximate
6
location of the leak? 1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas. 2. Check for leaks at the following locations: • Sealing surfaces
7
• Fittings • Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak? Use J 28428-E, Dye and Light Kit, in order to identify the type of fluid and the approximate location of the leak. Refer to manufacturer’s instructions when using
8
the tool. Can you identify the type of fluid and the approximate location of the leak? 1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas. 2. Check for leaks at the following locations: • Sealing surfaces
9
• Fittings • Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak? 1. Inspect the engine for mechanical damage. Special attention should be shown to the following areas: • Higher than recommended fluid levels • Higher than recommended fluid pressures • Plugged or malfunctioning fluid filters or pressure bypass valves • Plugged or malfunctioning engine ventilation system
10
11
19
Symptoms - Drive Belt Important: Review the system operation in order to familiarize yourself with the system functions. Refer to Drive Belt System Description.
Visual/Physical Inspection • Inspect for aftermarket devices which could affect the operation of the drive belts. • Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. • Inspect the drive belt for excessive wear, shredding or missing sections. • Inspect the drive belt for contamination of excessive dirt, oil, coolant or other substances that may affect the drive belt operation.
Intermittent
Failure of an accessory drive component. • Drive belt symptoms may occur from changes in load of the accessory drive components. .• Ambient temperatures, moisture or engine operating temperature can affect the drive belt operation.
Symptoms List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: • Drive Belt Chirping Diagnosis • Drive Belt Squeal Diagnosis • Drive Belt Whine Diagnosis • Drive Belt Rumbling Diagnosis • Drive Belt Vibration Diagnosis • Drive Belt Falls Off Diagnosis • Drive Belt Excessive Wear Diagnosis
• Drive belt symptoms may be from intermittent
Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component or other items of the vehicle may cause the chirping noise.
Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise, do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s), the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of
20
rubber dust.
6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley .using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.
21
Drive Belt Chirping Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: The following items are indications of chirping: • A high pitched noise that is heard once per revolution of the drive belt or a pulley. • It usually occurs on cold damp mornings. Go to Symptoms -
Did you review the Drive Belt Symptom operation and perform
1
the necessary inspections?
—
Go to Step 2
Verify that there is a chirping noise.
2
Does the engine make the chirping noise?
Drive Belt Go to
—
Go to Step 3
Diagnostic Aids
1. Remove the drive belt. 3
Go to Engine
2. Operate the engine for no longer than 30 to 40 seconds. Does the chirping noise still exist?
—
Noise Diagnosis
Go to Step 4
Inspect for severe pilling exceeding 1/3 of the belt groove depth. Does the belt grooves have pilling?
—
Go to Step 5
Go to Step 6
Did you complete the repair?
—
Go to Step 15
Go to Step 6
6
Inspect for misalignment of the pulleys. Are any of the pulleys misaligned?
—
Go to Step 7
Go to Step 8
7
Replace or repair any misaligned pulleys. Did you complete the repair?
—
Go to Step 15
Go to Step 8
8
Inspect for bent or cracked brackets. Did you find any bent or cracked brackets?
—
Go to Step 9
Go to Step 10
9
Replace any bent or cracked brackets. Did you complete the repair?
—
Go to Step 15
Go to Step 10
10
Inspect for improper, loose or missing fasteners Did you find the condition?
—
Go to Step 11
Go to Step 12
Did you complete the repair?
—
Go to Step 15
Go to Step 12
12
Inspect for a bent pulley. Did you find the condition?
—
Go to Step 13
Go to Step 14
13
Replace the bent pulley. Did you complete the repair?
—
Go to Step 15
Go to Step 14
14
Replace the drive belt. Refer to Drive Belt Replacement. Did you complete the repair?
—
Go to Step 15
Go to Diagnostic Aids
15
Operate the system in order to verify the repair. Did you correct the condition?
—
System OK
Go to Step 3
4 5
Clean the drive belt pulleys with a suitable wire brush.
Tighten any loose fasteners. 11
Replace any improper or missing fasteners. Refer to Fastener Tightening Specifications.
22
Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component or other items of the vehicle may cause the chirping noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid or a generator failing are suggested items to inspect.
5.
6.
Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise, do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s), the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt removed, test the bearings in the
7.
8.
accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping, which could cause a squeal noise. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also, if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper installation procedure for that pulley. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
Drive Belt Squeal Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: The following items are indications of drive belt squeal: • A loud screeching noise that is caused by a slipping drive belt (this is unusual for a drive belt with multiple ribs) • The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compressor engagement, snapping the throttle or slipping on a seized pulley or a faulty accessory drive component. Go to Symptoms -
Did you review the Drive Belt Symptom operation and perform
1
the necessary inspections?
—
Go to Step 2
Verify that there is a squeal noise.
2
Does the engine make the squeal noise?
Drive Belt Go to
—
Go to Step 3
Diagnostic Aids
1. Remove the drive belt(s). 3
Go to Engine
2. Operate the engine for no longer than 30 to 40 seconds.
4
23
Does the chirping noise still exist?
—
Noise Diagnosis
Go to Step 4
Inspect for an accessory drive component seized bearing or faulty accessory drive component. Did you find and correct the condition?
—
Go to Step 9
Go to Step 5
Drive Belt Squeal Diagnosis (cont’d) Step
Action
Value(s)
Yes
No
Did you find and correct the condition?
—
Go to Step 9
Go to Step 6
Inspect for the correct drive belt length. Refer to Drive Belt Replacement. Did you find and correct the condition?
—
Go to Step 9
Go to Step 7
7
Inspect for a misalignment of a pulley. Did you find and correct the condition?
—
Go to Step 9
Go to Step 8
8
Inspect for the correct pulley size. Did you find and correct the condition?
—
Go to Step 9
Go to Diagnostic Aids
9
Operate the system in order to verify the repair. Did you correct the condition?
—
System OK
Go to Step 3
Test the drive belt tensioner for proper operation. Refer to Drive 5
Belt Tensioner Diagnosis.
6
Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid or a generator failing are suggested items to inspect.
Test Description The number(s) below refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being
caused by the drive belt(s) or the accessory drive components. When removing the drive belt(s), the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt(s) removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure.
Drive Belt Whine Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing. 1
Did you review the Drive Belt Symptom operation and perform the necessary inspections?
—
Go to Step 2
Go to SymptomsDrive Belt
2
Verify that there is a whine noise. Does the engine make the whine noise?
—
Go to Step 3
Go to Diagnostic Aids
3
1. Remove the drive belt(s). 2. Operate the engine for no longer than 30 to 40 seconds. Does the whine noise still exist?
—
Go to Engine Noise Diagnosis
Go to Step 4
4
Inspect for a failed accessory drive component bearing. Did you find and repair the condition?
—
Go to Step 5
Go to Diagnostic Aids
9
Operate the system in order to verify the repair. Did you correct the condition?
—
System OK
—
24
Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that cannot be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description The number(s) below refer to the step number(s) on the diagnostic table.
2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also, DTC’s may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plies of the belt separating and may be seen at the edge of the belt, or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe, the drive belt does not have a smooth surface for proper operation.
Drive Belt Rumbling Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: • A low pitch tapping, knocking or thumping noise heard at or just above idle. • Heard once per revolution of the drive belt or a pulley. • Rumbling may be caused from: - Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove - The separation of the drive belt - A damaged drive belt 1
Did you review the Drive Belt Symptom operation and perform the necessary inspections?
—
Go to Step 2
Go to SymptomsDrive Belt
2
Verify that there is a rumbling noise. Does the engine make the rumbling noise?
—
Go to Step 3
Go to Diagnostic Aids
3
1. Remove the drive belt(s). 2. Operate the engine for no longer than 30 to 40 seconds. Does the rumbling noise still exist?
—
Go to Engine Noise Diagnosis
Go to Step 4
Inspect the drive belt(s) for damage, separation or sections of missing ribs. Did you find and repair the condition?
—
Go to Step 7
Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt pulley grooves. Did you find severe pilling?
—
Go to Step 6
Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush. 2. Reinstall the drive belt. Refer to Drive Belt Replacement. Did you complete the repair?
—
Go to Step 8
Go to Step 7
4
5
6
25
Drive Belt Rumbling Diagnosis (cont’d) Step
Action
Value(s)
Yes
No
7
Install a new drive belt. Refer to Drive Belt Replacement. Did you complete the replacement?
—
Go to Step 8
—
8
Operate the system in order to verify the repair. Did you correct the condition?
—
System OK
Go to Diagnostic Aids
Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an effect on engine vibration. Such as, but not limited to the A/C system overcharged, the power steering system restricted or the incorrect fluid or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.
Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also, DTC’s may set when the engine is operating with the drive belt removed.
4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed, inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked or loose may put extra strain on that accessory component causing it to vibrate.
Drive Belt Vibration Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: • The vibration is engine-speed related. • The vibration may be sensitive to accessory load. 1
Did you review the Drive Belt Symptom operation and perform the necessary inspections?
—
Go to Step 2
Go to SymptomsDrive Belt
2
Verify that the vibration is engine related. Does the engine make the vibration?
—
Go to Step 3
Go to Diagnostic Aids
3
1. Remove the drive belt(s). 2. Operate the engine for no longer than 30 to 40 seconds. Does the rumbling noise still exist?
Go to Engine Related Vibration in Vibration and Diagnosis
Go to Step 4
26
—
Inspect the drive belt(s) for wear, damage, debris build-up and missing drive belt ribs. Did you find any of these conditions?
4
27
—
Go to Step 5
Go to Step 6
Drive Belt Vibration Diagnosis (cont’d) Step
Action
Value(s)
Yes
No
5
Install a new drive belt. Refer to Drive Belt Replacement. Did you complete the replacement?
—
Go to Step 11
—
6
Inspect for improper, loose or missing fasteners. Did you find any of these conditions?
—
Go to Step 5
Go to Step 6
7
Tighten any loose fasteners. Replace improper or missing fasteners. Refer to Fastener Tightening Specifications. Did you complete the repair?
—
Go to Step 11
—
Inspect for damaged fan blades or bent fan clutch shaft, if the fan is belt driven. Refer to Fan Clutch Replacement in Engine Cooling. Did you find and correct the condition?
—
Go to Step 11
Go to Step 9
Inspect for bent water pump shaft, if the water pump is belt driven. Refer to Water Pump Replacement (4.3L Engine) in Engine Cooling. Did you find and correct the condition?
—
Go to Step 11
Go to Step 10
10
Inspect for bent or cracked brackets. Did you find and correct the condition?
—
Go to Step 11
Go to Diagnostic Aids
11
Operate the system in order to verify the repair. Did you correct the condition?
—
System OK
Go to Step 3
8
9
Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied and released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.
Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive
28
component, incorrect installation of the accessory drive component pulley or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer or washer was installed. Missing, loose or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
Drive Belt Falls Off Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys. 1
Did you review the Drive Belt Symptom operation and perform the necessary inspections?
—
Go to Step 2
Go to SymptomsDrive Belt
2
Inspect for a damaged drive belt. Did you find the condition?
—
Go to Step 3
Go to Step 4
3
Install a new drive belt. Refer to Drive Belt Replacement. Does the drive belt continue to fall off?
—
Go to Step 4
System OK
4
Inspect for misalignment of the pulleys. Did you find and repair the condition?
—
Go to Step 12
Go to Step 5
5
Inspect for a bent or dented pulley. Did you find and repair the condition?
—
Go to Step 12
Go to Step 6
6
Inspect for a bent or cracked bracket. Did you find and repair the condition?
—
Go to Step 12
Go to Step 7
7
Inspect for improper, loose or missing fasteners. Did you find loose or missing fasteners?
—
Go to Step 8
Go to Step 9
8
Tighten any loose fasteners. Replace improper or missing fasteners. Refer to Fastener Tightening Specifications. Does the drive belt continue to fall off?
—
Go to Step 9
System OK
Test the drive belt tensioner for operating correctly. Refer to Drive Belt Tensioner Diagnosis. Does the drive belt tensioner operate correctly?
—
Go to Step 11
Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement. Does the drive belt continue to fall off?
—
Go to Step 11
System OK
Inspect for failed drive belt idler and drive belt tensioner pulley bearings. Did you find and repair the condition?
—
Go to Step 12
Go to Diagnostic Aids
Operate the system in order to verify the repair. Did you correct the condition?
—
System OK
Go to Step 2
9
10
11
12
Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off.
Test Description The number(s) below refer to the step number(s) on
29
the diagnostic table.
2. This inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle.
30
Drive Belt Excessive Wear Diagnosis Step
Action
Value(s)
Yes
No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt. 1
Did you review the Drive Belt Symptom operation and perform the necessary inspections?
—
Go to Step 2
Go to SymptomsDrive Belt
2
Inspect the drive belt(s) for the proper installation. Refer to Drive Belt Replacement. Did you find the condition?
—
Go to Step 5
Go to Step 3
3
Inspect for the proper drive belt. Did you find this condition?
—
Go to Step 5
Go to Step 4
4
Inspect for the drive belt rubbing against a bracket, hose or wiring harness. Did you find and repair the condition?
—
Go to Step 6
Go to Diagnostic Aids
5
Replace the drive belt. Refer to Drive Belt Replacement. Did you complete the replacement?
—
Go to Step 6
—
6
Operate the system in order to verify the repair. Does the drive belt continue to fall off?
—
System OK
—
31
Drive Belt Tensioner Diagnosis Inspection Procedure Important When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm.
1.
Remove the drive belt.
2. Position a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 3. Move the drive belt tensioner through its full travel.
• The movement should feel smooth • There should be no binding • The tensioner should return freely 4. If any binding is observed, replace the drive belt tensioner 5. Install the drive belt.
Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner.
32
Engine Identification A Power Solutions International (PSI) 4.3 Liter engine will be identified with PSI branding throughout the engine. “PSI” will be found on the valve covers, timing cover, engine block, and oil pan.
The engine serial number is located on the valve cover of the engine as well as stamped into the left rear of the engine block. It will be formatted 43P followed by a sequence of numbers.
33
Draining Fluids and Oil Filter Removal 1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container.
2. Remove the oil filter (if applicable). 3. Discard the oil filter (if applicable).
4. Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container.
34
Engine Flywheel Removal 1. Remove the engine flywheel bolts. 2. Remove the engine flywheel (automatic transmission) (1), if applicable. 3. Remove the engine flywheel (manual transmission) (2), if applicable.
188129
Important: If replacing the engine flywheel (manual transmission), then NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel. 4. Note the position of any flywheel weights for assembly (if applicable).
Clutch Pilot Bearing Removal Tools Required J 43276 Clutch Pilot Bearing Remover Caution: Refer to Safety Glasses Caution in Cautions and Notices Notice: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 Clutch Pilot Bearing Remover tool body to rotate. Failing to do so will cause damage to the J 43276-1 Clutch Pilot Bearing Remover tool body. 1. Remove the clutch pilot bearing using the J 43276 1.1. Install the J 43276 tool body into the clutch pilot bearing.
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1.2. Using a wrench secure the J 43276-1 tool body. 1.3. Insert the J 43276-2 forcing screw into the J 43276-1 tool body. 1.4. Rotate the J 43276-2 forcing screw clockwise into the J 43276-1 tool body until the clutch pilot bearing is completely removed from the crankshaft. 1.5. Rotate the J 43276-2 forcing screw counterclockwise to remove the J 43276-2 forcing screw from the J 43276-1 tool body. 1.6. Remove the J 43276-1 tool body from the clutch pilot bearing. 2. Discard the clutch pilot bearing.
Exhaust Manifold Removal (Left) Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 1. Remove the spark plug wires from the spark plugs. 1.1. Rotate the spark plug wire boot one-half turn. 1.2. Pull outward on the spark plug wire boot to release from the spark plug. 2. Remove the spark plug wires from the spark plug wire retainers. 3. Remove the exhaust manifold bolts and the stud. 4. Remove the spark plug wire shields (if applicable) and the exhaust manifold.
5. Remove and discard the exhaust manifold gaskets.
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Exhaust Manifold Removal (Right) Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 1. Remove the spark plug wires from the spark plugs. 1.1. Rotate the spark plug wire boot one-half turn. 1.2. Pull outward on the spark plug wire boot to release from the spark plug. 2. Remove the spark plug wires from the spark plug wire retainers. 3. Remove the exhaust manifold bolts and the stud. 4. Remove the spark plug wire shields (if applicable) and the exhaust manifold.
5. Remove and discard the exhaust manifold gaskets.
Oil Level Indicator and Tube Removal 1. Remove the oil level indicator from the oil level indicator tube, if applicable.
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2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine block.
Water Pump Removal 1. Remove the bolts and the fan and water pump pulley using the
2. Remove the clamps and water pump inlet hose.
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3. 4. 5. 6.
Remove the water pump bolts. Remove the water pump. Remove the water pump gaskets. Discard the water pump gaskets.
Crankshaft Balancer Removal Tools Required J 23523-F Balancer Remover and Installer 1. Remove the crankshaft balancer bolt and washer.
2. Remove the bolts and the crankshaft pulley.
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Notice: Refer to Fastener Notice in Cautions and Notices. 3. Use the J23523-F in order to remove the crankshaft balancer. 3.1. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten Tighten the bolts to 25 N•m (18 lb ft.). 3.2. Install the J 23523-F forcing screw into the plate. 3.3. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer. 4. Remove the J 23523-F from the crankshaft balancer.
5. Note the position of any front groove pins (crankshaft balancer) (if applicable)
Valve Rocker Arm Cover Removal (Left) 1. Remove the valve rocker arm cover bolts. 2. Remove the valve rocker arm cover bolt grommets. 3. Discard the valve rocker arm cover bolt grommets.
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4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket. 6. Discard the valve rocker arm cover gasket.
Valve Rocker Arm Cover Removal (Right) 1. Remove the valve rocker arm cover bolts. 2. Remove the valve rocker arm cover bolt grommets. 3. Discard the valve rocker arm cover bolt grommets.
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4. Remove the valve rocker arm cover.
5. Remove the valve rocker arm cover gasket. 6. Discard the valve rocker arm cover gasket.
Distributor Removal 1. Remove the ignition coil wire harness from the ignition coil and distributor cap.
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2. Remove the distributor clamp bolt. 3. Remove the distributor and the distributor clamp.
4. Remove the distributor gasket and discard.
Intake Manifold Removal 1. Remove the engine coolant temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket. 2. Remove the lower intake manifold bolts. 3. Remove the intake manifold assembly. 4. Remove and discard the lower intake manifold gaskets.
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Valve Rocker Arm and Push Rod Removal Important: Mark, sort and organize all the components for assembly. 1. Remove the valve rocker arms.
2. Remove the valve pushrods.
Cylinder Head Removal (Left) 1. Remove the engine coolant temperature sensor (if applicable).
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2. Remove the engine coolant temperature gauge sensor (if applicable).
3. Remove the spark plugs.
4. Remove the bolts and the spark plug wire support.
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5. Remove the bolts and the spark plug wire support.
6. Remove the cylinder head bolts and discard.
Notice: After removal, place the cylinder head on two wood blocks to prevent damage. 7. Remove the cylinder head.
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8. Remove and discard the cylinder head gasket.
9. Remove the dowel pins (cylinder head locator) (if required).
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Cylinder Head Removal (Right) 1. Remove the spark plugs.
2. Remove the bolts and the spark plug wire support.
3. Remove the cylinder head bolts and discard.
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Notice: After removal, place the cylinder head on two wood blocks to prevent damage. 4. Remove the cylinder head.
5. Remove and discard the cylinder head gasket.
6. Remove the dowel pins (cylinder head locator) (if required).
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Valve Lifter Removal Tools Required J 3049-A Valve Lifter Remover Important: Place the components in a rack so that the components can be reinstalled to their original location. 1. Remove the bolts and the valve lifter pushrod guide.
Important: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters. 2. Remove the valve lifters.
Important: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049-A for removal. 3. Use the J 3049-A in order to remove the stuck valve lifters.
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Oil Pan Removal 1. Remove the oil pan bolts and nuts.
2. Remove the oil pan.
1. Remove the oil pan gasket. 2. Discard the oil pan gasket.
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Oil Pump Removal 1. Remove the oil pump bolt.
2. Remove the oil pump.
3. Inspect the pins (oil pump locator) for damage, and replace the pins if required.
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Engine Front Cover Removal 1. Remove the crankshaft position sensor bolt. 2. Remove the crankshaft position sensor.
3. Remove the crankshaft position sensor seal (O-ring). 4. Discard the crankshaft position sensor seal (O-
1. Remove the engine front cover bolts. 2. Remove the engine front cover. 3. Discard the engine front cover seal.
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Timing Chain and Sprockets Removal Tools Required J 5825-A Crankshaft Gear Remover 1. Remove the crankshaft position sensor reluctor ring.
2. Check the camshaft timing chain free play. 2.1. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2). 2.2. Measure the free play on the slack side (3) of the camshaft timing chain. If the camshaft timing chain can be moved side to side in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprockets is recommended during assembly.
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3. Remove the camshaft sprocket bolts.
4. Remove the camshaft sprocket and the camshaft timing chain.
Caution: Refer to Safety Glasses Caution in Cautions and Notices. 5. Remove the crankshaft sprocket using the J 5825-A.
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6. Remove the crankshaft balancer key.
Balance Shaft Removal 1. Remove the balancer shaft drive gear.
Important: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt. 2. Remove the balance shaft driven gear bolt from the balance shaft. 2.1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 2.2. Remove the balance shaft bolt. 2.3. Remove the wrench from the balance shaft. 3. Remove the balance shaft driven gear from the balance shaft.
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4. Remove the bolts and the balance shaft retainer.
Important: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft. 5. Use a soft-faced hammer in order to remove the balance shaft from the engine block.
Camshaft Removal 1. Remove the camshaft retainer bolts and
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Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 2. Remove the engine camshaft. 2.1. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. 2.2. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings. 2.3. Remove the bolts from the front of the engine camshaft.
Piston, Connecting Rod, and Bearing Removal Tools Required
• J 5239 Connecting Rod Bolt Guide Set • J 24270 Cylinder Bore Ridge Reamer 1. Use the J 24270 in order to remove the cylinder ring ridge. 1.1. Turn the crankshaft until the piston is at the bottom of the stroke. 1.2. Place a cloth on top of the piston. 1.3. Use the J 24270 to remove all of the cylinder ring ridge. 1.4. Turn the crankshaft so the piston is at the top of the stroke. 1.5. Remove the cloth. 1.6. Remove the cutting debris. Important: Place match marks or numbers on the connecting rods and the connecting rod caps, also indicate direction on both. 2. Remove the connecting rod nuts. 3. Remove the connecting rod cap.
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4. Use the J 5239 in order to protect the crankshaft journals and remove the connecting rod and the piston out of the top of the engine block.
Important: Always assemble the connecting rod caps to the matching connecting rods. 5. Remove the connecting rod bearings. 5.1. Keep the connecting rod bearings with the original connecting rod and connecting rod cap. 5.2. Wipe the oil from the connecting rod bearings. 5.3. Wipe the oil from the crankpins.
Crankshaft Rear Oil Seal and Housing Removal 1. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. 2. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing. 3. Discard the crankshaft rear oil seal.
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4. Remove the crankshaft rear oil seal housing nut and bolts. 5. Remove the crankshaft rear oil seal housing.
6. Remove the crankshaft rear oil seal housing gasket. 7. Discard the crankshaft rear oil seal housing gasket.
8. Remove the crankshaft rear oil seal housing retainer stud from the engine block.
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Crankshaft and Bearings Removal 1. Mark or identify the crankshaft bearing cap locations, direction and positions for assembly. 2. Remove the crankshaft bearing cap bolts. 3. Remove the crankshaft bearing caps.
4. Remove the crankshaft.
5. Remove the crankshaft bearings from the crankshaft bearing caps.
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6. Remove the crankshaft bearings from the engine block.
Engine Block Plug Removal Tools Required J 41712 Oil Pressure Switch Socket Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the engine oil pressure gauge sensor using the J 41712.
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2. Remove the engine oil pressure sensor fitting.
3. Remove the dowel straight pins (transmission locator) (if required).
4. Remove the engine block left side oil gallery plug. 5. Remove the rear crossover cover. Discard O-Ring.
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6. Remove the expansion cup plug (camshaft rear bearing hole) and discard.
7. Remove the expansion cup plug (balance shaft rear bearing hole) and discard.
8.
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Remove the spring type S pin (crankshaft rear oil seal housing locator) (if required).
9.
Remove the front oil gallery plugs or balls from the front of the engine block and discard. 10. Insert a 3/8 x 26 in. rod into the rear oil gallery holes in order to drive out the front oil gallery plugs or balls.
11. Remove the engine block core hole plugs. 11.1. Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket. 11.2. Use a suitable tool in order to pull the engine block core hole plugs from the coolant jacket. 11.3. Discard the engine block core hole plugs.
12. Remove the oil filter bypass valve and discard.
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Engine Block Clean and Inspect Tools Required J 8087 Cylinder Bore Gauge Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean all the remaining sealing or gasket material from the sealing surfaces. 2. Clean the engine block with cleaning solvent. 3. Flush the engine block with clean water or steam. 4. Clean the cylinder bores. 5. Clean the oil galleries and the oil passages. 6. Clean the scale and the deposits from the coolant passages. Notice: Clean all debris, dirt and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to the components. 7. Clean the engine block cylinder head bolt holes. 8. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil. 9. Inspect the following areas: • Coolant jackets (1) for cracks
• Cylinder bores (2) for scratches or gouging • Valve lifter bores (3) for excessive scoring or wear
• Threaded holes (4) for damage • Crankshaft bearing webs (5) for cracks
• Crankshaft bearing caps (6) and the crankshaft bearing bores (7) for damage - The crankshaft bearing bores should be round and uniform when measuring the inside diameter (ID). - The surface where the crankshaft bearings contact the crankshaft bearing bore should be smooth. - If a crankshaft bearing cap is damaged and requires replacement, replace the crankshaft bearing cap first, then rebore the engine block crankshaft bearing bores and check for proper alignment. Finally, check the crankshaft for the proper clearances. • Engine block core hole plug bores (8) for damage
• Engine block (9) for cracks or damage • Engine mount bosses (10) for damage
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10. Measure the cylinder bores for taper and out-of-round. 10.1. Depress the plunger on the J 8087 7 mm (0.275 in) or until the J 8087 enters the cylinder bore. 10.2. Center the J 8087 in the cylinder bore and turn the indicator dial to 0. 10.3. Move the J 8087 up and down the cylinder bore to determine the cylinder bore taper. Refer to Engine Mechanical Specifications. 10.4. Turn the J 8087 to different points around the cylinder bore to determine the cylinder bore out-of-round condition. Refer to Engine Mechanical Specifications.
Cylinder Boring and Honing Honing Procedure Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. When honing the cylinder bores, follow the manufacturer’s recommendations for equipment use, cleaning and lubrication. • Use only clean sharp stones of the proper grade for the amount of material to be removed.
• Dull, dirty stones cut unevenly and generate excessive heat. • DO NOT hone to a final grade with a coarse or mediumgrade stone.
• Leave sufficient metal so that all the stone marks will be remove with the fine grade stones. • Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross-hatch pattern at 45-65 degrees to obtain the proper clearance. 2. During the honing operation, thoroughly check the cylinder bore. • Repeatedly check the cylinder bore fit with the selected piston.
• All measurements of the piston or cylinder bore should be made with the components at normal room temperature. 3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. 4. Repeatedly check the measurement at the top, the middle and the bottom of the cylinder bore. • The finish marks should be clean but not sharp.
• The finish marks should be free from imbedded particles or torn or folded material.
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5. By measuring the selected piston at the sizing point and then by adding the average of the clearance specification, the final cylinder bore honing dimension required can be determined. 6. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements. 7. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. 7.1. Scrub the cylinder bores with a stiff bristle brush. 7.2. Rinse the cylinder bores thoroughly with clean hot water. 7.3. Dry the cylinder bores with a clean rag. 7.4. Do not allow any abrasive material to remain in the cylinder bores. • Abrasive material may cause premature wear of the new piston rings and the cylinder bores.
• Abrasive material will contaminate the engine oil and may cause premature wear of the bearings. 8. Perform final measurements of the piston and the cylinder bore. 9. Permanently mark the top of the piston for the specified cylinder to which it has been fitted. 10. Apply clean engine oil to each cylinder bore in order to prevent rusting.
Boring Procedure Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Before starting the honing or reboring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline. 2. File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar. 3. Follow the instructions furnished by the manufacturer regarding the use of the boring equipment. 4. When reboring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction. 5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly. 6. When making the final cut with the boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for finish honing. This gives the required position to the cylinder clearance specifications. (Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons, the piston rings and the cylinder bores).
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Piston and Connecting Rod Disassemble Tools Required J 24086-C Piston Pin Remover/Installer Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove the piston rings from the pistons.
2. Press the piston pin from the connecting rod using the J 24086-C. 3. The piston pin has an interference fit into the connecting rod, and is full floating in the piston.
4. Mark, separate and organize the parts for assembly.
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Piston, Connecting Rod and Bearings Clean/ Inspect Important: Measurement of all components should be taken with the components at room temperature. Do not use a wire brush in order to clean any part of the piston. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the piston and connecting rod in solvent. 2. Dry the components with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots. 5. Inspect the piston for the following: • Eroded areas (1) on the top of the piston • Scuffed or damaged skirt (2) • Damage to the pin bore (3) • Cracks in the piston ring lands, the piston skirt or the pin bosses • Piston ring grooves for nicks, burrs or other warpage which may cause the piston ring to bind 6. Inspect the piston pin for scoring, wear or other damage
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7. Measure the piston ring-to-piston ring groove side clearance. 7.1. Insert the edge of the piston ring into the piston ring groove. 7.2. Roll the piston ring completely around the piston. • If binding is caused by a distorted piston ring groove, MINOR imperfections may be removed with a fine file. • If binding is caused by a distorted piston ring, replace the piston ring.
8. Measure the piston ring side clearance with a feeler gauge. 9. If the side clearance is too small, try another piston ring set. 10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly. 11. To determine the proper piston ring side clearance, refer to Engine Mechanical Specifications.
12. To determine piston pin-to-bore clearance, use a micrometer and measure the piston pin.
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13. To determine piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore. 14. To determine the piston pin-to-bore clearance, subtract the piston pin diameter from the piston pin bore diameter. Refer to Engine Mechanical Specifications.
15. Measure the piston with a micrometer at a right angle to the piston pin bore, measure the piston at 11 mm (0.433 in) from the bottom of the skirt. Refer to Engine Mechanical Specifications. If the piston is not within specifications, replace the piston and pin as an assembly.
16. Inspect the connecting rod for an out-of-round bearing bore. Refer to Engine Mechanical Specifications.
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17. Inspect the connecting rod for twisting. 18. Inspect the connecting rod for damage to the bearing cap and bolt threads.
19. Measure the piston compression ring end gap. Important: Fit each compression ring to the cylinder in which it will be used. 20. Place the compression ring into the cylinder bore. 20.1. Push the compression ring into the cylinder bore to approximately 6.5 mm (0.25 in) above the ring travel. The ring must be square to the cylinder wall. 20.2. Use a feeler gauge in order to measure the end gap. 20.3. Select another size ring set if the end gap exceeds specifications. Refer to Engine Mechanical Specifications.
Piston Selection Tools Required J 8087 Cylinder Bore Gauge Important: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores should not have excessive wear or taper. A used piston and piston pin set may be reinstalled if, after cleaning and inspection, the piston and piston pin are within specifications. 1. Use the J 8087 in order to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore and 90 degrees to the crankshaft centerline.
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2. Measure the J 8087 with a micrometer and record the reading.
3. With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 in) from the bottom of the skirt. 4. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance. Refer to Engine Mechanical Specifications. 5. If the proper clearance cannot be obtained, then select another piston and measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing or boring. 6. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder.
Piston and Connecting Rod Assemble Tools Required J 24086-C Piston Pin Remover/Installer Caution: Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury. Notice: Applying excessive heat to the connecting rod may damage or distort the rod. Rod temperature SHOULD NOT exceed 315°C (600°F). At this temperature, the end of the connecting rod will turn a straw color upon visual inspection. Notice: After the J 24086-C installer hub bottoms on the support assembly, DO NOT exceed 35,000 kPa (5,000 psi) or the tool may be damaged.
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Important: When assembling the piston and connecting rod, the mark on the top of the piston must point to the front of the engine block. The left bank connecting rods should have the flange face toward the front of the engine block. The right bank connecting rods should have the flange face toward the rear of the engine block. The piston pin has an interference fit into the connecting rod and is full floating in the piston. 1. Install the piston pin and connecting rod assembly. 1.1. Lubricate the piston pin bores with clean engine oil. 1.2. Use a torch and apply MILD heat to the piston pin end of the connecting rod. 1.3. Use the J 24086-C in order to press the piston pin into the piston and connecting rod assembly. 1.4. Inspect for the proper installation of the piston and piston pin. The piston must move freely on the piston pin with no binding or interference. Notice: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. 2. Install the piston rings onto the piston. 2.1. Install the oil control piston ring spacer. 2.2. Install the lower oil control piston ring. 2.3. Install the upper oil control piston ring. 2.4. Install the lower compression piston ring. The mark on the side of the piston ring should face the top of the piston. 2.5. Install the upper compression piston ring. The mark on the side of the piston ring should face the top of the piston.
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3. Space the compression piston ring end gaps 120 degrees apart. 4. Space the oil control piston ring end gaps a minimum of 90 degrees apart.
Crankshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator J 36660 Electronic Torque Angle Meter Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Use care when handling the crankshaft. Avoid damage to the crankshaft bearing surfaces. 1. Clean the crankshaft in cleaning solvent. Remove all sludge or restrictions from the oil passages. 2. Dry the crankshaft with compressed air.
3. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth, do not scratch the crankshaft bearing surface. 4. Dry the crankshaft bearings with compressed air.
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5. Inspect the crankshaft for the following: • Crankshaft journals (1) should be smooth with no evidence of scoring or damage. • Deep grooves (2) • Scratches or uneven wear (3) • • • • •
Pitted surfaces (4) Wear or damage to the thrust journal surfaces Scoring or damage to the rear seal surface Restrictions to the oil passages Damage to the threaded bolt holes
6. Inspect the crankshaft balancer key (1), the keyway (2) and the threaded hole (3) for damage. Repair or replace the crankshaft as necessary.
7. Measure the crankpins for out-of-round and taper. Refer to Engine Mechanical Specifications.
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8. Use a suitable support to support the crankshaft on the front and rear journals. 9. Use the J 7872 in order to measure the crankshaft journal runout. The crankshaft runout should not exceed 0.025 mm (0.0040 in).
10. Measure the crankshaft end play. Important: In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearings and the crankshaft bearing caps, the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened to specifications. Firmly thrust the crankshaft first rearward, then forward. This will align the crankshaft rear bearings and the crankshaft thrust surfaces. 10.1. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance. Refer to Engine Mechanical Specifications. 10.2. If the correct end play cannot be obtained, verify that the correct size crankshaft bearing has been installed. Refer to Engine Mechanical Specifications. 10.3. Inspect the crankshaft for binding. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, then loosen the crankshaft bearing cap bolts, one bearing cap at a time, until the tight crankshaft bearing is located. Burrs on the crankshaft bearing cap, foreign matter between the crankshaft bearing and the engine block or crankshaft bearing cap or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing.
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11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.
12. Inspect the crankshaft bearings for excessive scoring or discoloration. 13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material.
14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings. • If the lower half of the crankshaft bearing is worn or damaged, both the upper and lower halves of the crankshaft bearing should be replaced. • Generally, if the lower half of the crankshaft bearing is suitable for use, the upper half of the crankshaft bearing should also be suitable for use.
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Measuring Crankshaft Bearing Clearances
• The crankshaft bearings are of the precision insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required. The service crankshaft bearings are available in the standard size and an undersize.
• The selective fitting of the crankshaft bearings are necessary in production in order to obtain close tolerances. For this reason, in one journal bore you may use one-half of a standard crankshaft bearing with one-half of an undersize crankshaft bearing
• In order to determine the correct replacement crankshaft bearing size, the crankshaft bearing clearance must be measured accurately. Either the micrometer or plastic gauge method may be used; however, the micrometer method gives more reliable results and is preferred. When checking connecting rod bearing clearances, the plastic gauge method will result in unreliable measurements. The use of J 43690 is preferred.
• Normally the crankshaft bearing journals wear evenly and are not out-of-round. However, if a crankshaft bearing is being fitted to an out-of-round crankshaft bearing journal, be sure to fit to the maximum diameter of the crankshaft bearing journal. If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal will result in rapid crankshaft bearing failure.
• If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications, replace the crankshaft bearing. Always replace both the upper and lower crankshaft bearings as a set.
• A standard or oversize crankshaft bearing combination may result in the proper clearance. If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings, it may be necessary to repair or replace the crankshaft. Micrometer Method for Crankshaft Bearings 1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements. 2. Determine the taper and the out-of-round of the crankshaft journal. Refer to Engine Mechanical Specifications.
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3. Install the crankshaft bearings into the engine block or connecting rod assembly.
4. Install the bearing cap bolts and tighten to specifications. 5. Measure the bearing inside diameter (ID) at two points 90 degrees apart. Average the measurements. 6. In order to determine the bearing clearance, subtract the average journal diameter from the average bearing inside diameter. 7. Compare the readings to specifications. Refer to Engine Mechanical Specifications. 8. Replace bearing halves as required to obtain the proper bearing clearances.
Measuring Connecting Rod Bearing Clearances (J 43690 Method) 1. Remove the oil pan and other necessary components to gain access to the connecting rods. Remove the oil pump, screen and deflector (when applicable). 2. Rotate the crankshaft until the crankshaft journal/connecting rod to be measured is in the 10 o’clock position. Important: The crankshaft must be secure with no movement or rotation in order to obtain an accurate reading. Remove an intermediate bearing cap (as required) in order to secure the crankshaft and allow measurement of connecting rod bearing clearances. 3. Remove the bearing cap bolts (1), cap (2) and bearing half. Notice: Refer to Fastener Notice in Cautions and Notices.
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4. Insert a piece of paper card stock onto the crankshaft journal. Install the bearing half, bearing cap and bolts. Refer to Fastener Tightening Specifications.
5. Install the foot (1) and bolt (2) to the pivot arm assembly (3). Tighten the bolt until snug.
6. Install the screw (1 or 3) to the pivot arm assembly (2).
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7. Install the pivot arm assembly (1) onto the connecting rod.
8. Position the foot of the pivot arm assembly over the large end of the connecting rod bolt. 9. Position the screw (1) onto the small end of the connecting rod bolt and tighten securely.
10. Install the base (1) and bolt (2) to the oil pan rail.
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11. Align the center of the base (1) with the screw (3) of the pivot arm assembly. Tighten the bolt (2) until snug.
12. Align the link (1) of the pivot arm assembly on a plane (3) equal to that of the connecting rod beam (2).
13. With the link of the pivot arm assembly aligned to the beam of the connecting rod, position the pivot arm to the base and insert the pin (1).
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14. Install the handle (1) to the pivot arm assembly.
15. Select the adapter (2) (as required) and install to the swivel base (1). Tighten until snug.
Important: The clamp of the swivel base and the shaft of the indicator should be free of oil or other debris. A loose or improperly clamped indicator may indicate incorrect readings. 16. Install the indicator (2) to the swivel base (1). Tighten the clamp of the base until snug.
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17. Install the swivel base (1) to the oil pan rail of the engine block. Tighten until snug.
18. Adjust the swivel base as required and position the indicator tip slightly above the connecting rod cap. Lock the swivel base in position by rotating the locking lever (1). Do not allow the tip of the indicator to contact the connecting rod at this time.
19. The tip of the indicator should be positioned above and NOT in contact with the cap end of the connecting rod.
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20. Rotate the fine adjustment knobs on the dial indicator end of the swivel base to position the tip of the indicator in contact with the connecting rod.
21. Lightly actuate the handle of the pivot arm assembly (multiple times in both directions) to ensure the oil film is removed from the journal.
22. Load the handle in the forward position and zero the dial indicator. Load the handle multiple times in both directions and record the reading. Important: During this procedure, card stock may enter the crankshaft journal oil galleries. Be sure to remove all card stock from the bearing journal and oil galleries prior to reassembly. 23. Remove the bearing cap bolts, cap and paper stock. 24. Replace the bearing halves as required to obtain the proper bearing clearances. 25. Install the bearings, cap and bolts. Refer to Fastener Tightening Specifications.
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Measuring Crankshaft Bearing Clearances (Plastic Gauge Method) 1. Install the crankshaft bearings into the engine block.
2. Install the crankshaft.
3. Install the gauging plastic the full width of the journal.
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4. Install the crankshaft bearings into the crankshaft bearing caps.
5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the crankshaft bearing cap bolts. Tighten 6.1. Tighten the crankshaft bearing cap bolts on the first pass to 20 N•m (15 lb ft.). 6.2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660. 7. Remove the crankshaft bearing cap bolts. 8. Remove the crankshaft bearing caps. The gauging plastic may adhere to either the crankshaft bearing journal or the crankshaft bearing surface.
9. Without removing the gauging plastic, measure the compressed width at the widest point using the graduated scale on the edge of the gauging plastic envelope. If the flattened gauging plastic tapers toward the middle or the ends, there may be a difference in clearance indicating taper, low spot or other irregularity of the crankshaft bearing or the crankshaft bearing journal. 10. Remove the flattened gauging plastic. 11. Measure the remaining crankshaft bearing journals.
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Measuring Connecting Rod Bearing Side Clearance 1. Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance. Refer to Engine Mechanical Specifications. 2. Connecting rod side clearances may also be measured with a dial indicator set.
Crankshaft Balancer Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the crankshaft balancer in cleaning solvent. 2. Dry the crankshaft balancer with compressed air. 3. Inspect the crankshaft balancer for the following: • Loose or improperly installed front groove pin (1) (if applicable) A properly installed front groove pin should be installed until flush or below flush with the face of the crankshaft balancer. Important: A crankshaft front oil sealing surface with excessive scoring, grooves, rust or other damage must be replaced. • Worn, grooved or damaged crankshaft front oil sealing surface (2) Minor imperfections on the crankshaft balancer crankshaft front oil seal surface may be removed with a polishing compound or fine grade emery cloth. • Worn, chunking or deteriorated rubber (3) between the hub and the outer ring • Worn or damaged keyway (4) • Worn or damaged bolt hole threads (5)
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Engine Flywheel Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the engine flywheel (1) or (2) in cleaning solvent. 2. Dry the engine flywheel with compressed air.
3. Inspect the engine flywheel (automatic transmission) (if equipped) for the following: • Stress cracks around the engine flywheel-to-torque converter bolt hole locations (1) • Missing balance weights • Stress cracks around the engine flywheel-to-crankshaft bolt hole locations (2) or (3) Important: Do not attempt to repair the welded areas (if present) that retain the ring gear to the engine flywheel plate. Always install a NEW engine flywheel. • Welded areas that retain the ring gear onto the engine flywheel for cracking (4) (if present) • Damaged ring gear teeth (5)
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4. Inspect the engine flywheel (manual transmission) (if equipped) for loose or improperly installed flywheel weights (if applicable). A properly installed flywheel weight should be installed until flush or below flush with the face of the engine flywheel.
5. Inspect the engine flywheel (manual transmission) (if equipped) for the following: • Pitted friction surface (1) • Scoring or grooves (2) • Rust or other surface damage (3) • Damaged ring gear teeth (4) • Loose or improperly positioned ring gear The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the engine flywheel.
Camshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Dial Indicator Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the engine camshaft in cleaning solvent. 2. Dry the engine camshaft with compressed air. 3. Inspect the camshaft retainer plate for damage. If the camshaft retainer plate is damaged, replace as necessary. 4. Inspect the camshaft bearings for correct fit into the engine block camshaft bearing bores. The camshaft bearings have an interference fit to the engine block camshaft bearing bores and must not be loose in the engine block camshaft bearing bores.
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Important: If any camshaft bearing is excessively worn or scored, replace all the camshaft bearings. 5. Inspect the camshaft bearings for excessive wear or scoring. 6. Inspect the engine camshaft for the following: • Worn, scored or damaged bearing journals (1) • Worn engine camshaft lobes (2) • Damaged bolt hole threads (3) • Damaged camshaft sprocket locator pin (4)
7. Measure the engine camshaft journals with a micrometer. If the camshaft journals are more than 0.05 mm (0.0020 in) out-of-round, then replace the engine camshaft.
8. Measure for a bent engine camshaft or excessive engine camshaft runout using the J 7872. 8.1. Mount the engine camshaft in a suitable stand between centers. 8.2. Use the J 7872 in order to check the intermediate engine camshaft journals. 9. Measure the engine camshaft lobe lift using the J 7872. 9.1. Place the engine camshaft on the V-blocks. 9.2. Use the J 7872 in order to measure the engine camshaft lobe lift. 10. Replace the engine camshaft if the engine camshaft lobe lift is not within specifications. Refer to Engine Mechanical Specifications.
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Camshaft Bearing Removal Tools Required J 33049 Camshaft Bearing Service Kit 1. Select the cone (1), the handle (10), the expanding driver (48), the washer (2 or 3) and the expander assembly (15) from the J 33049. 2. Assemble the J 33049.
Important: A loose camshaft bearing may be caused by an enlarged, out-of-round or damaged engine block camshaft bearing bore. Important: Always remove the camshaft inner bearings #2 and #3 first. The camshaft outer bearings #1 and #4 serve as a guide for the J 33049. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 3. Remove the camshaft inner bearings #2 and #3. 3.1. Insert the J 33049 through the front of the engine block and into the camshaft inner bearing #2. 3.2. Tighten the J 33049 expander assembly nut until snug. 3.3. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049. 3.4. Drive the camshaft inner bearing #2 from the camshaft inner bearing bore #2. 3.5. Loosen the J 33049 expander assembly nut. 3.6. Remove the camshaft inner bearing #2 from the J 33049 expander assembly. 3.7. Insert the J 33049 expander assembly into the camshaft inner bearing #3. 3.8. Tighten the J 33049 expander assembly nut until snug. 3.9. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049. 3.10. Drive the camshaft inner bearing #3 from the camshaft inner bearing bore #3. 3.11. Loosen the J 33049 expander assembly nut. 3.12. Remove the camshaft inner bearing #3 from the J 33049 expander assembly.
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4. Remove the J 33049 from the engine block. 5. Remove the camshaft outer bearings #1 and #4. 5.1. Insert the J 33049 into the camshaft outer bearing #1. 5.2. Tighten the J 33049 expander assembly nut until snug. 5.3. Drive the camshaft outer bearing #1 from the camshaft outer bearing bore #1. 5.4. Loosen the J 33049 expander assembly nut. 5.5. Remove the camshaft outer bearing #1 from the J 33049 expander assembly. 5.6. Remove the J 33049 from the engine block. 5.7. Insert the J 33049 expander assembly into the camshaft outer bearing #4. 5.8. Tighten the J 33049 expander assembly nut until snug. 5.9. Drive the camshaft outer bearing #4 from the camshaft outer bearing bore #4. 5.10. Loosen the J 33049 expander assembly nut. 5.11. Remove the camshaft outer bearing #4 from the J 33049 expander assembly. 6. Remove the J 33049 from the engine block. 7. Discard the camshaft bearings.
Camshaft Bearing Installation Tools Required J 33049 Camshaft Bearing Service Kit Important: When installing the camshaft bearings, always look in order to ensure that the camshaft bearing lubrication hole is located above the 3 o’clock position (1) or the 9 o’clock position (2). The proper positioning of the camshaft bearing lubrication hole is in order to ensure the best lubrication of the engine camshaft journals.
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1. Select the handle (10), the expanding driver (4-8), the washer (2 or 3) and the expander assembly (15) from the J 33049. 2. Assemble the J 33049.
Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: The camshaft bearings vary in size. When ordering the new camshaft bearings, be sure to order the correct camshaft bearings for the application to be serviced. Always install the camshaft outer bearings #1 and #4 first. The camshaft outer bearings serve as a guide for the J 33049 and help center the camshaft inner bearings during the installation process. 3. Install the NEW camshaft outer bearings #4 and #1. 3.1. Install the NEW camshaft outer bearing #4 onto the J33049 expander assembly. 3.2. Tighten the J 33049 expander assembly nut until snug. 3.3. Align the lubrication hole of the camshaft outer bearing #4 above the 3 o’clock position or the 9 o’clock position of the camshaft outer bearing bore #4 at the rear of the engine block. 3.4. Drive the camshaft outer bearing #4 into the camshaft outer bearing bore #4 at the rear of the engine block. 3.5. Loosen the J 33049 expander assembly nut. 3.6. Remove the camshaft outer bearing #4 from the J33049 expander assembly. 3.7. Install the NEW camshaft outer bearing #1 onto the J33049 expander assembly. 3.8. Tighten the J 33049 expander assembly nut until snug. 3.9. Align the lubrication hole of the camshaft outer bearing #1 above the 3 o’clock position or the 9 o’clock position of the camshaft outer bearing bore #1 at the front of the engine block. 3.10. Drive the camshaft outer bearing #1 into the camshaft outer bearing bore #1 at the front of the engine block. 3.11. Loosen the J 33049 expander assembly nut. 3.12. Carefully slide the J 33049 into the engine block until the J 33049 expander assembly is positioned between the camshaft inner bearing bores.
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4. Install the NEW camshaft inner bearings #3 and #2. 4.1. Install the NEW camshaft inner bearing #3 onto the J33049 expander assembly. 4.2. Tighten the J 33049 expander assembly nut until snug. 4.3. Align the lubrication hole of the camshaft inner bearing #3 above the 3 o’clock position or the 9 o’clock position of the camshaft inner bearing bore #3 of the engine block. 4.4. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049. 4.5. Drive the camshaft inner bearing #3 into the camshaft inner bearing bore #3 of the engine block. 4.6. Loosen the J 33049 expander assembly nut. 4.7. Carefully slide the J 33049 until the J 33049 expander assembly is positioned between the camshaft inner bearing bore #2 and the camshaft outer bearing bore #1. 4.8. Install the NEW camshaft inner bearing #2 onto the J33049 expander assembly. 4.9. Tighten the J 33049 expander assembly nut until snug. 4.10. Align the lubrication hole of the camshaft inner bearing #2 above the 3 o’clock position or the 9 o’clock position of the camshaft inner bearing bore #2 of the engine block. 4.11. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049. 4.12. Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2 of the engine block. 4.13. Loosen the J 33049 expander assembly nut. 5. Carefully remove the J 33049 from the engine block.
Balance Shaft Bearing and/or Bushing Removal Tools Required J 26941 Bushing/Bearing Remover J 38834 Balance Shaft Service Kit Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Use the J 38834 and the J 26941 in order to remove the balance shaft rear bearing. 1.1. Install the J 26941 legs behind the balance shaft rear bearing and secure. 1.2. Install the J 38834-1 with the short threaded end through the balance shaft bore in the front of the engine block. 1.3. Install the J 38834-1 into the J 26941.
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1.4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. 1.5. Install the J 38834 bearing, washer and nut onto the J 38834-1. 1.6. Using a wrench, secure the J 38834-1 and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block. 1.7. Remove the J 26941 from the balance shaft rear bearing. 2. Discard the balance shaft rear bearing.
Balance Shaft Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft. 1. Clean the following components in cleaning solvent: • The balance shaft (1) • The balance shaft retainer (2) • The balance shaft rear bearing • The balance shaft driven gear (4) • The balance shaft drive gear 2. Dry the following components with compressed air: • The balance shaft (1) • The balance shaft retainer (2) • The balance shaft rear bearing • The balance shaft driven gear (4) • The balance shaft drive gear 3. Inspect the balance shaft bearings for the following: • Front ball bearing for damage or wear • Front ball bearing for smoothness of operation • Rear sleeve bearing for wear, scoring or other damage 4. Inspect the balance shaft (1) for the following: • Wear or scoring on the rear bearing journal • Damaged bolt hole threads • Damaged to the balance shaft driven gear locator pin 5. Inspect the balance shaft retainer (2) for wear or damage. 6. Inspect the balance shaft retainer bolts (3) for damaged threads. 7. Inspect the driven gear (4) for the following: • Excessive wear or damage • Nicks, burrs or scoring
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8. Inspect the driven gear bolt (5) for damaged threads. 9. Inspect the balance shaft drive gear for the following: • Excessive wear or damage • Nicks, burrs or scoring
Balance Shaft Bearing and/or Bushing Installation Tools Required J 38834 Balance Shaft Service Kit Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Use the J 38834 in order to install the balance shaft rear bearing. 1.1. Install the J 38834-3 onto the short threaded end of the J 38834-1. 1.2. Install the J 38834 nut, the washer and the bearing on the long threaded end of the J 38834-1. 1.3. Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. 1.4. Install the J 38834-2 on the inside of the balance shaft front bearing bore. 1.5. Lubricate the NEW balance shaft rear bearing with clean engine oil. 1.6. Install the balance shaft rear bearing onto the J 388342. 1.7. Align the balance shaft rear bearing for installation. 1.8. Using a wrench, secure the J 38834-1 into place. 1.9. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore. 2. Remove the J 38834.
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Timing Chain and Sprockets Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the components with cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the camshaft timing chain for binding or wear.
4. Inspect the camshaft sprocket and the crankshaft sprocket for the following: • Broken teeth (1) • Damaged teeth (2) • Chipped teeth (3) • Worn teeth • Uneven wear on the edge of the teeth • Worn valleys between the sprocket teeth • Crankshaft sprocket keyway for wear
Valve Rocker Arm and Push Rods Clean and Inspect Important: Parts that are to be reused must be marked, sorted and organized for assembly. 1. Mark, sort and organize the components for assembly. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 2. Clean the components with cleaning solvent. 3. Dry the components with compressed air. 4. Inspect the valve rocker arm components for the following: • Valve rocker arm valve push rod socket contact surface (1). The contact surface must be smooth with no scoring or excessive wear. • Valve rocker arm roller pivot for binding or damage (2) • Valve rocker arm valve stem contact surface (3) • Valve rocker arm bolt threads for damage (4)
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5. Inspect the valve push rods for the following: • Restriction of the oil passage (1) • Wear or scoring of the end contact surfaces (2). The end contact surfaces must be smooth with no scoring or excessive wear. • Shaft for bends (3). Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent.
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Valve Lifters and Guides Clean and Inspect Important: Parts that are to be reused must be marked, sorted and organized for assembly. 1. Mark, sort and organize the components for assembly. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 2. Clean the components with cleaning solvent. 3. Dry the components with compressed air.
4. Inspect the valve lifter pushrod guides for excessive wear. 5. Inspect the valve lifter pushrod guides for cracks or damage.
• • •
• •
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6. Inspect the valve lifter for the following: Broken or damaged clip (1) Worn pushrod socket (2) Scuffed or worn lifter body (3) If the valve lifter shows scuffing or wear, inspect the engine block valve lifter bores for wear. • Worn roller (4) Loose or damaged pin (5) Plugged oil hole (6)
Cylinder Head Disassemble Tools Required J 8062 Valve Spring Compressor Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Use the J 8062 in order to compress the valve springs.
Important: Mark, sort and organize the components so that the components can be reinstalled in their original location and position. 2. 3. 4. 5. 6. 7. 8.
Remove the valve stem keys (1). Remove the J 8062 from the cylinder head. Remove the valve spring cap (2). Remove the valve spring (3). Remove the valve stem oil seal (4). Discard the valve stem oil seal. Remove the valve.
Cylinder Head Clean and Inspect Tools Required J 8001 Dial Indicator Set J 8089 Carbon Removing Brush J 9666 Valve Spring Tester Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the valve stems and cylinder heads on a buffing wheel. 2. Clean the following components in cleaning solvent: • Valve stem keys (1) • Valve spring cap (2) • Valve spring (3) • Cylinder head
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3. Dry the components with compressed air. 4. Use the J 8089 to clean the carbon from the cylinder head combustion chambers. Be careful not to scuff the combustion chambers. 5. Inspect the cylinder head for the following: • Damage to the gasket surfaces • Damage to the threaded bolt holes • Burnt or eroded areas in the combustion chambers • Cracks in the exhaust ports and combustion chambers • External cracks in the water chambers • Restrictions in the intake or exhaust passages • Restrictions in the cooling system passages • Rusted, damaged or leaking core plugs
6. Measure the cylinder head for warpage with a straight edge and feeler gauge • A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced. • A cylinder head exhaust manifold deck with warpage in excess of 0.05 mm (0.002 in) within a 152.4 mm (6.0 in) area must be repaired or replaced. • A cylinder head intake manifold deck with warpage in excess of 0.10 mm (0.004 in) within a 152.4 mm (6.0 in) area must be repaired or replaced.
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7. Use the J 9666 in order to measure the valve spring. Replace the valve spring if the valve spring tension is less than 445 N (100 lb) at 43.2 mm (1.80 in).
8. Inspect the valve springs for squareness.
9. Valve stems (1) with excessive valve guide (2) clearance must be repaired or the cylinder head replace
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10. Measure the valve stem-to-guide clearance. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness. 10.1. Clamp the J 8001 on the exhaust port side of the cylinder head. 10.2. Position the dial indicator so that the movement of the valve stem from side to side (crosswise to the cylinder head) will cause a direct movement of the dial indicator stem. The dial indicator stem must contract the side of the valve stem just above the valve guide. 10.3. Drop the valve head about 1.6 mm (0.063 in) off the valve seat. 10.4. Use light pressure and move the valve stem from side to side in order to obtain a valve stem-to-guide clearance reading. Refer to Engine Mechanical Specifications.
Valve Guide Reaming/Valve and Seat Grinding Tools Required J 5830-02 Valve Guide Reamer Set J 8001 Dial Indicator Set 1. Measure the valve stem-to-guide clearance. Refer to Cylinder Head Clean and Inspect.
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2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption.
Caution: Refer to Safety Glasses Caution in Cautions and Notices. 3. Use the J 5830-3 in order to ream the exhaust valve guide in order to achieve the correct valve stem-to-guide clearance. 4. Always recondition the exhaust valve seat after reaming the exhaust valve guide bores and installing new exhaust valves.
5. Inspect the valves for the following: • Burnt or damaged areas (1) • Undersize margin (2) • Bent stem (3) • Scoring or other damage to the stem (4) • Worn key groove (5) • Worn stem tip (6)
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6. Inspect the valve contact surface for the following: • Undersized margin (1) • Pitted surfaces (2) • Burnt or eroded areas (3) • Acceptable edge (margin) (4) Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired. 7. Reconditioning of the valves and valve seats: • The valves must seat perfectly for the engine to deliver optimum power and performance. • Cooling the valve heads is another important factor. Good contact between each valve and valve seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away. • Regardless of what type of equipment is used, it is essential that the valve guide bores are free from carbon or dirt in order to ensure the proper centering of the pilot in the valve guide. The valve seats should be concentric to within 0.05 mm total indicator reading. • Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the valve head and the valve stem. Replace the valve if the valve stem is excessively worn or warped. Replace the valve if the edge margin (4) of the valve head is less than 0.79 mm (0.031 in) thick after grinding. • Several different types of equipment are available for reconditioning valves and valve seats. Follow the equipment manufacturer’s recommendations for equipment use to attain the proper results.
Cylinder Head Assemble Tools Required J 8062 Valve Spring Compressor SK69070 Valve Stem Seal Installer 1. Assemble the valve into the proper valve guide. 2. Select the proper valve stem oil seal for the specific valve guide. 3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil.
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4. Assemble the valve stem oil seal onto the valve stem. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 5. Install the valve stem oil seal onto the valve guide using the special tool SK69070. 6. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. The distance measured between the top of the seal and the bottom of the head should be between 0.860”-0.900” as shown on the image.
7. Install the valve spring (3). 8. Install the valve spring cap (2) onto the valve spring (3) and over the valve stem.
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Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 9. Use the J 8062 in order to compress the valve springs. 10. Install the valve stem keys. 10.1 Use grease in order to hold the valve stem keys in place while disconnecting the J 8062. 10.2. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 10.3. Tap the end of the valve stem with a plastic-faced in order to seat the valve stem keys, if necessary.
Oil Pump Disassemble 1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
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2. Remove the oil pump screen (if necessary). • The oil pump screen has a press fit into the oil pump cover. • DO NOT remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
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5. Remove the oil pump drive gear and the oil pump driven gear. 6. Matchmark the gear teeth for assembly.
Caution: Refer to Safety Glasses Caution in Cautions and Notices. 7. Remove the following items: 7.1. The oil pump pressure relief valve spring straight pin 7.2. The oil pump pressure relief spring 7.3. The oil pump pressure relief valve
Oil Pump Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the oil pump components in cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the oil pump for the following conditions: • Scoring on the top of the gears (1) • Damaged gears (2) for the following:
– Chipping – Galling – Wear • Scoring, damage or casting imperfections to the body (3) • Damaged or scored gear shaft (4) • Damaged or scored gear shaft (5)
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• Damaged bolt hole threads • Worn oil pump driveshaft bore • Damaged or sticking oil pump pressure relief valve (minor imperfections may be removed with a fine oil stone) • Collapsed or broken oil pump pressure relief valve spring 4. If the oil pump is to be reused, install a NEW oil pump pressure relief valve spring. 5. During oil pump installation, install a NEW oil pump driveshaft retainer.
Oil Pump Assemble Tools Required J 21882 Oil Suction Pipe Installer 1. Apply clean engine oil GM P/N 12345610 or equivalent to the oil pump pressure relief valve, oil pump pressure relief valve spring and oil pump body. Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Replace the oil pump pressure relief valve spring when you reuse the oil pump. 2. Install the following items: 2.1. The oil pump pressure relief valve 2.2. The oil pump pressure relief valve spring 2.3. The oil pump pressure relief valve spring straight pin
3. Apply clean engine oil GM P/N 12345610 or equivalent to the oil pump drive gear, the oil pump driven gear and the oil pump body internal surfaces. 4. Install the oil pump drive gear and the oil pump driven gear into the oil pump body. 4.1. Align the matchmarks on the oil pump drive and driven gears. 4.2. Install the smooth side of the oil pump drive and driven gears toward the oil pump cover.
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4. Install the oil pump cover.
Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the oil pump cover bolts. Tighten Tighten the bolts to 12 N•m (106 lb in). 6. Inspect the oil pump for smoothness of operation by turning the oil pump driveshaft by hand.
7. Install the oil pump screen. 7.1. If removed, replace the oil pump screen. The oil pump screen must have a good press fit into the oil pump body. 7.2. Mount the oil pump in a soft jawed vise. 7.3. Apply PTFE Thread Sealant or equivalent to the end of the oil pump screen pipe. 7.4. Use the J 21882 and a soft-faced hammer in order to tap the oil pump screen into the pump body. The oil pump screen must align parallel with the bottom of the oil pan when the oil pan is installed.
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Important: Install a NEW oil pump driveshaft retainer during assembly. 8. Install the oil pump driveshaft and the NEW oil pump driveshaft retainer.
Valve Rocker Arm Cover Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the valve rocker arm cover in cleaning solvent. 2. Dry the valve rocker arm cover with compressed air. 3. Inspect the valve rocker arm cover for the following: • Damage to the PCV valve grommet (1) • Damage to the bolt holes (2) A damaged valve rocker arm cover may interfere with the valve rocker arms. • Damage to the exterior of the valve rocker arm cover (3) • Gouges or damage to the sealing surface (4) • Damage to the oil fill tube grommet (5) • Restrictions to the ventilation system passages
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Oil Pan Clean and Inspect 1. Remove the oil pan baffle bolts and the oil pan baffle.
Caution: Refer to Safety Glasses Caution in Cautions and Notices. 2. Clean the oil pan and the oil pan baffle in cleaning solvent. 3. Dry the oil pan and the oil pan baffle with compressed air. 4. Inspect the oil pan for the following: • • • • •
Gouges or damage to the oil pan sealing surfaces (1) Damage to the threaded holes (2) Damaged oil pan drain hole threads (3) Damage to the oil pan baffle Damage to the exterior of the oil pan A damaged oil pan may interfere with the proper position of the oil pump screen, or may not distribute oil properly in the oil pan sump area.
Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the oil pan baffle and the bolts. Tighten Tighten the oil pan baffle bolts to 12 N•m (106 lb in).
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Exhaust Manifold Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the exhaust manifolds in cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the exhaust manifolds for the following: • • • •
Damage to the gasket sealing surfaces (1) Damage to the threaded holes (3) Restrictions within exhaust passages Broken or damaged exhaust manifold heat shields (4) (if applicable) • Broken or damaged exhaust manifold
4. Measure the alignment or surface flatness of the exhaust manifold flanges using a straight edge and a feeler gauge. Refer to Engine Mechanical Specifications. If the surface flatness is not within the specifications, the exhaust manifold is warped and must be replaced.
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Water Pump Clean and Inspect Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove all the old gasket material from the water pump sealing surfaces. 2. Clean all the dirt and any debris from the water pump. 3. Inspect the water pump for the following: • Leakage or damage to the housing cover or gasket (1) • Excessive scratches or gouging
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To the gasket sealing surfaces (2) • Leakage from the water pump vent hole (3) A stain around the vent hole is acceptable. If leakage occurred (dripping) with the engine operating and the cooling system pressurized, then replace the water pump. • Damaged bolt hole threads (4) • Excessive side-to-side movement of the water pump shaft (5) • Leakage around the water inlet pipe (6) • Leakage around the heater hose pipe (7) • Restrictions within the internal coolant passages
Thread Repair General purpose thread repair kits are available commercially. Caution: Refer to Safety Glasses Caution in Cautions and Notices. Important: Refer to the thread repair kit manufacturer’s instructions regarding the size of the drill and which tap to use. Always avoid any buildup of chips. Back out the tap every few turns and remove the chips. Determine the size, the pitch and the depth of the damaged thread. 1. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depths. 2. Drill out the damaged thread. 3. Remove the chips. 4. Apply clean engine oil to the top thread. 5. Use the tap in order to cut new thread. 6. Clean the thread. 7. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel. Important: The thread insert should be flush to 1 turn below the surface. 8. Lubricate the thread insert with clean engine oil (except when installing in aluminum) and install the thread insert. 9. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.
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Service Prior to Assembly • Dirt will cause premature wear of the rebuilt engine. Clean all the components. • Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer’s specification must be repaired or replaced.
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• When the components are re-installed into an engine, return the components to the original location, position and direction. • During assembly, lubricate all the moving parts with clean engine oil (unless otherwise specified). The engine oil will provide the initial lubrication when the engine is first started.
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Engine Block Plug Installation Tools Required J 41712 Oil Pressure Switch Socket Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Install a NEW oil filter bypass valve.
Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block.
Using a pointed punch, stake the engine block area around the oil filter bypass valve.
2. Apply Green Locktite or equivalent to the outside diameter of the NEW front engine oil gallery plugs. 3. Install the NEW front engine block oil gallery plugs. A properly installed front engine oil gallery plug must be installed slightly below flush with the front face of the engine block.
4. Apply Aviation Form-A-Gasket Liquid Sealant or equivalent to the outside diameter of the NEW engine block core hole plugs. 5. Install the NEW engine block core hole plugs. A properly installed engine block core hole plug must be installed flush with the bottom of the chamfer (1) of the engine block core hole.
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6. Apply Green LockTite or equivalent to the outside diameter of the NEW expansion cup plug (balance rear bearing hole). 7. Install the NEW expansion cup plug (balance shaft rear bearing hole).
8. Apply Aviation Form-A-Gasket Liquid Sealant or equivalent to the outside diameter of the NEW expansion cup plug (camshaft rear bearing hole). 9.
Install the NEW expansion cup plug (camshaft rear bearing hole).
10. Apply PTFE Sealant or equivalent to the threads of the engine block left side oil gallery plug. Located above oil filter housing. Tighten Tighten the engine block left rear oil gallery plug to 150 in lbs Plus 3/4 turn.
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11. Tighten 4 rear crossover cover bolts to 96 in lbs. Ensure the O-ring is fully seated and does not move or get pinched during install.
12. Install the dowel straight pins (if required). Ensure tapered end is facing outward.
13. Install the left side dowel pins (cylinder head locator).
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14. Install the right side dowel pins (cylinder head locator).
15. Apply PTFE Sealant or equivalent to the threads of the engine block coolant drain hole plugs. 16. Install the engine block coolant drain hole plugs. Tighten Tighten the engine block coolant drain hole plugs to 22 Ft. Lbs plus ½ turn.
17. If reusing the engine oil pressure sensor fitting, apply PTFE sealant or equivalent to the threads of the engine oil pressure sensor fitting. Important: Do not loosen the engine oil pressure fitting after the initial torque has been obtained. 18. Install the engine oil pressure sensor fitting. Tighten Tighten the engine oil pressure sensor fitting to 15 N•m (11 lb ft.). Important: Do not rotate the engine oil pressure fitting clockwise more than 359 degrees after the initial torque has been obtained. 19. Rotate the engine oil pressure sensor fitting clockwise to the proper position (1), 50 degrees from the centerline (2). Roughly the 4 O’clock Position.
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20. If reusing the engine oil pressure gauge sensor, apply PTFE sealant or equivalent to the threads of the engine oil pressure gauge sensor. 21. Install the engine oil pressure gauge sensor using the J 41712. Tighten Tighten the engine oil pressure gauge sensor to 30 N•m (22 lb ft.).
Crankshaft and Bearings Installation Tools Required J 36660 Electronic Torque Angle Meter 1. Install the crankshaft bearings into the engine block. Align tang on the bearing to the keyway in the block. Ensure bearings are even across the top of the block. 2.
Apply engine assembly lubricant on the main bearings.
3. Apply clean engine oil to the crankshaft bearing journals. 4. Gently install the crankshaft into the crankshaft journals.
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5. Install the crankshaft bearings into the crankshaft bearing caps. Align the tang on the bearing to the keyway in the main caps. Be sure the bearing is flat along the top of the main cap. Apply engine assembly lubricant to the bearings in the main cap bearings.
6. Apply clean engine oil to the crankshaft bearings.
7. Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the crankshaft bearing cap bolts until snug. 9. Thrust the crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps. 10. Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings. 11. Tighten the crankshaft bearing cap bolts. Tighten Tighten the crankshaft bearing cap bolts on the first pass to 20 N•m (15 lb ft.). Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660. 12. Measure the crankshaft end play. Firmly thrust the crankshaft rearward, and then forward. This will align the crankshaft rear bearing thrust surfaces. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance.
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Specification Crankshaft end play 0.05-0.20 mm (0.001-0.0089 in) 13. Rotate the crankshaft in order to check for binding. A bent crankshaft or lack of proper crankshaft bearing clearance may cause binding. 14. If the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on 1 crankshaft bearing cap at a time in order to determine the location of the binding. A lack of proper crankshaft bearing clearance may be caused by the following: • Burrs on the crankshaft bearing cap • Foreign material between the crankshaft bearing and the engine block • Foreign material between the crankshaft bearing and the crankshaft bearing cap • Damaged crankshaft bearing • Improper size crankshaft bearing
Crankshaft Rear Oil Seal and Housing Installation Tools Required J 35621-B Rear Main Seal Installer Notice: Refer to Fastener Notices in Cautions and Notices. 1. Install the crankshaft rear oil seal housing retainer stud. Tighten Tighten the crankshaft rear oil seal housing retainer stud to 6 N•m (53 lb in).
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Important: Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing. 2. Install the NEW crankshaft rear oil seal housing gasket.
3. Install the crankshaft rear oil seal housing onto the crankshaft rear oil seal housing retainer stud. 4. Install the crankshaft rear oil seal housing nut and bolts. Tighten Tighten the crankshaft rear oil seal housing nut and bolts to 12 N•m (106 lb in).
5. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing. 6. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange. 7. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin. 8. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface. 9. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. Minor imperfections may be removed with a fine grade emery cloth. Important: DO NOT allow oil or any other lubricants to contact the seal lip of the crankshaft rear oil seal.
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10. Remove the sleeve from the crankshaft rear oil seal. 11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal. 12. Install the crankshaft rear oil seal onto the J 35621-B. 13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail. 14. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. 14.1. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. 14.2. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the crankshaft rear oil seal. 15. Remove the J 35621-B from the crankshaft. 16. Wipe off any excess engine oil with a clean rag.
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Piston, Connecting Rod and Bearing Installation Piston Selection Tools Required J 8087 Cylinder Bore Gauge J 5239 Connecting Rod Bolt Guide Set J 8037 Ring Compressor J 36660 Electronic Torque Angle Meter Important: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores should not have excessive wear or taper. A used piston and piston pin set may be reinstalled if, after cleaning and inspection, the piston and piston pin are within specifications. 1. Use the J 8087 in order to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore and 90 degrees to the crankshaft centerline.
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2. Measure the J 8087 with a micrometer and record the reading.
3. With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 in) from the bottom of the skirt. 4. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance. Refer to Engine Mechanical Specifications. 5. If the proper clearance cannot be obtained, then select another piston and measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing or boring. 6. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder.
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Installation Procedure 1. Apply Engine Assembly Lubricant to the following components: • The piston • The piston rings • The cylinder bore • The bearing surfaces 2. Install the J 5239 onto the connecting rod bolts.
3. With the piston facing upright install the piston rings in the following order. Notice: Align rings on piston as shown in picture prior to installing piston assembly in block. 1. Lower oil control spacer ring 2. Oil control ring 3. Upper oil control spacer ring 4. Lower compression piston ring Ensure 5. Upper compression piston ring
4. Install the J 8037 onto the piston and compress the piston rings.
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Important: The mark on the top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank. 5. Apply a thin even coat of clean motor oil on piston skirt. 6. Install the piston and connecting rod assembly, and the J 8037 into the proper cylinder bore.
7. Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore. Use the J 5239 in order to guide the connecting rod onto the crankshaft journal.
8. Remove the J 5239
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Notice: Refer to Fastener Notice in Cautions and Notices. 9. Install the connecting rod caps, bearings and nuts. Tighten Tighten the nuts evenly on the first pass to 27 N•m (20 lb ft.). Use the J 36660 in order to tighten the nuts on the final pass an additional 70 degrees.
10. After the piston and connecting rod assemblies have been installed, then lightly tap each connecting rod assembly (parallel to the crankpin) in order to ensure that the connecting rods have side clearance. 11. Use a feeler gauge or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.15- 0.44 mm (0.006-0.017 in).
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Camshaft Installation 1. Apply clean engine oil, to the following components: • The engine camshaft lobes • The camshaft bearing journals • The camshaft bearings Use Clevite Gear Lubricant or equivalent on oil pump gear 2. Install three 5/16-18 x 4.0 in. bolts into the engine camshaft front bolt holes. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Use the bolts as a handle in order to install the engine camshaft. 4. Remove the 3 bolts from the front of the engine camshaft. Notice: Refer to Fastener Notice in Cautions and Notices. 5. If reusing the fasteners, apply Blue Threadlock or equivalent to the threads of the camshaft retainer bolts. Apply Clevite Gear Lubricant or equivalent to camshaft retainer, where contact with the camshaft is made. 6. Install the camshaft retainer and bolts. Tighten the camshaft retainer bolts to 12 N•m (106 lb in).
Balance Shaft Installation Tools Required J 8092 Universal Driver Handle J 36660 Electronic Torque Angle Meter J 36996 Balance Shaft Installer Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft. 1. Apply clean engine oil GM P/N 12345610 or equivalent to the balance shaft front bearing. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 2. Use the J 36996 and the J 8092 in order to install the balance shaft. Apply Clevite Gear Lubricant or equivalent to balance shaft retainer.
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Notice: Refer to Fastener Notice in Cautions and Notices. 3. Apply Blue Locktite or Equivalent to balance shaft retainer bolts. 4. Install the balance shaft retainer and bolts. Tighten Tighten the balance shaft retainer bolts to 12 N•m (106 lb in).
Install the balance shaft driven gear onto the balance shaft. 5. If reusing the fastener, apply Blue threadlock or equivalent to the threads of the balance shaft driven gear bolt. Use BLUE Locktite 6. Install the balance shaft driven gear bolt. 6.1. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Install the balance shaft driven gear bolt. Tighten 6.2.1. Tighten the balance shaft driven gear bolt on the first pass to 20 N•m (15 lb ft.). 6.2.2. Tighten the balance shaft driven gear bolt on the final pass using the J 36660 an additional 35 degrees. 7. Remove the wrench from the balance shaft. 8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case. 9. Install timing chain guide plate and timing chain guide.
Tighten Tighten timing chain guide bolt to 106 in lb.
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10. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time. Apply Clevite Gear Lubricant or equivalent to the Balance Shaft Drive Gear.
11. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o’clock position.
12. Remove the balance shaft drive gear.
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13. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o’clock position.
14. Position the balance shaft drive gear onto the engine camshaft. 15. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.
Timing Chain and Sprockets Installation Tools Required J 5590 Installer 1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.
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2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. Caution: Refer to Safety Glasses Caution in Cautions and Notices. 3. Use the J 5590 in order to install the crankshaft sprocket.
4. Rotate the crankshaft until the crankshaft sprocket is at the 12 o’clock position. Important: Install the camshaft sprocket with the alignment mark at the 6 o’clock position. 5. Install the camshaft sprocket and the camshaft timing chain.
6. Look to ensure that the crankshaft sprocket is aligned at the 12 o’clock position and the camshaft sprocket is aligned at the 6 o’clock position.
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Notice: Refer to Fastener Notice in Cautions and Notices. Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole). 7. Install the camshaft sprocket bolts very loosely. Install timing chain tensioner. Tighten Tighten the camshaft sprocket bolts to 18 lb ft.
8. Install the crankshaft position sensor reluctor ring. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. Ensure the indent of the reluctor wheel is facing out from the engine
Engine Front Cover Installation Important: Once the composite engine front cover is removed, DO NOT reinstall the engine front cover. Always install a NEW engine front cover. 1. Install the NEW engine front cover. Notice: Refer to Fasteners Notice in Cautions and Notices. 2. Install the engine front cover bolts. Tighten Tighten the engine front cover bolts to 12 N•m (106 lb in). Use Blue Locktite on bolts.
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Important: DONOT reuse the original crankshaft position sensor seal (O-ring). When installing the crankshaft position sensor, be sure the crankshaft position sensor is fully seated and held stationary in the engine front cover crankshaft position sensor bore. A crankshaft position sensor that is not completely seated will cock in the engine front cover and may result in erratic engine operation. 3. Lubricate the NEW crankshaft position sensor seal (O-ring) with clean engine oil. 4. Install the NEW crankshaft position sensor seal (O-ring) onto the crankshaft position sensor.
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5. Install the crankshaft position sensor until fully seated into the engine front cover. 6. Install the crankshaft position sensor bolt. Tighten Tighten the crankshaft position bolt to 106 lb in.
Oil Pump Installation 1. Inspect for properly installed pins (oil pump locator).
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Important: DO not reuse the oil pump driveshaft retainer. During assembly, install a NEW oil pump driveshaft retainer. 2.Install the oil pump. 3.Position the oil pump onto the pins.
Notice: Refer to Fasteners Notice in Cautions and Notices. 4. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten Tighten the oil pump bolt to 90 N•m (66 lb ft.). Apply Red Locktite
Oil Pan Installation 1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of Ultra Gray RTV or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces.
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Important: Always install a NEW oil pan gasket. The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. 2. Install the NEW oil pan gasket into the groove in the oil pan.
Important: The oil pan alignment must always be flush or forward no more than 0.3 mm (0.011 in) from the rear face of the engine block. 3. Install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing.
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Notice: Refer to Fastener Notice in Cautions and Notices. Tighten the oil pan bolts and nuts in sequence (1-12). Tighten Tighten the oil pan bolts to 25 N•m (18 lb ft.).
4. 5.
Install a NEW oil pan drain plug seal (O-ring) onto the oil pan drain plug. Install the oil pan drain plug into the oil pan. Tighten Tighten the oil pan drain plug to 21 lb ft.
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Crankshaft Balancer Installation Tools Required J 23523-F Balancer Remover and Installer 1. Look to ensure that the front groove pin (crankshaft balancer) is installed in the proper location (if applicable).
Notice: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. 2. Apply a small amount of Ultra Gray RTV or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint. 3. Apply a light amount of oil to crankshaft mating surface on balancer. 4. Align the keyway of the crankshaft balancer with the crankshaft balancer key. 5. Install the crankshaft balancer onto the end of the crankshaft.
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6. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. 6.1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten Tighten the J 23523-F plate bolts to 25 N•m (18 lb ft.). 6.2. Install the J 23523-F screw into the end for the crankshaft. 6.3. Install the J 23523-F bearing, the washer and the nut onto the J 23523-F screw. 6.4. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring. 7. Remove the J 23523-F.
Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the crankshaft pulley and bolts. Tighten Tighten the crankshaft pulley bolts to 35 lb ft. with Blue Locktite
9. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine.
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10. Install the crankshaft balancer washer and the bolt. Tighten Tighten the crankshaft balancer bolt to 58 lb ft.
Valve Lifter Installation 1. Apply engine assembly lubricant or equivalent to the valve lifter rollers. Clean motor oil will also suffice. Important: If reusing the valve lifters, install the valve lifters in the original positions. 2. Install the valve lifters.
Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the valve lifter pushrod guides. Tighten Tighten the valve lifter pushrod guide bolts to 16 N•m (12 lb ft.).
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Cylinder Head Installation (Left) Tools Required J 36660 Electronic Torque Angle Meter 1. Clean the cylinder head gasket surfaces on the engine block. 2. Inspect the dowel pins (cylinder head locators) for proper installation. 3. Clean the cylinder head gasket surfaces on the cylinder head.
Important: Do not use any type of sealer on the cylinder head gasket (unless specified). 4. Install the NEW cylinder head gasket in position over the dowel pins (cylinder head locators).
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
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Important: Cylinder head bolts are torque-to-yield. New bolts should be installed during the installation procedure. 6. Apply PTFE sealant or equivalent to the underside of the bolt head and the threads of the NEW cylinder head bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the cylinder head bolts finger tight. Note: Bolt number locations refer to torque sequence in steps 12 and 13. 8. Place the (5) long bolts into positions 1, 4,5,8,9. 9. Place the (2) medium bolts into positions 12 and 13. 10. Place the (6) short bolts into positions 2, 3,6,7,10,11. 11. Snug each bolt.
12. Tighten the cylinder head bolts in sequence on the first pass. Tighten Tighten the bolts in sequence on the first pass to 30 N•m (22 lb ft.). 13. Use the J 36660 in order to tighten the cylinder head bolts in sequence on the final pass. • Tighten the long bolts (1,4,5,8 and 9) on the final pass in sequence to 75 degrees. • Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. • Tighten the short bolts (2,3,6,7,10 and 11) on the final pass in sequence to 55 degrees.
14. Install the spark plug wire support and bolts. Tighten Tighten the spark plug wire support bolts to 12 N•m (106 lb in).
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15. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 0.030” 16. Install the spark plugs. Tighten • Tighten the spark plugs for a USED cylinder head to 15 N•m (11 lb ft.) • Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N•m (22 lb ft.).
17. If reusing the engine coolant temperature gauge sensor (if applicable), apply PTFE sealant or equivalent to the threads of the engine coolant temperature gauge sensor. 18. Install the engine coolant temperature gauge sensor (if applicable). Tighten Tighten the engine coolant temperature gauge sensor to 20 N•m (15 lb ft.).
19. If reusing the engine coolant temperature sensor (if applicable), apply PTFE sealant or equivalent to the threads of the engine coolant temperature sensor. 20. Install the engine coolant temperature sensor (if applicable). Tighten Tighten the engine coolant temperature sensor to 20 N•m (15 lb ft.).
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Cylinder Head Installation (Right) Tools Required J 36660 Electronic Torque Angle Meter 1. Clean the cylinder head gasket surfaces on the engine block. 2. Inspect the dowel pins (cylinder head locators) for proper installation. 3. Clean the cylinder head gasket surfaces on the cylinder head.
Important: Do not use any type of sealer on the cylinder head gasket (unless specified). 4. Install the NEW cylinder head gasket in position over the dowel pins (cylinder head locators).
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
Important: Cylinder head bolts are torque-to-yield. New bolts should be installed during the installation procedure. 6. Apply PTFE sealant or equivalent to the underside of the bolt head and the threads of the NEW cylinder head bolts. Notice: Refer to Fastener Notice in Cautions and Notices.
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7. Place the (5) long bolts into positions 1, 4,5,8,9. 8. Place the (2) medium bolts into positions 12 and 13. 9. Place the (6) short bolts into positions 2, 3,6,7,10,11. Snug each bolt.
10. Tighten the cylinder head bolts in sequence on the first pass. Tighten Tighten the bolts in sequence on the first pass to 30 N•m (22 lb ft.). 11. Use the J 36660 in order to tighten the cylinder head bolts in sequence on the final pass. • Tighten the long bolts (1,4,5,8 and 9) on the final pass in sequence to 75 degrees. • Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. • Tighten the short bolts (2,3,6,7,10 and 11) on the final pass in sequence to 55 degrees.
12. Install the spark plug wire support and bolts. Tighten Tighten the spark plug wire support bolts to 12 N•m (106 lb in). 13. Remove the front spark plug wire support bolt. The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.
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14. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to 0.030” 15. Install the spark plugs. Tighten • Tighten the spark plugs for a USED cylinder head to 15 N•m (11 lb ft.) • Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N•m (22 lb ft.).
Valve Rocker Arm and Push Rod Installation Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. We put motor oil on push rods 1. Install the valve pushrods. Apply a light coat of engine assembly lube or motor oil to the ends of the pushrod. Intake and exhaust push rods are different Intake marked with 7.271.080 Exhaust marked with 7.365.080
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2. Apply engine assembly lube , or equivalent to the following valve rocker arm contact surfaces: • Valve pushrod socket (1) • Roller pivot (2) • Valve stem tip (3) • Rocker arm bolt
Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the valve rocker arm assemblies as follows: Turn the crank until cylinders 1 & 4 are at top dead center. This will position the lifter in the resting position. Torque the rocker bolts when the lifters are in this position only. Continue turning crank to put cylinders 3 & 6 and then 5 & 2 at TDC for rocker bolt torqueing. Note: Intake and Exhaust rocker arms are different. Tighten: Torque each bolt to 30 ft./lbs.
4. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 5. Tighten the valve rocker arm bolts. Tighten Tighten the valve rocker arm bolts to 30 N•m (22 lb ft.).
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Intake Manifold Installation Notice: Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly. 1. Apply a 4.0 mm (0.157 in) patch of Ultra Gray RTV or equivalent to the cylinder head side of the lower intake manifold gasket at each end. Important: The lower intake manifold gasket must be installed while the adhesive is still wet to the touch. 2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.
Notice: Care must be used to apply the correct amount of sealant onto the gaskets. Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly. Important: The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch. 3. Apply a 5.0 mm (0.197 in) bead of Ultra Gray RTV or equivalent to the front top of the engine block. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
4. Apply a 5.0 mm (0.197 in) bead of Ultra Gray RTV or equivalent to the rear top of the engine block. Extend the adhesive bead roughly 0.5 to 1 inch onto each lower intake manifold gasket.
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5. Install the lower intake manifold onto the engine block. Notice: Refer to Fastener Notice in Cautions and Notices. 6. If reusing the fasteners, apply PTFE Sealant or equivalent to the threads of the lower intake manifold bolts. 7. Install the lower intake manifold bolts.
Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. 8. Tighten the lower intake manifold bolts. Tighten 8.1. Tighten the bolts in sequence (1-8) on the first pass to 3 N•m (27 lb in). 8.2. Tighten the bolts in sequence (1-8) on the first pass to 12 N•m (106 lb in). 8.3. Tighten the bolts in sequence (1-8) on the first pass to 15 N•m (132 in lb).
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Distributor Installation Important: The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at Top Dead Center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke.
1. Remove the distributor cap bolts. 2. Remove the distributor cap.
3. Install a NEW distributor gasket onto the distributor.
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4. Align the indent hole on the driven gear with the paint mark on the distributor housing. 5. Ensure that the distributor rotor segment points to the cap hold area.
6. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary. 7. Align the flat (1) in the distributor housing toward the front of the engine.
8. Install the distributor and distributor clamp. The flat in the distributor housing must point toward the front of the engine.
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9. Once the distributor is fully seated, align the distributor rotor segment with the number 6 pointer (1) that is cast into the distributor base. If the distributor rotor segment does not come with a few degrees of the number 6 pointer (1), the gear mesh between the distributor and camshaft may be off a tooth or more. Repeat the procedure again in order to achieve proper alignment.
Notice: Refer to Fastener Notice in Cautions and Notices. 10. Install the distributor clamp bolt. Tighten Tighten the distributor clamp bolt to 25 N.m (18 lb ft.).
11. Install the distributor cap and NEW distributor cap bolts. Tighten Tighten the distributor cap bolts to 2.4 N.m (21 lb in).
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Valve Rocker Arm Cover Installation (Left) Important: Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover grommets. 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover. 2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in). Torque from the center out.
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Valve Rocker Arm Cover Installation (Right) Important: Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover bolt grommets. 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover. 2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in). Torque from the center out.
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Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the valve rocker arm cover bolts. Tighten Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in). Torque from the center out.
Oil Level Indicator and Tube Installation 1. Apply PTFE sealant or equivalent around the oil level indicator tube 13 mm (0.50 in) below the tube bead. 2. Install the oil level indicator tube into the engine block. Rotate the oil level indicator tube into position. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the oil level indicator tube bolt. Tighten Tighten the oil level indicator tube bolt to 12 N•m (106 lb in).
4. Install the oil level indicator into the oil level indicator tube, if required.
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Water Pump Installation Tools Required J 41240 Fan Clutch Remover and Installer 1. If reusing the fasteners, apply PTFE sealant or equivalent to the threads of the water pump bolts. 2. Install the water pump and the NEW water pump gaskets. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the water pump bolts. Tighten Tighten the water pump bolts to 45 N.m (35 lb ft.).
Important: After final assembly, the water pump inlet hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose. 4. Install the water pump inlet hose and the water pump inlet hose clamps.
5. Install the fan and water pump pulley and bolts using the J 41240. Tighten Tighten the fan and water pump pulley bolts to 35 lb ft.
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Exhaust Manifold Installation (Left) 1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold. 3. Install the spark plug wire shields. Notice: Refer to Fastener Notice in Cautions and Notices. 4. If reusing the fasteners, apply Blue Loctite or equivalent to the threads of the exhaust manifold bolts and stud. 5. Install the exhaust manifold bolts and stud. Tighten 5.1. Tighten the exhaust manifold bolts and stud on the final pass to 35 lb ft. 6. Install the spark plug wires to the spark plug wire retainers. 7. Install the spark plug wires onto the spark plugs.
Exhaust Manifold Installation (Right) 1. Install the NEW exhaust manifold gaskets.
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2. Install the exhaust manifold. 3. Install the spark plug wire shields. Notice: Refer to Fastener Notice in Cautions and Notices. 4. If reusing the fasteners, apply Blue Loctite or equivalent to the threads of the exhaust manifold bolts and stud. 5. Install the exhaust manifold bolts and stud. Tighten 5.1. Tighten the exhaust manifold bolts and stud on the final pass to 35 lb ft. 6. Install the spark plug wires to the spark plug wire retainers. 7. Install the spark plug wires onto the spark plugs.
Clutch Pilot Bearing Installation Caution: Refer to Safety Glasses Caution in Cautions and Notices. 1. Install the NEW clutch pilot bearing using a suitable clutch pilot bearing installation tool. 2. Measure to ensure the proper installation depth is obtained.
Engine Flywheel Installation Important: If replacing the engine flywheel (manual transmission), note the position of the original flywheel weights (if applicable). Flywheel weights must be installed into the new engine flywheel in the same location as the old flywheel weights were in the old engine flywheel. Note the position of the flywheel weights and install the NEW flywheel weights as required. A properly installed flywheel weight will be flush or slightly below flush with the face of the engine flywheel.
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1. Install the engine flywheel (1) or (2) to the crankshaft. Align the engine flywheel locator hole to the flywheel locator pin.
Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the engine flywheel bolts. Tighten Tighten the engine flywheel bolts in sequence (1-6) to 60 lb ft.
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Engine Set-Up and Testing After overhaul, the engine must be tested before it is installed in the vehicle. If a suitable test stand is not available, the following procedures can be used after the engine is installed in the vehicle. 1. Fill the crankcase with the proper quantity and grade of engine oil. 2. Add engine oil supplement GM P/N 1052367 or equivalent to the engine oil. Notice: DO NOT use cooling system seal tabs (or similar compounds) unless otherwise instructed. The use of cooling system seal tabs (or similar compounds) may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. 3. Fill the cooling system with the proper quantity and grade of coolant. 4. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding. 5. Start the engine and listen for unusual noises. 6. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure. If necessary, install an oil pressure gauge and measure the engine oil pressure. 7. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature. 8. Listen for improperly adjusted or sticking valves, sticking valve lifters or other unusual noises. 9. Inspect for oil and/or coolant leaks while the engine is operating. 10. Verify that the distributor is properly positioned. 11. Perform a final inspection for the proper engine oil and coolant levels.
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Description and Operation Engine Component Description Balance Shaft The cast iron balance shaft is mounted in the crankcase above and in-line with the camshaft. A camshaft gear drives the gear attached to the balance shaft. The front end of the balance shaft is supported by a ball-type bearing. The rear end of the balance shaft uses a sleeve-type bearing. Camshaft The steel camshaft is supported by four bearings pressed into the engine block. The camshaft timing chain sprocket mounted to the front of the camshaft is driven by the crankshaft sprocket through a camshaft timing chain. Crankshaft The cast nodular iron crankshaft is supported by four crankshaft bearings. The number four crankshaft bearing at the rear of the engine is the end thrust bearing. The crankshaft bearings are retained by bearing caps that are machined with the engine block for proper alignment and clearances. The crankshaft position sensor reluctor ring has three lugs used for crankshaft timing and is constructed of powdered metal. The crankshaft position sensor reluctor ring has a slight interference fit onto the crankshaft and an internal keyway for correct positioning. Cylinder Heads The cast iron cylinder heads have one intake and one exhaust valve for each cylinder. A spark plug is located between the valves in the side of the cylinder head. The valve guides and seats are integral to the cylinder head. The 4.3L heavy duty applications have pressed in exhaust valve seats. The valve rocker arms are positioned on the valve rocker arm supports and retained by a bolt. Engine Block The cast iron engine block has six cylinders arranged in a V shape with three cylinders in each bank. Starting at the front side of the engine block, the cylinders in the left bank are numbered 1-3-5 and cylinders in the right bank are numbered 2-4-6 (when viewed from the rear). The firing order of the cylinders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets. Exhaust Manifolds The cast iron exhaust manifolds direct exhaust gases from the combustion chambers to the exhaust system. The left side exhaust manifold has a port for the EGR valve inlet pipe. Valve Train Motion is transmitted from the camshaft through the hydraulic roller valve lifters and the tubular valve
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pushrods to the roller type valve rocker arms. The roller type valve rocker arm pivots on a needle type bearing in order to open the valve. The valve rocker arms for each bank of cylinders are mounted to a one piece valve rocker arm support. Each valve rocker arm is retained on the valve rocker arm support and the cylinder head by a bolt. The hydraulic valve lifters keep all the parts of the valve train in constant contact. Each hydraulic valve lifter acts as an automatic adjuster and maintains zero lash in the valve train. This eliminates the need for periodic valve adjustment.
Drive Belt System Description The drive belt system consists of the following components: • The drive belt • The drive belt tensioner • The drive belt idler pulley • The crankshaft balancer pulley • The accessory drive component mounting brackets • The accessory drive components – The generator – The A/C compressor, if equipped – The engine cooling fan, if belt driven – The water pump, if belt driven
The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or ply’s containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory.
New Product Information The purpose of New Product Information is to highlight or indicate important product changes from the previous model year. Changes may include one or more of the following items:
• • • • • • • •
A component comparison from the previous year Fastener changes Torque values and/or fastener tightening strategies
• Cylinder head bolts, the crankshaft bearing cap bolts, the connecting rod bolts and balance shaft bolt apply a torque angle strategy. In an onvehicle situation where a torque angle meter may not fit into the vehicle packaging, a three step tightening process may be followed using a torque wrench.
• Certain fasteners should not be reused. Bolts, studs or other fasteners that must be replaced will be called out in the specific service procedures. Changed Engine Specifications Engine mechanical specifications are listed at the beginning of this manual. New Sealants and/or Adhesives No new sealants or adhesives have been added. Disassembly and Assembly Procedure Revisions
• Valve rocker arm and pushrod • Timing chain and sprockets • Discard all used gaskets, seals or O-ring seals unless otherwise indicated Gaskets, seals or O-ring seals that can be reused will be identified in the specific service procedure. Engine Mechanical Diagnostic Procedure Revisions
• Valve Train diagnostic information is now provided in table form. Potential or probable causes are supplied for each specific concern.
• Engine Noise diagnostic information is now
Disassembly and assembly procedure revisions
provided in table form. Potential or probable causes are supplied for each specific concern. New Special Tools Required
Engine mechanical diagnostic procedure revisions
No new special tools are required.
Changed engine specifications New sealants and/or adhesives
New special tools required
Component Comparison
• • • • •
Torque Values and/or Fastener Tightening Strategies
Eliminated the oil filter adapter assembly Revised the water pump seal Revised the engine coolant thermostat New roller type timing chain and sprockets New roller pivot type valve rocker arm assemblies using a one piece valve rocker arm support to replace the ball pivot type valve rocker arm system
• Cylinder heads revised using dry holes for the valve rocker arm bolts
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Lubrication Engine Lubrication
Full pressure lubrication, through a full-flow oil filter is supplied by a gear-type oil pump. Oil is drawn up through the oil pump screen and passes through the pump to the oil filter. The oil filter is full-flow paper element unit with an anti-drain back valve. An oil filter bypass valve is used to ensure adequate oil supply, in the event the filter becomes plugged or develops excessive pressure drop. Filtered oil flows into the main gallery and then to the camshaft, the balance shaft, the rear bearing and the crankshaft bearings. The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the valve lifters through the hollow valve pushrods to the valve rocker arms. Oil drains back to the crankcase through the oil drain holes in the cylinder head. The camshaft timing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oil splash.
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Cleanliness and Care • Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.
• When any internal engine parts are serviced, care and cleanliness is important.
• When components are removed for service, the components should be marked, organized or retained in a specific order for re-assembly.
• At the time of installation, the components should be installed in the same location and with the same mating surface as when removed.
• An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch. The surfaces should be protected to avoid component damage.
• Apply a liberal amount of clean engine oil to friction areas during assembly.
• Proper lubrication will protect and lubricate friction areas during initial operation.
Replacing Engine Gaskets Gasket Reuse and Applying Sealant
• Do not reuse any gasket unless specified. • Gaskets that can be reused will be identified in the service procedure.
• Do not apply sealant to any gasket or sealing surface unless specified in the service procedure. Separating Components
• Use a rubber mallet in order to separate the components.
• Bump the part sideways in order to loosen the components.
• Bumping of the component should be done at bends or reinforced areas of the component to prevent distortion of the components. Cleaning Gasket Surfaces
• Use care to avoid gouging or scraping the sealing surfaces.
the component sealing surfaces.
– Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil. This fine grit is abrasive and can cause internal engine damage. Assembling Components
• Assemble components using only the sealant (or equivalent) that is specified in the service procedure.
• Sealing surfaces must be clean and free of debris or oil.
• Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
• Components requiring lubrication will be identified in the service procedure.
• Apply only the amount of sealant specified in the service procedure to a component.
• Do not allow the sealant to enter into any blind threaded holes, as the sealant may prevent the fastener from clamping properly or cause component damage when tightened.
• Tighten fasteners to the proper specifications. DO NOT over tighten the fasteners.
Use of RTV and Anaerobic Sealer Sealant Types Important: The correct sealant and amount of sealant must be used in the proper location to prevent oil leaks, coolant leaks or the loosening of the fasteners. DO NOT interchange the sealants. Use only the sealant (or equivalent) as specified in the service procedure. The following 2 major types of sealant are commonly used in engines:
• Aerobic sealant [Room Temperature Vulcanizing (RTV)]
• Anaerobic sealant, which include the following: – Gasket eliminator – Pipe – Threadlock
to clean the gasket surfaces.
Aerobic Type Room Temperature Vulcanizing (RTV) Sealant Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type of sealant is used where 2 components (such as the intake manifold and the engine block) are assembled together.
– These methods of cleaning can cause damage to
Use the following information when using RTV sealant:
• Use a plastic or wood scraper in order to remove all the sealant from the components. Do not use any other method or technique to remove the sealant or the gasket material from a part.
• Do not use abrasive pads, sand paper or power tools
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• Do not use RTV sealant in areas where extreme temperatures are expected. These areas include:
– The exhaust manifold – The head gasket – Any other surfaces where a different type of sealant is specified in the service procedure
• Always follow all the safety recommendations and the directions that are on the RTV sealant container.
• Use a plastic or wood scraper in order to remove all the RTV sealant from the components. Important: Do not allow the RTV sealant to enter any blind threaded holes, as it may prevent the fasteners from clamping properly or cause damage when the fastener is tightened. The surfaces to be sealed must be clean and dry.
• Use a RTV sealant bead size as specified in the service procedure.
• Apply the RTV sealant bead to the inside of any bolt hole areas.
• Assemble the components while the RTV sealant is still wet to the touch (within 3 minutes). Do not wait for the RTV sealant to skin over.
• Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT over tighten the fasteners.
• The threaded surfaces must be clean and dry. • Apply the threadlock sealant as specified on the threadlock sealant container. Important: Fasteners that are partially torqued and then the threadlock sealant allowed to cure more than five minutes, may result in incorrect clamp load of assembled components.
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Anaerobic Type Gasket Eliminator Sealant Anaerobic type gasket eliminator sealant cures in the absence of air. This type of sealant is used where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no sealant or gasket is readily noticeable, then the 2 parts were probably assembled using an anaerobic type gasket eliminator sealant. Use the following information when using gasket eliminator sealant: •
• Always follow all the safety recommendations and directions that are on the gasket eliminator sealant container.
• Apply a continuous bead of gasket eliminator sealant to one
– – – •
flange. The surfaces to be sealed must be clean and dry. Important: Do not allow the gasket eliminator sealant to enter any blind threaded holes, as the gasket eliminator sealant may prevent the fasteners from clamping properly, seating properly or • cause damage when the fastener is tightened. • Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket eliminator sealant on the sealing surface. Important: Gasket eliminator sealed joint fasteners that are partially torqued and the gasket eliminator sealant allowed to cure more than 5 minutes, may result in incorrect shimming and sealing of the joint.
• Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT over tighten the fasteners.
• After properly tightening the fasteners, remove the excess gasket eliminator sealant from the outside of the joint. Anaerobic Type Threadlock Sealant
the proper torque specification. DO NOT over tighten the fasteners. Anaerobic Type Pipe Sealant Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type of sealant is used where 2 parts are assembled together and require a leak proof joint. Use the following information when using pipe sealant: Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: The exhaust manifold The head gasket Surfaces where a different sealant is specified Always follow all the safety recommendations and directions that are on the pipe sealant container. Their surfaces to be sealed must be clean and dry. Use a pipe sealant bead of the size or quantity as specified in the service procedure. Important: Do not allow the pipe sealant to enter any of the blind threaded holes, as the pipe sealant may prevent the fastener from clamping properly, or cause component damage when the fastener is tightened.
• Apply the pipe sealant bead to the inside of any bolt hole areas.
• Apply a continuous bead of pipe sealant to 1 sealing surface.
• Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT over tighten the fasteners.
Separating Parts Important: Many internal engine components will
•
Anaerobic type threadlock sealant cures in the absence of air. This develop specific wear patterns on their friction surfaces. type of sealant is used for thread locking and sealing of bolts, fittings, nuts and studs. This type of sealant cures only When disassembling the engine, internal components when confined between 2 close fitting metal surfaces. MUST be separated, marked and organized in a way to ensure reinstallation to the original location and Use the following information when using threadlock sealant: position. Always follow all safety recommendations and directions that Mark or identify the following components: are on the threadlock sealant container.
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• • • • • • • •
Piston and the piston pin Piston to the specific cylinder bore Piston rings to the specific cylinder bore Connecting rod to the crankshaft journal Connecting rod to connecting rod cap Crankshaft bearings and connecting rod bearings Engine camshaft and valve lifters Valve lifters, valve rocker arms and valve rocker arm supports
• Valve to the valve guide • Valve spring to cylinder head location • Engine block bearing cap location and direction • Oil pump drive and driven gears Tools and Equipment Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. The tools (or equivalents) are specially designed to
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quickly and safely accomplish the operations for which the tools are intended. The use of special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners. To properly service the engine assembly, the following items should be readily available:
• • • • •
Approved eye protection and safety gloves A clean, well-lit, work area A suitable parts cleaning tank A compressed air supply Trays or storage containers to keep parts and fasteners organized
• An adequate set of hand tools • Approved engine repair stand • An approved engine lifting device that will adequately support the weight of the components
Special Tools and Equipment Illustration
Tool Number/Description
J 3049-A Valve Lifter Remover
J 5239 Connecting Rod Bolt Guide Set
J 5590 Installer
J 5830-02 Valve Guide Reamer Set
J 5825-A Crankshaft Gear Remover
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Illustration
Tool Number/Description
J 7872 Magnetic Base Dial Indicator
J 8001 Dial Indicator Set
J 8037 Ring Compressor
J 8062 Valve Spring Compressor
J 8087 Cylinder Bore Gauge
Illustration
Tool Number/Description
J 8089 Carbon Removing Brush
Illustration
Tool Number/Description
J 24086-C Piston Pin Remover/Installer
J 8092 Universal Driver Handle
J 24270 Cylinder Bore Ridge Reamer
J 9666 Valve Spring Tester
J 26941 Bushing/Bearing Remover
J 33049
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J 21882 Oil Suction Pipe Installer
Camshaft Bearing Service Kit
J 23523-F Balancer Remover and Installer
J 35621-B Rear Main Seal Installer
Illustration
Tool Number/Description
J 36660 Electronic Torque Angle Meter
J 36996 Balance Shaft Installer
J 38834 Balance Shaft Service Kit
J 41240 Fan Clutch Remover and Installer
J 41427 Engine Lift Bracket
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Illustration
Tool Number/Description
J 41712 Oil Pressure Switch Socket
SK6970 Valve Stem Seal Installer (shown as item 1 & 2)
J 43276 Clutch Pilot Bearing Remover
J 43690 Rod Bearing Clearance Checking Tool
Please e-mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2121 W. Sam Houston Parkway N. Houston, Texas 77043-2305 Email: lift.central@mcfa.com
Mitsubishi Forklift Trucks
Service Manual
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PSI 4X LPG Engine
99739-7C100
Mitsubishi Caterpillar Forklift America Inc. 2121 W. Sam Houston Parkway N.Houston, TX 77043-2305 © 2016 MCFA. All rights reserved. All registered trademarks are the property of their respective owners. Some products may be shown with optional equipment. 99739-7C100
05/16
Service Manual Chassis & Mast GC35K GC40K GC40K GC45K GC45K GC55K GC55K GC60K GC70K GC70K
AT87B-10011-up
STR SWB STR STR
AT87B-10011-up AT87B-10011-up AT87B-10011-up AT87B-10011-up AT88B-10011-up AT88B-10011-up AT89B-10011-up
STR
AT89B-10011-up AT89B-10011-up
For use with PSI 4X LPG Engine Service Manual and Fuel System Supplements
99739-8D100
FOREWORD This service manual is a guide for servicing Cat® forklift trucks. The long productive life of your forklift truck(s) depends on regular and proper servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair, or rebuild the forklift truck. The descriptions, illustrations, and specifications contained in this manual are for forklift trucks with serial numbers in effect at the time of printing. Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference. The PSI 4.3 liter engine’s fuel system was changed to comply with the EPA guidelines in 2004 and again at the beginning of 2007. This manual has minimal information on the fuel systems. Please see the Fuel System Supplement for information regarding the Multi Port Fuel Injection System (MPFI). Also see the engine service manual for general engine repair or rebuild. For the items pertaining to the engine, see the following service manuals: • PSI 4.3L 4X Engine Service Manual Safety related signs
Meanings
R WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
R CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTE
NOTE indicates a condition that can cause damage to or shorten the service life of the machine.
Unauthorized copying and lending is prohibited.
i
1. Safety R WARNING -
-
The proper safe lubrication and maintenance for these forklift trucks, recommended by Mitsubishi Forklift Trucks, are outlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication or maintenance on these forklift trucks. Incorrect performance of lubrication or maintenance procedures is dangerous and could result in injury or death. The serviceman or mechanic may be unfamiliar with many of the systems on this forklift truck. This makes it important to use caution when performing service work. DO NOT operate these forklift trucks unless you have read and understood the instructions in the SERVICE MANUAL. Incorrect forklift truck operation is dangerous and could result in injury or death.
A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the forklift truck components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. The following is a list of basic precautions that should always be observed: (1) Read and understand all warning plates and decals on the forklift truck before operating, lubricating or repairing the product. (2) Always wear protective glasses and protective shoes when working around forklift trucks. In particular, wear protective glasses when using a hammer or sledge on any part of the forklift truck or its attachments. (3) Use welders gloves, hood/goggles, apron, and other protective clothing appropriate to the welding job being performed. DO NOT wear loose fitting or torn clothing. Remove all rings from fingers when working on machinery. (4) DO NOT work on any forklift truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the forklift truck before performing any disassembly. (5) Lower the forks or other implements to the ground before performing any work on the forklift truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from falling unexpectedly. (6) Use steps and assist grips (if applicable) when mounting or dismounting a forklift truck. Clean any mud or debris from steps, walkways, or work platforms before using. Always face forklift truck when using steps, ladders, and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. (7) To avoid back injury, use a hoist when lifting components which weigh 23 kg (51 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (8) To avoid burns, be alert of the hot sections and hot fluids in lines, tubes, and compartments, even when forklift truck is idle or off.
ii
(9) Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any springs or other pressures, before removing the last two bolts or nuts completely. (10) Be careful when removing filler caps, breathers, and plugs on the forklift truck. Wrap a cloth around the cap or plug to prevent being sprayed or splashed by liquids under pressure. Be aware that the danger of being sprayed or splashed is ever greater if it is immediately after stopping the forklift truck, as fluids is very hot. (11) Use well maintained tools in a proper way. (12) Install all fasteners with same part number. DO NOT use a lesser quality fastener if replacements are necessary. (13) If possible, make all repairs with the forklift truck parked on level, hard surface. Block forklift truck so it does not roll while working on or under forklift truck. (14) Before starting to work on forklift truck, hang "DO NOT Operate" tag in the Operator Compartment. (15) Repairs, which require welding, should be performed only with the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods, or wire to provide a weld metal strength equivalent at least to that of parent metal. (16) DO NOT damage wiring during the removal process. DO NOT reuse the damaged wiring. Install the wiring making sure not to contact sharp corners or hot parts. Place wiring away from oil pipe. (17) Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. (18) Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position. (19) Loose or damaged fuel, lubricant, hydraulic lines, tubes, and hoses could cause fires. DO NOT bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes, and hoses carefully. DO NOT check for leaks with your hands. Pin hole (very small) leaks could result in a high velocity oil stream that will be invisible close to the hose. This oil could penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.
(20) Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube, or seal failure, must be installed correctly. (21) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Place blocks to prevent a device from falling if it is in the raised position. Release the residual pressure when removing a pressurized device. (22) DO NOT operate a forklift truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
2. Symbols and Abbreviations Symbol or abbreviation
Meanings
OP.
Option
R1/4
Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8
Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A
Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8
Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
3. Units -
SI Units are used in this manual. The following table shows the conversion of SI unit and customary unit.
Item Force
SI unit
Metric unit
1N
0.102 kgf
Yard-pound unit 0.225 lbf 2
Pressure
1 MPa
10.1972 kgf/cm
145.038 psi
Torque
1 N·m
0.102 kgf·m
0.7376 lbf·ft
1 mm
-
0.039 in.
1m
-
3.281 feet
Weight
1 kg
-
2.205 lb
Temperature
1 °C
-
°F=1.8 x °C+32
Volume
1L
-
0.264 US.gal.
Length
iii
TABLE OF CONTENTS
Chapter 1 GENERAL INFORMATION 1. 2. 3. 4. 5. 6. 7.
Model View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Applicable Lift Truck Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Chassis and Mast Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Chapter 2 COOLING SYSTEM 1. 2. 2.1 2.2 2.3
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Removing Fan Belt (Method by Removing Radiator) . . . . . . . . . . . . . . . . . . .2-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Chapter 3 ELECTRICAL SYSTEM 1. 1.1
2. 2.1 2.2 2.3
3. 3.1 3.2 3.3
4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13
6. 6.1
Electrical Components and Wiring Outline . . . . . . . . . . . . . . . . . . . . . .3-1 Locations of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Console Box Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Disassembling Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Assembling Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Disassembling Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Assembling Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Warning Icons and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Main Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Key Switch (With Anti-restart Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Light Switch and Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Direction (FNR) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Stop Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Speed Sensor (Pulse Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Head Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19 Rear Combination Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 List of Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Mast Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 Mast interlock system functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
TOC-1
TABLE OF CONTENTS
7. 7.1
8. 8.1
9. 9.1 9.2 9.3
10.
Driving Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Driving Interlock System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Neutral System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Neutral System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Battery and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment . . . . . 3-24 Specific Gravity Reading and State of Charge . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Precautions for Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Wire Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
10.1 List of Wire Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
11. 11.1 11.2 11.3 11.4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-26 3-26 3-27 3-27
Chapter 4 POWER TRAIN 1. 2. 3. 3.1 3.2
4. 4.1 4.2 4.3 4.4
5. 5.1
6. 6.1 6.2 6.3
7. 7.1
8.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Structure (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Structure (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Reduction Ratio (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Reduction Ratio (6.0 ton 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Sequence (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Sequence (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Sequence (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5 4-6 4-7 4-8
Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removing Transmission and Reduction Differential . . . . . . . . . . . . . 4-10 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installing Transmission and Reduction Differential . . . . . . . . . . . . . . 4-12 Suggestions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Chapter 5 POWERSHIFT TRANSMISSION 1. 1.1
2. 2.1 2.2 2.3 2.4
TOC-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1-Speed Transmission (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Transmission 1-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Powershift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
TABLE OF CONTENTS
2.5
3. 3.1 3.2
4. 4.1 4.2
5. 5.1 5.2 5.3 5.4 5.5
6. 6.1 6.2
7. 7.1 7.2 7.3 7.4 7.5 7.6 7.7
8. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11
9. 9.1
10.
Powershift Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Disassembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
After Disassembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Pump Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Turbine Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Pilot Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Flexible Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Assembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 Control Valve and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 Pump Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 Countershaft (2nd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 Forward-Reverse Clutch Shaft (Current Production) . . . . . . . . . . . . . . . . . . .5-17 Forward-Reverse Clutch Shaft (First Production) . . . . . . . . . . . . . . . . . . . . . . .5-18
Inspection and Repair After Disassembling Transmission . . . . . . . .5-19 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 Pump Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Stator Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Clutch Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Friction Plates and Mating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Clutch Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 Clutch Gears (Forward and Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 Turbine Shaft and Clutch Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22 Clutch Shaft, Countershaft, and Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . .5-22 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22 Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
Assembling Forward-Reverse Clutch Shaft Subassembly . . . . . . . . .5-23 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Assembling Forward-Reverse Clutch Shaft (1st Shaft) . . . . . . . . . . . .5-24
10.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 10.2 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 10.3 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
11.
Assembling Output Shaft (4th Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
11.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26 11.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
12.
Assembling Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
12.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 12.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
TOC-3
TABLE OF CONTENTS
13.
Assembling Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
13.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 13.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
14.
Assembling Pump Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
14.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 14.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
15. 16.
Assembling Control Valve and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Disassembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
16.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
17. 18.
After Disassembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Assembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
18.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 18.2 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
19. 19.1 19.2 19.3 19.4 19.5 19.6
20.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Inching Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Stall Speed Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 10 Meters (33-ft) Starting Acceleration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Adjusting Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Adjusting Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
20.1 Automatic 2-speed Transmission (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . 5-40
21. 21.1 21.2 21.3 21.4 21.5 21.6 21.7 21.8
22. 22.1 22.2 22.3 22.4 22.5 22.6 22.7 22.8
23.
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Transmission 2-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Automatic 2-speed Change Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Powershift Transmission Hydraulic System Schematic 1-Speed . . . . . . . . 5-45 Powershift Transmission Hydraulic System Schematic 2-Speed . . . . . . . . 5-46 Hydraulic Control (Forward 1st Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 Hydraulic Control (Forward 2nd Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Control Valve and Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Output Shaft (4th Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Input Shaft (1st Shaft / Current Production) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 Input Shaft (1st Shaft ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Countershaft (2nd Shaft / Current Production) . . . . . . . . . . . . . . . . . . . . . . . . 5-57 Countershaft (2nd Shaft / First Production) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
After Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
23.1 Input Shaft, Servo Case, and Sealrings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
24. 24.1 24.2 24.3 24.4
TOC-4
Assembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 Ball Bearing and Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Countershaft (2nd Shaft) and Input Shaft (1st Shaft) . . . . . . . . . . . . . . . . . . Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-60 5-61 5-63 5-64
TABLE OF CONTENTS
24.5 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65 24.6 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66
25.
Assembling Control Valve and Side Cover . . . . . . . . . . . . . . . . . . . . . . .5-67
25.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-67
26.
Disassembling Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68
26.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68
27. 28.
After Disassembling Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68 Assembling Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69
28.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 28.2 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69
29. 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.8 29.9
30.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 Hydraulic Pressure Test Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-70 2nd Speed/Auto Selector Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-71 2-Speed Transmission Electrical Systems Part Numbers . . . . . . . . . . . . . . . .5-71 ECU Self-Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-72 ECU Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-72 Pulse Generator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 Solenoid Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 Oscilloscope Shop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-74
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-76
30.1 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-76
31. 31.1 31.2 31.3 31.4 31.5 31.6 31.7 31.8
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-81 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-81 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-84 Torque Converter Drive Transmission (1-Speed Transmission) . . . . . . . . .5-85 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) 5-86 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) 5-87 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-89 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-90
Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 1. 2. 3. 3.1
4. 5. 5.1 5.2 5.3
6. 7. 8. 8.1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Removing Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Installing Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Removing Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Installing Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 Removing and Installing Reduction and Differential . . . . . . . . . . . . .6-6 Disassembling Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
TOC-5
TABLE OF CONTENTS
8.2 8.3
9. 9.1 9.2 9.3
10.
Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Inspection and Repair After Disassembling Axle Shaft and Hub . . 6-9 Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Front Hub Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Assembling Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
10.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 10.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
11. 11.1 11.2 11.3 11.4
12.
Disassembling Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Removing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Inspection and Repair After Disassembling Reduction Differential 6-14
12.1 Reduction Bevel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 12.2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
13.
Assembling Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
13.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 13.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
14. 14.1 14.2 14.3 14.4 14.5
15. 16.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Adjusting Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Inspecting Back Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Adjusting Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Adjusting Tooth Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Tooth Contact of Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
16.1 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Chapter 7 REAR AXLE 1. 2. 2.1 2.2 2.3
3. 3.1 3.2 3.3
4. 4.1
5. 5.1 5.2
6. TOC-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Rear Axle (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Rear Axle (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Removing Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installing Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Removing Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Installing Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
TABLE OF CONTENTS
7. 7.1 7.2
8. 8.1 8.2
9. 9.1
10. 11.
Disassembling Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 Rear Axle (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 Rear Axle (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Assembling Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Suggestion for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Disassembling Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Inspection and Repair After Disassembling Steering Cylinder . . . .7-16 Assembling Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
11.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17 11.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
12.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
12.1 Adjusting Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
13. 14.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Chapter 8 BRAKE SYSTEM 1. 2. 2.1 2.2 2.3 2.4 2.5
3. 3.1
4. 4.1 4.2 4.3
5. 5.1 5.2
6. 6.1
7. 7.1 7.2 7.3 7.4
8. 9. 9.1 9.2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Master Cylinder and Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Brake Booster (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 Brake Booster (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Disassembling Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Inspection and Repair After Disassembling Master Cylinder . . . . . .8-8 Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
Assembling Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Disassembling Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 Disassembling Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Inspection and Repair After Disassembling Wheel Cylinder . . . . . .8-11 Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Piston Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Assembling Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Disassembling Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
TOC-7
TABLE OF CONTENTS
9.3
10. 10.1 10.2 10.3 10.4 10.5 10.6
11.
Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Inspection and Repair After Disassembling Wheel Brake . . . . . . . . 8-14 Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Shoe and Lining Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Brake Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Adjusting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Parking Brake Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Other Inspection Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Assembling Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
11.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 11.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
12.
Inspecting and Repairing Parking Brake Lever . . . . . . . . . . . . . . . . . . 8-18
12.1 Parking Brake Lever Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 12.2 Suggestions for Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 12.3 Installing Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
13. 13.1 13.2 13.3 13.4 13.5 13.6
14. 15.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Automatic Adjuster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Procedure for Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Brake Fluid Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Inspecting Reserve Tank Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Procedures for Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Brake Booster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Chapter 9 STEERING SYSTEM 1. 2. 2.1 2.2 2.3
3. 3.1 3.2
4. 4.1 4.2 4.3
5. 5.1 5.2
6. 7. 7.1 7.2
TOC-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Tilt Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Removing Tilt Steering and Steering Control Valve Assembly . . . . 9-5 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Inspection After Installing Tilt Steering and Steering Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Steering Wheel Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Disassembling Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Inspection and Repair After Disassembling Steering Control Valve 9-10 Assembling Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
TABLE OF CONTENTS
8. 9. 9.1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
Chapter 10 HYDRAULIC SYSTEM 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13
3. 3.1 3.2 3.3
4. 4.1 4.2
5. 5.1 5.2
6. 6.1
7. 7.1 7.2
8. 9. 9.1 9.2 9.3
10.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 Hydraulic Line (6 to 7 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 Inlet Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 Solenoid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Lift Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Tilt Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9 Attachment Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10 Control Valve Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20 Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21
Removing Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23
Removing Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24 Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
Removing Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . .10-25 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25
Installing Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . .10-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-27
Removing Lift Cylinders (Duplex and Triplex Mast) . . . . . . . . . . . . . .10-28 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-28 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-29
Installing Lift Cylinders (Duplex and Triplex Mast) . . . . . . . . . . . . . . .10-31 Removing Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32
Disassembling Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33
10.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33 10.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33
11.
Inspection After Disassembling Gear Pump . . . . . . . . . . . . . . . . . . . . .10-34
11.1 Drive and Driven Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34 11.2 Pump Covers, Body, and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34
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12.
Assembling Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
12.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 12.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
13.
Inspection After Disassembling Control Valve . . . . . . . . . . . . . . . . . . . 10-36
13.1 Sections, Spools, and Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
14. 15. 15.1 15.2 15.3 15.4
16.
Assembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 Disassembling Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . 10-38 Disassembly Sequence (A40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Sequence (A45A, A55A, and A70A) . . . . . . . . . . . . . . . . . . . . . . Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-38 10-38 10-39 10-39
Inspection After Disassembling Lift Cylinders (Simplex Mast) . . . . 10-40
16.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 16.2 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 16.3 Packings and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
17.
Assembling Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . 10-40
17.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 17.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
18.
Disassembling Lift Cylinders (Duplex and Triplex Masts) . . . . . . . . . 10-42
18.1 Disassembly Sequence for First Lift Cylinders (B55A and C40A Through C70A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 18.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 18.3 Disassembly Sequence for Second Lift Cylinders (B40A) . . . . . . . . . . . . . . . 10-43 18.4 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 18.5 Disassembly Sequence for Second Lift Cylinders (B45A and B55A) . . . . . 10-44 18.6 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
19.
Inspection After Disassembling Lift Cylinders (Duplex and Triplex Masts ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
19.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 19.2 Piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 19.3 Packings and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
20.
Assembling Lift Cylinders (Duplex and Triplex Masts) . . . . . . . . . . . 10-45
20.1 First Lift Cylinder (B40A Through B55A, and C40A Through C70A) . . . . . 10-45 20.2 Second Lift Cylinders (B40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 20.3 Second Lift Cylinders (B45A and B55A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
21.
Disassembling Lift Cylinders (Triplex Masts) . . . . . . . . . . . . . . . . . . . . . 10-48
21.1 Second Lift Cylinders (C40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 21.2 Second Lift Cylinders (C45A and C55A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 21.3 Second Lift Cylinders (C70A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
22.
Inspection After Disassembling Lift Cylinders (Triplex Masts) . . . . 10-51
22.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 22.2 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 22.3 Packings and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
23.
Assembling Lift Cylinders (Triplex Masts) . . . . . . . . . . . . . . . . . . . . . . . 10-52
23.1 Second Lift Cylinder (C40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 23.2 Second Lift Cylinders (C45A and C55A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 23.3 Second Lift Cylinders (C70A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
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24.
Disassembling Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-54
24.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-54 24.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55
25.
Inspection After Disassembling Tilt Cylinders . . . . . . . . . . . . . . . . . . . .10-55
25.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55 25.2 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55 25.3 Packings and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-56
26.
Assembling Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-57
26.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-57
27.
Disassembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-58
27.1 Flow Regulator Valve (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-58
28. 29.
Inspection After Disassembling Flow Regulator Valve . . . . . . . . . . .10-58 Assembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
29.1 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
30. 31. 32. 32.1 32.2 32.3 32.4 32.5 32.6 32.7 32.8 32.9
33. 34. 35. 35.1 35.2 35.3 35.4 35.5
Inspection After Disassembling Flow Regulator Valve . . . . . . . . . . .10-59 Assembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60 Test-run of Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-62 Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-63 Attachment Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-63 Priority Relief Valve Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-64 Flow Regulator Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-64 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-65 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-67
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-68 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-69 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-72 Lift Cylinder (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-73 Second Lift Cylinders (Duplex Mast Second Cylinders) . . . . . . . . . . . . . . . .10-74 First Lift Cylinders (Duplex Mast, Triplex Mast First Cylinder) . . . . . . . . . . .10-75 Second Lift Cylinders (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-76 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-77
Chapter 11 MAST AND FORKS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 Removal Sequence of Mast and Lift Bracket Assembly . . . . . . . . . . . . . . . . .11-4 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . .11-4 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . .11-7 Removal Sequence of Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 Suggestions for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . .11-8 Inspecting Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9 Assembly Sequence of Lift Bracket Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10
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1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29
TOC-12
Adjusting Lift Bracket Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Installing Outer/Inner Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Installing Mast Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Installing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23 Inspecting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23 Inspecting and Adjusting Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24 Checking Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25 Adjusting Clearance Between Lift Bracket Roller and Inner Mast . . . . . . . 11-26 Adjusting Mast Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28 Inspecting and Adjusting Mast Strip Clearance . . . . . . . . . . . . . . . . . . . . . . . 11-30 Adjusting Mast Tilt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 Inspecting and Adjusting Right and Left Lift Cylinder Stroke . . . . . . . . . . 11-31 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33
Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36 Removal Sequence of Mast and Lift Bracket Assembly . . . . . . . . . . . . . . . . 11-38 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . 11-38 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . 11-40 Removal Sequence of Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41 Preparation for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . . . 11-41 Suggestions for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . . 11-42 Inspecting Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43 Assembly Sequence of Lift Bracket Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44 Adjusting Lift Bracket Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 Installing Outer/Inner Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-49 Installing Mast Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50 Installing Second Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51 Installing First Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-58 Inspecting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-58 Inspecting and Adjusting Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-59 Checking Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-60 Adjusting Clearance Between Lift Bracket Roller and Inner Mast . . . . . . . 11-61 Adjusting Mast Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63 Inspecting and Adjusting Mast Strip Clearance . . . . . . . . . . . . . . . . . . . . . . . 11-65 Adjusting Mast Tilt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke . . 11-66 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-67 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-68
TABLE OF CONTENTS
3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29
Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-70 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-70 Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-71 Removal Sequence of Mast and Lift Bracket Assembly . . . . . . . . . . . . . . . . .11-73 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . .11-73 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . .11-75 Removal Sequence of Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .11-76 Preparation for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . . .11-76 Suggestions for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . .11-77 Inspecting Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-78 Assembly Sequence of Lift Bracket Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-79 Adjusting Lift Bracket Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-80 Installing Outer/Inner Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-84 Installing Mast Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-85 Installing Second Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-86 Installing First Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-87 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-88 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-89 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-91 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-93 Inspecting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-93 Inspecting and Adjusting Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-94 Checking Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-95 Adjusting Clearance Between Lift Bracket Roller and Inner Mast . . . . . . .11-96 Adjusting Mast Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-98 Inspecting and Adjusting Mast Strip Clearance . . . . . . . . . . . . . . . . . . . . . . . .11-102 Adjusting Mast Tilt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-102 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke . . .11-103 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-104 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-105
Chapter 12 SERVICE DATA 1. 2. 2.1 2.2
3. 3.1
4. 4.1 4.2 4.3
5. 5.1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . .12-5 Metric Fine Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5 Metric Coarse Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7
Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9 Safety Critical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11 Adjustment Value and Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
TOC-13
TABLE OF CONTENTS
Chapter 13 HOW TO READ CIRCUIT DIAGRAMS 1. 1.1 1.2
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
3. 4.
Description of Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Connector Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
How to Read Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 Sheet Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Connecting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 Relay Contactor and Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 Indication of Connecting Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 Indication of GND (Earth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 Indication of Another Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
How to Read Connector Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Abbreviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Chapter 14 CIRCUIT DIAGRAM
TOC-14
CHAPTER 1 GENERAL INFORMATION
Chapter 1 GENERAL INFORMATION 1.
Model View
505703
2.
Applicable Lift Truck Models
This manual applies to the following lift truck models. Lift truck model
Transmission
3.5 ton class
Engine mounted
GC40K GC40K STR 1-Speed
AT87B-10011-up
GC45K SWB GC45K STR GC55K
5.5 ton class
GC55K STR
6.0 ton class 7.0 ton class
Serial number
GC35K
4.0 ton class
4.5 ton class
Lift truck model
PSI 4X LPG Engine AT88B-10011-up
GC60K Automatic 2-Speed
GC70K
AT89B-10011-up
GC70K STR
1-1
CHAPTER 1 GENERAL INFORMATION
3.
Serial Number Locations
1
4
2
3
5
6 505704
1. 2. 3.
1-2
Name Plate Chassis Serial Number (Former models) Engine Serial Number
4. 5. 6.
Mast Number Transmission Serial Number Chassis Serial Number (New models)
CHAPTER 1 GENERAL INFORMATION
4.
Chassis and Mast Model Identification
Chassis
GC 55 K
1 2
3 1. 2.
Generation designator Maximum capacity 55 : 5500 kg (12000 lb)
3.
505819
Engine type GC: Gasoline (LPG) engine type
Mast
A
55
A
33
1
2
3
4 1. 2.
Maximum lifting height (“33” stands for 3300 mm.) Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on)
3. 4.
505706
Applicable truck model designation 55: 5.5 ton class Kind of mast A: Simplex mast B: Duplex mast C: Triplex mast
1-3
CHAPTER 1 GENERAL INFORMATION
5.
Dimensions
6
10
11
4
9 1 7
8 2
14 3
12
13
5
505707
1-4
CHAPTER 1 GENERAL INFORMATION
6.
Specifications Unit: mm (in.)
1
2
Class
3.5 ton class
Lift truck model
GC35K
Maximum lift
Free lift (Floor to fork top)
GC45K STR
Simplex mast
150 (5.9)
160 (6.3)
Duplex mast
920 (36.2) 3.0 m (118 in.) mast
895 (35.2) 2.8 m (112 in.) mast
Triplex mast
800 (31.5) 4.0 m (157 in.) mast
895 (35.2) 4.0 m (157 in.) mast
Tilt angle (forward – backward) degree
5
Overall length (OLH)
6
Overall width (outside)
1220 (48) 5/10 Simplex, Duplex mast 6/5 Triplex mast 2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
2730 (107)
Standard
1180 (46.5)
1320 (52.0)
Wide tread (option)
1270 (50.0)
1420 (56.0)
Overall height (to top of mast lowered)
2155 (85.0)
Overall height (to top of overhead guard)
2155 (85.0)
Simplex mast Overall height (mast extended)
GC45K SWB
2900 (114)
4
9
GC40K STR
3050 (120)
Fork length
8
GC40K
4.5 ton class
Simplex mast
3
7
4 ton class
4250 (167)
4125 (162)
Duplex mast
4250 (167) 3.0 m (118 in.) mast
4080 (160.6) 2.8 m (112 in.) mast
Triplex mast
5250 (206.7) 4.0 m (157 in.) mast
5560 (218.9) 4.0 m (157 in.) mast
Standard
940 (37.0)
1015 (40.0)
Wide tread (option)
1040 (41.0)
1120 (44.0)
11 Tread (rear)
980 (38.5)
965 (38.0)
12 Wheelbase
1575 (62.0)
1780 (70.0)
10 Tread (front)
13 Rear overhang 14 Under clearance (at frame)
485 (18.8)
525 (20.3)
335 (13.3)
565 (22.1)
470 (18.1)
150 (5.9)
1-5
CHAPTER 1 GENERAL INFORMATION Class
5.5 ton class
Lift truck model 1
2
Maximum lift
Free lift (Floor to fork top)
GC55K
GC55K STR
2350 (93)
Simplex mast
160 (6.3)
165 (6.5)
Duplex mast
895 (35.2) 2.8 m (112 in.) mast
-
Triplex mast
895 (35.2) 4.0 m (157 in.) mast
900 (35.4) 3.5 m (138 in.) mast
4
Tilt angle (forward – backward) deg.
5/10 Simplex, Duplex mast 6/5 Triplex mast
5
Overall length (OLH)
2910 (115)
6
Overall width (outside)
9
GC70K
2900 (114)
Fork length
8
GC60K
7.0 ton class
Simplex mast
3
7
6.0 ton class
1220 (48)
2640 (104)
6/10 Simplex mast 6/5 Triplex mast 2950 (116)
2730 (107)
Standard
1320 (52.0)
1440 (56.5)
Wide tread (option)
1420 (56.0)
-
Overall height (to top of mast lowered)
2155 (85.0)
2205 (87.0)
Overall height (to top of overhead guard)
2155 (85.0)
2205 (87.0)
Simplex mast
4125 (162)
3585 (141)
Duplex mast
4080 (160.6) 2.8 m (112 in.) mast
-
Triplex mast
5560 (218.9) 4.0 m (157 in.) mast
4785 (188.3) 3.5 m (138 in.) mast
Standard
1015 (40.0)
1130 (44.5)
Wide tread (option)
1120 (44.0)
-
Overall height (mast extended)
10
Tread (front)
11
Tread (rear)
965 (38.0)
1160 (45.5)
12
Wheelbase
1780 (70.0)
1830 (72.0)
13
Rear overhang
14
Under clearance (at frame)
1-6
GC70K STR
650 (26.1)
380 (15.1)
150 (5.9)
590 (23.1) 200 (7.9)
340 (13.1)
CHAPTER 1 GENERAL INFORMATION
7.
Performance Class
3.5 ton class
Lift truck model
GC35K kg/mm
Work performance
Capacity/load center
(lb/in.)
Lift speed (loaded) Lowering speed (loaded)
mm (fpm)/ sec.
Mast tilt (forward-backward)
degree
Traveling performance
Powershift Travel transmission speed models Minimum turning radius Minimum intersecting isle Gradability at 1 mph (1.6 km/h) Gradability at stall
Standard
Loaded No loaded
km/h (mph)
mm (in.)
Loaded No loaded Loaded No loaded
%
4.5 ton class
GC40K STR
4000/500 (8000/24)
GC45K SWB
GC45K STR
4500/600 (10000/24)
3050 (120)
2900 (114)
540 (105)
390 (78.0)
550 (108)
440 (86.5) 5/10
mm (in.)
Free lift
GC40K
3500/500 (7000/24)
mm (in.)
Maximum lift height Simplex
4 ton class
150 (6.0)
160 (6.5)
19 (12.0)
18.5 (11.5) 19.5 (12.5)
2235 (88.0)
2285 (90)
2090 (82.5)
2340 (92.0)
2440 (96.0)
2245 (88.5)
2295 (90.5)
2100 (82.5)
2350 (92.5)
2345 (94.5)
37
33
32
27
26
23.8
21.1
21.5
17.7
23.8
42
37
36
23.8
21.1
21.5
30 17.7
23.8
1-7
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Lift truck model
GC35K
GC40K
GC40K STR
GC45K SWB
GC45K STR
2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
2730 (107)
Overall length to fork face
Overall width
Dimensions
Overall height
1180 (46.5)
1320 (52.0)
Wide tread (optional)
1270 (50.0)
1420 (56.0)
To top of mast (lowered)
2200 (86.5)
2350 (92.5)
To top of mast (extended)
4250 (167.5)
4130 (162.5)
mm (in.)
2155 (85.0)
Wheelbase Front
1575(62.0)
1780 (70.0)
Standard
940 (37.0)
1015 (40.0)
Wide tread (optional)
1040 (41.0)
1115 (44.0)
980 (38.5)
965 (38.0)
Rear Overhang
485 (18.8)
Rear
525 (20.3)
Under clearance (at frame) Front Tire size
Single wheels
Weight
1-8
565 (22.1)
470 (18.1)
Front Rear
22x9x16
22x12x16
18x7x12.12
18x8x12.1 2
mm
Service weight-no load Axle loading
335 (13.3) 150 (5.9)
Rear
Single wheels (without load)
4.5 ton class
Standard
To top of overhead guard
Tread
4 ton class
kg (lb)
5200 (11500)
5600 (12300)
5700 (12700)
6500 (14300)
6600 (14500)
2050 (4600)
2025 (4400)
2150 (4900)
1925 (4200)
2625 (5700)
3150 (6900)
3575 (7900)
3550 (7800)
4575 (10100)
3975 (8800)
CHAPTER 1 GENERAL INFORMATION Class
5.5 ton class
Lift truck model kg/mm
Work performance
GC60K
GC70K
5500/600 (12000/24)
mm (in.)
2900 (114)
2360 (93)
390 (78.0)
360 (71.0)
Lowering speed (loaded)
mm (fpm)/ sec.
440 (86.5)
540 (106.0)
Mast tilt (forward-backward)
degree
5/10
6/10
Free lift
mm (in.)
160 (6.5)
165 (6.5)
Maximum lift height Simplex Lift speed (loaded)
Travel speed Traveling performance
7.0 ton class
(lb/in.)
Capacity/load center
Powershift transmission models
Loaded No loaded
km/h (mph)
Minimum intersecting isle Gradability at 1 mph (1.6 km/h)
Overall height
22.5 (14.0)
2455 (96.5)
2255 (89)
2395 (94.5)
2220 (87.5)
Loaded
22.6
22.2
24.5
21.7
21.4
20.2
20.9
22.2
19.7
20.4
26
25
30
27
26
20.2
20.9
22.2
19.7
20.4
2910 (115)
2460 (104)
No loaded
%
Loaded No loaded
2950 (116)
2700 (106)
Standard
1320 (52.0)
1440 (56.5)
Wide tread (optional)
1420 (56.0)
-
To top of mast (lowered)
2350 (92.5)
2530 (99.5)
To top of mast (extended)
4130 (162.5)
2370 (93.0)
2155 (85.0)
2205 (87.0)
1780 (70.0)
1830 (72.0)
Standard
1015 (40.0)
1135 (44.5)
Wide tread (optional)
1115 (44.0)
-
965 (38.0)
1160 (45.5)
mm (in.)
650 (26.1)
Rear
Under clearance (at frame) Tire size
23 (14.5)
Standard
mm (in.)
Rear Overhang
19.5 (12.5)
20.5 (12.5)
2400 (94.5)
Wheelbase
Tread
21 (13.0)
2570 (101.0)
To top of overhead guard
Front
18 (11.5)
7000/600 (15500/24)
2350 (92.5)
Overall length to fork face Overall width
6000/600 (13500/24)
GC70K STR
2550 (100)
Minimum turning radius
Gradability at stall
Dimensions
GC55K STR
GC55K
6.0 ton class
Front Rear
Single wheels
mm
380 (15.1)
590 (23.1)
150 (5.9)
200 (7.9)
22x12x16
28x12x12
18x8x12.12
22x8x16
340 (13.1)
1-9
CHAPTER 1 GENERAL INFORMATION Class
Lift truck model
Weight
Service weight-no load Single wheels (without load)
Axle loading
Front Rear
Application
GC55K STR
GC60K
GC70K
GC70K STR
7200 (15800)
7400 (16200)
8800 (19300)
9500 (20900)
9700 (21300)
2425 (5300)
2625 (5700)
3300 (7300)
3300 (7200)
3500 (7500)
5500 (12000)
6200 (13700)
6200 (13800)
4775 (10500)
Specification 4X
Manufacturer
PSI
Type
LPG Water cooled
No. of cylinders-arrangement No. of strokes
6-90°V 4
Type of combustion chamber Valve arrangement
Semi-spherical Overhead
Type of cylinder liners Cylinder bore × stroke, mm (in.) Displacement, cc (cu in.) Engine
kg (lb)
7.0 ton class
GC55K
Engine model
Cooling system
Compression ratio
Integral 101.6×88.39 (4.00×3.48) 4300 (262.4) 9.8 : 1
-1
Rated output, PS/min
96.3/2600
Rated torque, kgf·m/min-1
28.5/1400
-1
Min. min
Max. min-1 Dimensions (L×W×H), mm (in.) Weight, kg (lb)
650-700 2600 710×620×740 (28.0×24.4×29.1) 272.2 (600)
Installation position
Rear
Ignition
Spark
Firing order Initial ignition timing, BTDC deg
1-10
6.0 ton class
5.5 ton class
1-6-5-4-3-2 Not Adjustable
Rotation (Viewed from pulley)
CW
Voltage for Electric system
12V
CHAPTER 1 GENERAL INFORMATION Application
Specification
Ignition system
Ignition system
Ignition coil
Distributor
Type
Carburetor
Governor Air cleaner
AC Delco
Type
Pointless
Manufacturer
AC Delco
AC R44LTS
Manufacturer
AC Delco
Size, mm (in.)
14 (0.55)
Gap, mm (in.)
0.77 (0.030)
Mixer-Type
E-330-19
Manufacturer
EControls
Type Manufacturer Type X Number
Engine lubrication system Cooling system Battery
Drive by wire BOSCH Cyclone with paper element x 1 Pressure feed
Oil pump
Gear pump
Oil filter
Paper element
Oil cooler Refill capacities, liter (U.S.gal)
Oil to water type Oil pan
4.0 (1.06)
Oil filter & cooler
0.7 (0.18)
Total
4.7 (1.2)
Type Refill capacity, liter (U.S.gal) Water pump Thermostat/ Opening Temp C° ( F°) Type × number
Forced circulation 18.2 (4.82) Centrifugal type, V-belt driven Wax type/ 180 (180) Group 24
Voltage, V
12
Capacity, AH (5Hr)
45
Type Alternator
Internal solid state circuit
Model
Type
Manufacturer Rated output, V-A Regulator Type
Starter
Mold
Manufacturer
Type of spark advance control
Spark plug
Fuel system
EST
Manufacturer Voltage-output, V-kW
3-Phase AC AC Delco 12-70 Built in IC type Electromagnetic Delco Remy 12 - 0.75
1-11
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Lift truck model
GC35K
Type Torque converter
4 ton class GC40K STR
GC40K
Manufacturer’s model
Power train
Reduction gear
Differential
3.2
Ratios
2.898
Reverse
2.907
Type of gear
Spiral bevel
Gear ratio
4.571
Housing
Banjo
Type of gear and pinion number
Gear
Straight bevel-2
Pinion
Straight bevel-4
Differential gear oil liter (U.S. gal) Type Steering system
Power cylinder ID × rod diam., mm (in.) Effective stroke, mm (in.) Relief pressure, kPa (kgf/cm2) [psi] Flow rate, liter (U.S.gal)/min
Traveling system
Transmissi on/ Torque oil 15 (3.9)
14 (3.7)
9.1 (2.4) Full hydrostatic power steering
Steering wheel diameter, mm (in.)
1-12
Hydraulic and column shift
Forward
Transmission/ torque converter oil liter (U.S. gal)
Power steering
330 (13)
328 (12.9)
85×60 (3.3×2.4) 155 (6.1) 11768 (120) [1706] 23 (6.07)
Front axle
Full-floating tubular type
Rear axle
Elliott type
Suspension system
Front
Fixed type
Rear
Center-pivot type
Toe-in, mm (in.) Wheel alignment
GC45K STR
Okamura M15
Control and shift Powershift
GC45K SWB
3-element, 1-stage, 2-phase
Stall torque ratio
Transmission
4.5 ton class
Camber
0 1.0°
Caster
0°
Kingpin inclination
0°
CHAPTER 1 GENERAL INFORMATION Class Lift truck model
GC55K STR
GC55K
Type Torque converter
6.0 ton class
5.5 ton class
Manufacturer’s model
Power train
Reduction gear
Ratios
Hydraulic and column shift
Forward
2.898
(1st/2nd) 5.104/2.882
Reverse
2.907
(1st/2nd) 5.104/2.882
Spiral bevel
Hypoid gear
4.571
4.857
Type of gear Gear ratio
Banjo
Type of gear and pinion number
Gear
Straight bevel-2
Pinion
Straight bevel-4 Transmission/ Torque oil 15 (3.9)
Transmission/ torque converter oil liter (U.S. gal) Differential gear oil liter (U.S. gal)
9.1 (2.4)
Type
Full hydrostatic power steering
Steering system
Steering wheel diameter, mm (in.)
328 (12.9)
Power cylinder ID × rod diam., mm (in.) Power steering
Effective stroke, mm (in.) Relief pressure, kPa (kgf/cm2) [psi]
Traveling system
Flow rate, liter (U.S.gal)/min
85×60 (3.3×2.4) 155 (6.1)
180 (7.1)
11768 (120) [1706]
14710 (150) [2133] 23 (6.07)
Front axle
Full-floating tubular type
Rear axle
Elliott type
Suspension system
Front
Fixed type
Rear
Center-pivot type
Toe-in, mm (in.) Wheel alignment
GC70K STR
3.2
Housing Differential
GC70K
Okamura M15
Control and shift Powershift
GC60K
3-element, 1-stage, 2-phase
Stall torque ratio
Transmission
7.0 ton class
Camber
0 1.0°
Caster
0°
Kingpin inclination
0°
1-13
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Lift truck model
GC35K
Brake system
Type
Service brakes
Parking brake
4 ton class GC40K STR
GC40K
317.5 (12.50)
Lining (length×width thick×number), mm (in.)
330×63×10-2 (13×2.48×0.39-2)
Master cylinder ID, mm (in.)
28.57 (1.125)
Wheel cylinder ID, mm (in.)
31.75 (1.250)
130 (7.9) Mastervac (vacuum suspended)
Body
Assembled-frame type Type
Gear pump
Gear
Manufacturer’s type
KFP3240 AMBAS
Rated discharge, liter (U.S.gal)/min-1
98 (25.89)/2450
Drive line
Universal joint
Type Control valve
Hydraulic system
Flow regulator valve
Relief pressure, MPa (kgf/ cm2) [psi] Type
6000-C193 19.12
+0.5 +5 +71 0 (195 0 ) [2773 0 ]
Variable (Adjustable)
Regulated flow rate, valve liter (U.S.gal)/min
100 (26.4)
115 (30.38)
Simplex mast Lift cylinders
ID, mm (in.)
60 (2.36)
70 (2.75)
Duplex mast First lift cylinders
ID, mm (in.)
Duplex mast Second lift cylinders
ID, mm (in.)
Triplex mast First lift cylinders
ID, mm (in.)
Triplex mast Second lift cylinders
ID, mm (in.)
Tilt cylinders
Stroke, mm (in.)
Stroke, mm (in.)
Stroke, mm (in.)
Stroke, mm (in.)
Stroke, mm (in.)
1650 (65) 90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
55 (2.17)
60 (2.36)
1590 (62.60)
1585 (62.40)
90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
60 (2.36)
70 (2.75)
1480 (58.27)
1530 (60.24)
ID, mm (in.)
100 (3.937)
Stroke, mm (in.)
120 (4.724)
Hydraulic tank capacity, liter (U.S.gal)
1-14
GC45K STR
Mechanical, mounted on wheels
Brake fluid cc (cu.in) Brake booster
GC45K SWB
Self-adjusting, duo-servo
Drum diameter, mm (in.)
Type
4.5 ton class
46 (12.1)
52 (13.6)
CHAPTER 1 GENERAL INFORMATION Class Lift truck model
GC55K
GC55K STR
Brake system
Type
Service brakes
Parking brake
6.0 ton class
5.5 ton class
317.5 (12.50)
Lining (length×width thick×number), mm (in.)
330×63×10-2 (13×2.48×0.39-2)
Master cylinder ID, mm (in.)
28.57 (1.125)
Wheel cylinder ID, mm (in.)
31.75 (1.250)
Type
130 (7.9) Mastervac (vacuum suspended) Assembled-frame type Type
Gear
Manufacturer’s type
KFP3240 AMBAS
SPG2-48L194
Rated discharge, liter (U.S.gal)/ min-1
98 (25.89)/2450
117.6 (31.07)/2450
Drive line
Universal joint
Type
Hydraulic system
6000-C193
Relief pressure, MPa (kgf/cm2) [psi]
19.12
Type Regulated flow rate, valve liter (U.S.gal)/min
+0.5 +5 +71 0 (195 0 ) [2773 0 ]
Variable (Adjustable) 115 (30.38)
165 (43.56)
Simplex mast Lift cylinders
ID, mm (in.)
Duplex mast First lift cylinders
ID, mm (in.)
110 (4.33)
-
Stroke, mm (in.)
845 (33.27)
-
Duplex mast Second lift cylinders
ID, mm (in.)
60 (2.36)
-
1585 (62.40)
-
Triplex mast First lift cylinders
ID, mm (in.)
110 (4.33)
125 (4.92)
Stroke, mm (in.)
845 (33.27)
855 (33.66)
Triplex mast Second lift cylinders
ID, mm (in.)
70 (2.75)
80 (3.15)
Stroke, mm (in.)
1530 (60.24)
1495 (58.86)
ID, mm (in.)
100 (3.937)
110 (4.33)
Stroke, mm (in.)
120 (4.724)
139 (5.472)
52 (13.6)
69 (18.2)
Tilt cylinders
GC70K STR
Mechanical, mounted on wheels
Body
Flow regulator valve
GC70K
Drum diameter, mm (in.)
Brake booster
Control valve
GC60K
Self-adjusting, duo-servo
Brake fluid cc (cu.in)
Gear pump
7.0 ton class
70 (2.75)
Stroke, mm (in.)
Stroke, mm (in.)
Hydraulic tank capacity, liter (U.S.gal)
80 (3.15) 1650 (65)
1-15
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Lift truck model
GC35K
4 ton class GC40K STR
GC40K
Mast model
Mast and forks
Side rollers
Outer Inner, Middle
130×30×26×15 (5.1×1.2×1.0×0.6)
118×24×24×12 (4.6×0.9×0.9×0.47)
130×26×26×13 (5.1×1.0×1.0×0.5)
Bearing
Ball bearing
Diam × width, mm (in.)
118×32 (4.65×1.26)
Bearing Diam × width, mm (in.)
52×36 (2.05×1.42) BL834
BL1034
1220×150×50 (48×6×2)
Fork spread (outer width), mm (in.)
1060 (41.5)
Class
5.5 ton class
Lift truck model
GC55K
GC55K STR
Mast model
Mast and forks
6.0 ton class
7.0 ton class
GC60K
GC70K
GC70K STR
CJ type
Flange ID × flange back Thickness × flange front Thickness × web thickness
Outer
130×30×26×15 (5.1×1.2×1.0×0.6)
150×34×30×20 (5.9×1.3×1.2×0.8)
Inner, Middle
130×26×26×13 (5.1×1.0×1.0×0.5)
150×30×30×15 (5.9×1.2×1.2×0.6)
Bearing Diam × width, mm (in.) Bearing Diam × width, mm (in.)
Ball bearing 130×34 (5.12×1.34)
Fork (length × width × thick), mm (in.) Fork spread (outer width), mm (in.)
150×36 (5.91×1.42)
Lubricated type needle roller bearing 52×36 (2.05×1.42)
Lift chains
1-16
130×34 (5.12×1.34)
Lubricated type needle roller bearing
Fork (length × width × thick), mm (in.)
Side rollers
GC45K STR
118×28×24×13 (4.6×1.1×0.9×0.5)
Lift chains
Main rollers
GC45K SWB
CJ type
Flange ID × flange back Thickness × flange front Thickness × web thickness
Main rollers
4.5 ton class
58×40 (2.3×1.6) BL1034
1220×150×60 (48×6×2.4)
1220×150×65 (48×6×2.56)
1060 (41.5)
1230 (48.5)
CHAPTER 2 COOLING SYSTEM
Chapter 2 COOLING SYSTEM 1.
Structure 6 5 8 9
4 1
7
3
2 1. 2. 3. 4. 5.
Engine Universal joint Gear pump Fan belt Cooling fan
6. 7. 8. 9.
505708
Upper hose Lower hose Radiator Transmission oil cooler
2-1
CHAPTER 2 COOLING SYSTEM
2. 2.1
Removal and Installation Removing Fan Belt (Method by Removing Radiator)
Preparation Remove the radiator cover. Removal sequence
3
2
1
505709
1. 2.
Universal joint Tension pulley bolt (loosening only)
3.
Belt
Suggestions for removal and installation (1) Loosen the tension pulley bolt 2 until the fan tension becomes loose.
R CAUTION DO NOT loosen the lock bolt to such an extent that the tension pulley is removed. (2) Move the tension pulley toward the fan, then remove the belt.
2-2
CHAPTER 2 COOLING SYSTEM 2.2
Installation
To install, follow the reverse of removal procedure and do the following steps: (1) Before installing the belt, rotate the fan to check for smooth movement. If it generates an abnormal sound, replace the bearing. (2) After putting the belt on the drive and driven pulleys, push it midway between the pulleys to make sure the tension pulley moves freely. Then tighten the pulley bolt.
2.3
Inspection and Adjustment
Fan belt inspection (1) Check to make sure the belt is free of oil, grease, or other foreign matter. Replace the belt if necessary. A slightly dirty belt can be re-used by cleaning with cloth or paper. Do not attempt to clean the belt with gasoline or the like. (2) During engine overhaul or belt tension adjustment, closely examine the belt and replace if defective. Fan belt adjustment (1) Loosen the tension pulley bolt 1 by one to two full turns with ratchet wrench.
1 505710 1. Tension pulley bolt
(2) The belt will be properly secured by the tension spring. Tighten the tension pulley bolt 1.
2-3
CHAPTER 3 ELECTRICAL SYSTEM
Chapter 3 ELECTRICAL SYSTEM 1. 1.1
Electrical Components and Wiring Outline Locations of Electrical Components
1
2 3 4
609254
1. 2.
Switch box Horn
3. 4.
IGN relay Power relay
3-1
CHAPTER 3 ELECTRICAL SYSTEM
2 1
3
609244
1. 2.
Direction lever Meter panel
3.
Light switch and turn signal lever
Console box
1
2 3
Front side
609289
1. 2.
3-2
Direction (FNR) lever Light switch and turn signal lever
3.
Key switch
CHAPTER 3 ELECTRICAL SYSTEM IGN relay
609255
Power relay
609257
Thermoswitch
609245
3-3
CHAPTER 3 ELECTRICAL SYSTEM Speed sensor
609246
Fuse box
609251
3-4
CHAPTER 3 ELECTRICAL SYSTEM
2.
Console Box
2.1
Console Box Outline
1
2 3
Front side
4
609241
1. 2.
Direction (FNR) lever Light switch and turn signal lever Item
Key switch Screw
3. 4.
Key switch Screw (4 pieces)
Tightening torque 4 to 6 N·m (0.41 to 0.61 kgf·m) [2.95 to 4.43 lbf·ft] 1.6 to 2.4 N·m (0.16 to 0.24 kgf·m) [1.18 to 2.77 lbf·ft]
Note: -
Make sure there is no LOCTITE leakage on column cover. Apply LOCTITE® 242 or equivalent to the threads of the key switch nut and tighten key switch nut to the specified tightening torque.
3-5
CHAPTER 3 ELECTRICAL SYSTEM 2.2
Disassembling Console Box
4
3 2 1 1 1
1 1
1
506000
1. 2.
Screw (6 pieces) Front cover
3. 4.
Rear cover Steering wheel
Preparation Place the key switch to the OFF position, and remove the cable from the ground side of the battery. (1) Remove screws 1 (2 pieces) that hold front cover 2. (2) Remove screws 1 (4 pieces) that hold rear cover 3. (3) Remove the steering wheel 4.
2.3
Assembling Console Box
To assemble console box follow the reverse of disassembly procedure.
3-6
CHAPTER 3 ELECTRICAL SYSTEM
3.
Meter Panel
3.1
Disassembling Meter Panel
2
3 1
1 5
4
505578
1. 2. 3.
Screw Meter cover Screw
4. 5.
Item Tightening torque of screw 1
Screw Connector
Value 0.2 to 0.4 N·m (0.02 to 0.04 kgf·m) [0.15 to 0.30 lbf·ft]
R CAUTION Be careful not to damage meter cover 2 when disassembling the meter panel.
3.2
Assembling Meter Panel
To assemble the meter panel, follow the reverse of disassembly procedure.
3-7
CHAPTER 3 ELECTRICAL SYSTEM 3.3
Warning Icons and Indicators
1
2
3
4
*
*
*
609243
1. 2.
Brake fluid warning icon Battery charge warning icon
3. 4.
Engine oil pressure warning icon Water temperature warning icon
1. Brake fluid warning icon
3. Engine oil pressure warning icon
-
This warning icon glows when the fluid level is lower than the specified level. 2. Battery charge warning icon
If this icon glows during operation, turn the engine OFF and check the oil level. Add oil as required.
-
If this icon glows during operation, stop the forklift truck and check engine coolant level.
-
This warning icon glows when the charging system is not functioning properly. First, check the battery voltage. If the battery is fine, check the alternator drive belt for slippage or breakage.
4.Water temperature warning icon
Note: Warning icons marked with * are not available.
R CAUTION If the forklift truck is operated with low engine oil level or with this warning icon glowing, overheating may result.
3-8
CHAPTER 3 ELECTRICAL SYSTEM
4.
Switch Box
1
4
1)
5 2
6
3
2) 2)
7
E00937
1. 2. 3. 4.
First speed mode/automatic mode selector switch (Only for 6 to 7 ton model) Driving interlock indicator icon, Neutral indicator icon ECM warning icon Clogged air cleaner element indicator icon
1. First speed mode/automatic mode selector switch (Only for 6 to 7 ton model) -
First speed mode is for jobs requiring low travel speed and greater drawbar pull. Travel speed is 0 to 13.3 km/ h (0 to8.3 mph) Automatic mode shifts transmission up and down automatically. First speed is 0 to 9.5 km/h (0 to 5.9 mph). Second speed is 9.5 to 22.8 km/h (5.9 to 14.2 mph) First speed mode for operating at the speed-limit area (14 km/h [8.7 mph] at maximum), climbing or towing a forklift truck.
2. Driving interlock indicator Icon/Neutral indicator icon Blinks if the operator leaves the seat with the direction lever in the FORWARD or REVERSE position while the engine is idling. Glows when the direction lever is placed in NEUTRAL (N) position.
5. 6. 7. 1) 2)
Mast interlock indicator icon Torque converter oil temperature warning icon LPG empty indicator icon Automatic mode (First speed, Second speed) First speed mode
3. ECM warning icon Glows when engine control module (ECM) is abnormal. Consult your authorized forklift Mitsubishi truck dealer. 4. Clogged air cleaner element indicator icon Glows when air cleaner element is clogged. 5. Mast interlock indicator icon This warning icon glows when the operator is not sitting properly in the operator seat for 2 seconds. The mast will not move even if the lift and/or tilt lever is operated. This warning icon goes OUT if the lift and/or tilt lever is placed in the NEUTRAL position and the operator sits in the operator seat properly. 6. Torque converter oil temperature warning icon This warning icon glows when the oil temperature is high and the danger of overheating is present. 7. Low LPG fuel icon This warning icon glows when LPG is low.
3-9
CHAPTER 3 ELECTRICAL SYSTEM
5. 5.1
Main Electrical Components Key Switch (With Anti-restart Lock)
The key switch has a built-in anti-restart lock to prevent the key from being turned from ON position to START position while the engine is running. The anti-restart key switch will protect the starter and flywheel from damage by preventing the operator from restarting a running engine.
(OFF) (ON) B
(START)
M
S
505717
Connection table Terminal
B
M
Component
Fuse box, battery, and alternator
Fuse box and fuel-cut solenoid
(OFF)
z
Yes
(ON)
z-------------- ---------- --z
No
(START)
3-10
z-------------- -------------z--------------
S
Key insert/removal
Starter and neutral switch (powershift transmission)
------------z
No
CHAPTER 3 ELECTRICAL SYSTEM 5.2
Light Switch and Turn Signal Lever
1 L 10q 10q
1((
N R
2
3 25q25 q
4
501212
1. 2.
Light switch and turn signal lever Light switch OFF
3. 4.
Light switch 1 (Clearance light) Light switch 2 (Head light)
Note: Arrow indicates the front of forklift truck.
1 T-1
T-3 L-2
T-2 L-1 L-3
2 505541
1.
Light switch and turn signal switch
2.
Horn contact
Light switch connection table Terminal
L-1
L-2
L-3
Destination
Power
Tail clearance light
Head light
Switch position OFF 1
z------------- -------------z
2
z------------- -------------z--------------
--------------z
3-11
CHAPTER 3 ELECTRICAL SYSTEM Turn signal switch connection table Terminal
T-1
T-2
T-3
Destination
Flash unit
Turn signal light (R side)
Turn signal light (L side)
Lever position
z------------- -------------z
R (RIGHT turn) N (NEUTRAL)
z------------- -------------z--------------
L (LEFT turn)
5.3
--------------z
Direction (FNR) Switch
FORWARD (F) NEUTRAL (N)
10q 10q
1
1((
REVERSE (R)
2 Terminal 4 Terminal 2
Terminal 3 Terminal 5 Terminal 1 505542
1.
Direction (FNR) lever
2.
Direction (FNR) switch
Note: Arrow indicates the front of forklift truck. Connection table Lever position
Terminal
1
2
3
4
5
Destination
Forklift truck controller
Grounding
Forklift truck controller
Grounding
Forklift truck controller
F (FORWARD) N (NEUTRAL) R (REVERSE)
3-12
z-------- ---------z z-------- ---------------------
---------------------
z-------- ---------------------
---------z ---------------------
---------z
CHAPTER 3 ELECTRICAL SYSTEM 5.4
Horn
Check that the horn sounds when applying the specified voltage to both terminals of the horn. Replace the horn with a new one if it does not sound or its sound is abnormal. Operating voltage: 9V to 16 V
609249
5.5
609250
Reserve Tank
This reserve tank is equipped with LPG empty indicator switch. Volume: Maximum 150 cc (9.2 cu. in) / Minimum 50 cc (3.1 cu. in) Note: LPG empty indicator light glows when the brake fluid level reaches the minimum level.
609247
5.6
Stop Light Switch
Connect a tester across the terminals and check that the lights turn ON and OFF when the amount of the push rod extended projection is within the specified value.
1
Measure the insulation resistance value across the terminals when the push rod is pushed in. Replace the switch if the measured insulation resistance value is less than the value listed below:
4mm (0.157 in.)
M10×1.25
2mm (0.079)
OFF ON 501216
1. Push rod
Item Insulation resistance
Limit value 1 M ohm or more with 500V insulation resistance tester
Rated voltage: DC12V
3-13
CHAPTER 3 ELECTRICAL SYSTEM 5.7
Thermoswitch
(1) Apply an ohmmeter between the terminal and body of the sender unit and check for continuity (resistance value). (2) Replace the sender unit if there is no continuity or the measured resistance value is outside the standard resistance value.
2
1
501217 1. Terminal
Item Working temperature range Internal resistance (Switch is in ON position) Insulation resistance (Switch is in OFF position)
Specified value -40°C (-40°F) to 130°C (266°F) 0.5 ohm or less 1M ohm or more
Note: When installing the thermoswitch, tighten to the specified torque. Tightening torque 31.4 to 47.1 N·m (3.2 to 4.8 kgf·m) [23.2 to 34.7 lbf·ft]
3-14
2. Body
CHAPTER 3 ELECTRICAL SYSTEM 5.8
Speed Sensor (Pulse Generator)
M16 x 1.5 mm (0.059 in.)
2
3 1 504590
1. 2.
O-ring Signal/yellow
3.
Ground/Black
Technical data DC resistance Insulation resistance
2.1 K ohm to 2.5 K ohm at +25°C (77°F) Over 1 M ohm at DC 500 V (Between connector terminal and body)
Operating temperature range
-30°C to +120°C (-22°F to +248°F)
Storage temperature range
-40°C to +120°C (-40°F to +248°F)
3-15
CHAPTER 3 ELECTRICAL SYSTEM 5.9
Relay
‣″•‧‟•‣ ••
‼″⁂″⁀
‵ ‴ ‣ ⁓› ‟ ⁄‟ ‣ ․ ⁈ ″‵‥․․‣‒‿•․ ․‧․‥• ‸‽‣‣•
IGN relay
‥• ‥•
‧
‧
1) 501222 1. Connecting diagram
Item Rated operating voltage
Specified value DC12 V
Working voltage
DC 3.0 to 7.0 V [initial, at 20 °C (68°F)]
Open-circuit voltage
DC 1.2 to 3.9 V [initial, at 20 °C (68°F)]
Coil resistance
80 ohm ± 10% [20 °C (68°F)]
Rated exciting current
168 mA ± 10% [20 °C (68°F)]
3-16
CHAPTER 3 ELECTRICAL SYSTEM Power relay
‿ ″ ‶ ⁁ ‒ ※⁀ ‒ ‼″ ⁂ ″ ⁀
‵″‣⁓‟‣․⁈‟⁀‟‧ ″ ‵″ ‣ ․ ‣ ‥ ‧ ‒ ‿ ⁁‧
609249
Item
Coil
Contact
Specified value
Nominal voltage
DC 12V
Pick-up voltage (Initial at 20°C)
DC 8V or less
Drop-out voltage (Initial at 20°C)
DC 0.6V to 6.0V
Coil resistance (at 20°C)
80 ohm ±10%
Rated excitation current
150mA ±10%
Rated consumption voltage
1.8W
Contact resistance (Initial)
Less than 50m ohm (at DC6V 1A)
Rated control capacity
20A 12V DC resistive load [at 85°C (185°F)]
3-17
CHAPTER 3 ELECTRICAL SYSTEM 5.10 Fuse Box
1
9
2
3
4
5
6
7
8 609257
Ref. No.
3-18
Circuit
Amp
1
Driving interlock indicator icon, FWD/REV solenoid, start safety relay, seat switch, mast interlock indicator icon, lift lock solenoid, and unload solenoid
10 A
2
Meter panel, T/M controller, T/C oil temp relay, dust indicator lamp, T/C oil temp lamp, and inter lock lamp relay 2
10 A
3
Engine harness, and engine check lamp
10 A
4
Back light, backup buzzer, flasher relay, turn signal light, strobe light, T/M change solenoid
15 A
5
Parking light, tail light, rear working light, head light
15 A
6
Stop light
10 A
7
Horn, IGN relay, and starter relay
10 A
8
Spare
15 A
9
Spare
10 A
CHAPTER 3 ELECTRICAL SYSTEM 5.11 Head Light
1
1)
2
609252
1. 2.
LED light Wire harness
1)
Light position should not be above the horizontal line
3-19
CHAPTER 3 ELECTRICAL SYSTEM 5.12 Rear Combination Light
1
2
3
1)
8
4
5
7
6
2)
1. 2. 3. 4. 5.
Turn signal light (Yellow) Stop/Tail light (Red) Backup (White) Ground Tail
6. 7. 8. 1) 2)
Stop Back up Turn signal Rear combination light Connector
5.13 List of Lights Light Type
Capacity
Head light
12V-24W
Working light (Option)
12V-12W
Front (option)
Turn signal light Clearance light
12V-6W
Tail / stop light Rear
Backup light Turn signal light
3-20
12V/4.8W
609253
CHAPTER 3 ELECTRICAL SYSTEM
6.
Mast Interlock System
The forklift truck senses when the operator is not properly seated in the operator seat and will prevent the mast from operating until the operator is properly seated. In the following cases, the mast interlock system disconnects power to the hydraulic control valve and the mast will not lift, lower, or tilt even if the operating control levers are operated: -
6.1
1) 1)
The operator leaves the operator seat for approximately 2 seconds with the key switch in the U (ON) position regardless of whether the engine is running or not.
1) E00397
Mast interlock system functions
Key Switch
Engine
z (OFF)
Stop
U (ON)
Stop
Z (START)
Running
Operating Control Lever
Mast Interlock indicator light
Lift Lever
Tilt Lever
Seated
OFF
Not Active
Not Active
Not Seated
OFF
Not Active
Not Active
Seated
OFF
Lowering only
Not Active
Not Seated
Blink
Not Active
Not Active
Seated
OFF
Active
Active
Not Seated
Blink
Not Active
Not Active
Operator Seat
R WARNING -
Check the function of the mast interlock system at the daily (prestart) inspection. Even when the engine is not running, while the operator is sitting correctly in the operator seat and with the key switch in the ON position, it is possible for the mast to descend. Please be very careful. The parking brake is not automatically applied when the interlock is activated. When replacing the operator seat, BE SURE to select a genuine Mitsubishi Forklift Truck seat with an operator presence switch and an operator restraint system.
Note: The mast interlock will work only for the lift and tilt levers. Attachments can be moved regardless of whether the mast interlock function is operating or not. Therefore, when the attachment lever is operated, some of the attachments will move, even though the engine is not running or the key switch is in the z (OFF) position, as a result of the handling load or of its own weight. When the key switch is in the U (ON) position, the lift lever will lower.
3-21
CHAPTER 3 ELECTRICAL SYSTEM
7.
Driving Interlock System R WARNING
-
Check the function of the driving interlock system at the daily (prestart) inspection. The parking brake is not automatically applied when the driving interlock is activated. When replacing the operator seat, BE SURE to order a genuine Mitsubishi Forklift Truck seat with an operator presence switch and an operator restraint system.
-
1) No Power Travel
No Power Travel
1)
E00398 1) No Power Travel
In normal operation, your forklift truck will drive in a creep mode when the direction lever is placed in the FORWARD or REVERSE position at engine idling (not depressing the accelerator pedal). If the operator then leaves the operator’s seat, the operator presence switch of the seat is activated to shift the FORWARD or REVERSE position into the NEUTRAL position electrically (the lever itself remains in the FORWARD or REVERSE position), and cut off the engine output to stop the forklift truck. In this case, the parking brake does not synchronize with the driving interlock and is not automatically applied the moment the interlock is activated. Depending on the condition of the road (grade, for example), the forklift truck may be accelerated, instead of being stopped.
R CAUTION (1) Prior to operating the forklift truck, BE SURE to check the driving interlock for function. (2) While driving the forklift truck, if you lift your hips above the seat for over 2 seconds, the driving interlock system will be activated, the same as in case of engine idling. (3) Always drive the forklift truck correctly with safety in mind. (4) To restore the forklift truck to its normal driving condition, sit properly in the operator's seat and depress the brake pedal to hold the forklift truck. Then, return the direction lever to the NEUTRAL position and then shift it back into the FORWARD or REVERSE position.
7.1
Driving Interlock System Functions
Conditions Key Engine Switch
ON
3-22
ON
Function
Safety Warning
Operator Seat
Direction Lever
Not Seated
F/R
Driving inoperative
Driving interlock indicator light [BLINK]
Seated
F/R
Driving operative
Driving interlock indicator light [OFF]
Seated to Not Seated
F/R
For approximately 2 seconds driving operative
After approximately 2 seconds driving interlock indicator light [BLINK]
Seated to Not Seated to Seated
F/R
Within approximately 2 seconds driving operative
Within approximately 2 seconds driving interlock indicator light [OFF]
Not Seated to Seated
F/R
Driving inoperative
Driving interlock indicator light [BLINK]
Not Seated to Seated
F / R to N to F/R
Driving inoperative, then Driving interlock indicator light [BLINK] operative after NEUTRAL then [OFF] after NEUTRAL
CHAPTER 3 ELECTRICAL SYSTEM
8.
Neutral System
The forklift truck is equipped with a device that prevents the engine from being started if the direction lever is not in the NEUTRAL position.
1 2 3 E00928 1. FORWARD (F) 2. NEUTRAL (N)
3. REVERSE (R)
R CAUTION Check the following when starting the engine: -
No one is around the forklift truck. The parking brake is applied. The direction lever is in the NEUTRAL position. Operator is seated in the normal operating position.
8.1
Neutral System Functions
Conditions Safety Function Key Switch
Operator Seat
Direction Lever
OFF or ON
Seated or Not Seated
NEUTRAL
Engine starts only when the direction lever is in the NEUTRAL position
3-23
CHAPTER 3 ELECTRICAL SYSTEM
9. 9.1
Battery and Maintenance State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
Specific gravity reading at 20 °C (68°F)
Condition
Adjustment
1.280 to 1.265
Good
If the difference in S.G. between any two cells is 0.020 or less, continue to use as is. If the difference is more than 0.020, discharge the battery in an efficient manner. If the battery recovers, charge the battery to adjust the electrolyte S.G.
1.260 to 1.225
Half charged
Recharge battery to adjust electrolyte S.G. Check for any shortcircuited cables or corroded cable connections in the electrical system.
1.220 or less
Low battery (caution required)
Recharge battery. If the difference in S.G. is too much, charge the battery to adjust the electrolyte S.G.
If the difference in S.G. is more than 0.040.
A cell with a low S.G. may cause a short circuit. It is caused when electrolyte leaks or electrolyte rate is too high or too low.
Recharge the battery until its voltage and S.G. stabilize and remain constant for more than 2 hours. Charge the battery to adjust the electrolyte S.G. It should read between 1.280 and 1.265. If the difference in S.G. is more than 0.040 and a low S.G. is found in any of the cells, replace the battery with a new one. Conduct a high current discharge test after leaving the battery for 12 to 96 hours.
9.2
Specific Gravity Reading and State of Charge
Fully charged condition can be verified by the electrolyte S.G. (1.280 to 1.265), and also the reduction speed of electrolyte implies the battery condition. If the electrolyte in battery cell decreases to the level where the pole plates are exposed within one month, it may be overcharged. If the electrolyte amount remains sufficient for more than three months, the battery may be charged less.
9.3
Precautions for Battery Charging R CAUTION
(1) In slow charging, the charging current should be about 1/10 the capacity of the battery being charged. (2) In quick charging, the battery capacity in ampere should not be exceeded. (3) During charging, adjust the charging current so that the electrolyte temperature does not exceed 45°C (113°F). (4) When connecting cables to battery terminals, always connect the (+) terminal first, and when disconnecting, remove the (-) terminal first. (5) During charging, hydrogen gas is generated, which requires proper ventilation.
-
1
+
501226
1. Identification
R CAUTION -
3-24
BE SURE to turn OFF the key switch and lighting switch before disconnecting or connecting the battery cables (to prevent IC regulator from damage). When connecting battery cables, BE SURE to obtain the correct connecting angle in order to prevent cables’ interference with other equipment.
CHAPTER 3 ELECTRICAL SYSTEM
10. Wire Color Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first color shows a base color and the second color a marking color. Example: The wire color of B/W shows that its base color is B with a marking W. Note: For wiring identification, the same wiring color must be used for the circuit between the power supply and the load.
R CAUTION Be careful that allowable current of solid wires and that of strand wires are different even if they are of the same diameter.
10.1 List of Wire Color Codes Wire color code
Color name
B
Black
W
White
R
Red
G
Green
Y
Yellow
Br
Brown
L
Blue
Lg
Light green
O
Orange
P
Pink
Gr
Gray
Sb
Sky blue
V
Violet
3-25
CHAPTER 3 ELECTRICAL SYSTEM
11. Troubleshooting 11.1 Starter System Condition
Key switch
Starter will not crank engine
Possible cause
Action
Weak or dead battery
Recharge or replace
Short or open circuit
Repair or replace
Poor continuity in key switch
Replace
Starter or starter relay defective
Replace
Direction (FNR) lever not in NEUTRAL position
Move the direction lever to NEUTRAL position
Turning OFF key switch Open or short circuit will not stop engine
Repair or replace
11.2 Lighting System Condition
Will not light
Lights (in general)
Will light dimly
Head light
Will not light
Will not blink
Will not go out Turn signal light Will blink too slow
Will blink too fast
Other lights
3-26
Backup light will not light
Possible cause
Action
Weak or dead battery
Recharge or replace
Open or short circuit
Repair or replace
Poor grounding
Clean ground spot and re-make connection
Switch defective
Replace
Weak battery
Check and recharge
Contact points in switches defective
Repair or replace
Loose terminals
Repair
Dirty lenses
Clean
Water drops inside lenses
Dry and replace packings
Bulbs expired in service life
Replace
Lighting switch defective
Replace
Bulbs burnt out
Replace
Turn signal switch defective
Replace
Turn signal relay defective
Replace
Turn signal relay defective
Replace
Bulbs burnt out
Replace
Low wattage of bulbs
Replace to a correct one
Bulbs burnt out
Replace
Turn signal relay defective
Replace
High wattage of bulbs
Replace to a correct one
Turn signal relay defective
Replace
Backup light switch defective
Repair or replace
Bulbs burnt out
Replace
CHAPTER 3 ELECTRICAL SYSTEM 11.3 Alarm Unit Condition
Possible cause
Will not give blast of sound Horn
Will give abnormal sound
Action
Fuses blown out
Check and replace
Short or open circuit
Repair or replace
Horn switch defective
Replace
Horn defective
Replace
Horn button defective
Repair or replace
Horn switch defective
Replace
Horn defective
Replace
11.4 Battery
Condition
Possible cause
Alternator
Tends to run down rapidly
Regulator
Battery
Wiring
Wiring Tends to get overcharged Regulator
Action
Drive belt slipping
Adjust
Stator coil grounded or open-circuited
Repair or replace
Rotor coil open
Replace
Brushes poorly seating on slip rings
Replace brushes if worn Clean holder and polish slip rings
Diode ruptured
Replace
Regulated voltage setting too low
Replace
Not enough electrolyte or wrong concentration of acid to water
Refill and check specific gravity
Battery cell plates deteriorated (forming, possibly internal short-circuit)
Replace
Terminal connections loose
Clean and retighten
Open or loose connection between F terminals of regulator and alternator
Repair
Regulator IC and F terminals shorted or wired wrong
Repair
Poor grounding of regulator F terminal
Repair
Pressure coil open-circuited
Replace
Regulated voltage too high
Replace
3-27
CHAPTER 3 ELECTRICAL SYSTEM Condition
Possible cause Alternator belt
Alternator
Regulator Weak battery Battery
Wiring
Wiring Battery excessive charging Regulator
3-28
Action
Slipping
Adjust the tension
Stator coil grounded or open circuit
Repair or replace
Rotor coil open
Replace
Brushes poorly seating on slip rings
Clean holder and polish slip rings
Brush movement defect
Adjust, replace brushes if worn
Diode short circuit or open circuit
Replace
Regulating voltage is too low
Adjust
Defective or inappropriate electrolyte
Refill or adjust the S.G.
Defective cell plates (internal short-circuit)
Replace
Poor terminal connections due to insufficient tightening torque
Clean and tighten
Open or loose connection between the key switch and regulator IC terminal
Repair
Fuse blown in the above mentioned circuit or poor contact in the holder
Replace fuse or repair the holder's contact part
Open or loose connection between the regulator F terminal and alternator F terminal
Repair
Regulator IC and F terminals shorted or incorrectly wired
Repair
Defective grounding of regulator F terminal
Repair
Pressure coil open circuit
Replace
Regulating voltage too high
Adjust
CHAPTER 4 POWER TRAIN
Chapter 4 POWER TRAIN 1.
Specifications Item
3.5 to 5.5 ton Type
Torque converter
Three-element one-stage two-phase
Manufacturer model
M15
Stall torque ratio
3.2 F/R electrical column shift, H/L automatic transmission
Operation method Transmission
Forward
First: 2.898
First: 5.104 Second: 2.882
Reverse
First: 2.907
First: 5.104 Second: 2.882
Spiral bevel gear
Hypoid gear
4.571
4.857
Transmission ratio
Transmission system
Reduction
Gear type Reduction ratio Housing
Differential
Running gear
6.0 to 7.0 ton
Type and number of gears
Front axle type Front wheel suspension
Banjo-type Large
Straight bevel gear × 2
Small
Straight bevel gear × 4 Full-floating axle tube type Fixed frame type
4-1
CHAPTER 4 POWER TRAIN
2.
Structure (3.5 to 5.5 Ton)
10 4
•
6
5
3
2
1
• •
•
• •
11 9 12
• •
7
8
505715
1. 2. 3. 4. 5. 6.
Engine Flywheel Torque converter (M15) Transmission Input shaft (First axle) Counter shaft (Second axle)
7. 8. 9. 10. 11. 12.
Counter shaft (Third axle) Output shaft (Fourth axle) Reduction differential Front wheel hub Wheel brake Front axle
The transmission system transmits drive power generated by the engine to the drive shaft. It consists of the following equipment: (1) Torque converter The torque converter plays the role of the clutch. It also increases and transmits engine torque to the transmission. (2) Transmission The transmission changes rotational speed when engine torque is transmitted to the universal joint. (3) Reduction differential The Reduction differential Reduces rotational speed and distributes power to the left and right driving wheels. It also prevents slippage by controlling the rotational speed of the two wheels (in turning to the left/right).
4-2
CHAPTER 4 POWER TRAIN
3.
Structure (6.0 to 7.0 Ton) 10 4
6
3
5
2
1
• •
•
•
• •
11 9 12
• •
7
8
505721
1. 2. 3. 4. 5. 6.
Engine Flywheel Torque converter (M15) Transmission Input shaft (First axle) Counter shaft (Second axle)
7. 8. 9. 10. 11. 12.
Counter shaft (Third axle) Output shaft (Fourth axle) Reduction differential Front wheel hub Wheel brake Front axle
The transmission has first and second shifts in FORWARD and REVERSE modes.
4-3
CHAPTER 4 POWER TRAIN 3.1
Reduction Ratio (3.5 to 5.5 Ton)
(25)
(29)
(32) (37) (7)
(22)
(40)
(32) (51)
505722
Note: Number in parentheses indicates the number of teeth on the gear.
4-4
CHAPTER 4 POWER TRAIN 3.2
Reduction Ratio (6.0 ton 7.0 Ton)
(34)
(52)
(34)
(52) (7)
(36)
(24)
(24)
(18)
(45)
(34)
505723
Note: Number in parentheses indicates the number of teeth on the gear.
4.
Removing Engine
Remove the power line in the following sequence: (1) Remove the engine. (2) Remove the transmission and the reduction differential.
4.1
Preparation
(1) Remove the ground button clamp from the battery. (2) Drain cooling water from the radiator. (3) Drain engine oil and oil in the oil cooler piping.
4-5
CHAPTER 4 POWER TRAIN 4.2
Removal Sequence (1)
1
3
5
5
6
10
3
8
5
8
2 7 4 4
7
9
505724
1. 2. 3. 4. 5.
4-6
Light harnesses, Overhead guard Engine cover, Seat Radiator cover Floor plate Battery cable, Battery
6. 7. 8. 9. 10.
Reserve tank Steering wheel, Forward/reverse lever assembly Transmission oil hoses Transmission oil cooler, Bracket Cowl
CHAPTER 4 POWER TRAIN 4.3
Removal Sequence (2)
16 11
14 19 16 15 13 17
12
18
505725
11. 12. 13. 14. 15.
Upper hose Fan belt Tension pulley Fan assembly Lower hose
16. 17. 18. 19.
Exhaust pipe (left and right) Air cleaner hose Air cleaner Engine control cable
Note: Exhaust pipe (left and right) 16 and engine control cable 19 were changed in 2004. Engine control cable 19 is not used, and exhaust pipe (left and right) 16 has the same O-ring and clamping flange on both ends.
4-7
CHAPTER 4 POWER TRAIN 4.4
Removal Sequence (3)
20
24 1)
25
22
25
1)
26
20
25
23
22
21
21
21 505726
20. Engine harnesses 21. Vacuum hoses, Vacuum tank 22. Engine oil hoses
Note: Fuel pump and hose 23 were changed in 2004. Lifting lugs were moved to opposite sides of engine.
4-8
23. 24. 25. 1)
Universal joint Engine mounting bolt, Cushions Engine assembly Lifting lug
CHAPTER 4 POWER TRAIN Suggestions for removal (1) (2) (3) (4)
When removing transmission oil cooler 9, be careful not to spill the oil out of the cooler. Remove fan assembly 14 and tension pulley 13 in subassembled condition. Remove the engine control cable 19 from the engine. Remove engine harnesses 20 from the engine at sockets and terminals. To prevent damage, tack the removed harnesses along the main harness. (5) Remove engine oil hoses 22 from the engine oil filter inlet/outlet.
(6) To remove the engine, attach a wire rope on engine lifting lugs 1 and lift the engine using a crane until the wire rope is stretched tight.
1 1 505727 1. Lifting lug
Item Engine unit (service weight)
Value 270 kg (595 lb)
(7) Place wood blocks or a jack under the transmission where the rear leg is removed. (8) Remove the universal joint 24 from the engine.
505728
4-9
CHAPTER 4 POWER TRAIN
5.
Installing Engine
Follow the removal sequence in reverse.
5.1
Suggestions for Installation
(1) When installing the engine mounting nut, tighten the nut a quarter rotation from the position where the nut contacts with the mounting bracket. (2) When installing the engine exhaust pipe, replace the gasket with a new one. (3) To connect battery cables, connect positive cables first. Make sure all cables are connected properly. (4) Refill radiator. Fill the radiator with antifreeze coolant to the specified level. Unless otherwise specified, use 60% antifreeze concentration and 40% soft water. (5) Add engine oil. (6) Check the oil level of the hydraulic tank and the transmission. Refill if necessary. (7) Make sure that the engine is correctly installed. (8) Checking with engine running Start the engine and check for vibration. If the vibration of engine is excessive, tighten the engine mounting bolts and check if the vibration decreases.
6.
1 2 3 505729 1. Bracket 2. Cushion
3. Bracket at frame
Removing Transmission and Reduction Differential
Remove the transmission and reduction differential after the engine is removed. To remove the engine, see the previous section.
6.1
Preparation
(1) Drain transmission oil. (2) Drain oil from the front axle housing.
4-10
CHAPTER 4 POWER TRAIN 6.2
Removal Sequence
2 1
1
1
2
1 4 8 7
6
3
5 1. 2. 3. 4.
6.3
Cords (ground), Harnesses Oil cooler hoses Tube (Brake fluid) Inching cable
5 505730
5. 6. 7. 8.
Brake pipe Pedal assembly Front axle shaft Transmission and reduction differential
Suggestions for Removal
(1) Remove oil cooler hoses 2 from the transmission. Tack the removed hoses along the right of the frame. (2) Remove inching cable 4 from the transmission. (3) When removing transmission and the reduction differential 8, use two slings. Attach the ropes to the location of center of gravity using a cow hitch.
4-11
CHAPTER 4 POWER TRAIN
7.
Installing Transmission and Reduction Differential
Follow the removal sequence in reverse.
7.1
Suggestions for installation
(1) Adjusting output shaft with shims (unit: mm) Replace the output shaft and the reduction gear as an assembly if the gear teeth are defective. When installing the output shaft, adjust shims and check the tooth contact. Torque converter drive automatic 2-speed transmission Determine the thickness of shims using the equation below before installing the bearing: Dimension “a” is punched on the upper surface of differential carrier.
c
1
Shim thickness C = 1.7 + a/100 – b a: Machining error of differential carrier b: Machining error of bevel pinion gear
±b ±
a 100
505731
1. Centerline of axle
(2) Before installing the differential assembly to the front axle housing, clean the mounting surfaces and apply liquid gasket on the surfaces, and tighten the bolts. (3) After the brake/inching pedal cables are connected, make sure that the level of each pedal and protrusion of the clutch valve plunger comply with the standard value. (4) Fill the transmission and the front axle housing with oil. Check for oil leaks. (5) Bleed air from the brake fluid lines.
8.
Service Data Unit: liter (U.S.gal) Item
Engine coolant
Engine oil
3.5 to 4.5 ton Engine
7.15 (1.9)
Radiator
3.2 (0.8)
Reserve tank
0.65 (0.2)
Total
11 (2.9)
Oil pan
4.2 (1.1)
Oil filter
0.8 (0.2)
Total
5.0 (1.3)
Transmission/torque converter oil
14 (3.7)
Differential gear oil Hydraulic oil Brake fluid cc (cu.in)
4-12
5.5 to 6.0 ton
7.0 ton
15 (3.9) 9.1 (2.4)
46 (12.1)
52 (13.6) 130 (7.9)
69 (18.2)
CHAPTER 5 POWERSHIFT TRANSMISSION
Chapter 5 POWERSHIFT TRANSMISSION 1. 1.1
Specifications 1-Speed Transmission (3.5 to 5.5 Ton) Item
3.5 to 5.5 ton Type
Torque converter
3 element 1 stage 2 phases
Manufacturer model
M15
Stool torque ratio
3. 2
Operation type
Power transmission Transmission
F/R electric column shift Forward
2.898 (
Backward
2.622 (
Gear ratio
40 32 40 32
×
×
51 22 40 32
)
×
51 22
)
5-1
CHAPTER 5 POWERSHIFT TRANSMISSION
2. 2.1
Structure Torque Converter
1 2
17
3
16
4 5 6 7
15
8
14
9
10
13 1. 2. 3. 4. 5. 6. 7. 8. 9.
5-2
Drive cover Flexible plate Turbine assembly Stator assembly Thrust washer Thrust bearing Thrust washer Spacer Pilot boss
12 , 11 10. 11. 12. 13. 14. 15. 16. 17.
609080
Ball bearing Spring cup Spring Roller Pump boss Ball bearing Stator hub Pump impeller
CHAPTER 5 POWERSHIFT TRANSMISSION 2.2
Transmission 1-Speed b
1
2 •
•
•
a
3
• 9
•
•
c
•
4
•
8 •
7 •
e •
5 •
h
d •
f •
6
g 2nd shaft 1st shaft 3rd shaft
4th shaft
609081
1. 2. 3. 4. 5.
Control valve Oil pump assembly Torque converter assembly Turbine shaft (1st shaft) Flexible plate Range
6. 7. 8. 9.
Output shaft (4th shaft) Countershaft (3rd shaft) Clutch shaft (1st shaft) Countershaft (2nd shaft)
Path
Forward
c6efgh
Reverse
dbaefgh
Note: Illustration shows 3.5 to 5.5 ton.
5-3
CHAPTER 5 POWERSHIFT TRANSMISSION 2.3
Powershift Control
8
1 2
7 4 9 6 1. 2. 3. 4. 5.
2.4
3
5
Transmission shift lever Inching bracket Control valve Solenoid valve (for FOWARD) Solenoid valve (for REVERSE)
6. 7. 8. 9.
609082
Clutch valve plunger Inching lever Cable Inching pedal
Control Valve
1 B
1)
B
2 C
3
4
2) D
D
3) 5 1. 2. 3. 4.
5-4
Accumulator piston Main regulator valve Clutch valve plunger Inching valve
609083
5. 1) 2) 3)
Directional spool Section B-B Section C-C Section D-D
CHAPTER 5 POWERSHIFT TRANSMISSION 2.5
Powershift Transmission Control
4
3
5
PC
2)
6
7
8
R
9
P2 F
7 P1
2
4)
10
PM
3) 11
1)
12
PD
5)
1 13 1. 2. 3. 4. 5. 6. 7. 8. 9.
PL
Oil cooler Torque converter Accumulator valve Main regulator valve Clutch (inching) valve FR filter Last chance filter Solenoid valve Directional valve (Valve top surface) Item
609084
10. 11. 12. 13. 1) 2) 3) 4) 5)
Solenoid valve Gear pump Suction strainer Lubrication oil Torque converter outlet pressure Valve top surface with D stamp Valve top surface with M stamp Torque converter inlet pressure Lubricating circuit Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.05 to 0.29 MPa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
All tests run
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine rpm
5-5
CHAPTER 5 POWERSHIFT TRANSMISSION
3. 3.1 (1) (2) (3) (4) (5) (6)
3.2
Removal and Installation Removal Drain coolant and oil from the engine, transmission, and oil cooler piping. Drain gear oil from the front axle housing. Remove the front axle shafts. Unscrew the torque converter flexible plate mounting bolts and remove the engine from the forklift truck. Remove the transmission and the differential as an assembled unit from the forklift truck. Separate the transmission from the differential.
Installation
(1) Couple the transmission to the differential. Install the torque converter into the transmission case. Install the torque converter so that the distance between the end face of the housing and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.). (2) Install the transmission and differential assembly on the front axle. (3) Install the front axle shafts. (4) Couple the transmission to the engine and mount it on the forklift truck. Make sure the clearance between the flywheel and the flexible plate is approximately 0 to 2 mm (0 to 0.078 in.) when the transmission is coupled to the engine. If the clearance is zero, it is an indication that the torque converter is improperly coupled to the pump gear or splines. Recouple the transmission to the engine correctly. Tighten the flexible plate mounting bolts to the flywheel through the access hole in the case. Note: Tighten the bolts evenly in a criss-cross pattern. (5) Connect pipes to the radiator. (6) Fill the following parts with oil or water. Front axle: Gear oil Transmission: Torque converter oil Radiator, engine: Coolant, anti-freeze coolant Fill engine oil, hydraulic oil, etc. Note: For removal/installation of the engine, and the transmission and differential assembly, See “POWER TRAIN”.
5-6
CHAPTER 5 POWERSHIFT TRANSMISSION
4. 4.1
Disassembling Torque Converter Disassembly Sequence
5
4
6
7 3
6
4 7 1 2 3 608989
1. 2. 3. 4.
4.2
Bolts, Spring washers, Plate Flexible plate, Pilot boss, O-ring Bolts, Drive cover, Ball bearing Spacer, Turbine assembly
5. 6. 7.
Thrust washer, Thrust bearing Stator assembly, Rollers, Hub, Spring, Spring cup Ball bearing, O-ring, Pump boss, Pump impeller, Bolts
Suggestions for Disassembly
The torque converter assembly has no drain plug and cannot be drained completely. Drain oil by turning pump boss 7 downward when the assembly is removed.
5-7
CHAPTER 5 POWERSHIFT TRANSMISSION
5.
After Disassembling Torque Converter
5.1
Pump Impeller
(1) Check for cracks. (2) Check for oil leaks due to loose pump boss bolts at impeller or defective O-ring. (3) Check the face of pump boss for wear in contact with oil seal.
1
608990 1. O-ring
5.2 (1) (2) (3) (4) (5) (6)
Stator Assembly Check the stator assembly blade for cracks and loose fit to the clutch cam. Check the clutch hub and cam for wear or flaws. Check the springs and spring caps for wear, breakage, or distortion. Check the rollers for flaws, distortion, or wear. Check the clutch hub splines for defects. Check the thrust washers for wear or other defects.
4) •
2) 1)
3) 608991
Ref.
Item
Standard
Limit
1)
Outside diameter of clutch hub
65 -0.049mm (2.56 -0.00193 in.)
2)
Diameter of clutch rollers
8.1 -0.015mm (0.32 -0.00059 in.)
3)
Thickness of thrust washer
2.0 -0.05mm (0.08 -0.0020 in.)
4)
Thickness of thrust washer
3 -0.05mm (0.12 -0.0020 in.)
5.3
-0.03
-0.0012
6.49 mm (2.555 in.)
0
0
7.985 mm (0.31437 in.)
0
0
1.75 mm (0.0689 in.)
0
Turbine Runner
(1) Check the blades for cracks. (2) Check the fit of turbine boss in the runner. (3) Check the turbine boss splines for wear or other defects.
5-8
0
2.75 mm (0.1083 in.)
CHAPTER 5 POWERSHIFT TRANSMISSION 5.4
Pilot Boss
Check the portion in contact with the pilot bearing for wear or other defects.
1)
608992
Ref.
Item
Standard
1)
Diameter of portion in contact with pilot bearing
20 -0.020mm (0.78 -0.00079 in.)
5.5
-0.007
Limit
-0.00028
19.85 mm (0.781 in.)
Flexible Plate
(1) After installing flexible plate, measure the face runout of the plate with a dial gauge. Replace the plate if the runout exceeds the service limit. Item Face runout of flexible plate
Standard
Limit
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
(2) When the flexible plate is installed on the transmission, make sure the clearance between the end face of the transmission case and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.).
1)
608993
Ref. 1)
Item Distance between T/C housing and surface and Flywheel fitting surface of Flexible plate
Standard 4 to 6 mm (0.157 to 0.236 in.)
Note: After installing the flexible plate, fasten the plate to the transmission case with wire.
5-9
CHAPTER 5 POWERSHIFT TRANSMISSION
6. 6.1
Assembling Torque Converter Assembly Sequence
•
1
11
•
7
12
3
•
2 •
16
•
15
•
•
•
13 14
• •
• ••
• •
•
10 9 8
6
4
5
608994
1. 2. 3. 4. 5. 6. 7. 8.
5-10
Pump impeller Pump boss, O-ring, Bolt, Washer Ball bearing Stator assembly Spring, Spring cap Rollers Stator hub Thrust washer
9. 10. 11. 12. 13. 14. 15. 16.
Thrust bearing Thrust washer Turbine assembly Drive cover, O-ring, Bolt, Washer Spacer Ball bearing Pilot boss, O-ring Flexible plate, Bolt, Washer
CHAPTER 5 POWERSHIFT TRANSMISSION 6.2
Suggestions for Assembly 5 5
Stator assembly (1) Position stator hub 7 in the stator as shown. Put spring 5 and spring cup 5 in each hole, and press in the roller 6 while pushing the spring cap. (2) Install total of ten rollers, and return the stator hub in its original position. (3) Upon assembling, rotate the stator hub by hand, making sure that it rotates in one direction.
6
7
608995
Selection of spacer
A
Measure the dimensions A, B and C, and select spacer D so that the clearance is 0.2 to 0.8 mm (0.0078 to 0.0315 in.) and insert it in place.
D
B
C
608996
Part numbers
Thickness of spacer
91823-01700
2.5 mm (0.098 in.)
91823-01600
2.7 mm (0.106 in.)
91823-01400
3.0 mm (0.118 in.)
Standard dimensions
A
22.1 mm (0.87 in.)
B
16 mm (0.63 in.)
C
3.5 ± 0.05 mm (0.138 ± 0.002 in.)
5-11
CHAPTER 5 POWERSHIFT TRANSMISSION
7.
Disassembling Transmission
7.1
Control Valve and Strainer
Disassembly sequence
3
4
2 1
6
5 6
1) 5 608997
1. 2. 3.
Drain plug, Washer Torque converter thermo unit Control valve
Note: Suction pipe replaced by hose on 3.5 to 5.5 ton models.
5-12
4. 5. 6. 1)
Subplate, Gasket Strainer pipe, Bolts Strainer assembly, Gasket, Bolts New for 3.5 to 5.5 ton models
CHAPTER 5 POWERSHIFT TRANSMISSION 7.2
Pump Body Assembly
Disassembly sequence
6 1 2 4
5
3 4
608998
1. 2. 3.
Pump body, Oil seal, Bushing Internal gear, Drive gear, O-ring Stator shaft, Cap, Dowel pin
4. 5. 6.
Valve, Spring, Washer, Snapring Gasket Turbine shaft, Sealring, Snapring
Note: It is not unnecessary to remove the cap and dowel pin from the stator shaft or the bushing and oil seal from the pump body unless they are defective. Suggestion for disassembly Removing pump body assembly
1
Unscrew all bolts securing the pump body assembly, and remove the assembly by making use of the jacking bolt holes in the stator shaft.
608999 1. Bolt
Special tool Bolt
Part number 67284-15400
5-13
CHAPTER 5 POWERSHIFT TRANSMISSION 7.3
Countershaft (2nd Shaft)
Disassembly sequence
3 51
2
6 7 4 609000
1. 2. 3. 4.
Snapring Rear cover, O-ring Countershaft Ball bearing
5. 6. 7.
Countergear Ball bearing Countergear, Snapring
Suggestion for disassembly Removing bearings Remove snapring 1 from its groove in advance. Screw a sliding hammer into the tapped hole in shaft 3, pull off the shaft, and remove bearings 4 and 6 from the transmission case.
5-14
CHAPTER 5 POWERSHIFT TRANSMISSION 7.4
Countershaft (3rd Shaft)
Disassembly sequence
7
6
3 4
2
5
1
609001
1. 2. 3. 4.
7.5
Snapring Rear cover, O-ring Countershaft Ball bearing
5. 6. 7.
Countergear Roller bearing (inner) Countergear, Snapring
Countershaft (3rd Shaft)
Disassembly sequence
4
3
2 1 5
609002
1. 2. 3.
Output cover Output shaft subassembly Ball bearing
4. 5.
Output gear Shims
5-15
CHAPTER 5 POWERSHIFT TRANSMISSION Suggestion for disassembly Removing output shaft Using the special tool, pull out the output shaft. The output gear will interfere with the input shaft drum; this makes it necessary to remove the output shaft by tapping the output gear with a copper hammer through the countershaft (3rd shaft) mounting hole.
1 1. Special tool
Special tool Puller
Part number 91868-02100
Shims Reuse the shims removed during disassembly.
5-16
609003
CHAPTER 5 POWERSHIFT TRANSMISSION 7.6
Forward-Reverse Clutch Shaft (Current Production)
Disassembly sequence
1
2
4
3
5
7
6
8 20
2625 28 2927 30
29
23
16
2214 21
24
15 16
19 18
13 17
11
12
10
9
19
609005
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Servo case, O-ring O-ring Seal ring Ball bearing Thrust washer Forward gear Needle bearing Thrust washer Ball bearing Thrust washer Reverse gear Needle bearing Thrust washer Snapring Pressure plate
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Friction plate, Mating plates Snapring Pressure plate Friction plate, Mating plates Snapring Retainer Spring Clutch piston, Ball, Screw Seal ring Snapring Retainer Spring Clutch piston, Ball, Screw Sealring Clutch shaft
Note: It is unnecessary to remove the balls and screw from the clutch piston, the screw from the clutch shaft, or the steel ball from the servo case.
5-17
CHAPTER 5 POWERSHIFT TRANSMISSION 7.7
Forward-Reverse Clutch Shaft (First Production)
Disassembly sequence
2
4
3
5
7
6
8 20 28 30
1
2625 2927
29
23
16
14 22 21
24 19
15 16
18
11 13 17
10 12
9
19
609006
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Servo case (O-ring) O-ring Sealring Ball bearing Thrust washer Forward gear Needle bearing Thrust washer Ball bearing Thrust washer Reverse gear Needle bearing Thrust washer Snapring Pressure plate
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Friction plate, Mating plates Snapring Pressure plate Friction plate, Mating plates Snapring Retainer Spring Clutch piston (Ball, Screw) Sealring Snapring Retainer Spring Clutch piston (Ball, Screw) Sealring Clutch shaft
Note: It is unnecessary to remove the balls and screws from the clutch piston, the screw from the clutch shaft, or the steel ball from the servo case.
5-18
CHAPTER 5 POWERSHIFT TRANSMISSION
1
Suggestion for disassembly Disassembling clutch drum Using the special tool or an arbor press, compress return springs 22 and 27, and remove snaprings 20 and 25.
609007 1. Special tool
Special tool
Part number
Piston tool
8.
92267-00300
Inspection and Repair After Disassembling Transmission
8.1 (1) (2) (3) (4)
Oil Pump Install the internal gear and the drive gear in the pump body, and measure top clearance 2. Using a dial gauge, measure side clearance 1 between the gears and the pump case. Measure clearance 3 of the drive gear in the pump boss (notch). Check the relief valve for distortion or other defects.
1 3 2
609008
Ref.
Item
Standard
Limit
1
Side clearance
0.05 to 0.11 mm (0.0019 to 0.0043 in.)
0.20 mm (0.0079 in.)
2
Top clearance
0.6 to 0.66 mm (0.0236 to 0.0259 in.)
0.8 mm (0.031 in.)
3
Drive gear clearance in pump boss notch
0.2 to 0.4 mm (0.008 to 0.016 in.)
1.0 mm (0.039 in.)
5-19
CHAPTER 5 POWERSHIFT TRANSMISSION 8.2
Pump Boss
2
1
Ref.
Item
Standard
1
Diameter of portion in contact with oil seal and bushing
70 -0.0046mm (2.76 -0.00181 in.)
6.90 mm (2.7520 in.)
2
Inside diameter of boss bushing
70.06 to 70.10 mm (2.7583 to 2.7598 in.)
70.3 mm (2.768 in.)
8.3
0
609009
Limit 0
Stator Shaft
(1) Make sure that bearings fit tight to the shaft. (2) Check the splines for wear or damage. (3) Check the oil passages for clogging.
8.4
Clutch Pistons
(1) Shake each piston, making sure that the balls move freely in the piston. Note: Do not overhaul the pistons unless they are defective. (2) Check the seal rings and their grooves for wear or damage.
1 1. Sealring
8.5
Friction Plates and Mating Plates
(1) Check for sign of seizure, uneven contact, warpage, or excessive wear. (2) Check the splines for wear or damage. (3) Check the oil passages for clogging.
5-20
609010
CHAPTER 5 POWERSHIFT TRANSMISSION 8.6
Clutch Drums
(1) Check the mating plate sliding surfaces for wear or damage. (2) Check the clutch piston sliding surfaces for wear or damage.
8.7
Clutch Gears (Forward and Reverse)
(1) Check the gear and the splines for wear or damage. (2) Check the gear surface in contact with needle roller bearing for wear or damage.
7, 8
6
3
2
1 4
5 Ref.
Item
Standard
Limit
1
Thickness of mating plate
2.3 ± 0.07 mm (0.091 ± 0.028 in.)
2.1mm (0.0028 in.)
2
Thickness of friction plate
2.6 ± 0.1 mm (0.102 ± 0.004 in.)
2.2 mm (0.087 in.)
3
Backlash of friction plate with gear
0.10 to 0.30 mm (0.0039 to 0.0118 in.)
-
4
Width of seal ring
4 -0.03mm (0.16 -0.0012 in.)
5
Width of seal ring groove in piston
6
-0.01
-0.0004
3.5 mm (0.138 in.)
4 +0.1mm (0.16 +0.004 in.)
+0.2
+0.008
4.5 mm (0.177 in.)
Free length of clutch spring spring constant
62.9 mm (2.476 in.) 31.312 N·m (3.193 kgf·m) [178.648 lbf·in.]
62 mm (2.440 in.)
7
Width of clutch piston seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
2.0 mm (0.079 in.)
8
Width of clutch piston seal ring groove
2.5 +0.1mm (0.098 +0.004 in.)
+0.2
+0.008
609011
3.1 mm (0.122 in.)
5-21
CHAPTER 5 POWERSHIFT TRANSMISSION 8.8
Turbine Shaft and Clutch Shaft
Check the sealring and the contact surface for wear or damage.
1)
4) 5)
6)
2)
3) 609012
Ref.
Item
Standard
Limit
1)
Width of turbine shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
2.0 mm (0.079 in.)
2)
Width of piston seal ring groove in turbine shaft
3)
Inside diameter of turbine shaft in contact with seal ring
4)
Width of clutch shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
5)
Width of clutch shaft seal ring groove
2.5 +0.1mm (0.098 +0.004 in.)
6)
Inside diameter of servocase in contact with seal ring
8.9
+0.2
35
+0.025 +0.00098 0 mm (1.38 0 in.)
+0.2
35
+0.008
+0.025 +0.00098 0 mm (1.38 0 in.)
Clutch Shaft, Countershaft, and Output Shaft
(1) Check the splines for wear or damage. (2) Check oil passages for clogging.
8.10 Gears Check each gear for worn teeth or splines.
8.11 Strainer Assembly Disassemble and clean. Replace the strainer if defective.
5-22
+0.008
2.5 +0.1mm (0.098 +0.004 in.)
3.0 mm (0.118 in.) 35.2 mm (1.386 in.) 2.0 mm (0.079 in.) 3.0 mm (0.118 in.) 35.2 mm (1.386 in.)
CHAPTER 5 POWERSHIFT TRANSMISSION
9. 9.1
Assembling Forward-Reverse Clutch Shaft Subassembly Assembly Sequence
10 6
9 ••
18 19
7 8 •
•
3
8
7
9 10 6
• •
•
•
14 •
•
20
•
13
•
•
•
•
••
• ••
•
•
15 •
• 1 12
21 •
• 17 16
5
4
2
3
11 5
• 2
4 609013
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Input shaft Seal ring, Piston seal Piston Spring Retainer Snapring Mating plates Friction plate Pressure plate Snapring Thrust washer
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Needle bearing Gear (R drive) Thrust washer Ball bearing Thrust washer Needle bearing Gear (F drive) Thrust washer Ball bearing Seal ring
5-23
CHAPTER 5 POWERSHIFT TRANSMISSION
10. Assembling Forward-Reverse Clutch Shaft (1st Shaft) 10.1 Preparation (1) (2)
Install the following parts on the transmission case in advance: Ball bearing B for output shaft Outer race C of roller bearing for countershaft (3rd shaft) Ball bearing D for countershaft (2nd shaft) Put outer gear E in the transmission case.
10.2 Assembly Sequence
2
•
•
D
•
1 •
C •
B •
E
609014
1.
Servo case (O-ring, Bolt, Washer)
2.
10.3 Suggestions for Assembly (1) Install the forward-reverse clutch shaft in an assembled unit. (2) Apply ATF oil on the inside surface of servo case and the seal ring.
5-24
Forward-reverse clutch shaft assembly
CHAPTER 5 POWERSHIFT TRANSMISSION (3) When inserting pistons 3 into clutch drum, put ATF oil on its seal ring portion. (4) Installing return spring Using the special tool or an arbor press, compress springs 4, retainer 5 and install snapring 6.
1
609007 1. Special tool
Special tool Piston tool
Part number 92267-00300
(5) Installing clutch plates Make sure that the combination and number of the plates are correct. Install the plates while putting ATF oil on them. When replacing the friction plates 8, also replace the mating plates 7.
1 2
609015 1. Friction plate
-
2. Mating plate
Installing thrust washers Make sure that the oil-groove side of thrust washers 11, 14, 16, and 19 faces the gear when installed. Put ATF oil on washers before installing thrust washers.
609016
(6) After assembling the clutch, apply air pressure of approximately 98 kPa (1.0 kgf/cm2) [14.2 psi] to the oil hole to make sure that the piston moves smoothly without any sign of air leaks.
5-25
CHAPTER 5 POWERSHIFT TRANSMISSION
11. Assembling Output Shaft (4th Shaft) 11.1 Assembly Sequence
4 6 15 7 12 1011 8 9 13 14 • •
•
•
•• • •
4
• • • 5
1 2
3
609017
1. 2. 3. 4. 5. 6. 7. 8.
Ball bearing Gear Shims Output shaft assembly Bolt, Washer Output shaft Taper roller bearing O-ring
9. 10. 11. 12. 13. 14. 15.
Oil seal race Bearing case Oil seal O-ring Nut Snapring Output cover
11.2 Suggestions for Assembly (1) Install the output shaft as an assembly. (Install 6 through 15 as an assembled unit.) (2) Put LG2 grease on the oil seal. (3) Tighten nut 13 to the specified torque, and stake it in place to prevent loosening. Tightening torque 353 to 392.2 N·m (36 to 40 kgf·m) [79.3 to 88.1 lbf·ft]
Special tool Wrench
5-26
Part number 91868-00300
CHAPTER 5 POWERSHIFT TRANSMISSION
12. Assembling Countershaft (3rd Shaft) 12.1 Assembly Sequence
3
2 7 6 5
• •
•
•
4
• • •
• 1
609018
1. 2. 3. 4.
Countershaft Snapring Snapring, gear Roller bearing inner race (Install 1 to 4 as an assembled unit.)
5. 6. 7.
Gear Ball bearing Cover, O-ring, Bolt, Washer
12.2 Suggestions for Assembly Assemble shaft 1, snapring 2, gear 3, and roller bearing inner race 4 outside the transmission case, without fitting the snapring in its groove. Then fit the shaft to gear 5 inside the case.
2
1
3
4 609019
5-27
CHAPTER 5 POWERSHIFT TRANSMISSION
13. Assembling Countershaft (3rd Shaft) 13.1 Assembly Sequence
6 8 2 7
• •
3
•
•
5
4
•
•
1
• •
•
609020
1. 2. 3. 4. 5.
Ball bearing Countershaft Snapring Snapring, Gear Collar (Install 2 through 5 as an assembled unit.)
6. 7. 8.
Gear Ball bearing Cover, O-ring, Bolt, Washer
13.2 Suggestions for Assembly Install shaft 2 on the transmission case with snapring 3 temporarily fitted on the shaft.
3
2
5
4 •
•
609021
5-28
CHAPTER 5 POWERSHIFT TRANSMISSION
14. Assembling Pump Body Assembly 14.1 Assembly Sequence
5 •
1
2
3
•
•
•
• • • •
6
• 4 609022
1. 2. 3. 4.
Pump body, Oil seal, O-ring Internal gear, Drive gear, O-ring Stator shaft Dowel pin (Install 1 through 4 as an assembled unit.)
5. 6.
Pump body assembly, Gasket, Bolt, Washer Turbine shaft, Snapring, Seal ring
14.2 Suggestions for Assembly (1) (2) (3) (4)
Install the pump body on the transmission case in assembled condition. Put engine oil on the internal gear and drive gear 2 when installing them on pump body 1. Put grease on the oil seal and bushing of pump body 1. After assembly, measure each gear backlash with a dial gauge. Item
Standard
Backlash of countergear with output gear
0.14 to 0.27 mm (0.005 to 0.0106 in.)
Backlash of other gears
0.14 to 0.26 mm (0.0055 to 0.0102 in.)
5-29
CHAPTER 5 POWERSHIFT TRANSMISSION
15. Assembling Control Valve and Strainer To assemble, follow the reverse of disassembly sequence. Replace the gaskets.
16. Disassembling Control Valve 16.1 Disassembly Sequence
9
13
14
4
4
5
12 6 6 11
15
8
7
1
2
3
10 2 1
609023
1. 2. 3. 4. 5. 6. 7. 8. 9.
Solenoid valve, O-ring O-ring, Spring seat, Spring Directional spool Cover, O-ring, Bolt, Washer Accumulator piston, Accumulator spring Regulator valve, Spring seat, O-ring, Main relief spring, Slug Stopper pin, O-ring Clutch valve plunger, Clutch valve spring, Clutch valve, Return spring, Slug Filter, O-ring (last chance filter)
10. 11. 12. 13. 14. 15.
Oil seal Plug, Bearing roller, O-ring Accumulator spring seat, Pin, O-ring Drain plug, Gasket Orifice screw, O-ring Control valve body
Note: Do not remove oil seal 10 unless it is defective. To remove stopper pin 7, use a M4 x 0.7 threaded bolt or screw 25 mm (1 in.) long.
5-30
CHAPTER 5 POWERSHIFT TRANSMISSION
17. After Disassembling Control Valve (1) Check the valve housing for clogged oil passages. (2) Check each plunger for sign of wear, damage, or seizure. (3) Check the oil seals for damaged lips. (4) Check the orifice in the main regulator valve for clogging. Also check the valve spring for weakness or damage.
609024
7) 6) 1) 2) 3) 4) 8)
8)
5)
609025
5-31
CHAPTER 5 POWERSHIFT TRANSMISSION
Ref.
Item
Standard
Limit
1)
Free length of main relief valve inner spring
75 mm (2.95 in.) 2.122 N·m (0.215 kgf·m) [12.050 lbf·in.]
72 mm (2.83 in.)
2)
Free length of main relief valve outer spring
50 mm (1.97 in.) 0.838 N·m (0.0855 kgf·m) [4.783 lbf·in.]
48 mm (1.89 in.)
3)
Free length of clutch valve spring
39 mm (1.54 in.) 2.128 N·m (0.217 kgf·m) [12.141 lbf·in.]
38 mm (1.50 in.)
4)
Free length of clutch valve spring
28 mm (1.10 in.) 0.479 N·m (0.0488 kgf·m) [2.730 lbf·in.]
26.5 mm (1.04 in.)
5)
Free length of torque converter inlet/outlet pressure regulating valve spring
32 mm (1.26 in.) 4.560 N·m (0.465 kgf·m) [26.017 lbf·in.]
31 mm (1.22 in.)
6)
Free length of accumulator valve outer spring
91 mm (3.58 in.) 7.303 N·m (0.0745 kgf·m) [41.666 lbf·in.]
89 mm (3.50 in.)
7)
Free length of accumulator valve inner spring
130 mm (5.12 in.) 0.597 N·m (0.0609 kgf·m) [3.408 lbf·in.]
128 mm (5.04 in.)
8)
Free length of directional spool spring
32.5 mm (1.279 in.) 8.616 N·m (0.8786 kgf·m) [49.158 lbf·in.]
32 mm (1.26 in.)
5-32
CHAPTER 5 POWERSHIFT TRANSMISSION
18. Assembling Control Valve 18.1 Preparation Thoroughly wash the oil passages in the valve, and make sure that they are not clogged.
18.2 Assembly Sequence
Section B-B
1
12 11
4 B
B
2
10
5
12
Section C-C
10
C
C
8 12 7
6
D
15
8
7
13
D
14
15
9 Section D-D
3 609026
1. 2. 3. 4. 5. 6. 7. 8.
Control valve body Orifice screw Filter Accumulator spring seat, O-ring, Pin Plug, O-ring, Bearing roller Oil seal Filter, O-ring (last chance filter) Clutch valve plunger, Clutch valve, Clutch valve spring, Return spring, Slug
9. Stopper pin, O-ring 10. Regulator valve, Slug, Main relief spring, Spring seat, Oring 11. Accumulator piston, Accumulator spring 12. Cover, O-ring, Bolt, Washer 13. Directional spool 14. Spring seat, Spring, O-ring 15. Solenoid valve, O-ring
5-33
CHAPTER 5 POWERSHIFT TRANSMISSION
19. Adjustment 19.1 Oil Pressure Measurement (1) Connect a pressure gauge (20 kgf/cm2) to the main pressure and the clutch pressure taps (Rp1/8) 9206700300.
1
• • •
3
2
609027
1. Torque converter inlet pressure 3. Main pressure 2. Clutch pressure
Special tool
Part number
Connector
92067-00300
* Hose
64309-17722
* Meter
64309-17713
Tools marked with (*) are included in the gauge kit 64309-17700. (2) Start and run the engine at idling speed, and check to make sure that the oil level is correct in the transmission case. (3) Warm up until the torque converter oil temperature gauge indicates the GREEN zone. (4) Run the engine at 1000 to 1500 min-1. Note: Observe the engine tachometer reading. Item
Standard
Main pressure (engine at 1600 ± 100 min-1)
0.98 to1.23 Mpa (10.0 to 12.5 kgf·cm2) [142.2 to 177.8 psi]
Clutch pressure (engine at 1600 ± 100 min-1)
0.98 to1.23 Mpa (10.0 to 12.5 kgf·cm2) [142.2 to 177.8 psi]
Torque converter inlet pressure (engine at 1600 ± 100 rpm)
0.10 to0.49 Mpa (1.0 to 5.0 kgf·cm2) [14.2 to 71.1 psi]
Lubrication pressure (engine at 1600 ± 100 min-1)
0.05 to0.29 Mpa (0.5 to 3.0 kgf·cm2) [7 to 43 psi]
5-34
CHAPTER 5 POWERSHIFT TRANSMISSION Hydraulic pressure test tools (reference) for single speed transmission Special tool
Part number
Remarks
Torque converter inlet
* Connector
64309-17733
PT1/8 thread
z
* Hose
64309-17722
-
z
* Connector
64309-17731
For gauge
z
* Gauge
64309-17714
588 kPa (6 kgf/cm2) [85 psi]
z
Note: Tools marked with (*) are included in the gauge kit 64309-17700.
19.2 Inching Valve Test Preparation (1) Raise the front axle housing with a jack and place wood blocks under the outer mast. Tilt the mast FORWARD to raise the front wheels. (2) Block the rear wheels.
R CAUTION Remember, the front wheels will rotate when the clutch pressure is tested. Adjusting procedure (1) Set the inching pedal stroke to the specified value. (2) Connect a pressure gauge to the clutch pressure tap (Rp1/8) 92067-00300. Use the same special tools. (3) Move the forward-reverse lever to the FORWARD position. (4) Gradually pull out the clutch (inching) valve plunger from its fully pushed position, and plot the oil pressure curve relative to the plunger stroke. Make sure that the pressure curve is identical with the curve shown.
981 (10) [142]
1) 216 (2.2) [31] 0
5 (0.20)
10 (0.39)
2)
609028
1) Torque converter inlet pressure 2) Clutch pressure kPa (kgf/cm2) [psi]
19.3 Stall Speed Measurement (1) (2) (3) (4) (5)
Run the engine at idling speed, and check that the oil level is correct in the transmission case. Warm up the torque convertor oil. Block the front and rear wheels, and apply the parking brake. Run the engine at idling speed. Move the forward-reverse lever to the FORWARD position and depress the brake pedal with left foot and gradually depress the accelerator pedal all the way. Under this condition, observe the engine tachometer reading to measure the stall speed. Item
Stall speed, min-1 (tolerance: ± 100 min-1)
3.5 to 5.5 ton
6.0 to 7.0 ton
2000
2080
5-35
CHAPTER 5 POWERSHIFT TRANSMISSION R CAUTION DO NOT attempt to depress the inching pedal. DO NOT continue “Stall speed” run for more than 10 seconds. Failure to follow this precaution could result in destruction of the torque converter. (6) Read the stall speed for reverse drive the same way. Note: -
Any stall speed within ± 100 min-1 of the specification is satisfactory. If the engine or torque converter is changed, the stall speed will vary since the stall speed is determined by the combination of engine and torque converter.
19.4 10 Meters (33-ft) Starting Acceleration Test (1) (2) (3) (4)
Be ready with the engine idling and the direction lever in the NEUTRAL position. At the signal, shift into FORWARD and, at the same time, depress the accelerator pedal all the way. Measure the amount of time that elapses for the forklift truck to travel 10 meters (33 ft) with a stop watch. Measure for reverse travel, too.
Travel time (No load)
5 seconds, maximum
19.5 Adjusting Brake Pedal 1) 2) 3)
Bleed air out of the brake lines from the reserve tank through master cylinder to the wheel cylinder. Adjust and check the clearance between the drum and brake lining. Install locknut 2 (right-hand thread), push rod 3 (righthand thread), locknut 4 (left-hand thread) and clevis 5 (left-hand thread) on push rod 1 of the brake booster. Make sure that L1 dimension is within the standard values. L2 dimension is used for actual check. Screw-in length should be the same for left-hand and right-hand threads.
5
4
3
2
L2
1
L1 609029
1. Push rod 2. Locknut 3. Push rod
5-36
L1
155 mm (6.1 in.)
L2
88 mm (3.46 in.)
4. Locknut 5. Clevis
CHAPTER 5 POWERSHIFT TRANSMISSION 4) 5) 6) 7)
Install the push rod assembly on the brake pedal. Adjust the brake pedal height A to 160 mm (6.3 in.) by turning the stopper bolt, and tighten the locknut. Turn ON the engine. Depress the brake pedal by hand to check play B of the brake pedal.
C
B A
1 2
3
609030 1. Locknut 2. Stopper bolt
Item Brake pedal play B
3. Push rod assembly
Standard 5 mm (6.1 in.)
If the play is not within the standard values, loosen locknuts 2 and 4 and turn push rod 3 to adjust dimension L1. Item Brake pedal stroke C
Standard 37 mm (1.456 in.)
5-37
CHAPTER 5 POWERSHIFT TRANSMISSION 19.6 Adjusting Inching Pedal 1) Connect a pressure gauge to the clutch pressure tap. Note: For the special tools to be used with the pressure gauge, see 5-34 "Oil Pressure Measurement". 2) 3)
4)
F
1
E
Adjust the above-floor height A of the inching pedal to 175 mm (6.89 in.) with the stopper bolt. Adjust clearance B between the inching pedal and the brake pedal contact surface to be 16 mm (0.63 in.) with the stopper bolt and secure this clearance with the locknut. Turn ON the engine, and release the brake pedal. Depress the inching pedal until the brakes start applying (resistance is felt on the pedal). Under this condition, adjust the inching cable length so that spool stroke D becomes 16.5 mm (0.649 in.) (oil pressure: 0 kPa (0 kgf/cm2) [0 psi]).
2 A
3
B
609031 1. Stopper bolt 2. Locknut
Item Inching pedal stroke E (brake functioning) 5)
-
3. Stopper bolt
Standard 82.4 mm (3.24 in.)
Release the inching pedal, and make sure that clutch valve plunger stroke C is 8 to 9.5 mm (0.314 to 0.374 in.) at the pressure of 883 to 1079 kPa (9 to 11 kgf/cm2) [128 to 156 psi]. If plunger stroke C is not within the standard values, adjust the brake and the brake pedal as shown below: The stroke is 9.6 mm (0.378 in.) or more: The shoe to lining clearance is too small. The stroke is 7.9 mm (0.311 in.) or less: The shoe to lining clearance is too large.
1
609032 1. Inching cable
5-38
CHAPTER 5 POWERSHIFT TRANSMISSION
D
C
2)
10 5 (0.39) (0.20)
981 (10) [142] 216 (2.2) [31] 0
1) 609033 1) Clutch valve plunger stroke mm (in.)
Item
2) Clutch oil pressure kPa (kgf/cm2) [psi]
Standard
A
Inching pedal height from frame to top of pedal pad
175 mm (6.89 in.)
B
Clearance between inching pedal stopper bolt and brake pedal
16 mm (0.63 in.)
C
Clutch valve plunger stroke
8 to 9.5 mm (0.314 to 0.374 in.)
D
Clutch valve plunger stroke at brake functioning
16.5 mm (0.649 in.)
E
Inching pedal stroke (brake functioning)
82.4 mm (3.24 in.)
F
Inching pedal stroke
152 mm (5.98 in.)
5-39
CHAPTER 5 POWERSHIFT TRANSMISSION
20. Specifications 20.1 Automatic 2-speed Transmission (6.0 to 7.0 Ton)
Item
Torque converter
6.0 to 7.0 ton Type
3 element 1 stage 2 phases
Manufacturer model
M15
Stool torque ratio
3. 2
Operation type
F/R electric column shift H/L automatic transmission 1-speed 5.104 (
Power transmission
Forward 2-speed 2.882 (
Transmission Gear ratio
1-speed 5.104 ( Backward 2-speed 2.882 (
5-40
45 24 36 34 45 24 36 34
×
×
×
×
49 18 49 18 49 18 49 18
)
)
)
)
CHAPTER 5 POWERSHIFT TRANSMISSION
21. Structure 21.1 Transmission 2-speed
b
1
c
h
•
a
10
•
•
•
•
2 •
g
•
9
• •
e
8 •
d
4
•
•
•
k
•
•
•
• •
• f
7 12
• 1
2nd shaft
3
•
i
5 j
6
1st shaft
3rd shaft 4th shaft
11
609034
1. 2. 3. 4. 5. 6.
Control valve Torque converter assembly Flexible plate Pump body assembly Speed sensor Magnet strainer
7. 8. 9. 10. 11. 12.
Output shaft (4th shaft) Countershaft (3rd shaft) Input shaft (1st shaft) Countershaft (2nd shaft) Pulse generator Solenoid valve
5-41
CHAPTER 5 POWERSHIFT TRANSMISSION Power flow Range
Path
Forward 1st (F1)
h f i j k
Forward 2nd (F2)
g d i jk
Reverse 1st (R1)
e bc f i j k
Reverse 2nd (R2)
ebad ij k
21.2 Automatic 2-speed Change Mechanism
3
4
2
1 0.5 mm (0.02 n)
7
5 6
1) 2)
8
609035
1. 2. 3. 4. 5.
5-42
Output gear Electronic control unit (ECU) Speed selector switch Speed (solenoid) valve 1st speed clutch
6. 7. 8. 1) 2)
2nd speed clutch Pulse generator Transmission case Electric signal Hydraulic pressure signal
CHAPTER 5 POWERSHIFT TRANSMISSION 21.3 Control System Location of control devices
3
2
1
5
4 1. 2. 3.
ECU (Electronic Control Unit) Power source Speed selector switch
609036
4. 5.
Speed sensor Solenoid valve
The automatic 2-speed transmission consists of an F2-R2 powershift transmission and a control system comprising speed sensor, electronic control unit (ECU) and solenoid valve. Speed can be changed from “Automatic” to “1st speed” mode by means of the speed selector switch. The speed selector switch was moved to the overhead guard pillar in 2006. Selector switch position
Travel speed 1-speed
0 to 9 km/h (0 to 5.6 mph)
2-speed
9 to 24.5 km/h (5.6 to 15.2 mph)
Automatic 2 speeds
1st speed
0 to 14 km/h (0 to 8.7 mph)
5-43
CHAPTER 5 POWERSHIFT TRANSMISSION 21.4 Solenoid Valve
• 4
3
1
2
5
6 609037
1. 2. 3.
Solenoid body Solenoid valve Spring
4. 5. 6.
Cover Cover Solenoid valve (electric)
Note: For the three systems below, see 5-1 "1-Speed Transmission (3.5 to 5.5 Ton)". (1) Torque converter (2) Control system (3) Control valve Removing and Installing Solenoid Valve For removal and installation, see 5-30 "Disassembling Control Valve". Disassembling Solenoid Valve For disassembly, see 5-68 "Disassembling Solenoid Valve".
5-44
CHAPTER 5 POWERSHIFT TRANSMISSION 21.5 Powershift Transmission Hydraulic System Schematic 1-Speed
4
3
5
PC
2)
6
7
8
R
9
P2 F
7 P1
2
4)
10
PM
3) 11
1)
12
PD
5)
1 13 1. 2. 3. 4. 5. 6. 7. 8. 9.
PL
Oil cooler Torque converter Accumulator valve Main regulator valve Clutch (inching) valve FR filter Last chance filter Solenoid valve Directional valve (Valve top surface) Item
609084
10. 11. 12. 13. 1) 2) 3) 4) 5)
Solenoid valve Gear pump Suction strainer Lubrication oil Torque converter outlet pressure Valve top surface with D stamp Valve top surface with M stamp Torque converter inlet pressure Lubricating circuit Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.05 to 0.29 MPa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
All tests run
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine min-1
5-45
CHAPTER 5 POWERSHIFT TRANSMISSION 21.6 Powershift Transmission Hydraulic System Schematic 2-Speed
3 2 1
PO
15
4
1)
PL
5
5)
6)
P1
4)
6
PM
3) 13
2) 7
PC
10 14
9
9
F
R
P2
11
12
8
609038
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Oil cooler air to oil Torque converter Solenoid valve plunger Solenoid valve Accumulator valve Main regulator valve Clutch pressure Solenoid valve Last chance filter FR filter Directional valve Item
12. 13. 14. 15. 1) 2) 3) 4) 5) 6)
Solenoid valve Gear pump Suction strainer with magnet Lubrication oil pressure Torque converter outlet pressure Valve top surface with D stamp Main Pressure Valve top surface with M stamp Torque converter inlet pressure Lubricating circuit
Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.05 to 0.29 MPa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
All tests run
5-46
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine min-1
CHAPTER 5 POWERSHIFT TRANSMISSION 21.7 Hydraulic Control (Forward 1st Speed)
1
2
3
4 8
5
6
7 1) 2) 609039
1. 2. 3. 4. 5.
Pilot pressure Solenoid valve plunger Solenoid valve OFF (open) ECU Transmission
6. 7. 8. 1) 2)
Output gear Pulse generator Solenoid valve Pilot pressure Lubricating circuit
5-47
CHAPTER 5 POWERSHIFT TRANSMISSION 21.8 Hydraulic Control (Forward 2nd Speed)
5
4
1
2 3
6 7 11
10
9
8 1) 2) 3) 609040
1. 2. 3. 4. 5. 6. 7.
5-48
Pilot pressure Solenoid valve plunger Last chance Filter Plunger Signal input Solenoid valve ON (open) ECU
8. 9. 10. 11. 1) 2) 3)
Pulse generator Output gear Transmission Solenoid valve Pilot pressure High-pressure oil Signal
CHAPTER 5 POWERSHIFT TRANSMISSION
22. Disassembling Transmission 22.1 Control Valve and Side Cover Disassembly sequence
4
5
3
6
7 1 2 9 8
609041
1. 2. 3. 4. 5.
Drain plug, Washer Thermo unit Oil level gauge Solenoid valve Control valve
6. 7. 8. 9.
Subplate, O-ring, Gasket Speed sensor, Speed sensor cover, O-ring Strainer assembly, O-ring Side cover, Gasket
5-49
CHAPTER 5 POWERSHIFT TRANSMISSION 22.2 Output Shaft (4th Shaft) Disassembly sequence
2 4
1 3
609042
1. 2.
Output cover Output gear
3. 4.
Output shaft subassembly Tapered roller bearing, Race, Nut, Snapring
Suggestions for disassembly (1) Removing output shaft Use the special tool to remove output shaft subassembly 3. Output gear 2 will interfere with the gear of the countershaft (3rd shaft). This makes it necessary to remove output shaft subassembly 3 by tapping output gear 2 with a copper hammer through the side cover hole
1 1. Special tool
Special tool Special tool
Part number 91868-02100
Note: -
5-50
The same tool is used for 1-speed transmission. The ball bearing remains in the transmission case.
609043
CHAPTER 5 POWERSHIFT TRANSMISSION (2) Disassembling output shaft Usually, it is not unnecessary to disassemble output shaft subassembly 3. When it has to be disassembled, use an arbor press to remove the bearing. Make sure not to lose the shims during disassembly. (3) When removing the nut, the caulked area is ground off. Replace the nut with a new one during assembly.
609044
5-51
CHAPTER 5 POWERSHIFT TRANSMISSION 22.3 Pump Body Disassembly sequence
1 1
2
3
609045
1.
Pump body, Roller bearing (outer race), Bushing, Oil seal, Gasket, O-ring
2. 3.
Stator shaft, Valve, Spring washer, Snapring, Steel ball Drive gear, Driven gear
Suggestions for disassembly (1) Removing pump body assembly Unscrew all body mounting bolts. Using the jacking bolts, remove the subassembly.
609046
Special tool Jacking bolt
Part number 67284-15400
(2) It is unnecessary to remove the steel ball and the plug fitted on the pump body or the bushing, oil seal, steel ball, cap, etc. fitted to the stator shaft unless they are defective.
5-52
CHAPTER 5 POWERSHIFT TRANSMISSION 22.4 Countershaft (3rd Shaft) Disassembly sequence
1
8 6 7
4
3
2
5
9 1. 2. 3. 4. 5.
Cover, O-ring Roller bearing (inner race) Spacer Output gear (countergear) Gear (forward 1st speed countergear)
609047
6. 7. 8. 9.
Spacer Gear (forward 2nd speed countergear) Ball bearing Countershaft
Suggestions for disassembly (1) Removing countershaft Attach a sliding hammer to countershaft 9, and remove the shaft complete with ball bearing 8. Roller bearing 2 comes off first. Or install a bearing puller on the backside of output gear 4 to remove bearing inner race 2 and gear out the front of transmission case. Tap end of countershaft 9 to the rear. Then remove gear and countershaft.
5-53
CHAPTER 5 POWERSHIFT TRANSMISSION 22.5 Input Shaft (1st Shaft / Current Production) Disassembly sequence
6 13
5 1
3
2
16 14
15 17
4
13
15 16 12
13
14
8
7
2
9
11
10 12 12
11 12
609048
1. 2. 3. 4. 5. 6. 7. 8.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (forward 2nd speed drive), Needle roller bearing Thrust washer Ball bearing Thrust washer
9. 10. 11. 12. 13. 14. 15. 16. 17.
Gear (forward 1st speed drive), Needle roller bearing Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch ring Clutch piston, Steel ball, Screw, Sealring Seal ring Input shaft
Note: Do not remove the steel ball fitted on the servo case or the screw fitted on the input shaft.
5-54
CHAPTER 5 POWERSHIFT TRANSMISSION 22.6 Input Shaft (1st Shaft ) Disassembly sequence
5 1
3
6
13
2 4
13
17 16
15
12 9 14 13
16
15
14
11
8
7
2
10 12 12
11 12
609049
1. 2. 3. 4. 5. 6. 7. 8.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (forward 2nd speed drive), Needle roller bearing Thrust washer Ball bearing Thrust washer
9. 10. 11. 12. 13. 14. 15. 16. 17.
Gear (forward 1st speed drive), Needle roller bearing Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch ring Clutch piston, Steel ball, Screw, Sealring Seal ring Input shaft
Note: Do not remove the steel ball fitted to the servo case or the screw fitted to the input shaft.
5-55
CHAPTER 5 POWERSHIFT TRANSMISSION Suggestions for disassembly
1
(1) Removing input shaft ball bearing Use the special tools to remove ball bearing 3 from the input shaft.
2 1. Special tool (Puller)
Special tool
Part number
Puller
91268-13810
Plate
91268-13820
Bolt
F1035-10020
Puller
609050
2. Special tool (Plate)
T24
Disassembling input shaft Using the special tool or a press, compress clutch spring 14, and remove snapring 13.
1
609051 1. Special tool
Special tool Piston tool
Part number 92267-00300
Clutch piston Shake clutch piston 15 and make sure that the balls move freely in the piston. It is unnecessary to disassemble the clutch piston, if the balls move freely.
5-56
CHAPTER 5 POWERSHIFT TRANSMISSION 22.7 Countershaft (2nd Shaft / Current Production) Disassembly sequence
1
23
4
17
5 16
15
12
6
13
14
11
11 12 12
15
1614
9
8
7
3 2
10 13 12
609052
1. 2. 3. 4. 5. 6. 7. 8. 9.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (reverse 2nd speed drive), Needle roller bearing Thrust washer Snapring Thrust washer Gear (reverse 1st speed drive), Needle roller bearing
10. 11. 12. 13. 14. 15. 16. 17.
Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch spring Clutch piston, Seal ring, Steel ball, Screw Sealring Countershaft
5-57
CHAPTER 5 POWERSHIFT TRANSMISSION 22.8 Countershaft (2nd Shaft / First Production) Disassembly sequence
5 1
2
17
34
15 16 12
3
2
11 6
13
14
12
8
7
9
15
16
14
13
10
11 12
609053
1. 2. 3. 4. 5. 6. 7. 8. 9.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (reverse 2nd speed drive), Needle roller bearing Thrust washer Snapring Thrust washer Gear (reverse 1st speed drive), Needle roller bearing
10. 11. 12. 13. 14. 15. 16. 17.
Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch spring Clutch piston, Seal ring, Steel ball, Screw Sealring Countershaft
Suggestions for disassembly To disassemble the countershaft and the clutch piston, See 5-54 "Input Shaft (1st Shaft / Current Production)"5-55 "Input Shaft (1st Shaft )" disassembly of input shaft.
5-58
CHAPTER 5 POWERSHIFT TRANSMISSION
23. After Disassembling Transmission For the following parts, see 5-1 "1-Speed Transmission (3.5 to 5.5 Ton)". (1) Oil pump (2) Pump boss (3) Stator shaft (4) Clutch pistons (5) Friction plates and Mating plates (6) Clutch drums (7) Clutch gears (8) Input shaft, Countershaft, Output shaft (9) Gears (10) Strainer assembly
23.1 Input Shaft, Servo Case, and Sealrings Check the contact surfaces of each part for wear or damage. Note: The dimensions of the seal rings and their grooves for the countershaft (2nd shaft) are identical with those for the input shaft.
1), 2)
4), 5) 6)
3) 609054
5-59
CHAPTER 5 POWERSHIFT TRANSMISSION Ref.
Item
Standard value
Repair limit 2.0 mm (0.079 in.)
1)
Width of input shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
2)
Width of seal ring groove in input shaft
2.5 +0.1mm (0.098 +0.004 in.)
3)
Inside diameter of stator shaft in contact with seal ring
4)
Width of input shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
5)
Width of input shaft seal ring groove
2.5 +0.1mm (0.098 +0.004 in.)
6)
Inside diameter of clutch shaft in contact with seal ring
+0.2
35
3.0 mm (0.118 in.)
+0..025 +0.00098 0 mm (1.38 0 in.)
+0.2
35
+0.008
35.2 mm (1.386 in.) 2.0 mm (0.079 in.)
+0.008
3.0 mm (0.118 in.)
+0..025 +0.00098 0 mm (1.38 0 in.)
35.2 mm (1.386 in.)
24. Assembling Transmission 24.1 Ball Bearing and Oil Seals Assembly sequence
2
•
1
609055
1.
Ball bearing
2.
Oil seals
Note: Removal of the output shaft will leave the ball bearing and oil seals in the transmission case. Remove them for replacement only when they are found defective.
5-60
CHAPTER 5 POWERSHIFT TRANSMISSION
1
Suggestions for assembly Use the special tool to install the oil seals. Pay attention that the two oil seals face opposite to each other as shown in the illustration.
2
3
609056 1. Transmission case 2. Oil seals
Special tool
3. Special tool
Part number
Installer
91868-02200
24.2 Countershaft (2nd Shaft) and Input Shaft (1st Shaft) Preparation Assemble the input shaft subassembly. Assemble the countershaft subassembly. Assembly sequence
1 • • 2 1
3
• •
609057
1. 2.
Servo case, O-ring Countershaft subassembly
3.
Input shaft subassembly
5-61
CHAPTER 5 POWERSHIFT TRANSMISSION Assembly of input shaft subassembly and countershaft subassembly Assembly sequence is the same as the forward-reverse clutch shaft subassembly of the 1- speed Transmission.
1
Suggestions for assembly Installing clutch spring (1) Using the special tool or a press, compress clutch spring, and fit snapring.
609007 1. Special tool
Special tool Piston tool
Part number 92267-00300
(2) When inserting clutch piston into the drum of the countershaft or input shaft, put ATF oil on the seal rings. (3) Installing clutch plate Make sure that the combination and number of the plates are correct. Assemble the plates while putting ATF oil on each plate. When replacing the friction plates, replace the mating plates as a set. (4) After assembling, apply air pressure of approximately 98 kPa (1.0 kgf/cm2) [14.2 psi] to the oil hole to make sure that the pistons move freely without any sign of air leaks.
5-62
CHAPTER 5 POWERSHIFT TRANSMISSION 24.3 Countershaft (3rd Shaft) Assembly sequence
5
9 1
•
• • •
2
•
6 • • •
•
8
3
7
4 1. 2. 3. 4. 5.
Countershaft Ball bearing Gear (F2 countergear) Spacer Gear (F1 countergear)
609058
6. 7. 8. 9.
Output gear (counter) Spacer Roller bearing (inner race) Cover, O-ring
Suggestions for assembly (1) Install ball bearing 2 on countershaft 1 and insert it into the transmission case. (2) When placing gear (forward 2nd speed countergear) 3 in the transmission case, slightly pull out the input shaft subassembly and countershaft subassembly (2nd shaft) to prevent interference of these shafts with the gear. (3) Align ball bearing 2 and inner race 8 of roller bearing, which are installed at the ends of countershaft 1, with the end surfaces of the countershaft.
5-63
CHAPTER 5 POWERSHIFT TRANSMISSION 24.4 Pump Body Assembly sequence
1
• • •
2 • 3
609059
1. 2.
Pump body, Outer race of roller bearing, Oil seal, Bushing Pump drive gear, Pump driven gear
3.
Stator shaft, Valve, Spring washer, Snapring
Suggestions for assembly (1) Install the pump body to the transmission case in the assembled state. (2) Put ATF oil in the internal gear and drive gear when installing them to the pump body. (3) Put LG2 grease on the oil seal and bushing of the pump body 1.
5-64
CHAPTER 5 POWERSHIFT TRANSMISSION 24.5 Output Shaft Assembly sequence
3
2
• • • 1 609060
1. 2.
Output gear Output shaft subassembly
3.
Output cover
Suggestions for assembly (1) Install the output shaft subassembly 2. (2) Shim adjustment of output shaft (Unit: mm) Before installing the bearing, determine the required thickness of shims by referring a and b to this formula: c
1) ±b a ± 100
609061
1) Centerline of axle
Thickness of shims (C) =
1.7
+
a 100
-
b
5-65
CHAPTER 5 POWERSHIFT TRANSMISSION (3) (4)
a: machining error indicated in a unit of 1/100 mm on differential carrier by pushing. b: machining error of bevel pinion. Put light grease on the oil seals fitted on the transmission case. Upon assembling, measure each gear backlash with a dial gauge. Item
Standard
Backlash of forward 1st speed gear with forward 2nd speed
0.14 to 0.23 mm (0.0055 to 0.0091 in.)
Backlash of forward gear with reverse gear
0.14 to 0.24 mm (0.0055 to 0.0094 in.)
Backlash of countergear with output gear
0.14 to 0.25 mm (0.0055 to 0.0098 in.)
24.6 Torque Converter
1
2
•
•
•
3 4
609062
1. 2.
5-66
Stator shaft Turbine shaft
3. 4.
Torque converter assembly Pump boss
CHAPTER 5 POWERSHIFT TRANSMISSION Suggestions for assembly (1) Align the splines of the transmission-side stator shaft, turbine shaft, and the pump boss completely. The distance between the end face of the housing and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.) if the torque converter is properly placed in the transmission. Apply ATF oil on the sliding surfaces of the oil seal and the bushing. (2) The torque converter is only inserted and not secured. Attach the flexible plate to the housing with a wire. Assembly Install the torque converter assembly into the transmission. 4 to 6 mm (0.157 to 0.236 in.) 609063
25. Assembling Control Valve and Side Cover To assemble, follow the reverse sequence of disassembly.
25.1 Suggestions for Assembly (1) Replace the gaskets and O-rings with new ones.
5-67
CHAPTER 5 POWERSHIFT TRANSMISSION
26. Disassembling Solenoid Valve 26.1 Disassembly Sequence
5 4 6
3
1 2 1 609064
1. 2. 3.
Cover, Gasket Solenoid valve, O-ring Cover, O-ring
4. 5. 6.
Spring Solenoid valve Solenoid body, Gasket
27. After Disassembling Solenoid Valve (1) Check the valve body for clogged oil passages. (2) Check the valve for wear, damage, or seizure. (3) Check the spring for damage or fatigue. Item Free length of solenoid valve spring
5-68
Standard
Limit
65 mm (2.56 in.) 0.183 kgf·m (10.25 lbf·in.)
63 mm (2.48 in.)
CHAPTER 5 POWERSHIFT TRANSMISSION
28. Assembling Solenoid Valve 28.1 Preparation Wash the valve body thoroughly, making sure that all oil passages are free from clogging.
28.2 Assembly Sequence
4
3
1
6
2
5 609065
1. 2. 3.
Solenoid body Solenoid valve Spring
4. 5. 6.
Cover, O-ring, Bolt, Washer Solenoid valve, O-ring Cover, Gasket, Bolt, Washer
29. Adjustment 29.1 Oil Pressure Measurement The taps differ from those for the 1-speed transmission. For the test method and oil pressure specifications, see 5-1 "1Speed Transmission (3.5 to 5.5 Ton)".
2
1
5
• • • •
4 3
•
609066
4. Main pressure 1. Lubrication oil pressure 2. Torque converter inlet pressure 5. Alternate Lubrication oil test port 3. Clutch pressure
5-69
CHAPTER 5 POWERSHIFT TRANSMISSION Item
Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.01 to 0.15 MPa (0.1 to 1.5 kgf/cm2) [1.42 to 21.3 psi]
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine min-1
All tests run
29.2 Hydraulic Pressure Test Tools Hydraulic pressure test tools for 2-speed transmission
Remarks
Main/clutch
Torque converter inlet/ Lubrication oil
Connector 92067-00300
Rp1/8 thread
z
-
*Connector 64309-17733
Rp1/8 thread
-
z
Connector 91268-02300
Rp1/8 thread
-
-
*Gauge 64309-17714
588 kpa (6 kgf/cm2) [86 psi]
-
z
*Gauge 64309-17713
1961 kpa (20 kgf/cm2) [284 psi]
z
-
*Hose 64309-17722
-
z
z
*Connector 64309-17731
For gauge
z
z
Tool name/ number
Tools marked with (*) are included in the 64309-17700 gauge kit. For the following four items, see 5-1 "1-Speed Transmission (3.5 to 5.5 Ton)". -
Measurement of oil pressure Measurement of stall speed 10 meters (33 ft) starting acceleration Inching pedal adjustment
609067
5-70
CHAPTER 5 POWERSHIFT TRANSMISSION 29.3 2nd Speed/Auto Selector Switch Test Move the selector switch mounted on the side face of the sub panel mounted on the right front overhead guard leg to each position, and make sure that the transmission works properly. In the 1st speed position, the forklift truck runs at a maximum speed of 14 km/hr (8.7 mph) and a greater torque is available at the drive axle. In the auto position, the transmission automatically shifts from 1st to 2nd range when the travel speed reaches 9 km/hr (5.6 mph) to allow the forklift truck to run at a maximum speed of 24.5 km/hr (15.2 mph).
609068
29.4 2-Speed Transmission Electrical Systems Part Numbers ECU and Pulse Generator / Speed Sensor Parts
Models
Transmissions
ECU 6.0 to 7.0 ton
2-Speed
Pulse Generator / Speed Sensor
Part numbers
System type
16A20-28001
Carburation
16A23-18001
MPFI
69321-08101
Carburation
97433-01100
MPFI
Solenoid Parts
Models
Solenoid types Speed
Solenoids
6.0 to 7.0 ton Directional
Part numbers
Voltage
91828-11200 93728-00901 93728-20701
12V
Type
System type
N/O
Carburation
N/C
MPFI
N/O
Carburation and MPFI
Note: 12 Volt: Working voltage 8 to 16 V The part numbers listed above should be used as reference only. Parts numbers are subject to change without notice. Check parts system for updated part information.
5-71
CHAPTER 5 POWERSHIFT TRANSMISSION 29.5 ECU Self-Diagnostic Test The Electronic Control Unit (ECU) has a self diagnostic feature built in a 1-chip microcomputer. The computer processes the signal received from the pulse generator through the ECU speed selector and automatically selects the speed according to the signal received from the pulse generator. It has two LED indicator fault lights that flash a pattern of flashes for testing the ECU, pulse generator and shift solenoid. The self diagnostic feature is intended to help take the guesswork out of troubleshooting the power shift transmission electrical system. The indicator fault lights are located on the rear mounting face of the ECU. Remove the ECU mounting bolts to access the fault lights. The indicator lights will flash in the following patterns (ECU with no fault, Pulse Generator / Speed Selector Fault and Shift Solenoid Fault) when a problem occurs in the electrical control system of the 2-speed transmission. A fault code will continue to glow until the key switch is turned to the OFF position. If any other blinking pattern of flashes occurs, the ECU is defective and should be replaced.
1
1) 2) 609069
ECU 1. Failure Indicator Lights 1) GREEN
2) RED
R CAUTION It is possible to have a combination of failed components at the same time. BE SURE to check all components (pulse generator, speed and directional solenoids) before replacing the ECU.
29.6 ECU Test (1) Turn the key switch to the ON position. (2) For the first 10 seconds, the GREEN light turns ON and the RED light blinks. (3) For 10 seconds or more, the GREEN light is ON and the RED light is OFF. ECU with no fault
Condition Light Colors GREEN RED
Key Switch ON 0-10 Sec.
Key Switch ON after 10 Sec.
ON
ON
GLOW
OFF
Pulse Generator / Speed Sensor Fault GREEN Light
ON ON
RED Light
OFF
ON OFF
Note: System resets automatically after repair.
5-72
OFF
CHAPTER 5 POWERSHIFT TRANSMISSION 29.7 Pulse Generator Test (1) Set the parking brake and block the rear wheels. (2) Raise the front wheels off the ground either by lifting with a crane or tilting the mast BACKWARD and placing a wood block which can bear the weight of the forklift truck under the outer the mast, and tilt FORWARD until the front tires are off the ground. (3) Disconnect the pulse generator (speed sensor) from the wire harness. (4) Connect a digital voltmeter (VOM) to the wires coming from the pulse generator. Note: The pulse generator is not polarity sensitive. (5) Set the VOM to 0 - 20 AC voltage scale. (6) Start the forklift truck and place the directional lever to FORWARD or REVERSE. (7) Slowly raise the engine speed while watching the VOM. (8) The minimum reading at shifting point should be 0.860 AC volts. Note: The minimum volt reading will vary depending on the gear ratio of the forklift truck. (9) The maximum output reading is 1.004 AC volts. Note: Moving the pulse generator closer or further away from the output gear will change the readings and frequency pattern from the generator. Shift solenoid fault Transmission must be accelerated to shift the speed before fault will appear. GREEN Light
ON ON
RED Light
OFF
ON OFF
OFF
Note: System resets automatically after repair.
29.8 Solenoid Voltage Test Use a voltmeter set on 0 to 40 DC volts to test the solenoid for proper voltage to the shift speed solenoids. Note: 12 V solenoid: working voltage 8 to 16 V. Solenoid
NEUTRAL
-
-
F1
F2
R1
R2
Forward solenoid
OFF
ON
ON
ON
ON
Reverse solenoid
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
1985 - 12/2003 models First speed solenoid 2004 and up models First speed solenoid
FORWARD
REVERSE
5-73
CHAPTER 5 POWERSHIFT TRANSMISSION 29.9 Oscilloscope Shop Test (1) Set the parking brake and block the rear wheels. Raise the front wheels off the ground either by lifting with a crane or tilting the mast BACKWARD and placing a wood block which can bear the weight of the forklift truck under the outer mast, and tilting the mast FORWARD until the front tires are off the ground. (2) Disconnect the pulse generator (speed sensor) from the wire harness. Sometimes called speed sensor. (3) Connect an oscilloscope to the wires coming from the pulse generator and check the following reading and frequency pattern to ensure the pulse generator is working properly. Note: The pulse generator is not polarity sensitive. Moving the pulse generator closer or further away from the output gear will change the readings and frequency pattern from the generator. Scope reading
B
A
1) 2)
1) Ref. A: 500 m Volt 2ms
5-74
609070 2) Ref. B: 500 m Volt 2ms
CHAPTER 5 POWERSHIFT TRANSMISSION Meter readings Good
Bad
Ref. A
Ref. B
Histogram
Min/Max
Period
4.23 ms
360 us
Frequency
236 Hz
2.78 kHz
Pos. Pulse Width
2.14 ms
302 us
Neg. Pulse Width
2.09 ms
57.7 us
Rise Time
1.93 ms
9.61 ms
Fall Time
878 us
6.4 us
Pos. Duty Cycle
50.67%
83.96%
Neg. Duty Cycle
49.33%
16.04%
Pos. Overshoot
5.10%
0.00%
Neg. Overshoot
4.46%
0.00%
Peak to Peak
3.44V
800 mV
Amplitude
3.14V
800 mV
High
1.56V
400 mV
Low
-1.58V
-400 mV
Maximum
1.72V
400 mV
Minimum
-1.72V
-400 mV
Mean
-25.3 mV
6.93 mV
Cycle Mean
-4.03 mV
-22 mV
RMS
1.04V
86 mV
AC RMS
1.04V
95.8 mV
Cycle RMS
1.03V
72.7 mV
Cycle AC RMS
1.03V
67.8 mV
Burst Width
17 ms
19.9 ms
Item Measure Mode
5-75
CHAPTER 5 POWERSHIFT TRANSMISSION
30. Troubleshooting 30.1 Torque Converter Drive Transmission Condition Engine
Torque converter
Low output
Transmission
Body
5-76
Possible causes
Corrective action
Low engine output
Adjust the engine
Low engine performance
Adjust the engine
Insufficient oil
Replenish
Air intake from intake side
Retighten or replace pipe and gasket
Spool failure of main regulator valve
Repair or replace
Worn spring of main regulator valve
Replace spring
Worn oil pump (Low or insufficient discharge)
Disassemble or replace defective part
Clogging of magnet strainer
Replace magnet strainer
Worn sealring and O-ring
Replace after measurement of oil pressure
Seizure of stator free wheel
Replace stator assembly, hub and roller
Damage and contact of impeller
Repair or replace impeller Replace bearing
Air intake from intake side
Retighten or replace
Water inclusion into oil
Replace oil
Insufficient oil
Replenish
Adjustment failure of pedal link (Brake shift and forward-reverse)
Adjust
Clutch slippage due to low main pressure
Adjust pressure after measurement of oil pressure
Worn sealring and O-ring
Replace after measurement of oil pressure
Damaged clutch piston
Replace piston
Seizure or drag of friction plate
Replace plate
Large driving resistance on underbody parts
Inspect or adjust brake parts
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Torque converter
No transmission of power Transmission
Body
Possible causes
Corrective action
Damaged flexible plate
Replace
Insufficient oil
Replenish
Defective oil pump drive system
Replace
Broken turbine shaft
Replace
Low oil pressure (Main pressure)
Check for wear of the oil pump gear, or replace
Insufficient oil
Replace
Adjustment failure of inching pedal link
Adjust
Worn servo case seal ring
Replace
Worn input shaft O-ring
Replace
Non-removal of input shaft plug
Repair
Seizure of clutch
Replace
Broke shaft
Replace
Damaged clutch drum (Snapring groove)
Replace
Broken snapring for clutch drum
Replace
Clogging of clutch oil circuit
Clean or replace
Worn splines of shaft
Replace
Damaged transmission system (Reduction gear, Differential, Front axle
See each section
5-77
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Torque converter
Transmission
Abnormal noise High abnormal noise
Low abnormal noise
Oil leakage
5-78
Possible causes
Corrective action
Broke flexible plate
Replace
Damaged bearings
Replace
Contact of impeller
Replace
Loose bolt
Retighten or replace bolt
Worn splines
Replace
Worn oil pump
Disassemble or replace
Dragging noise due to clutch seizure
Replace clutch plate
Wear or seizure of bearing
Replace
Damaged gear
Replace
Loose bolt
Retighten or replace bolt
Worn splines
Replace
Clogging of oil strainer
Clean or replace
Failure of main regulator valve spool
Disassemble or replace
Large pipe resistance
Replace
Cold time (High viscosity)
Check applicable lubrication oil before replacement
Failure of instruments
Replace
Use of incorrect oil
Check applicable lubrication oil before replacement
Clogging of oil strainer
Clean or replace
Failure of oil pump
Replace
Excessive oil leakage (1) Failure of main regulator spring (2) Failure of main regulator valve spool
Replace spring
Air intake
Repair or replace spool
Insufficient oil
Retighten or replace packing
From oil seal
Check lip and sliding surface for wear Replace seal
From case connection
Retighten or replace packing
From various joints and pipes
Repair or replace pipe, gasket and Oring
From drain plug
Retighten or replace gasket
From cracks
Replace
Oil leak from transmission case (1) Water inclusion into oil (2) Air intake from intake side joint (3) Oil leak from air breather hole
Replace oil Retighten and replace packing Repair
Excessive oil quantity
Drain oil to the proper level
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Torque converter
Abnormally high oil temperature
Transmission
Body
Abnormally high main pressure
Abnormally low main pressure
Possible causes
Corrective action
Incorrect oil quantity
Replenish or drain
Clogging of oil strainer
Clean or replace
Contact of impeller
Repair or replace impeller
Failure of stator
Replace stator assembly
Air intake
Retighten or replace O-ring
Inclusion of water into oil
Replace oil
Large resistance on pipe (Low circulation flow rate)
Repair or replace
Wear or seizure of bearings
Repair or replace
Failure of instruments
Replace
Drag of clutch
Replace clutch plate
Wear or seizure of bearings
Repair or replace
Failure of control link
Repair or replace
Incorrect use of body
Use correctly
Failure of body (1) Damaged fan belt (2) Clogging of oil cooler (3) Drag of brake
Replace Clean or replace Inspect or adjust
Failure of main regulator valve
Repair or replace valve assembly
Cold time
Check applicable lubrication oil before replacement
Use of incorrect oil
Check applicable lubrication oil before replacement
Clogging of magnet strainer
Clean or replace
Failure of oil pump
Replace
Defective coil spring of main regulator valve
Replace spring
Defective spool of main regulator valve
Repair or replace spool
Intake of air
Retighten or replace packing
Insufficient oil quantity
Replenish
Defective control link
Repair or replace
Defective clutch valve
Repair or replace
5-79
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Abnormally low clutch oil pressure
Stall speed is not within the standard value
No speed change (2-speed T/M)
5-80
Possible causes
Corrective action
Clogging of magnet strainer
Clean or replace
Failure of oil pump (Wear)
Replace
Defective coil spring of main regulator valve
Replace spring
Defective spool of main regulator valve
Repair or replace spool
Intake of air
Retighten or replace packing
Insufficient oil quantity
Replenish
Defective control link
Repair or replace
Defective clutch valve
Repair or replace
Broken sealring of servo case
Replace
Broken clutch seal ring
Replace
Low engine output if both forward and reverse speed are a little low
Adjust engine
Failure of stator and free wheel if both forward and reverse speed are abnormally low
Replace stator assembly
Defective inching link or clutch slippage if the value exceeds the standard
Repair or replace
Mode selector switch remains at 1speed
Set the switch to Auto
Failure of solenoid valve
Replace
Clogging of solenoid valve inlet orifice
Clean or replace
Defective solenoid valve spool
Repair or replace spool
Defective solenoid valve spring
Replace spring
Defective ECU control box
Inspect and replace shim
CHAPTER 5 POWERSHIFT TRANSMISSION
31. Service Data 31.1 Torque Converter Drive Transmission Specifications Item 3.5 to 5.5 ton
6.0 to 7.0 ton
2000 mm
2080 mm
Stall speed (tolerance ± 100 min-1)
Standard
Oil pressure standard value
Standard
-
Main oil pressure at Eng. 1600 ± 100 min-1
Standard
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm²) [142.2 to 177.8 psi]
Clutch oil pressure at Eng. 1600 ± 100 min-1
Standard
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm²) [142.2 to 177.8 psi]
T/C inlet oil pressure at Eng. 1600 ± 100 min-1
Standard
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm²) [142.2 to 71.1 psi]
Lubrication oil pressure at Eng. 1600 ± 100 min-1
Standard
10 m (33 ft) standing acceleration (without load) (sec.)
Standard
0.05 to 0.29 Mpa (0.5 to 3.0 kgf/cm²) [7.11 to 42.7 psi]
0.01 to 0.15 Mpa (0.1 to 1.5 kgf/cm²) [1.42 to 21.3 psi]
Within 5
Pump boss Ref. 1
2
Item Oil seal and bushing contact face (inside diameter)
Boss bushing inside diameter
Specifications Standard Limit
0
69.90 mm (2.7520 in.)
Standard Limit
1
0
70 -0.046 mm (2.76 -0.00181 in.)
70.06 to 70.10 mm (2.7583 to 2.7598 in.) 70.3 mm (2.768 in.)
2 609071
5-81
CHAPTER 5 POWERSHIFT TRANSMISSION Pilot boss Ref. 1
Item Diameter of flywheel insertion area
Specifications -0.007
Standard
-0.00028
20 -0.020 mm (0.78 -0.00079 in.)
Limit
19.85 mm (0.781 in.)
1
609072
31.2 Torque Converter Drive Transmission Oil pump Ref.
Item
1
Side clearance
2
Top clearance
Specifications Standard
0.05 to 0.11 mm (0.002 to 0.0043 in.)
Limit
0.20 mm (0.008 in.)
Standard
0.6 to 0.66 mm (0.236 to 0.0259 in.)
Limit 3
Clearance at notch between drive gear and pump boss
0.8 mm (0.031 in.)
Standard
0.2 to 0.4 mm (0.008 to 0.016 in.)
Limit
1.0 mm (0.04 in.)
1 3 2 609073
5-82
CHAPTER 5 POWERSHIFT TRANSMISSION Stator Ref. 1
Item Outside diameter of clutch hub
Specifications -0.03
Standard Limit
2
Outside diameter of clutch roller
64.9 mm (2.555 in.) 0
Standard
Outside diameter of thrust washer
7.985 mm (0.31437 in.) 0
Standard
1.75 mm (0.0689 in.) 0
Standard
Thickness of thrust washer
0
2.0 -0.05 mm (0.08 -0.0020 in.)
Limit 4
0
8.1 -0.015 mm (0.32 -0.00059 in.)
Limit 3
-0.0012
65 -0.049 mm (2.56 -0.00193 in.)
0
3.0 -0.05 mm (0.12 -0.0020 in.)
Limit
2.75 mm (0.1083 in.)
4 • 2
1
3 609074
Flexible plate Ref.
Item
1
Runout of flexible plate (in free condition)
2
Distance between end face of case and mating face of flexible plate
Specifications Standard
0.2 mm (0.008 in.)
Limit
0.5 mm (0.020 in.)
Standard
4 to 6 mm (0.157 to 0.236 in.)
1 2 609075
5-83
CHAPTER 5 POWERSHIFT TRANSMISSION 31.3 Torque Converter Drive Transmission Clutch Ref.
Item
Specifications Standard
1
Thickness of mating plate
2
Thickness of friction plate
3
Backlash between friction plate and gear
4
Width of seal ring
2.3 ± 0.07 mm (0.091 ± 0.0028 in.)
Limit
2.1 mm (0.083 in.)
Standard
2.6 ± 0.1 mm (0.102 ± 0.004 in.)
Limit
2.2 mm (0.087 in.)
Standard
0.1 to 0.3 mm (0.004 to 0.012 in.)
Standard
4 -0.03 mm (0.16 -0.0012 in.)
-0.01
Limit 5
3.5 mm (0.138 in.) +0.2
Standard
Seal ring groove width of piston
4.5 mm (0.177 in.) 62.9 mm (2.476 in.) / 31.312 N·m (3.193 kgf·m) [178.648 lbf·in.]
Standard
Free length of clutch spring
Limit
6
3
+0.008
4 +0.1 mm (0.16 +0.004 in.)
Limit 6
-0.0004
62 mm (2.440 in.)
2 1
4 5
609076
Output shaft (4th shaft) Ref. 1
Item Locknut tightening torque
Specifications Standard
353 to 392.3 N·m (36 to 40 kgf·m) [79.4 to 88.2 lbf·ft]
1
609077
5-84
CHAPTER 5 POWERSHIFT TRANSMISSION 31.4 Torque Converter Drive Transmission (1-Speed Transmission) Main shaft and servo case Specifications Ref.
Item 3.5 to 5.5 ton
1
Seal ring width of turbine shaft
2
Piston seal ring groove width of turbine shaft
Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit
2.0 mm (0.08 in.)
Standard
+0.2
Limit 3
4
5
Seal ring contact surface inside diameter of stator shaft
3.0 mm (0.118 in.)
Standard
+0.2
35.2 mm (1.386 in.) 2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit
Clutch piston seal ring groove width
2.0 mm (0.08 in.)
Standard
+0.2 +0.008 2.5 +0.1 mm (0.098 +0.004
Limit Clutch shaft seal ring width
7
Clutch shaft seal ring groove width
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit
2.0 mm (0.08 in.)
Standard
+0.2
Seal ring contact surface inside diameter of servo case
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit 8
in.)
3.1 mm (0.122 in.)
Standard
6
+0.008
35 +0.1 mm (1.386 +0.004 in.)
Limit Standard
Clutch piston seal ring width
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
3.0 mm (0.118 in.)
Standard Limit
35
+0.025 +0.00098 0 mm (1.38 0
in.)
35.2 mm (1.386 in.)
6, 7
1, 2
8
4,5
3 609078
Gear backlash Specifications Item 3.5 to 5.5 ton Countergear and output gear
Standard
0.14 to 0.27 mm (0.0055 to 0.0106 in.)
Other gears
Standard
0.14 to 0.26 mm (0.0055 to 0.0102 in.)
5-85
CHAPTER 5 POWERSHIFT TRANSMISSION Shaft Specifications Item 3.5 to 5.5 ton Backlash at each shaft spline
Standard
0.036 to 0.206 mm (0.0014 to 0.0081 in.)
31.5 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) Input shaft and servo case Specifications Ref.
Item 6.0 to 7.0 ton
1
Seal ring width of input shaft
2
Seal ring groove width of input shaft
Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit Standard
2.0 mm (0.08 in.) +0.2
Limit 3
4
5
Seal ring contact surface inside diameter of stator shaft Input shaft seal ring width
Input shaft seal ring groove width
Standard
3.0 mm (0.118 in.) 35
Limit Standard
6
7
Clutch piston seal ring width
8
Clutch piston seal ring groove width
Standard Limit Standard Limit Standard Limit
in.)
2.5 ± 0.05 mm (0.098 ± 0.002 in.) 2.0 mm (0.08 in.) +0.2
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit Seal ring contact surface inside diameter of servo case
+0.025 +0.00098 0 mm (1.38 0
35.2 mm (1.386 in.)
Limit Standard
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
3.0 mm (0.118 in.) 35
+0.025 +0.00098 0 mm (1.38 0
in.)
35.2 mm (1.386 in.) 2.5 ± 0.05 mm (0.098 ± 0.002 in.) 2.0 mm (0.08 in.) +0.2
+0.008
2.5 +0.1 mm (0.098 +0.004 in.) 3.0 mm (0.118 in.)
6
4, 5
5-86
7, 8
3
1, 2 609079
CHAPTER 5 POWERSHIFT TRANSMISSION 31.6 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) Counter shaft and servo case Specifications Ref.
Item 6.0 to 7.0 ton
1
Seal ring width of countershaft
2
Seal ring groove width of countershaft
Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit Standard
2.0 mm (0.08 in.) +0.2
Limit 3
4
5
Seal ring contact surface inside diameter of pump body
Standard
3.0 mm (0.118 in.) 35
Limit Standard
Clutch piston seal ring width
Standard
Countershaft seal ring width
7
Countershaft seal ring groove width
Standard
2.0 mm (0.08 in.) +0.2 +0.008 2.5 +0.1 mm (0.098 +0.004
2.5 ± 0.05 mm (0.098 ± 0.002 in.) 2.0 mm (0.08 in.) +0.2
Seal ring contact surface inside diameter of servo case
6, 7
8
4, 5
Standard Limit
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit 8
in.)
3.1 mm (0.118 in.)
Limit Standard
in.)
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit 6
+0.025 +0.00098 0 mm (1.38 0
35.2 mm (1.386 in.)
Limit
Clutch piston seal ring groove width
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
3.0 mm (0.118 in.) 35
+0.025 +0.00098 0 mm (1.38 0
in.)
35.2 mm (1.386 in.)
3
1, 2 609085
5-87
CHAPTER 5 POWERSHIFT TRANSMISSION Gear backlash Specifications Item 6.0 to 7.0 ton Gears for forward 1-speed and 2-speed
Standard
0.14 to 0.23 mm (0.0055 to 0.0090 in.)
Forward and reverse gears
Standard
0.14 to 0.24 mm (0.0055 to 0.0094 in.)
Shaft Specifications Item 6.0 to 7.0 ton Countergear and output gear
Standard
0.14 to 0.25 mm (0.0055 to 0.0098 in.)
Backlash at shaft splines
Standard
0.036 to 0.206 mm (0.0014 to 0.0081 in.)
5-88
CHAPTER 5 POWERSHIFT TRANSMISSION 31.7 Torque Converter Drive Transmission Control valve Ref. 1
2
3
4
5
6
7
8
Item
Specifications
Free length of main relief valve inner spring
Standard
Free length of main relief valve inner spring
Standard
Free length 3 of clutch valve spring
Standard
Free length 3 of clutch valve spring
Standard
75 mm (2.95 in.) / 2.122 N·m (0.215 kgf·m) [12.050 lbf·in.]
Limit
72 mm (2.83 in.) 50 mm (1.97 in.) / 0.838 N·m (0.0855 kgf·m) [4.783 lbf·in.]
Limit
48 mm (1.89 in.) 39 mm (1.54 in.) / 2.128 N·m (0.217 kgf·m) [12.141 lbf·in.]
Limit
38 mm (1.50 in.) 28 mm (1.10 in.) / 0.479 N·m (0.0488 kgf·m) [2.730 lbf·in.]
Limit
26.5 mm (1.04 in.) 32 mm (1.26 in.) / 4.560 N·m (0.465 kgf·m) [26.017 lbf·in.]
Free length of torque converter Standard inlet/outlet oil pressure regulating valve spring Limit Free length of accumulator valve outer spring
Standard
Free length of accumulator valve inner spring
Standard
Free length of directional spool spring
Standard
31 mm (1.22 in.) 91 mm (3.58 in.) / 7.303 N·m (0.0745 kgf·m) [41.666 lbf·in.]
Limit
89 mm (3.50 in.) 130 mm (5.12 in.) / 0.597 N·m (0.0609 kgf·m) [3.408 lbf·in.]
Limit
128 mm (5.04 in.) 32.5 mm (1.279 in.) / 8.616 N·m (0.8786 kgf·m) [49.158 lbf·in.]
Limit
32 mm (1.26 in.)
7 6 1 2 3 4
8
5
8 609086
5-89
CHAPTER 5 POWERSHIFT TRANSMISSION 31.8 Torque Converter Drive Transmission Solenoid valve Specifications Item 6.0 to 7.0 ton 1
Free length of solenoid valve spring
Standard Limit
65 mm (2.56 in.) / 1.795 N·m (0.183 kgf·m) [10.239 lbf·in.] 63 mm (2.48 in.)
1 609087
5-90
CHAPTER 5 POWERSHIFT TRANSMISSION Inching pedal control Ref.
Item
Specifications
1
Inching pedal height (from top of frame to top of pedal pad)
Standard
175 mm (6.89 in.)
2
Clearance between stopper bolt and brake pedal
Standard
16 mm (0.63 in.)
3
Plunger stroke
Standard
8 to 9.5 mm (0.314 to 0.374 in.)
4
Plunger stroke at brake functioning
Standard
16.5 mm (0.649 in.)
5
Inching pedal stroke (brake functioning)
Standard
82.4 mm (3.24 in.)
6
Inching pedal stroke
Standard
15.2 mm (5.98 in.)
6 5 1
2
4
3
609088
5-91
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 1.
Specifications Item Reduction gear
Transmission
Reduction ratio Housing type
Differential gear
Running gear
Gear type
Gear type and quantity
6.0 to 7.0 ton
Spiral bevel gear
Hypoid gear
4.571
4.857 Banjo type
Large
Straight bevel gear x 2
Small
Straight bevel gear x 2
Front axle type Suspension system
3.5 to 5.5 ton
Full-floating axle tube type Front wheel
Frame fixing type
6-1
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
2.
Structure 2
1
•
•
3
4
5
•• •
• •
•
8
7
6 609175
1. 2. 3. 4.
6-2
Front wheel hub drum Reduction bevel pinion Reduction bevel gear Differential case
5. 6. 7. 8.
Differential carrier Axle housing Axle shaft Front axle support
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
3. 3.1
Removing Front Tire Preparation
(1) Set the parking brake, and block the rear wheels. (2) Loosen the wheel nuts about two rotations, and lift the forklift truck with a crane or a hydraulic unit.
2
1
609176 1. Wheel nut
2. Front tire
Removal method (1) Lifting the forklift truck with a crane Attach a sling on the outer and inner mast crossmembers, and lift the forklift truck. Use cloth for the sling for protection. Note: For both methods, place jack stands under the frame to prevent the forklift truck from falling off.
609177
(2) Lifting the forklift truck with the mast Tilt the mast fully BACKWARD, place wood blocks which can bear the weight under the mast, and tilt the mast FORWARD until the front tires are off the ground.
609178
6-3
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
4.
Installing Front Tire
Follow the removal sequence in reverse. Observe the following key points: Tighten wheel nuts evenly to the specified torque to prevent the wheels from wobbling. After tire replacement, drive the forklift truck for a while and then check the torque of the wheel nuts again. Note: Make sure wheel nut mounting holes are free of paint and grease before installing wheel nuts.
1 8
5 3
4 7
6 2
Tightening sequence Item Wheel nut
6-4
Tightening torque 551 ± 55 N·m (56.2 ± 5.6 kgf·m) [406.5 ± 40.6 lbf·ft]
609179
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
5. 5.1
Removing Front Axle Assembly Preparation
(1) Pull the parking brake lever, and place wheel stoppers at the front and rear tires. (2) Remove the mast and the lift bracket assembly. See “MAST AND FORKS”. (3) Loosen the front tire nuts about two rotations, and jack up the forklift truck. (4) Place a jack stand under the frame on both sides at the front so that the lift truck becomes level. (5) Remove the front tires. See 6-3 "Removing Front Tire". (6) Drain differential oil. Note: When replacing the front axle housing, carry out the above preparation.
5.2
Removal Sequence
3
2
3
4
1
609180
1. 2.
Axle shaft, Bolt, Spring washer Bolt, Spring washer
3. 4.
Nuts, Spring washers, Bolts Front axle assembly
6-5
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 5.3
Suggestions for Removal
Removing axle support bolts (1) Place wood blocks under the front of the transmission for support.
1 609181 1. Wood block
(2) Attach a sling with protection cloth on the mast fitting in the front axle assembly, and lift the assembly until the wire is braced. Wind the sling twice firmly. (3) To remove bolts, remove the bolts at the top on both sides, and insert a guide bar. Then remove the other bolts.
6.
Installing Front Axle Assembly
Follow the removal sequence in reverse. Be careful with the following key points,: (1) Clean the mounting surface on the differential carrier completely, and apply liquid gasket before installation. (2) Apply liquid gasket to the mounting surface of the axle shaft, and tighten bolts. Item Axle shaft bolts
Tightening torque 128.3 ± 12.8 N·m (13.1 ± 1.3 kgf·m) [94.7 ± 9.4 lbf·ft]
(3) Tighten axle support bolts to the specified torque. Item Axle support bolts
7.
3.5 to 5.5 ton
6.0 to 7.0 ton
693.8 N·m (70.8 kgf·m) [512 lbf·ft]
877.1 N·m (89.5 kgf·m) [647.3 lbf·ft]
Removing and Installing Reduction and Differential
When replacing the reduction gear, replace the gear and pinion as a set. Tooth contact of the reduction gear and the reduction pinion must be adjusted by mating the transmission on the pinion side and the differential carrier on the gear side. Therefore remove the transmission and the differential carrier from the frame before adjusting the tooth contact. Remove the engine before removing or installing the transmission. See “POWER TRAIN”. Place the transmission on a stable work bench, and remove the differential carrier.
6-6
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
8. 8.1
Disassembling Axle Shaft and Hub Preparation
(1) Loosen front wheel nuts about two rotations, and jack up the forklift truck. (2) Place jack stands under the frame on both sides at the front so that the forklift truck is at the level position when viewed from the front. (3) Remove the front tires. (4) Drain differential oil.
8.2
Disassembly Sequence
6
1
5 4
3 2
609182
1. 2. 3. 4.
Front tire Axle shaft, Bolt, Spring washer Bolt, Lock washer, Locknut Taper roller bearing (inner)
5. 6.
Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal Retainer, O-ring
Note: In general, disassemble the front axle with the axle housing installed on the frame.
6-7
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 8.3
Suggestions for Disassembly
(1) Removing locknut Use the special tool to remove the locknut.
1
609183 1. Special tool
Special tool needed Item Socket wrench
3.5 to 5.5 ton
6.0 to 7.0 ton
100 mm (3.94 in.)
03703-49000
(2) Removing front wheel hub Use a hub puller 1 to remove the front wheel hub. If the taper roller bearing (inner race) is tight, the inner oil seal may fall off and the taper roller bearing may remain in the axle housing.
1
609184 1. Hub puller
(3) Using a bearing puller 1, remove the inner race of tapered roller bearing left on the axle housing, along with the seal retainer.
1
609185 1. Bearing puller
6-8
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
9. 9.1
Inspection and Repair After Disassembling Axle Shaft and Hub Axle Shaft
(1) Check the splines for wear. Install the differential bevel gear on the splined end of axle shaft, and turn the gear back and forth. Measure the free movement of the gear (looseness between mating splines) with a dial gauge as shown.
609186
(2) Measuring axle shaft bend - Attach a dial gauge on the center of the axle shaft, and rotate the axle shaft. Measure bend of the axle shaft. - Attach a dial gauge to the edge of the flange, and rotate the axle shaft. Measure deflection of the flange.
609187
Item
Value
Looseness of axle shaft spline
Standard
Axle shaft bend (1/2 of gauge reading)
Standard Limit Standard
Flange deflection
9.2
Limit
Limit
0.07 to 0.17 mm (0.0028 to 0.0067 in.) 0.5 mm (0.020 in.) 1.0 mm (0.039 in.) or less 2.0 mm (0.079 in.) 0.04 mm (0.0015 in.) 0.5 mm (0.020 in.)
Retainer
Check for wear or damage on the retainer circumference.
9.3
Front Hub Drum
If uneven wear or damage is found on the inner surface of the brake drum, grind and repair. Item Inner diameter of brake drum
Value Standard Limit
317.5
+0.2 +0.078 0 mm (12.5 0 in.)
318.5 mm (12.539 in.)
6-9
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
10. Assembling Axle Shaft and Hub 10.1 Assembly Sequence
6
•
•
4 •• •
5
• •
3 5
• •
•
•
• • ••
•
1
2
609188
1. 2.
6-10
Retainer, O-ring Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal
3. 4. 5. 6.
Taper roller bearing (inner) Locknut, Lock washer, Bolt Axle shaft, Bolt, Spring washer Front tire, Wheel nut
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 10.2 Suggestions for Assembly Front hub drum assembly (1) Press in the taper roller bearing (outer). (2) Press in a new oil seal. Make sure that the lip is in correct direction. (3) Press in the taper roller bearing (outer). (4) Insert the spacer. (5) Fill the roller holder of the taper roller bearing (inner) with grease. Use your palm to push grease into the roller holder. Insert the taper roller bearing (inner). (6) Press in a new oil seal. Make sure that the lip is in the correct direction. (7) Fill the front hub with grease. (See the illustration on the right.) Apply grease thinly on oil seal lips. Make sure that no grease is in the drum.
1 1) 5 2 3 4 6
609189
Hub bearing preload Wind a wire around the hub bolt twice, attach a spring balance on the wire. Pull and measure the tangential force. Hub bolt pitch: ø260 mm (10.23 in.)
609190
Item Hub bolt
Tangential force 25.5 to 40 N (2.3 to 4.1 kgf) [5.06 to 9.02 lbf]
If the preload is within the standard range, insert the lockring, apply LOCTITE 271, and tighten bolts. Item
Tightening torque 9.8 ± 1.0 N·m (1.0 ± 0.1 kgf·m) [7.2 ± 0.7 lbf·ft]
Bolt
Axle shaft When installing the axle shaft, apply liquid gasket on the mating surface with the hub, and tighten bolts to the specified torque. Item Axle shaft
Tightening torque 128.3 ± 12.8 N·m (13.1 ± 1.3 kgf·m) [94.7 ± 9.4lbf·ft]
Wheel nuts Tighten wheel nuts to the specified torque evenly to prevent tire shimmy. See 6-4 "Installing Front Tire"
6-11
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
11. Disassembling Reduction Differential 11.1 Preparation Remove the differential carrier from the transmission case.
11.2 Disassembly Sequence
3
5 6
4
7 7 8
5
9
7 7
2 1. 2. 3. 4. 5.
6-12
10
1
Bolt, Lockwasher, Lockplate Bolt, Lockwasher, Bearing cap Side bearing nuts Differential carrier Taper roller bearing, Bolt, Spring washer, Differential case (right)
6. 7. 8. 9. 10.
3
609191
Differential bevel gear, Thrust washer Differential bevel pinion, Thrust washer Spider Differential bevel gear, Thrust plate Taper roller bearing, Bolt, Differential case (left), Reduction bevel gear
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 11.3 Suggestions for Disassembly Note: (1) Measure the backlash of the gear before disassembly, and use the measurement for assembly. (2) Put a matchmark across one of the bearing cap adjusting screws and the carrier, and use the mark for assembly.
609192
Item Backlash between Reduction gear and pinion
Standard
3.5 to 5.5 ton
6.0 to 7.0 ton
0.07 to 0.17 mm (0.0028 to 0.0067 in.)
0.07 to 0.17 mm (0.0028 to 0.0067 in.)
11.4 Removing Bearing Remove the inner bearing with a bearing puller.
609193
6-13
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
12. Inspection and Repair After Disassembling Reduction Differential 12.1 Reduction Bevel Gear Check the tooth contact pattern of the reduction bevel gear and pinion. Check the gear teeth for wear, pitting, flaking, or chipping. Minor flaws on the tooth surfaces can be repaired by grinding with an oil stone or sandpaper. If the gear is badly damaged and requires replacement, replace the gear and pinion as a set.
12.2 Differential (1) Check for scoring at the mating part of the differential case and the side bearing inner race. (2) Check for cracks on the differential case, and for wear or damage on the sliding part between the gear and the thrust washer. (3) Check for wear, loss, or scoring on the differential bevel gear and the pinion gear teeth. Check for wear or damage on the thrust washer plate. (4) Check the internal diameter of the differential pinion gear and for wear of the spider shaft. Item Clearance between pinion gear and spider
6-14
Value Standard Limit
0.169 to 0.278 mm (0.0066 to 0.0109 in.) 0.5 mm (0.020 in.)
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
13. Assembling Reduction Differential 13.1 Assembly Sequence
5
7
9
•
•
•
•
• 8
•
11 12
•
•
8
•
•• •
•
11
••
• • •
• • •
10
6
1
•
5 4
3
10
2 609194
1. 2. 3. 4. 5. 6.
Differential case (left) Reduction bevel gear, Bolt Differential gear, Thrust washer Spider Differential bevel pinion, Thrust washer Differential bevel gear, Thrust washer
7. 8. 9. 10. 11. 12.
Differential case (right), Bolt Taper roller bearing Differential carrier Bearing cap, Bolt, Lockwasher Side bearing nut Bolt, Lockplate, Lockwasher
13.2 Suggestions for Assembly Tightening Reduction bevel gear Apply LOCTITE 271 on bolts, and tighten to the specified torque. Item Reduction gear
Tightening torque 225.5 ± 9.8 N·m (23.0 ± 1.0 kgf·m) [166.3 ± 7.2 lbf·ft]
6-15
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL Installing differential bevel pinions The thrust washers of bevel gear are used for adjusting the backlash of the bevel gears with the pinion. Measure the backlash and, if it exceeds the service limit, replace the thrust washers.
609195
Item Backlash of the differential bevel gear
Value Standard
0.20 to 0.40 mm (0.008 to 0.016 in.)
Limit
0.6 mm (0.024 in.)
Installing differential case (1) Assemble the left and right cases by using the matchmark, and tighten bolts. (2) Apply LOCTITE 271 to the threads of the bolts, and tighten the bolts evenly to ensure free gear movement.
609196
Item Differential case
Tightening torque 122.5 ± 9.8 N·m (12.5 ± 1.0 kgf·m) [90.4 ± 7.2 lbf·ft]
Installing differential case assembly (1) After positioning the case assembly on the carrier, fit the bearing caps tentatively by making the cap bolts snug tight. The caps should be secured tight after the bearing preload has been adjusted. (2) Tighten bolts to the specified torque. Note: The bearing caps and the differential carrier are machined together in the factory. Pay attention to the match marks so that they are positioned on the side as they were before disassembly. 609192
Item Bearing cap
6-16
Tightening torque 161.8 ± 9.8 N·m (16.5 ± 1.0 kgf·m) [119.3 ± 7.2 lbf·ft]
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
14. Adjustment 14.1 Adjusting Bearing Preload Wind a coil on a reduction gear bolt, attach a spring scale on the coil and pull. Read the tangential force when the gear starts rotation. Adjust the preload by tightening the side bearing nuts on both sides. Note: Before measuring the preload, tap the back of the bevel gear with a copper hammer while winding the gear by hand. 609197
Item
Tangential force 12.7 to 25.4 N (1.3 to 2.6 kgf) [2.8 to 5.7 lbf]
Side bearing
14.2 Inspecting Back Runout Attach a dial gauge on the back surface of the reduction gear at the largest radius, and measure the back runout while rotating the gear. If the measurement exceeds the standard value, inspect the reduction gear tightening and the taper roller bearing. If the measurement exceeds the standard value, replace together with the pinion gear.
609198
Item Back runout of reduction bevel gear
Value Standard Limit
0.15 mm (0.006 in.) or less 0.20 mm (0.008 in.)
6-17
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 14.3 Adjusting Backlash Adjust the backlash after installing the differential carrier assembly in the transmission case. Attach the dial gauge needle vertically on the tooth surface of the bevel gear. Move the bevel gear forward and backward (in rotating direction) and check the deflection of the needle. Adjust the backlash with the side bearing nut.
609199
1
2)
1)
1)
2)
1 1)
1. Backlash
Item Reduction gear and pinion gear
Standard
2) 609200
1) Small 2) Large
3.5 to 5.5 ton
6.0 to 7.0 ton
0.25 to 0.33 mm (0.0098 to 0.0129 in.)
0.33 to 0.41 mm (0.0129 to 0.0161 in.)
14.4 Adjusting Tooth Contact Apply machinist’s dye on three or four teeth of the reduction gear thinly and evenly. Rotate the reduction gear forward and backward by hand several times. Check tooth contact by the shape of contact area. Adjust faulty tooth contact as follows:
609201
6-18
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 14.5 Tooth Contact of Reduction Gear Tooth contact conditions
1 500471
Adjusting procedure
Extends from toe to middle portion, covering 50% or more of tooth length.
Good
2
1. Move the gear away from pinion.
Short contact at toe of tooth (Toe).
2
1
500472
502121
2
Short contact at heel of tooth (Heel)
3
502122
2
500474
502123
Heavy contact on flank root portion of tooth (Root)
5 500475
2. Move pinion away from gear by removing shim(s) to secure correct backlash. 1. Slightly move pinion toward gear by adding shims.
1
Heavy contact on flank top portion of tooth (Top)
4
1. Move gear toward pinion. 1
500473
2. Move pinion toward gear by adding shim(s) to secure correct backlash.
1
2. Slightly move gear away from pinion to secure correct backlash. 1. Slightly move pinion away from gear by removing shim(s).
2 502124
2. Slightly move gear toward pinion to secure correct backlash.
Note: “Toe” or “Heel” contact is determined by checking the contact pattern on the outside (convex side) of the reduction gear tooth. For “Top” or “Root” contact, repeat the above adjusting procedure until the correct tooth contact is obtained.
6-19
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
15. Troubleshooting Condition
Continuous gear noise during travel
Irregular noise during travel
Abnormal noise generated at curves
Overheated reduction case after travel
6-20
Possible causes
Corrective action
Wear of reduction gear teeth
Replace the reduction gear
Misadjustment or wear of the reduction gear bearing
Repair or replace the bearing
Breakage of hub bearing
Replace the bearing
Faulty engagement of the reduction pinion gear and the reduction gear of the output shaft
Adjust the tooth contact
Breakage of reduction gear bearing or hub bearing
Replace bearing
Loss of differential gear tooth or wear of thrust washer
Replace the gear or the washer
Mixing of foreign matter in axle housing
Clean the housing and replace oil
Loose axle shaft bolt or differential carrier bolt
Tighten bolts
Wear of contact area between differential gear and differential case
Replace
Loss or wear of the differential gear or the pinion gear teeth, or seizure, wear or tear with the spider
Replace
Breakage of bearing due to excessive preload on bearing
Replace the bearing and adjust the preload
Insufficient backlash of the output shaft reduction gear
Adjust the tooth contact and backlash
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
16. Service Data 16.1 Front Axle Hub and wheel Ref.
Item
3.5 to 5.5 ton Standard
-
0.04 mm (0.0016 in.)
Axle shaft flange deflection Limit
-
Axle shaft bend (1/2 of gauge reading)
6.0 to 7.0 ton
0.5 mm (0.02 in.)
Standard
1.0 mm (0.04 in.) or less
Limit
2.0 mm (0.08 in.)
1
Hub bearing preload Tangential force at the hub bolts position
Standard
2
Axle shaft bolts
Tightening torque
128.3 ± 12.8 N·m (13.1 ± 1.3 kgf·m) [94.7 ± 9.4 lbf·ft]
3
Wheel bolt nuts
Tightening torque
307.9 ± 30.7 N·m (31.4 ± 3.1 kgf·m) [227.1 ± 22.7 lbf·ft]
4
Front axle support bolts
Tightening torque
5
Wheel nuts
Tightening torque
551 ± 55 N·m (56.2 ± 5.6 kgf·m) [406.5 ± 40.6 lbf·ft]
5
Lock ring bolts
Tightening torque
9.8 ± 1.0 N·m (1.0 ± 0.1 kgf·m) [7.2 ± 0.7 lbf·ft]
6
Tire service limit
Limit
22.5 to 40 N (2.3 to 4.1 kgf) [5.06 to 9.02 lbf]
693.8 N·m (70.8 kgf·m) [512 lbf·ft]
877.1 N·m (89.5 kgf·m) [647.3 lbf·ft]
48.3 mm (1.9 in.)
4 5
7
3 •
6
•
•
•
• 2
1
609202
6-21
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
Ref. 1
Item Differential bevel gear backlash
3.5 to 5.5 ton Standard
6.0 to 7.0 ton
0.20 to 0.40 mm (0.008 to 0.016 in.)
Limit
0.6 mm (0.024 in.)
2
Clearance between Standard differential bevel pinion and Limit spider
3
Preload at differential side bearing Tangential force at reduction bevel gear bolt
4
Back runout of reduction bevel gear
5
Backlash between reduction bevel gear and T/M pinion gear
6
Looseness of the axle shaft spline
7
Reduction bevel gear bolts
Tightening torque
225.5 ± 9.8 N·m (23.0 ± 1.0 kgf·m) [166.3 ± 7.2 lbf·ft]
8
Differential case bolts
Tightening torque
122.5 ± 9.8 N·m (12.5 ± 1.0 kgf·m) [90.4 ± 7.2 lbf·ft]
9
Side bearing cap bolts
Tightening torque
161.8 ± 9.8 N·m (16.5 ± 1.0 kgf·m) [119.3 ± 7.2 lbf·ft]
0.169 to 0.278 mm (0.0066 to 0.0109 in.) 0.5 mm (0.02 in.)
Standard
12.7 to 25.4 N (1.3 to 2.6 kgf) [2.8 to 5.7 lbf]
Standard
0.15 mm (0.006 in.) or less
Limit
0.2 mm (0.08 in.) 0.25 to 0.33 mm (0.0098 to 0.0129 in.)
Standard Standard
0.30 to 0.41 mm (0.0118 to 0.0161 in.)
0.07 to 0.17 mm (0.0028 to 0.0067 in.)
Limit
0.5 mm (0.02 in.)
5
9
6-22
8 1
2 4 7
6
3 609203
CHAPTER 7 REAR AXLE
Chapter 7 REAR AXLE 1.
Specifications Item
3.5 to 5.5 ton
Axle type
Elliot
Suspension
Center pivot Toe-in
Rear axle
Wheel alignment
0 mm (0 in.)
Camber angle
1.0°
Caster angle
0°
Kingpin angle
0°
Steering cylinder inner diameter × Rod external diameter Effective stroke
6.0 to 70 ton
85 × 60 mm (3.34 × 2.36 in.) 155 mm (6.10 in.)
180 mm (7.07 in.)
7-1
CHAPTER 7 REAR AXLE
2. 2.1
Structure Rear Axle (3.5 to 5.5 Ton)
6
5
5
•
4 •
•
• 4
A
• 2
3
•
• •
1
6
A
3 609089
1. 2. 3.
2.2
Rear axle Steering cylinder Tie rods (left and right)
4. 5. 6.
Knuckles (left and right) Stopper bolts (left and right) Rear axle supports (front and rear)
Rear Axle (6.0 to 7.0 Ton)
•
1 • 4
•
2
3
•
6 • • Section A-A 5 1. 2. 3.
7-2
Rear axle Tires (left and right) Rims (left and right)
• 4
609090
4. 5. 6.
Knuckles (left and right) Pins (two pins for each side) Tie rods (left and right)
CHAPTER 7 REAR AXLE Note: The knuckle is operated with a double-action steering cylinder. The rims to which the tires are inserted serve as wheel hubs. Steering cylinder piping is different between 3.5 to 5.5 ton models and 6.0 to 7.0 ton models.
2.3
Steering Cylinder
3 1
4
5
3
2
13
12, 11 10
9
8
7
6 609091
1. 2. 3. 4. 5. 6. 7.
Spherical bushing Stopper ring Cylinder head Piston Bolt Cylinder tube Piston rod
8. 9. 10. 11. 12. 13.
Piston seal Wear ring Bushing Backup ring Oil seal Dust seal
Note: Double-action cylinder is used. The above figure shows a steering cylinder for 6.0 to 7.0 ton models. For 3.5 to 5.5 ton models, the stroke becomes shorter.
7-3
CHAPTER 7 REAR AXLE
3. 3.1
Removing Rear Tires Preparation
(1) Set the parking brake, and block the front wheels. (2) Use the counterweight lifting hole and lift the truck, or use a jack. (3) Lift the truck until the right and left rear tires are off the ground and rotate freely. (4) Place wood blocks under the flat bottom of the rear axle on both sides, and lower the truck.
609092
3.2
Removal Sequence
5
6
6 4
3 2 1
1. 2. 3.
3.3
Cap, Gasket Locknut, Lockplate Taper bearing (inner) Remove 4 through 6 together.
4. 5. 6.
609093
Rim tire assembly Oil seal Taper bearing (outer)
Suggestions for Removal
(1) Since the rim/tire assembly falls easily, prevent fall with a wood block before removal. Be careful not to damage the oil seal on the rim. (2) Knock out the outer race of the taper bearing by attaching a batten on the notch inside the rim.
7-4
CHAPTER 7 REAR AXLE
4.
Installing Rear Tires
Follow the removal sequence in reverse. BE SURE to follow the key points below:
4.1
Suggestions for Installation
(1) Replace the oil seal with a new one. (2) Clean grease off the taper bearing and the rim. Fill in new grease. Apply grease on the oil seal lip.
1 2 •
609094 1. Oil seal
2. Grease
(3) Adjust the hub bearing preload. (4) Tighten the inner nut temporarily. (5) Insert a ø24 round bar to the cast hole of the rim. Attach a spring scale on the round bar, and measure the tangential force.
609095
Item Starting torque of hub rotation (increment from when preload is zero)
Standard value 0.5 to 5 N·m (0.05 to 0.51 kgf·m) [0.369 to 3.688 lbf·in.]
Tighten the inner nut to obtain the specified value.
7-5
CHAPTER 7 REAR AXLE (6) After adjusting the preload, add a new lockwasher and tighten the outer nut to the specified torque.
1 •
•
2 3 609096
1. Lock washer 2. Outer nut
Item Outer nut
3. Inner nut
Tightening torque 157
+20 0
N·m (16
+2 0
kgf·m) [115.7
+14 0 lbf·in.]
(7) Bend the lockwasher to both sides (inward and outward). (8) Fill the cap with grease, and install the cap.
609097
7-6
CHAPTER 7 REAR AXLE
5.
Removing Rear Axle
Remove the rear tires before removing the rear axle. See 7-4 "Removing Rear Tires". BE SURE to carry out the preparation, and follow the key points for removal:
5.1
Suggestions for Removal
(1) Remove the steering hose. Put a plug on the removed hose to prevent oil leakage. Item Plug
05530-30300 (G 3/8)
(2) Before removing the rear axle support bolt, pry the rear axle assembly with a bar, and measure the front and rear clearances. If the total value is 0.8 mm (0.03 in.) or more, insert thrust washers and adjust the clearances when installing the bolt. (3) After removing the rear axle support bolt, remove the rear axle assembly squarely out of the truck.
5.2
Removal Sequence
2
3
2
1 609098
1. 2.
Steering hose Rear axle support, Bolt, and Washer
3.
Rear axle assembly, Thrust washer
7-7
CHAPTER 7 REAR AXLE Preparation (1) After removing the rear tires, remove the wood blocks under the rear axle, and insert a carriage. Insert the carriage so that the rear axle can be removed to the side. (2) Place wood blocks under the balance weight on both sides.
609099
6.
Installing Rear Axle
Follow the removal sequence in reverse. Carry out the following procedures.: (1) Adjusting bearing support clearances Adjust the front and rear clearances by using thrust washers so that the total clearance becomes 0.8 mm (0.03 in.) or less. Note: Insert thrust washers evenly.
0.8 mm (0.03 in.) or less
609100
Standard value Item
Thrust washer type
3.5 to 5.5 ton
6.0 to 7.0 ton
1.0 mm (0.039 in.)
3.2 mm (0.125 in.)
-
1.6 mm (0.062 in.)
2.0 mm (0.078 in.)
0.8 mm (0.031 in.)
(2) Removing support bushing Do not remove the bushing in the support if possible. If not, replace the bushing together with the support assembly, or break and remove the bushing. Assemble a new bushing so that the matchmark faces downward (toward the grease nipple). Note: Assemble a new bushing so that the joint faces downward (toward the grease nipple).
1 1. Bushing joint
7-8
609101
CHAPTER 7 REAR AXLE
7. 7.1
Disassembling Rear Axle Assembly Rear Axle (3.5 to 5.5 Ton)
Disassembly sequence
7
14
8 5 5 11
8
2 3
12
10
4
6
10
13
9 1
9
609102
1. 2. 3. 4. 5. 6. 7.
Taper roller bearing (inner), Retainer Bolt, Washer, Tie rod pin, Spacer, Dust seal, Ring, Bearing Tie rod Bolt, Washer, Clamp Oil pipes (L.H., R.H.) Bolt, Spring washer Steering cylinder
8. 9. 10. 11. 12. 13. 14.
Elbows, O-rings Cover, Plate, O-ring, Taper roller bearing (outer), Oil seal, Bolt, Washer Taper roller bearings (inner), Knuckle Plug Oil seal, Taper roller bearing (outer) Bolt, Locknut Rear axle housing
7-9
CHAPTER 7 REAR AXLE 7.2
Rear Axle (6.0 to 7.0 Ton)
Disassembly sequence
5
4
7
5 2
1 3 6 1 609103
1. 2. 3. 4.
Bolt, Washer, Clamp Oil pipes (L.H., R.H.) Bolt, Spring washer Bolt, Washer, Clamp
5. 6. 7.
Elbows, O-rings Bolt, Locknut Rear axle housing
Since different oil pipes are used for 6.0 to 7.0 ton models, clamps of different shapes are used. Elbows are also different.
7-10
CHAPTER 7 REAR AXLE Suggestions for disassembly (1) -
Removing cover Remove the six bolts from cover 9. Remove the plug at the center of the cover. Screw in a cover puller bolt (nominal diameter: 12 mm (0.47 in.), pitch: 1.25 mm (0.049 in.), thread length: 50 mm (1.97 in.) or more), and remove cover 9.
1)
9
609104 1) Puller bolt
(2) Inspect the taper roller bearing (outer) and the oil seal that are pressed into cover 9. Do not disassemble if possible. Do not disassemble the taper roller bearing (outer) and oil seal 12 that are pressed into rear axle 14 if possible. (3) Rings and bearings 2 remain at knuckle 10 and steering cylinder 7 respectively at disassembly. Inspect the rings and bearings, and do not disassemble if possible. (4) Remove oil pipes 5 from the elbows. Then remove elbows 8.
2
2
7
•
•
•
10
• 609105
7-11
CHAPTER 7 REAR AXLE
8.
Assembling Rear Axle Assembly
8.1
Assembly Sequence
12
12 10
13
9
9
B
A
•
B
• A
11
7 1
11
2
• •
•
8
7
5
• •
• •
11
1
••
3
•
•
•
•
14 •
• •
•
•
•
6 3 •
• • •
• •
3
•
4 609106
1. 2. 3. 4. 5. 6. 7.
7-12
Rear axle housing Taper roller bearing (outer), Oil seal Knuckle, Taper roller bearing (inner) Cover, Taper roller bearing (outer), Oil seal, O-ring, Plate, Plug Plug Bearing, Ring Steering cylinder
8. 9. 10. 11.
Bearing, Ring Elbows (L.H., R.H.) Bolt, Spring washer Tie rod, Tie rod pin, Dust seal, Collar, Spacer, Bolt, Spring washer 12. Oil pipes (L.H., R.H.) 13. Bolt, Locknut 14. Taper roller bearing (inner), Retainer
CHAPTER 7 REAR AXLE 8.2
Suggestion for Assembly
(1) Filling grease Fill the taper roller bearing at knuckle 3 with grease. In particular, apply sufficient grease in the roller holder. Apply grease on the oil seal lip, too. The taper roller bearing at knuckle was changed to a greasable type in 2007.
1
• •
2 3 4
• •
609107 1. Grease 2. Oil seal
(2) Tighten bolt 10 of steering cylinder 7 to the specified torque.
3. Oil seal 4. Grease
1)
2)
609108
Ref. 10
Item Bolt
Tightening torque 262 ± 40 N·m (26.7 ± 4 kgf·m) [193.1 ± 28.9 lbf·in.]
7-13
CHAPTER 7 REAR AXLE (3) Adjusting knuckle bearing preload Drive in cover 4 without inserting a plate, and measure the clearance between rear axle housing 1 and the cover. Insert a plate thinner than the clearance by 0.1 mm (0.0039 in.), and tighten the cover with a bolt. Attach a spring scale to the edge of the knuckle arm, and check that the tangential force is the specified value.
1) 1) Clearance
Tightening torque Item
Tangential force
3.5 to 5.5 ton
6.0 to 7.0 ton
30.4 to 79.4 N·m (3.1 to 8.1 kgf·m) [6.82 to 17.82 lbf·in.]
26.5 to 67.6 N·m (2.7 to 6.9 kgf·m) [5.94 to15.18 lbf·in.]
If the specified value is not obtained, adjust the plate.
7-14
609109
CHAPTER 7 REAR AXLE
9.
Disassembling Steering Cylinder
9.1
Disassembly Sequence
5 6
4
A
6 2
1
2
1
A
1
3
609110
1. 2. 3.
Nut, Spring washer, Bolt Cylinder head, Dust seal, Backup ring, Oil seal, O-ring, Bushing Cylinder tube
4. 5. 6.
Piston rod, Piston Wear rings (2 pieces), Piston seal Stopper ring, Bearing
Note: (1) Do not remove bushing 2 from the cylinder head if possible. (2) Do not remove bearing 6 from piston rod 4 if possible.
7-15
CHAPTER 7 REAR AXLE
10. Inspection and Repair After Disassembling Steering Cylinder (1) Cylinder tube 3 Check for wear, damage, or rust inside the cylinder. (2) Piston rod 4 Check for rust, damage, scratches, or impact marks on the rod surface. (3) Rings and gaskets Replace the entire seal kit with new one.
609111
2)
1)
609112
Ref.
Item
Standard value
Repair limit
1)
Internal diameter of cylinder tube
85 mm (3.346 in.)
85.15 mm (3.352 in.)
2)
External diameter of piston rod
60 mm (2.36 in.)
-
7-16
CHAPTER 7 REAR AXLE
11. Assembling Steering Cylinder 11.1 Assembly Sequence
1
3
6
1
5
4
6 2
*
*
*
*
* 609113
1. 2. 3. 4.
Piston rod, Piston Bearing, Stopper ring Wear rings (2 pieces), Piston seal Cylinder tube
5. 6.
Cylinder head, Bushing, O-ring, Oil seal, Backup ring, Dust seal Bolt, Spring washer, Nut
Note: Parts marked with * are included in the seal kit.
11.2 Suggestions for Assembly (1) Replace the seal kit parts shown in the above figure when assembling. (2) Clean the parts completely before assembly, and make sure that they are free of dust. (3) Apply oil on the piston seal, O-ring, gasket, dust seal, and inside the cylinder before assembly. (4) Procedure for installing piston seal Grip the piston seal lightly by hand five or six times to soften the seal before installation. Grip the piston rod in a vice so that the vice does not damage the rod. Apply a little oil on the piston seal. Insert one side of the seal into the fitting groove of the piston, and insert the other side. After installing the piston seal, insert the wear ring.
609114
7-17
CHAPTER 7 REAR AXLE (5) Make sure that seal and rings on the cylinder head are installed in correct directions. (6) Tighten nut 6 to the specified torque.
609115
Item Nut
Tightening torque 59.8 N·m (6.1 kgf·m) [44 lbf·in.]
12. Adjustment 12.1 Adjusting Minimum Turning Radius (1) Measure the turn angle of the rear wheel by using a turning radius gauge. (2) If the turning angle is out of the specified range, adjust the angle with the stopper bolt on the knuckle.
1 2
609116 1. Stopper bolt (left and right)
2. Locknut
Lift Truck Models Item 3.5 to 5.5 ton
6.0 to 7.0 ton
Turning angle (inward)
82°
80°
Turning angle (outward)
59°
55°
-
-
degree
Note: Check clearance between stopper bolt, thread end, and steer cylinder rod when fully turned in both directions.
7-18
CHAPTER 7 REAR AXLE (3) While driving the truck at low speed, turn the steering wheel fully in both directions, and check the diameter of the tire tracks at the outside of the rear wheel in both turning operations. (4) Minimum turning radius R is obtained from half of the turning diameter plus the length from the center of the rear tire to the outside edge of the counterweight.
R
609117
Item
Minimum turning radius
Lift Truck Models
Standard value
GC35K
2235 mm (87.99 in.)
GC40K
2285 mm (89.96 in.)
GC40K STR
2090 mm (82.28 in.)
GC45K SWB/STR
2340 mm (92.12 in.)
GC55K
2550 mm (100.39 in.)
GC55K STR
2350 mm (92.52 in.)
GC60K
2570 mm (101.18 in.)
GC70K
2570 mm (101.18 in.)
GC70K STR
2400 mm (94.48 in.)
7-19
CHAPTER 7 REAR AXLE
13. Troubleshooting Condition
Possible causes
Corrective action
Insufficient grease in rear axle or steering parts
Supply grease
Faulty steering system
See “STEERING SYSTEM”.
Slow return of steering wheel
Over-tightening of steering system or rear axle parts
Tighten to the specified torque
Steering wheel prone to move to one side
Gap in external diameters between right Replace with genuine tires and left tires
Heavy steering wheel operation
Shudder of steering wheel
Uneven or early wear of rear tires
7-20
Wear or breakage of taper roller bearing Replace the bearing Faulty steering system
See “STEERING SYSTEM”.
Misalignment of wheels
Realign wheels
Different tire types for right and left wheels
Replace with genuine tires
CHAPTER 7 REAR AXLE
14. Service Data Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Turning angle (L.H., R.H.)
Standard
3°
Toe-in
Standard
0°
Caster
Standard
0°
Camber
Standard
1°
Steering angle Inward
Standard
82°
80°
Steering angle Outward
Standard
59°
55°
Tightening torque
30.4 to 79.4 N·m (3.1 to 8.1 kgf·m) [6.82 to 17.82 lbf·ft]
26.5 to 67.6 N·m (2.7 to 6.9 kgf·m) [5.94 to 15.18 lbf·ft]
41.2 to 49.0 N (4.2 to 5.0 kgf) [9.2 to 11.0 lbf]
44.1 to 52.9 N (4.5 to 5.4 kgf) [9.9 to 11.9 lbf]
1
Tangential force at knuckle bearing
2
Tangential force at hub bearing
Standard
3
Front and back clearance for center pin
Standard
0.8 mm (0.031 in.) or less
Limit
1.2 mm (0.047 in.)
4
Steering cylinder bolt
Tightening torque
262 ± 40 N·m (26.7 ± 4 kgf·m) [193.1 ± 28.9 lbf·ft]
5
Outer nut
Tightening torque
6
Hose
Tightening torque
7
Tire service limit
Tightening torque
4
+20 +2 0 N·m (16 0
kgf·m) [115.7
+14 0 lbf·ft]
49 ± 4.9 N·m (5 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft] 45.7 mm (1.8 in.)
48.3 mm (1.9 in.)
7
1
← ⎯
6
157
←
2
• •
3
•
•
• 5
609118
7-21
CHAPTER 7 REAR AXLE Steering cylinder
Ref.
Item
1
Internal diameter of cylinder tube
2
External diameter of piston rod
3
Bolt
All truck model Standard
85 mm (3.346 in.)
Limit
85.15 mm (3.352 in.)
Standard
60 mm (2.36 in.)
Tightening torque
59.8 N·m (6.1 kgf·m) [44 lbf·ft]
3
2
1
609119
7-22
CHAPTER 8 BRAKE SYSTEM
Chapter 8 BRAKE SYSTEM 1.
Specifications Item
3.5 to 5.5 ton Type Drum diameter
Main brake Brake system
Lining dimension (Length × Width × Thickness Number of unit)
Hydraulic front-wheel braking drum internal expansion duo-servo type 317.5 mm (12.50 in.) 330 × 63 × 10 - 2 mm (13 × 2.48 × 0.39 - 2 in.)
324 × 100 × 10 - 2 mm (12.75 × 3.93 × 0.39 - 2 in.)
Master cylinder internal diameter
28.57 mm (1.125 in.)
Master cylinder internal diameter
31.75 mm (1.250 in.)
Brake booster Parking brake
6.0 to 7.0 ton
Type
Brake booster master back type (Vacuum booster) Hydraulic front-wheel braking drum internal expansion type
8-1
CHAPTER 8 BRAKE SYSTEM
2. 2.1
Structure Brake System 4
2
5
1)
3
6 7
8 1
609120
1. 2. 3. 4. 5.
8-2
Wheel brake Parking brake lever Reserve tank Brake pedal Vacuum tank
6. 7. 8. 1)
Brake booster Master cylinder Wheel cylinder To Engine (intake manifold)
CHAPTER 8 BRAKE SYSTEM 2.2
Master Cylinder and Reserve Tank
1 2 3
11 15
4
12
5
13
6 16
10
7 8
14 9 1)
609121
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder Snapring Secondary cup Piston Spacer Primary cup Thimble Snapring Spring
10. 11. 12. 13. 14. 15. 16. 1)
Piston assembly Cap seal Reserve cap Reserve tank Indicator assembly Cap assembly Reserve assembly 3 ± 2 mm (0.118 ± 0.078 in.) Indicator ON position (energized in emergency)
8-3
CHAPTER 8 BRAKE SYSTEM 2.3
Wheel Brake
4
3
2
5 6
1
7 A
A
8
11
9
10
13 1. 2. 3. 4. 5. 6. 7.
8-4
Parking lever Shoe and lining (primary) Strut Return spring Wheel cylinder Dust shield Shoe and lining (secondary)
Section A-A
12 609122
8. 9. 10. 11. 12. 13.
Fitting link assembly Adjusting lever Adjusting screw Return spring Parking cable Backing plate
CHAPTER 8 BRAKE SYSTEM 2.4
Brake Booster (3.5 to 5.5 Ton)
1
2 3
28 27
4 5 6 7 8 9 1011121314
15 16 17
26 25 24 23 22 21 20 19 18 609123
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Retainer Silencer Filter Retainer Spring Spring Retainer Valve body seal Bearing Retainer Key Reaction disc Pushrod body Rod
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Pushrod seal Plate Retainer Cylinder shell (front) Spring Diaphragm plate Diaphragm plate Diaphragm Cylinder shell (rear) Valve plunger Poppet washer Poppet assembly Valve body guard Operating rod
8-5
CHAPTER 8 BRAKE SYSTEM 2.5
Brake Booster (6.0 to 7.0 Ton)
2
1
22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
8-6
21
20
Silencer Filter Poppet washer Cylinder shell (rear) Diaphragm (rear) Diaphragm plate (rear) Pushrod Diaphragm (front) Diaphragm (front) Pushrod seal Project stud
3
19 18
4
17 16
6
5
15
7
14 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
8
13 Pipe Cylinder plate Cylinder shell (front) Spring Reaction disc Valve plunger Poppet assembly Spring Valve body guard Retainer Operating rod
9
10
12
11
609124
CHAPTER 8 BRAKE SYSTEM
3. 3.1
Disassembling Master Cylinder Disassembly Sequence
2 1
11
5
10
9
8
7
4 3
6
12 609125
1. 2. 3. 4. 5.
Clamp Filler union Snapring Piston Remove piston 4, and parts 6 through 10 as sub-assembly. Spring
6. 7. 8. 9. 10. 11. 12.
S-cup Snapring Thimble P-cup Spacer Cylinder Repair kit
8-7
CHAPTER 8 BRAKE SYSTEM
4. 4.1
Inspection and Repair After Disassembling Master Cylinder Cylinder Body
(1) Check the cylinder bore for rust, erosion, or scoring. (2) Check the condition of the inlet and relief ports. Check joint thread for damage.
4.2
Piston
Check the piston for damage and replace the piston if damaged. Insert the piston to the cylinder. If the clearance between the piston and cylinder exceeds the service limit, replace the master cylinder. Item Clearance between cylinder and piston
4.3
Standard value
Repair limit
0.020 to 0.105 mm (0.0008 to 0.00413 in.)
(Replace every year)
Return Spring
Measure the free length of the return spring. If the measurement exceeds the service limit, replace the return spring. Item Free length of return spring
8-8
Standard value
Repair limit
104 mm (4.09 in.)
(Replace every year)
CHAPTER 8 BRAKE SYSTEM
5.
Assembling Master Cylinder
5.1
Assembly Sequence
10
7
8
6
5 4
3
1
2
9 609126
1. 2. 3. 4. 5.
Piston Secondary cup Spacer Primary cup Thimble
5.2 (1) (2) (3) (4)
6. Snapring 7. Spring 8. Cylinder 9. Snapring 10. Filler union, Clamp Note: Parts 1 through 6 - Piston assembly
Suggestions for Assembly Do not reuse the disassembled piston and cups. Clean metal parts with volatile solvent, and dry with compressed air. Apply brake fluid thinly on the cylinder bore and the piston cup. Tighten the clamp to the specified torque. Item
Clamp
Tightening torque 6.9 to 8.8 N·m (0.7 to 0.9 kgf·m) [5.1 to 6.5 lbf·ft]
8-9
CHAPTER 8 BRAKE SYSTEM
6.
Disassembling Wheel Cylinder
6.1
Disassembling Sequence
1 2
6
*
5
8
3
7
3 1
4
2
609127
1. 2. 3. 4.
Connector ring Boot Piston Piston cup
Note: -
8-10
Parts marked with * are included in the seal kit. Repair kit parts should be replaced periodically.
5. 6. 7.
Return spring Breeder screw, Cap Cylinder body
CHAPTER 8 BRAKE SYSTEM
7. 7.1
Inspection and Repair After Disassembling Wheel Cylinder Cylinder Body
(1) Check the bore of the body for rust, erosion, or scoring. (2) Check the threads of the bleeder screw and oil pipe screw connections for damage.
7.2
Piston
(1) Check the outer surfaces for rust or scoring. (2) Insert the piston in the body. If the clearance between the piston and body exceeds the service limit, replace the wheel cylinder.
609128
Item Clearance between cylinder and piston
7.3
Standard value
Repair limit
0.020 to 0.105 mm (0.0008 to 0.00413 in.)
0.15 mm (0.0059 in.)
Piston Cups
Check each cup for swelling or other defects and replace if any defect is found. Item Fit of the piston cups in cylinder body
7.4
Standard value
Repair limit
1.85 mm (0.0728 in.)
0.65 mm (0.0256 in.)
Boot
Replace the boot if it is damaged or deteriorated due to aging. Replace the boot every year.
8.
Assembling Wheel Cylinder
Follow the disassembly sequence in reverse. Be careful with the following key points: (1) Apply brake fluid evenly to the cylinder bore and the piston cup. (2) Be careful not to damage the lip of the cup. (3) Assemble the cup in correct direction.
8-11
CHAPTER 8 BRAKE SYSTEM
9. 9.1 (1) (2) (3) (4)
9.2
Disassembling Wheel Brake Preparation Remove the front tires. Remove the wheel hub and drum. Separate the parking lever at the lower side of the wheel brake and the parking cable fitting. Remove the brake pipe from the wheel brake assembly.
Disassembly Sequence
6
13
12
11 2
8
2
1
2
4 5 10
6
9
7
3 609129
1. 2. 3. 4. 5. 6.
8-12
Return springs Fitting link assembly, Split pin, Plane washer, Spring and link assembly, Lever and Link Adjusting lever, Adjusting spring Return spring Adjusting screw Hold-down spring, Cup and Pin
7. 8. 9. 10. 11. 12. 13.
Strut, Retainer and Web washer Shoe and lining (secondary) Shoe and lining (primary) Parking lever, Retainer and Web washer Wheel cylinder Parking cable Backing plate
CHAPTER 8 BRAKE SYSTEM 9.3
Suggestions for Disassembly
Removing return springs Use the special tool to remove the return springs from the shoe guide plate.
1
609130 1. Special tool
Special tool Spring remover
Part number 64309-15400
Removing hold-down springs Use the special tool to remove the shoe hold-down springs from the backing plate.
1
609131 1. Special tool
Special tool Spring retainer
Part number 91868-00600
8-13
CHAPTER 8 BRAKE SYSTEM
10. Inspection and Repair After Disassembling Wheel Brake 10.1 Backing Plate (1) Check the backing plate for cracks. (2) Check the tightening torque of mounting bolts. Item
Tightening torque 238.3 to 284.3 N·m (24.3 to 29.3 kgf·m) [53.5 to 63.9 lbf·ft]
Check the mounting bolts
10.2 Shoe and Lining Assembly (1) Check the lining and shoe for cracks or breakage. (2) Replace the lining if severely stained with oil, burned, or deteriorated. (3) Check the lining thickness. If the thickness exceeds the service limit, replace the lining.
609132
Item Lining thickness
Standard value
Repair limit
10 mm (0.39 in.)
4.2 mm (0.16 in.)
10.3 Brake Drums If uneven wear or damage is found inside each brake drum, grind, and repair.
Item Brake drum internal diameter
Standard value 317.5
+0.2 +0.008 0 mm (12.500 0 in.)
Repair limit or Service limit 318.5 mm (12.539 in.)
10.4 Adjusting Screw Check for wear on wheel teeth. Also check if the wheel rotates smoothly.
609133
8-14
CHAPTER 8 BRAKE SYSTEM 10.5 Parking Brake Link (1) Check the lever support pin and pin hole for wear, and replace the link if severely worn. (2) Check the parking cable, and replace if it is stretched, damaged, or rusted.
10.6 Other Inspection Parts (1) Check the shoe return spring for cracks or fatigue. (2) Check the adjusting screw for cracks or fatigue.
8-15
CHAPTER 8 BRAKE SYSTEM
11. Assembling Wheel Brake 11.1 Assembly Sequence
3
13
1
7 5 4
12 8 6 A
A
10 11
9
Section A-A
2 609134
1. 2. 3. 4. 5. 6. 7. 8.
8-16
Backing plate Parking cable Wheel cylinder Parking lever, Retainer and Web washer Shoe and lining (primary) Shoe and lining (secondary) Strut, Retainer and Web washer Hold-down spring, Cup and Pin
9. 10. 11. 12.
Adjusting screw Return spring Adjusting lever, Adjusting spring Fitting link assembly, Link, Lever, Spring and link assembly, Plane washer, and Split pin 13. Return spring
CHAPTER 8 BRAKE SYSTEM 11.2 Suggestions for Assembly Installing wheel cylinder Apply liquid gasket on the mounting surface of cylinder, then tighten the bolt to the specified torque.
609135
Item
Tightening torque 17.6 to 26.4 N·m (1.8 to 2.7 kgf·m) [13.0 to 19.5 lbf·ft]
Bolt
Greasing Apply a thin coat of the specified brake grease on the following parts: -
Shoe ledges (6 places) (Backing plate surface contacting with the shoes) Anchor pin surface in contact with the shoe web Pin surface inner fitting to the automatic adjust lever hole Installing shoes and linings Make sure that the push rod of the wheel cylinder is correctly inserted to the shoe web. Installing return springs Use the special tool to install the return springs to the backing plate pins.
1
609136 1. Special tool
Special tool Spring installer
Part number 64309-15400
8-17
CHAPTER 8 BRAKE SYSTEM Installing automatic adjuster (1) Clean adjusting screw parts and apply grease on the threads and the fitting of screw socket. Make sure the screw rotates smoothly by hand. If the screw rotation is sluggish, replace the screw with a new one. (2) The adjusting screws in L.H. wheel brakes are different from those in R.H. wheel brakes. The L.H. screws are used on the L.H. wheel brake and the R.H. screws are used on the R.H. wheel brake. 609137
Installing parking cable Tighten the parking cable to the specified torque. Item
Tightening torque 41.1 to 54.9 N·m (4.2 to 5.6 kgf·m) [30.3 to 40.5 lbf·ft]
Parking cable
12. Inspecting and Repairing Parking Brake Lever 12.1 Parking Brake Lever Components
1)
2) 1 2
3 4
5 6 609138
1. 2. 3. 4.
8-18
Grip Set screw Stud Lever assembly
5. 6. 7.
Rod assembly Bracket Parking brake wire
CHAPTER 8 BRAKE SYSTEM 12.2 Suggestions for Inspection and Repair (1) Replace the lever support pin if the pin or pin hole is severely worn. (2) Replace the parking brake cable if stretched, damaged, or rusted.
12.3 Installing Parking Brake Lever After connecting the parking brake wire, the operating force of the parking brake lever should be 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]. The operating force of the parking brake lever should be (400 to 445 N (40 to 45 kgf) [90 to 100 lbf] for 7 ton model only)
8-19
CHAPTER 8 BRAKE SYSTEM
13. Adjustment 13.1 Automatic Adjuster Test (1) With all wheel brake components installed correctly, the drum-to-shoe clearance should be within the correct range of 0.4 to 0.6 mm (0.016 to 0.024 in.). Push the cable with thumb to pull the adjusting lever. Observe that the lever turns the adjusting screw by one tooth, and push to observe the adjusting screw returns to the original position.
609139
(2) If the lever fails or is sluggish to turn the adjusting screw in the above test, the possible cause is that the lever is not properly positioned relative to the sprocket wheel. BE SURE that the lever is positioned so that its actuating tip touches the sprocket wheel at a level about 9 mm (0.35 in.) under the center line of the screw as shown. (3) Where the automatic adjusting device is suspected of malfunctioning during normal operation, check the following for possible causes: - Check that springs A and B are correctly installed. - If any of following parts is in bad condition and requires replacement: - Fitting cable - Adjusting lever - Adjusting screw
A
B
9 mm
(0.35 in.) 609140
13.2 Procedure for Manual Adjustment Insert a screw driver in the adjustment hole on the back of the backing plate. Force down and rotate the wheel of adjusting screw to adjust the clearance between the drum and lining.
609141
Item Clearance between drum and lining (one side)
8-20
Standard value 0.14 to 0.6 mm (0.016 to 0.024 in.)
CHAPTER 8 BRAKE SYSTEM 13.3 Brake Fluid Line Bleeding When a part of the brake fluid line is disassembled for repair, or when brake pedal movement is spongy, bleed the brake fluid line. Bleeding work requires two people. Turn ON the engine and keep it idling during bleeding operation. (1) Fill the reserve tank with brake fluid. Always keep the brake fluid level more than half full of the reserve tank during bleeding operation. (2) Insert a vinyl tube on the bleeder screw of the wheel cylinder. Insert the other end of the tube to a container filled with brake fluid. (3) Have one person depress (pump) on the brake pedal several times and while holding the pedal depressed, release the bleeder screw. Before the brake fluid stops flowing in the vinyl tube, tighten the bleeder screw. (4) Repeat the above Steps until there is no air bubbles in the brake fluid. Fill the reserve tank with brake fluid to the specified level.
609142
Note: -
If brake pedal feels soft, a vacuum pump may be needed to bleed all the air out of the master cylinder, lines, and wheel cylinders. BE SURE to maintain sufficient fluid level in the reserve tank. Use brake fluid of the specified brand. Do not mix different types of brake fluids. Start bleeding work of the brake fluid of the wheel cylinder from the right side (far side from the master cylinder).
13.4 Inspecting Reserve Tank Level Sensor The sensor is normal if Brake fluid warning light on the meter panel illuminates when brake fluid level is under MIN. line of the reserve tank.
609143
609290
8-21
CHAPTER 8 BRAKE SYSTEM 13.5 Procedures for Brake Pedal Adjustment (1) Bleed brake fluid of the brake reserve tank from the master cylinder to the wheel cylinder. (2) Adjust and confirm the clearance between the drum and lining. (3) Attach locknut (right-hand thread) 2, push rod (righthand thread) 3, locknut (left-hand thread) 4, and clevis (left-hand thread) 5 to push rod 1 of the brake booster. Make sure that dimension L1 is the specified value. Use dimension L2 for checking. Screw in the right-hand and left-hand threads to the same length.
5
4
3
2
1
L2
L1 609144
Item
Standard value
L1
155mm (6.10 in.)
L2
88 mm (3.46 in.)
(4) Install the push rod assembly on the brake pedal. (5) Rotate the stopper bolt and adjust brake pedal height A to 175 mm (6.9 in.), and fix the stopper bolt with a locknut. (6) Start the engine. (7) Push the brake pedal by hand and check brake pedal free play B.
B
C
1 A
2
3
609145
Item
Brake pedal free play B
Standard value 3.5 to 5.5 ton
6.0 to 7.0 ton
21 to 35 mm (0.83 to 1.83 in.)
23 to 27 mm (0.9 to 1.45 in.)
If the play exceeds specified range, loosen locknuts 2 and 4, then turn push rod 3 to adjust dimension L1. Item Brake pedal stroke C
8-22
Standard value 37 mm (1.456 in.)
CHAPTER 8 BRAKE SYSTEM 13.6 Brake Booster Test Test method without a tester Carry out the following three tests. If no problem is found, the brake booster is in good condition. (1) Run the engine at an idling speed for 1 to 2 minutes, then stop it. Depress the brake pedal with normal stepping force several times. If the pedal stroke decreases every time the pedal is depressed, the brake booster is in good condition. If the stroke does not change, the brake booster is defective. (2) Depress the brake pedal several times while the engine is stopped. Turn ON the engine while the brake pedal is depressed. If the pedal goes down, the booster is in good condition. If not, the booster is defective. (3) Depress the brake pedal while the engine is running. While the pedal is depressed, turn the engine OFF, and keep the pedal depressed for about 30 seconds. If the pedal height does not change, the booster is in good condition. Test method with a simplified tester Use a vacuum gauge, pressure gauge, and force gauge. Bleed the pressure gauge, and proceed as follows: (1) Unloaded air-tightness test Turn ON the engine, and turn the engine OFF when the vacuum gauge reads approx. 66.5 kPa (500 mmHg). The brake booster is in good condition if the vacuum drop in 15 seconds after the engine stops is 3.32 kPa (25 mmHg) or less. (2) Loaded air-tightness test Turn ON the engine, and depress the brake pedal with a stepping force of 20 kg (44 lb). Turn the engine OFF when the vacuum gauge reads approx. 66.5 kPa (500 mmHg). The brake booster is in good condition if the vacuum drop in 15 seconds after the engine stops is 3.32 kPa (25 mmHg) or less. (3) Characteristic test of brake booster Carry out this test after tests (1) and (2). Non-booster action test Make sure that the vacuum gauge reads 0 kPa (0 mmHg) when the engine is stopped. Depress the brake pedal with stepping forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf]. The brake booster is in good condition if the generated hydraulic pressure meets the specified value. Item Generated hydraulic pressure
Stepping force:
Tightening torque
Standard value
98 N·m (10 kgf·m) [22 lbf·ft]
686 kPa (7.0 kgf/cm²) [99.5 psi]
196 N·m (20 kgf·m) [44 lbf·ft]
1373 kPa (14 kgf/cm²) [199 psi]
3
1
4
1)
2 609146 1. Pressure gauge 2. Vacuum gauge 3. Stepping force
4. Vacuum tank 1) To engine
8-23
CHAPTER 8 BRAKE SYSTEM Booster action test Turn ON the engine. Depress the brake pedal with stepping forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf] when the vacuum gauge reads 66.5 kPa (500 mmHg). The brake booster is in good condition if the generated hydraulic pressure meets the specified value. Note: The operation test outlined above is a simplified test. BE SURE to carry out a bench test for the individual booster as specified by the manufacturer if the booster is defective. Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Tightening torque
Generated hydraulic pressure
8-24
3.5 to 5.5 ton
6.0 to 7.0 ton
Standard value
98 N·m (10 kgf·m) [22 lbf·ft]
2354 kPa (24 kgf/cm²) [341 psi] or more
2942 kPa (30 kgf/cm²) [427 psi] or more
196 N·m (20 kgf·m) [44 lbf·ft]
3628 kPa (37 kgf/cm²) [526 psi] or more
5198 kPa (53 kgf/cm²) [757 psi] or more
Stepping force
CHAPTER 8 BRAKE SYSTEM
14. Troubleshooting Item
Condition
Possible causes Oil leakage from master cylinder primary cup Oil leakage from wheel cylinder cup
Insufficient braking force
Action Check cylinder for wear if possible, replace piston cup. If piston cup is deformed, replace cup and brake fluid. Use genuine parts and brake fluid
Oil leakage from oil pipe joint
Retighten or replace pipe and join
Worn lining
Replace
Oil on lining
Clean or replace lining
Air in hydraulic system
Bleed master cylinder and wheel cylinder
Defective master cylinder piston cup
Replace piston cup
Low oil level in reserve tank
Supply oil
Excessive clearance of master cylinder push rod Adjust Excessive pedal stroke
Brake fluid leakage
Check cylinder for wear if possible, replace piston cup. If piston cup is deformed, replace cup and brake fluid. Use genuine parts and brake fluid
Automatic adjuster not activate
Check cable guide and adjusting screw for correct installation. If automatic adjuster still does not activate, replace fitting link assembly, lever, and adjusting screw
Oil or grease on lining or drum
Clean with brake cleaner 21651 and repair. If oil and grease cannot be removed from lining, replace lining
Brake drum shimmy or loose mounting
Replace drum. Adjust and retighten loose mounting
Lining surface too smooth
Scrub lining surface with abrasive paper
Worn lining
Replace shoe and lining assembly
Loose mounting bolt of backing plate
Retighten
Loose wheel bearing
Adjust pre-load and retighten
Dirty drum
Clean drum with brake cleaner 21651
Shoe anchor end contacting with anchor
Repair or replace
Excessive wear of shoe ledge
Replace backing plate
Excessive wear of wheel cylinder piston
Replace wheel cylinder
Wheel brake
Imbalance in braking power
Brake squeaking
Abnormal noise from brake (clicking noise)
8-25
CHAPTER 8 BRAKE SYSTEM Item
Condition
Heavy pedal Wheel brake
Spongy pedal
Insufficient parking brake stroke Abnormal noise from parking brake in driving
Action
Loose connection of vacuum hose
Repair
Squashed or torn vacuum hose
Replace hose
Foreign matter adhesion or damage on Repair or replace vacuum valve or exhaust valve in brake booster Element clogging in brake booster
Clean or replace
Damaged diaphragm of brake booster
Replace
Foreign matter mixing in brake cylinder
Clean cylinder and supply cylinder liquid
Insufficient brake cylinder fluid
Supply
Brake cylinder liquid leakage
Repair or replace
Incorrect bleeding
Bleed
Insufficient clearance between brake and lining Adjust to standard clearance Insufficient clearance between brake lining and Adjust to standard clearance drum Warped brake drum
Repair brake drum according to repair standard, or replace
Adjust clearance between brake lining and drum. If parking brake still Parking brake cable exceeding specified length does not produce stopping force, check parking brake cable length
Parking brake Parking brake not producing stopping force
8-26
Possible causes
Brake lining worn beyond service limit
Replace shoe and lining assembly
Excessive clearance between brake lining and drum
Adjust clearance between brake lining and drum
Insufficient pulling force of parking brake lever
Adjust pulling force to 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]
CHAPTER 8 BRAKE SYSTEM
15. Service Data Brake system Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
1
Pedal height (between top surface of frame and upper pedal edge)
Standard
2
Free play of brake pedal
Standard
21 to 35 mm (0.83 to 1.38 in.)
23 to 37 mm (0.91 to 1.46 in.)
3
Brake pedal stroke
Standard
45 to 70 mm(1.77 to 2.76 in.)
45 to 70 mm (1.77 to 2.96 in.)
175 mm (6.9 in.)
Master cylinder mounting bolt
Tightening torque
117 N·m (1.2 kgf·m) [8.68 lbf·ft]
Brake booster mounting bolt
Tightening torque
39.2 to 49.0 N·m (4 to 5 kgf·m) [28.9 to 36.1 lbf·ft]
Vacuum pipe union nut mounting bolt
Tightening torque
12.7 to 17.6 N·m (1.3 to 1.8 kgf·m) [9.4 to 13.0 lbf·ft]
Brake pipe union nut mounting bolt
Tightening torque
11.7 N·m (1.2 kgf·m) [8.68 lbf·ft]
3
2
1
609148
8-27
CHAPTER 8 BRAKE SYSTEM Master cylinder Ref.
Item
All truck models
1
Cylinder body internal diameter
Standard
28.57 mm (1.125 in.)
2
Piston external diameter
Standard
28.57 mm (1.125 in.)
Standard
0.020 to 0.105 mm (0.0008 to 0.00413 in.)
Clearance between cylinder and piston
Limit 3
Primary cup lip-side external diameter
4
Secondary cup lip-side external diameter
5
Return spring free-movement length
0.2 mm (0.008 in.) (Replace every year)
Standard
28.57 mm (1.125 in.)
Limit
(Replace every year)
Standard
28.57 mm (1.125 in.)
Limit
(Replace every year)
Standard
104 mm (4.09 in.)
Limit
5
1
3
2
(Replace every year)
4 609149
8-28
CHAPTER 8 BRAKE SYSTEM Wheel cylinder Ref.
Item
All truck models +0.062 +0.00244 0 mm (1.25 0 in.)
1
Cylinder body internal diameter
Standard
31.75
2
Piston external diameter
Standard
31.75 -0.064 mm (1.2500 -0.00252 in.)
Standard
0.020 to 0.105 mm(0.0008 to 0.00413 in.)
Clearance between cylinder and piston
3
4
Limit
-0.00098
0.15 mm(0.006 in.)
Standard
Piston cup lip-side external diameter
Return spring
-0.025
33.6 ± 0.25 mm(1.32 ± 0.0098 in.)
Limit
(Replace every year)
Free-movement length
Standard
33.4 mm(1.31 in.)
Mount length
Standard
14 mm (0.55 in.)
Standard
13 ± 2 N·m (16 ± 0.1 kgf·m) [3.5 ± 0.2 lbf·ft]
Mount weight
Limit
(Replace every year)
5
Wheel cylinder mounting bolt
Tightening torque
18 to 26 N·m (1.8 to 2.7 kgf·m) [13.0 to 20 lbf·ft]
6
Bleeder screw
Tightening torque
6 to 9 N·m (0.6 to 0.9 kgf·m) [4.3 to 6.5 lbf·ft]
6
1
2
3
5
4 609150
8-29
CHAPTER 8 BRAKE SYSTEM Wheel brake Ref. 1
Item
All truck models Standard
Brake drum internal diameter
317.5
Limit 2
Lining thickness
3
Clearance between drum and lining (one-side)
4
Return spring
+0.2 +0.008 0 mm (12.500 0 in.)
318.5 mm(12.539 in.)
Standard
10 mm (0.39 in.)
Limit
4.2 mm (0.17 in.)
Standard
0.4 to 0.60 mm(0.016 to 0.024 in.)
Free-movement length
Limit
Mount length
Standard
101.2 mm(3.98 in.)
Mount weight
Standard
245 N·m (25 kgf·m) [55 lbf·ft]
Free-movement length
Standard
132.2 mm(4.85 in.)
Mount length
Standard
152 mm(5.98 in.)
Mount weight
Standard
78 N·m (8 kgf·m) [18 lbf·ft]
Link (upper)
Standard
Upper: 97 mm (3.82 in.)
Link assembly (lower) length
Standard
Lower: 97.8 mm (3.85 in.)
7
Backing plate mounting bolt
Tightening torque
238 to 284 N·m (24.3 to 29.0 kgf·m) [176 to 210 lbf·ft]
8
Parking cable
Tightening torque
41.1 to 54.9 N·m (4.2 to 5.6 kgf·m) [30.3 to 40.5 lbf·ft]
5
6
Adjusting spring
93 mm(3.66 in.)
1 4 2
4
3 6 7
A 5
A 6
Section A-A 8
8-30
609151
CHAPTER 8 BRAKE SYSTEM Parking brake
Item
All truck models
Lever swing angle A
Standard
Lever operating effort F
Tightening torque
71° to 76° deg 245 to 294 N·m (25 to 30 kgf·m) [55 to 66 lbf·ft]
F A
609152
8-31
CHAPTER 9 STEERING SYSTEM
Chapter 9 STEERING SYSTEM 1.
Specifications Item Steering angle
Steering device
3.5 to 5.5 ton
6.0 to 7.0 ton
Inward
82°
80°
Outward
59°
55°
External diameter of the steering wheel Steering control valve
Full-hydraulic power steering
320 mm (12.9 in.) 23 liter (6.07 U.S. gal)/min.
9-1
CHAPTER 9 STEERING SYSTEM
2. 2.1
Structure Steering System
5
F
4
3
G L
T P
LS
R
B
D
C
E C
D
3
E
2
A
A
6 1) 1. 2. 3.
Hydraulic tank Oil pump Control valve
A
1 B
C
Turning to the left E Turning to the right D 4. 5. 6. 1)
F
G 608816
Steering control valve Steering wheel Power cylinder Oil flow
The steering system reduces the operating effort through hydraulic pressure by using the load sensing mechanism which consists of steering control valve 4 (orbitrol), control valve 3, etc. The operating effort of steering wheel 5 is converted into the hydraulic pressure by steering control valve 4, then into the steering force on the rear axle by power cylinder 6. Control valve 3 supplies hydraulic oil from oil pump 2 to steering control valve 4. Excessive oil is sent to circuits of other devices. When the steering is in the NEUTRAL position, almost all the hydraulic oil can be used to operate other devices.
9-2
CHAPTER 9 STEERING SYSTEM 2.2
Steering Control Valve
13 14 15 16 17 18
Section B-B
T L
R P
B B
1
2 3
4 5 6 7
8
9 10 11 12 608817
1. 2. 3. 4. 5. 6. 7. 8. 9.
Thrust needle bearing Centering spring Pin Drive shaft Valve housing Control sleeve Control spool Wear plate O-ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Gerotor set Spacer End cap Pump port Ball Tank port Cylinder port (Left) Cylinder port (Right) Check ball retainer
9-3
CHAPTER 9 STEERING SYSTEM 2.3
Tilt Steering Assembly
5° 7°
2
1
4
3 608818
1. 2.
Steering column Shaft
3. 4.
Bracket Tilt lock lever
The tilt steering assembly is installed on the bracket under the dashboard. Push down knob 5, and move the steering wheel FORWARD and BACKWARD. Steering column tilt angle is adjustable in the range of 5 degrees FORWARD and 7 degrees BACKWARD.
9-4
CHAPTER 9 STEERING SYSTEM
3.
Removing Tilt Steering and Steering Control Valve Assembly
3.1
Removal Sequence
7 1 2
3
8
6
4
5 10 11 9
12
608819
1. 2. 3. 4. 5. 6.
Steering wheel cap, Nut, and Washer Steering wheel Upper cover (Front) Lower cover (Front) Console box Transmission shift lever assembly
7. 8. 9. 10. 11. 12.
Floor plate Floor plate (Front) Hoses Steering control valve Elbows, Connectors Tilt steering assembly
9-5
CHAPTER 9 STEERING SYSTEM 3.2
Suggestions for Removal
Removing steering wheel
1
Use the special tool to remove the steering wheel.
608820 1. Special tool
Special tool needed Steering wheel puller
91268-10600
R CAUTION DO NOT hit the end of steering shaft when removing the steering wheel.
9-6
CHAPTER 9 STEERING SYSTEM
4. 4.1
Inspection After Installing Tilt Steering and Steering Control Valve Assembly Steering Wheel Play
Check the steering wheel play while idling the engine.
4.2
Steering
(1) Apply the parking brake. Turn ON the engine and warm the hydraulic oil to an operation temperature of 40 to 60°C (104 to 140°F). (2) Attach a spring scale on the rim (or a spoke) of the steering wheel, and measure the steering torque to turn the steering wheel clockwise or counterclockwise.
608821
Item Steering torque Effort
4.3
value 1.96 N·m (0.2 kgf·m) [1.44 lbf·ft] 12.7 N (1.3 kgf) [2.87 lbf]
Air Bleeding
The air in the hydraulic system such as the steering cylinder, the flow divider valve, and the piping may cause a shimmy and abnormal noise. (1) Jack up the rear tires. For procedures, see “REAR AXLE”. (2) Depress and release the accelerator pedal repeatedly to change the engine speed, while turning the steering wheel to lock-to-lock positions.
9-7
CHAPTER 9 STEERING SYSTEM
5. 5.1
Disassembling Steering Control Valve Disassembly Sequence
4 6
11
5 12 7 9 8 10 3
2 1
608822
1. 2. 3. 4. 5. 6.
9-8
End cap, Bolt, O-ring, and Spacer Gerotor set, O-ring Drive shaft, Wear plate, and O-ring Retaining ring Seal gland bushing, O-ring, Oil seal, Dust seal Thrust needle and Race bearing
7. 8. 9. 10. 11.
Control sleeve Control spool Pin Centering spring Check valve, Retainer, Ball, O-ring, Check ball seat, Set screw 12. Valve housing
CHAPTER 9 STEERING SYSTEM 5.2
Suggestions for Disassembly
(1) Removing retaining ring Remove retaining ring 4 from valve housing 12 with a screwdriver.
608823
(2) Removing seal gland bushing Turn the control spool 8 together with the control sleeve 7 until pin 9 is parallel with port face. Remove the seal gland bushing 5.
608824
(3) Removing control spool and control sleeve Remove control spool 8 together with control sleeve 7 from valve housing 12 by pulling them toward the end of the housing, which is the opposite side of the flange. Remove pin 9. Note: Turn control spool 8 and control sleeve 7 in valve housing 12 slowly in both directions, making sure not to bind the spool and sleeve in the housing.
608825
(4) Disassembling control spool and control sleeve Push control spool 8 in control sleeve 7 to the front, and remove centering spring 10. Turn slowly and pull out the control spool from the rear end of the control sleeve. Note: Put a matchmark across the control spool and the control sleeve before disassembly.
608826
9-9
CHAPTER 9 STEERING SYSTEM
6.
Inspection and Repair After Disassembling Steering Control Valve
(1) Inspection on sliding surfaces between the spool and the valve housing and between the spool and the sleeve Check for defective sliding movement in subassembled condition. - If any defective movement is found, check sliding surfaces. - If any defects such as abnormal wear, rust, or scratches are found, replace the steering control valve assembly.
7. 7.1
Assembling Steering Control Valve Assembly Sequence
2
10 9 7
Section B-B
B
8 B
12
4
5 3
6 1 11 608827
1. 2. 3. 4. 5. 6.
Valve housing Check valve, Retainer, Ball, O-ring, Check ball seat, Set screw Control sleeve Control spool Centering spring Pin
Note: Carry out the following preparations before assembly: (1) (2) (3) (4)
9-10
Replace damaged parts. Clean all metal parts and apply compressed air for drying. Replace O-rings and seals with new ones. Apply grease on O-rings.
7. 8. 9. 10. 11. 12.
Thrust needle and Race bearings Seal gland bushing, Oil seal, Dust seal, O-ring Retaining ring Drive shaft, Wear plate, O-ring Gerotor set O-ring End cap, O-ring, Spacer, Bolts
CHAPTER 9 STEERING SYSTEM 7.2
Suggestions for Assembly
(1) Assembling check valve Install the retainer in the housing. Install the seat in the housing with the hole at bottom. Apply Locktite 271 on the threads of the set screw and tighten the screw to the specified torque.
608828
Item
Tightening torque
Set screw
11.3 N·m (1.2 kgf·m) [8.3 lbt·ft]
(2) Assembling control spool and sleeve Put the spool in the sleeve with the spring groove in alignment with the spring groove in the sleeve. Make sure the marks put during disassembly are in alignment. Note: Make sure the spool rotates freely in the sleeve.
2 1
3 608829 1. Spring groove 2. Spring groove
3. Matching marks
(3) Installing centering spring Hold two sets of three springs back to back. Using the spring inserting tool, put these sets of the springs in the groove with the bevel ends at the bottom.
608830
Special tool needed Spring inserting tool
97157-00100
(4) Installing control spool and sleeve assembly on the housing Put the pin in the holes of the spool and sleeve. Install the control spool and sleeve assembly in the housing from the rear side while rotating it in both directions with the pin being on the same level with center of the spool. Note: Make sure the rear end of the spool and sleeve assembly is flush with the rear end of the housing.
608831
9-11
CHAPTER 9 STEERING SYSTEM (5) Installing seal Install the dust seal on the seal gland bushing with its flat side facing down. Also install the oil seal on the bushing.
1 2
3 608832 1. Dust seal 2. Seal gland bushing
3. Quad ring seal
(6) Installing the seal gland bushing - Install the dust seal on the bushing with the flat side facing towards the bushing. - Install the quad ring seal on the bushing by smoothing it into place with your finger. - Install the bushing assembly over the spool end with a twisting motion. Tap it into place with a soft head mallet. Make sure the bushing is flush against the bearing race. 608833
-
1 2 3 4 5
Install the retaining ring in the housing and pry around the ring circumference with a screwdriver to ensure proper seating of the ring.
6
608834 1. Screwdriver 2. Dust seal 3. Retaining ring
9-12
4. Seal gland bushing 5. Quad ring seal 6. O-ring
CHAPTER 9 STEERING SYSTEM (7) Installing the wear plate - Clamp the housing in a vise, equipped with soft jaws or softened with rag. Clamp lightly over the edges of the mounting area. Do not overtighten the vise jaws. Note: Check that the spool and sleeve are flush with or slightly below the surface of the housing.
608835
- Install the O-ring in the housing. Place the wear plate on the housing and align the bolt holes with the tapped holes in the housing.
608836
(8) Installing the drive - Put a match mark across the splined end of the drive to indicate the direction of the slot at the opposite end of the drive. - Rotate the spool and sleeve assembly until the pin is parallel with the port surface. Install the drive and make sure that it engages the pin. The match mark should be parallel to the port surface.
1
2
3 4 1. Port surface 2. Drive
608837
3. Pin parallel with port surface 4. Pin
9-13
CHAPTER 9 STEERING SYSTEM (9) Installing the gerotor set - Install O-ring in the gerotor set. - Align the star valley A with the match mark on the drive B with the O-ring side of gerotor set facing the wear plate. Place A, B, C, and D in parallel, aligning the bolt holes without disengaging the gerotor set from the drive.
1
A B
4
C
2
3 1. Gerotor set star valley 2. Port surface
(10) Installing the end cap - Install the drive spacer in the gerotor set. Install the O-ring in the end cap. Install the end cap in the gerotor set and align the holes.
D
608838 3. Pin 4. Drive (marked)
1 2
4 1. End cap 2. Cap screw
3 608839
3. O-ring 4. Drive spacer
- Tighten all screws until they are snug, then tighten them progressively to the specified torque in the sequence shown in the illustration.
608840
Item
Tightening torque
Initial torque for screws
14.7 N·m (1.5 kgf·m) [10.8 lbf·ft]
Finishing torque for screws
23.5 N·m (2.4 kgf·m) [17.3 lbf·ft]
After installing the end cap, install the steering wheel on the spool and make sure the spool rotates smoothly.
9-14
CHAPTER 9 STEERING SYSTEM
8.
Troubleshooting Item
Possible cause
No steering flow
Stiff steering wheel
Defect in flow divider valve
Oil leak from relief valve
Disassemble and clean
Fatigued or damaged spring in the spool
Replace spring Adjust relief pressure 7355
+490 +5 +71 2 0 kPa (75 0 kgf/cm ) [1066 0 psi]
Damage on valve seating surface
Replace valve assembly
Fatigued or damaged spring
Replace springs and adjust relief pressure
Damaged O-rings on the valve body circumference
Replace O-rings
Clogging in metering section
Disassemble and clean
Malfunction of spool
Disassemble and clean
Faulty bearing
Disassemble and replace
Defect in steering cylinder
Bent piston rod
Repair or replace
Faulty piston seal
Replace
Misalignment
Faulty installation of steering valve or tilt column
Repair
Others
Flattened pipe or mixing of foreign materials
Clean or replace oil line
Defect in control valve
Sticking of spool or sleeve
Repair or replace
Breakage of centering spring
Disassemble and replace
Flattened pipe or mixing of foreign materials
Clean or replace oil line
Faulty piston seal of steering cylinder
Replace
Air trapped in hydraulic fluid
Bleed air
Defect in control valve
Unstable steering
Foreign materials clogged in spool pit
Decline in relief pressure Malfunction of relief valve
Remedy
Others
Abnormal noise
Loose installation of power cylinder and socket end Repair or replace
9-15
CHAPTER 9 STEERING SYSTEM
9.
Service Data Item
3.5 to 5.5 ton
Steering torque at steering wheel rim (While engine is running at low idle, rotate wheel at a rate of one full turn per second, while lift truck is idle.)
6.0 to7.0 ton
Standard
2.0 N·m (0.20 kgf·m) [1.475 lbf·ft]
Inside
Standard
82°
80°
Outside
Standard
59°
55°
Total turns of steering wheel
Standard
4.60 turns
4.27 turns
Steering wheel nut
Standard
Turning angle
9.1
53.9 to 58.8 N·m (5.5 to 6.0 kgf·m) [39.7 to 43.3 lbf·ft]
Steering Control Valve
Ref.
Item Displacement
Standard
Flow rate
3.5 to 5.5 ton
6.0 to7.0 ton
96 cc (5.8 cu.in.)/rev.
120 cc (7.3 cu.in.)/rev.
22.7 liter (5.99 U.S. gal)/min
Maximum operating pressure
Standard
15 MPa (153 kgf/cm²) [2176 psi]
1
End cap bolt
Tightening torque
28.4 N·m (2.9 kgf·m) [20.9 lbf·ft]
2
Check valve set screw
Tightening torque
11.7 N·m (1.2 kgf·m) [8.6 lbf·ft]
3
Steering bracket bolt
Tightening torque
29.4 N·m (3 kgf·m) [21.7 lbf·ft]
3
2
1
608841
9-16
CHAPTER 10 HYDRAULIC SYSTEM
Chapter 10 HYDRAULIC SYSTEM 1.
Specifications Item Gear pump
Rated discharge (Engine direct drive type)
Priority valve
Hydraulic system
Control valve
5.5 ton
6.0 to 7.0 ton
98 liter (25.89 U.S. gal)/2450 min-1
117.6 liter (31.07 U.S. gal)/ 2450 min-1
11768 kPa (120 kgf/cm2) [1706 psi]
14710 kPa (150 kgf/cm2) [2133 psi]
Main relief pressure
19361
+0.482 +5 +70 2 0 kPa (197.6 0 kgf/cm ) [1706 0 psi]
Attachment relief pressure
15503
+0.345 +3.5 +50 2 0 kPa (158 0 kgf/cm ) [2250 0 psi]
Flow regulator valve (Adjustable)
Control flow capacity
Simplex mast
Internal diameter
Lift cylinders
Stroke
Duplex mast
Internal diameter
First lift cylinders Stroke Duplex mast
Internal diameter
Second lift cylinders
Stroke
Triplex mast
Internal diameter
First lift cylinders Stroke Triplex mast
Internal diameter
Second lift cylinders
Stroke
Tilt cylinders
3.5 to 4.5 ton
100 liter/min (26.42 U.S.gal/min)
115 liter/min (30.38 U.S.gal/min)
165 liter/min (43.59 U.S.gal/min)
60 mm (2.36 in.)
70 mm (2.75 in.)
80 mm (3.15 in.)
1650 mm (65 in.) 90 mm (3.54 in.)
110 mm (4.33 in.)
820 mm (32.28 in.)
845 mm (33.27 in.)
55 mm (2.17 in.)
60 mm (2.36 in.)
1590 mm (62.60 in.)
1585 mm (62.40 in.)
90 mm (3.54 in.)
110 mm (4.33 in.)
125 mm (4.92 in.)
820 mm (32.28 in.)
845 mm (33.27 in.)
855 mm (33.66 in.)
60 mm (2.36 in.)
70 mm (2.75 in.)
80 mm (3.15 in.)
1480 mm (58.27 in.)
1530 mm (60.24 in.)
1495 mm (58.86 in.)
-
-
Internal diameter
100 mm (3.937 in.)
110 mm (4.33 in.)
Stroke
120 mm (4.724 in.)
139 mm (5.472 in.)
46 liter (12.1 U.S.gal) 52 liter (13.6 U.S.gal)
69 liter (18.2 U.S.gal)
Hydraulic oil N level
10-1
CHAPTER 10 HYDRAULIC SYSTEM
2. 2.1
Structure Hydraulic Line (6 to 7 Ton)
10 9 8
10
16 11
11 15 14 7 6 B2 B3 B4
A1 LS
12
P
A2 A3 A4
L
T
R
5 16
1
•
3 13
2
4 608842
1. 2. 3. 4. 5. 6. 7. 8.
Hydraulic tank Suction strainer Return filter Gear pump Main relief valve Lift spool Tilt spool Flow regulator valve
Note: For the steering control valve, see “STEERING SYSTEM”. For the steering cylinder, see “REAR AXLE”.
10-2
9. 10. 11. 12. 13. 14. 15. 16.
Down safety valve Lift cylinders Tilt cylinders Steering control valve Steering cylinder Attachment spool Attachment relief valve Hydraulic tank
CHAPTER 10 HYDRAULIC SYSTEM 2.2
Hydraulic Tank
6
•
1
1) •
2)
•
2 5
•
4
• •
1. 2. 3. 4.
Cap Level gauge Drain plug Suction strainer
5. 6. 1) 2)
3
608843
Return filter Hydraulic tank (for 6 to 7 ton) From control and priority valves To gear pump
The hydraulic tank has a steel-welded structure and is integrated into the frame. The tank is positioned at the center of the right side frame. Oil in the hydraulic tank is sucked into the gear pump via the suction strainer (100 μ). Return oil from the lift cylinder is combined with return oil from the control valve and the steering control valve, which returns to the hydraulic tank through the return filter (25μ).
10-3
CHAPTER 10 HYDRAULIC SYSTEM 2.3
Gear Pump
4
1
2
7
6
8 3
9
10
5
11
12 608844
1. 2. 3. 4. 5. 6.
Front cover Body Drive gear Driven gear Side plate Rear cover
7. 8. 9. 10. 11. 12.
Bushing Oil seal Snapring Gasket Backup strip Gasket
The gear pump is an external gear pump. It provides hydraulic oil required to operate the hydraulic system.
10-4
CHAPTER 10 HYDRAULIC SYSTEM 2.4
Control Valve
1
7
5
4
3
8
6
2 6
1) 7
B2
B3
B4
T1 T2 P1
PF
5)
4)
A1
A2
A3
A4
3) 10
2)
9 608846
1. 2. 3. 4. 5. 6. 7. 8.
PF relief valve Inlet section assembly Unload valve Lift section assembly Tilt section assembly Attachment section assembly Attachment relief valve Outlet section assembly
9. 10. 1) 2) 3) 4) 5)
Lift lock valve Main relief valve TI-port PI-port LS-port PF-port T2-port
The control valve consists of four sections: inlet, lift, tilt, and attachment, all of which are spool type. The inlet section has a built-in flow divider valve. The tilt section has a built-in tilt lock valve. The attachment section has a built-in shutoff valve or an optional overload relief valve. The main relief valve is in the oil passage from the oil pump and prevents high oil pressure which could damage the pump. The relief valve for flow divider valve controls the oil pressure below the maximum pressure in the steering circuit. The overload relief valve prevents high oil pressure occurring in the attachment circuit.
10-5
CHAPTER 10 HYDRAULIC SYSTEM 2.5
Inlet Section
4
5
6
3 2 7
1 8
609284
1. 2. 3. 4.
10-6
Tank passage Main relief valve FD spool PF passage
5. 6. 7. 8.
P1 port LS port MS passage PF relief valve
CHAPTER 10 HYDRAULIC SYSTEM 2.6
Solenoid Section
3
4
6
5
2
1 8
7
609285
1. 2. 3. 4.
Lift lock valve Lift lock control connecting passage Lift down connecting passage 1 Lift down connecting passage 2
5. 6. 7. 8.
MF passage Unload poppet Unload valve Tank passage
10-7
CHAPTER 10 HYDRAULIC SYSTEM 2.7
Lift Valve Assembly
5
6 7
4
8
3
9
2
10
11
1
609286
1. 2. 3. 4. 5. 6.
10-8
Lift down passage 1 Spring Lift lock control connecting passage Lift lock poppet A1 port Lift down connecting passage 2
7. 8. 9. 10. 11.
Emergency valve Load check Parallel passage Lift spool Tank passage
CHAPTER 10 HYDRAULIC SYSTEM 2.8
Tilt Valve Assembly
4
5
6
7
3
8
2
9
1
10 609287
1. 2. 3. 4. 5.
Pilot spool Spring Shutoff plug A2 port Load check
6. 7. 8. 9. 10.
B2 port Parallel passage Shutoff plug Tilt spool Tank passage
10-9
CHAPTER 10 HYDRAULIC SYSTEM 2.9
Attachment Valve Assembly
3
4
5 6
2
7
1
8
9 609288
1. 2. 3. 4. 5.
Spring Shutoff plug A3 port Load check B3 port
10-10
6. 7. 8. 9.
Parallel passage Shutoff plug Attachment spool Tank passage
CHAPTER 10 HYDRAULIC SYSTEM 2.10 Control Valve Hydraulic Circuit Diagram
Lift valve Tilt valve PF P2
A1
B2 A2
Attachment valve
Attachment valve
B3 A3
B4 A4
P1
T1 T LS T2
2
1
3
3 608848
1. 2.
Main relief valve PF relief valve
3.
Item
3.5 to 5.5 ton
Main relief valve 1 Relief pressure
PF relief valve 2 Attachment relief valve 3
Attachment relief valve
19.4 11.8
6.0 to 7.0 ton
+0.5 +5.1 +72 2 0 MPa (197.8 0 kgf/cm ) [2814 0 psi]
+0.5 +5.1 +72 2 0 MPa (120 0 kgf/cm ) [1711 0 psi]
15.5
+0.5 +5.1 +72 2 0 kPa (150 0 kgf/cm ) [2125 0 psi]
14.7
+0.5 +3.5 +50 2 0 MPa (158 0 kgf/cm ) [2250 0 psi]
10-11
CHAPTER 10 HYDRAULIC SYSTEM 2.11 Lift and Tilt Cylinders Second lift cylinder for simplex mast and triplex mast There are two types for the second lift cylinder: one with a return pipe and the other without a return pipe. The lift cylinder without a return pipe is provided with a check valve in the piston instead of a return pipe. This is called an internal drain type cylinder. Regardless of presence or absence of a return pipe, the bottom of the piston is provided with a cushion mechanism for soft landing. -
Cylinder without a return pipe - Mast used: (1) Simplex mast with raised height of 3.4 m (11.2 ft) or less (2) All triplex masts
Main components
9
10 3
1)
2)
1
3)
2
7 8 5 4) 5)
d ID OD
4 6
Cushion stroke: 23 mm (0.91 in.) 608849
1. 2. 3. 4. 5. 6. 7. 8.
Cylinder tube Piston rod assembly Cylinder head Pipe (integrated with cylinder tube) Cushion bearing Check valve U-ring, Backup ring Bushing
10-12
9. 10. 1) 2) 3) 4) 5)
Wiper ring X-ring Space One side only Groove Groove Inflow and outflow of oil
CHAPTER 10 HYDRAULIC SYSTEM Cushion mechanism when piston descends Action during piston descent
1
2
(B)
Entrapped oil (A)
Passage (a)
2) 1)
3)
5
Passage (b)
4 608850
1) 2)
Descent Groove
3)
Outflow
The above illustration shows a condition in which piston rod assembly 2 descends with its self weight, and pipe 4 and cushion bearing 5 are beginning to fit in. Cushion bearing 5 is pushed upward by entrapped oil (A), and the piston and cushion bearing 5 make surface contact at (B) area. This blocks the passage (a). The only outflow passage for entrapped oil (A) is clearance (b) between the bore of cushion bearing 5 and the outside of pipe 4. This passage (b) becomes narrower as the piston descends further. Therefore, the descending speed of the piston becomes gradually slower and impulsive contact is avoided.
1)
3)
2)
Clearance of approx. 0.1 mm (0.004 in.)
4)
608851
Image of pipe and cushion bearing 1) The inside diameter is further smaller. 2) Outside diameter without step
3) Cushion bearing 4) Pipe
10-13
CHAPTER 10 HYDRAULIC SYSTEM Action during piston ascent (initial stage)
1
2
(B)
Passage (a)
2) 1)
3)
5 1) 2)
Ascent Groove
3)
Passage (b)
4
608852
Inflow
The above illustration shows a condition immediately after the piston rod assembly ascends. Oil that flows in acts on the center of the piston, ascending piston rod assembly 2 slightly. At the same time, cushion bearing 5 descends by being pushed by oil that flows in. This action opens the (B) area, causing the passage (a) to open. Oil from the passage (a) and passage (b), which opens from the beginning flows in the piston bottom, acts on the entire bottom surface of the piston and pushes piston rod assembly 2 upward. Internal drain type cylinder
1
2
1)
3 608853
1.
Entrapped oil and air (Negative pressure tends to exist in this area.)
2. 3.
Groove Check valve
The above illustration shows a condition in which the piston rod assembly ascends to the vicinity of the highest position. When the pressure of oil and air entrapped between the rod and cylinder exceeds the set pressure of the check valve, the check valve opens and discharges oil and air to chamber (internal drain). In the cylinder with a return pipe, the entrapped oil and air are returned to the hydraulic tank.
10-14
CHAPTER 10 HYDRAULIC SYSTEM Lift cylinders of simplex mast with return pipe (A40A)
* * * 6 5 7 4 2
* 10 9
11
* 8
1
3 •• •
•
•
•
•
• ••
608854
1. 2. 3. 4. 5. 6.
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring
7. 8. 9. 10. 11.
Wiper ring U-ring Backup ring Bushing Spacer
Note: Parts marked with * are included in the seal kit. Lift cylinders of simplex mast with return pipe (A45A, A55A, and A70A)
* 2 7
5
* 6 3 4
* 8
* 13 9 10 11 12 1
• • •
•
• •
608855
1. 2. 3. 4. 5. 6. 7.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring
8. 9. 10. 11. 12. 13.
O-ring Piston ring U-ring assembly U-ring holder Stopper Spacer
Note: Parts marked with * are included in the seal kit.
10-15
CHAPTER 10 HYDRAULIC SYSTEM First lift cylinder of duplex mast (B40A, B45A, and B55A)/First lift cylinders of triplex mast (C40A through C70A)
* 6
* 8
3
•
* * * 5 4 7 13,14
2
• •
* 9
1
* 10
•
•
•
11 12
•
• •
608856
1. 2. 3. 4. 5. 6. 7.
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring
8. 9. 10. 11. 12. 13. 14.
O-ring Sealring assembly Slide ring Check valve Snapring Plug Gasket
Note: Parts marked with * are included in the seal kit. Second lift cylinder of duplex mast (B45A and B55A)
* 6
4
* 7 3 •
* 5 8 •
2 1 18 19 15 9 10
•
•
••
11 13 12
14
• •• • •
• 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
17
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring O-ring Piston Set screw
Note: Parts marked with * are included in the seal kit.
10-16
608857
11. 12. 13. 14. 15. 16. 17. 18. 19.
Slide ring Check valve Cushion spool Spring Snapring Valve Steel ball Spacer Snapring
CHAPTER 10 HYDRAULIC SYSTEM Second lift cylinder of duplex mast (B40A)
* * * * 8 7 6 5 9 4 3 18 17
•
•
• •
1 2
•
•
16 14 12 11 10 13 15
• • • • • •
•
608858
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Backup ring Wiper ring O-ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Piston Slide ring Set screw Check valve Cushion spool Spring Snapring Steel ball Set screw
Note: Parts marked with * are included in the seal kit. Second lift cylinder of triplex mast (C40A)
* * 6 5
* 3 7 4
2
1
16
* * 11 12 10 9 8 15 14 13
608859
1. 2. 3. 4. 5. 6. 7. 8.
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring U-ring
9. 10. 11. 12. 13. 14. 15. 16.
Backup ring Bushing Spring guide Spring Cushion spool Pin Snapring Spacer
Note: Parts marked with * are included in the seal kit.
10-17
CHAPTER 10 HYDRAULIC SYSTEM Second lift cylinder of triplex mast (C45A and C55A)
7 6 5 4 3
8
2
1
17 13
14 9 10 11 12 16 15
608860
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring O-ring Piston ring
10. 11. 12. 13. 14. 15. 16. 17.
U-ring assembly Holder Stopper Spring guide Spring Cushion rod Springpin Spacer
Note: Parts marked with * are included in the seal kit. Second lift cylinder of triplex mast (C70A)
7
6 5 8 4 3
2
1
19 14 15 16 18 9 17 10 11 12 13
608861
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring O-ring Piston
Note: Parts marked with * are included in the seal kit.
10-18
10. 11. 12. 13. 14. 15. 16. 17. 18.
Piston ring U-ring assembly Holder Stopper Spring guide Spring Cushion rod O-ring Set screw
CHAPTER 10 HYDRAULIC SYSTEM Tilt cylinder
5
* 9
* 8
* 10
* 7
3
•
•
1
2
12 4
• •
•
•
* 6
11
•
•
13, 14 1. 2. 3. 4. 5. 6. 7.
Cylinder tube Piston rod Guide bushing Piston Tilt socket Piston seal O-ring
608862
8. 9. 10. 11. 12. 13. 14.
Packing Dust seal Buffer ring Self-locknut Collar Bolt Spring washer
Note: Parts marked with * are included in the seal kit.
10-19
CHAPTER 10 HYDRAULIC SYSTEM 2.12 Flow Regulator Valve 3.5 to 5.5 ton
7
3
12
8 10
4 13
6
5 1
14 1. 2. 3. 4. 5. 6. 7.
2
11
9
608863
Valve body Plug Piston Plate Spring Look nut Valve
8. 9. 10. 11. 12. 13. 14.
Spring Washer Springpin O-ring O-ring Snapring Elbow nut assembly
6.0 to 7.0 ton
10
9 12 7 2
11 13 1. 2. 3. 4. 5. 6. 7.
Valve body Plug Piston Plate Spring Locknut Stopper
3
8
4 14 8. 9. 10. 11. 12. 13. 14.
5
1
6
608864
Valve Spring disc Connector Elbow nut assembly Springpin O-ring Snapring
The flow regulator valve is located between lift cylinder and control valve. It limits the flow of oil forced out of the cylinder when the loaded forks are lowered in order to keep a constant safe lowering speed regardless of the load.
10-20
CHAPTER 10 HYDRAULIC SYSTEM 2.13 Down Safety Valve
1
3 4
2
2)
1)
3)
608865
1. 2. 3. 4.
Connector Valve Spring Springpin
1) 2) 3)
Free flow Indication of cut-off flow rate Regulated flow
The down safety valve is located at the bottom of right-side lift cylinder. This valve prevents the load from falling down rapidly in the event of a hose burst. Cut-off flow rate Simplex
A40A
A45A, A55A
A70A
Duplex
B40A
B45A, B55A
-
Triplex
C40A
C45A, C55A
C70A
Cut-off flow rate
0
0
90 -15 liter (23.8 -4 U.S.gal)/min
+5
+1.3
120 -10 liter (31.7 -2.6 U.S.gal)/min 200
+20 +5.3 0 liter (52.8 0 U.S.gal)/min
R WARNING DO NOT reuse the down safety valve after a lift line hose failure.
10-21
CHAPTER 10 HYDRAULIC SYSTEM
3.
Removing Gear Pump
3.1
Preparation for Removal
(1) Remove the counterweight. (2) Loosen the fan belt.
3.2
Removal Sequence
4
3 2 1
5
608866
1. 2. 3.
Universal joint Drive pulley, Locknut, Boss Main hose, Connector, O-ring
10-22
4. 5.
Suction hose, Elbow, O-ring Gear pump
CHAPTER 10 HYDRAULIC SYSTEM 3.3
Suggestions for Removal
(1) Remove the drive pulley locknut 2 with special tools. Special tool needed 91868-00100
Wrench
93768-00100
Note: The drive pulley locknut has left-hand thread. (2) To assemble, follow the reverse of disassembly sequence. Tighten the counterweight bolts, pump outlet joint, and main hose to the specified torque. Ref.
Item
Tightening torque
1
Universal joint
21.6 N·m (2.2 kgf·m) [15.9 lbf·ft]
2
Locknut
78.5 N·m (8.0 kgf·m) [57.9 lbf·ft]
3
Counterweight bolt
4
Connector
167 N·m (17.0 kgf·m) [123 lbf·ft]
5
Main hose
117 N·m (12.0 kgf·m) [87 lbf·ft]
800 to 888 N·m (81.6 to 90.6 kgf·m) [590 to 654 lbf·ft]
10-23
CHAPTER 10 HYDRAULIC SYSTEM
4.
Removing Control Valve
4.1
Preparation for Removal
(1) Remove the floor plate and dashboard cover. (2) Before disconnecting pipes, tilt the mast to VERTICAL position, lower the forks all the way, and relieve the pressure in the pipes.
4.2
Removal Sequence
1
10
4 2 B2
B3
8 T2
LS
A1 A2
9
A3
PF
7
3 P1
6
3
5
4
608867
1. 2. 3. 4. 5. 6.
Clevis pin, Clevis, Boot, Rod Clamp, Return hose, Connector, O-ring Attachment pipe, Connector, O-ring Tilt pipe, Clamp, Connector, O-ring Lift pipe, Connector, O-ring Delivery pipe, Connector, O-ring
10-24
7.
Pipe from the steering control valve (to LS port), Hose, Connector, O-ring 8. Pipe to the steering control valve (to PF port), Hose, Connector, O-ring 9. Hose from the steering control valve (to T2 port), Connector, O-ring 10. Control valve
CHAPTER 10 HYDRAULIC SYSTEM
5. 5.1
Removing Lift Cylinders (Simplex Mast) Removal Sequence
6
7
8
5
3 8
1
4
2 608868
1. 2. 3. 4.
5.2
Nuts Fork, Lift bracket Return (low-pressure) hose Hose guard
5. 6. 7. 8.
High-pressure hose Set bolt, Shims Cylinder clamp, Cushion, Collar, Shims Lift cylinder, Bracket
Suggestions for Removal
Lift bracket removal (1) Tilt the mast FORWARD, and lower the inner mast to the bottom. Slacken the lift chains, and remove the nuts from the anchor bolts. It is unnecessary to remove the forks. (2) Tilt the mast back to VERTICAL position. Raise the inner mast until the lift bracket becomes free. Then, back the forklift truck away from the lift bracket and fork assembly. 608869
10-25
CHAPTER 10 HYDRAULIC SYSTEM Removing return hose Lift the mast to the maximum lift position, and turn the key switch OFF. Disconnect the return hose from the right and left lift cylinders at the connectors. (If applicable).
1)
608870 1) To hydraulic tank
Disconnecting high-pressure hoses Slowly push the lift lever FORWARD to lower the lift bracket to the ground. Disconnect the high-pressure hoses at the joints. Prepare a drip pan to catch oil flowing out of the hoses.
1
2
608871 1. Right cylinder
2. Left cylinder
Removing set bolts (1) Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, attach a sling around the mast with a protective rag. Note: The rod end of either lift cylinder is shim adjusted to eliminate the difference in stroke between the cylinders. Before removing the set bolts, make a record of the amount of shims and cylinders to which the shims are fitted. 608872
(2) Tie wood blocks under the inner mast and detach the sling. Make sure the right and left wood blocks are the same in height.
608873
10-26
CHAPTER 10 HYDRAULIC SYSTEM Removing lift cylinders Attach a sling on the lift cylinder from the rear side of the mast, and remove the cylinder. Attach the sling before removing the cylinder clamp.
608874
6. 6.1
Installing Lift Cylinders (Simplex Mast) Installation
To install, follow the reverse of removal sequence, and follow the Steps below after installation is completed: (1) Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly. (2) Check the oil level in the hydraulic tank with an oil level gauge. See 10-3 "Hydraulic Tank". (3) Check to make sure that the lift height is correct. (4) After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders. See “MAST AND FORKS”.
10-27
CHAPTER 10 HYDRAULIC SYSTEM
7.
Removing Lift Cylinders (Duplex and Triplex Mast)
The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full free panoramic mast (Triplex mast) is used to explain.
7.1
Removal Sequence
5
4 2
1
3 608875
1. 2. 3.
Nuts Lift bracket assembly First lift cylinder
10-28
4. 5.
Chain wheel support assembly Second lift cylinder
CHAPTER 10 HYDRAULIC SYSTEM 7.2
Suggestions for Removal
Removing lift bracket assembly 2 (1) Lower lift bracket assembly 2, and place wood blocks under the assembly. Tilt the mast FORWARD, lower the inner mast to the bottom, then remove nuts 1 from the anchor bolts of the first lift chains.
1
608876
(2) Position the mast VERTICAL. Raise the inner mast until main rollers 6 of lift bracket assembly 2 become free. Then, slowly move the forklift truck in reverse to separate from lift bracket 2.
6 2 608877
Removing first lift cylinder 3 (1) Attach a sling to first lift cylinder 3, and lift the cylinder with a hoist. Attach the sling securely to prevent slipping. (2) Remove lift cylinder connecting and mounting bolts, and gently remove first lift cylinder 3.
3
608878
10-29
CHAPTER 10 HYDRAULIC SYSTEM Removing second lift cylinders 5 (1) Disconnect hoses from second lift cylinders 5. (2) Remove stopper bolts at the upper sections of second lift cylinders 5, and lift the inner mast (dual-stage full free panoramic mast) or middle mast (triple-stage full free panoramic mast) approximately 550 mm (21.67 in.) using slings.
5
608879
(3) Place wood blocks under the inner mast (dual-stage full free panoramic mast) or middle mast (triple-stage full free panoramic mast). Make sure the right and left wood blocks are the same in height.
608873
(4) Attach a sling to second lift cylinder 5 behind the mast, remove cylinder clamp retaining bolts, and gently remove second lift cylinder 5. Attach the sling securely on the cylinder. The cylinder cannot be lifted straight up since the mast crossmember is located above the cylinder. Tilt the cylinder and move it away from the crossmember to remove. Be careful not have your hands caught between the cylinder and mast.
5
608880
10-30
CHAPTER 10 HYDRAULIC SYSTEM
8.
Installing Lift Cylinders (Duplex and Triplex Mast)
To install, follow the removal sequence in reverse, and observe the Steps below: (1) Install chain wheel support assembly 4 parallel to a line connecting the centers of chain anchor bolt holes on first lift cylinder 3 to prevent chains from twisting. (2) Adjust the chain tensions. See 10-60 "Inspection and Adjustment". (3) Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly. (4) After proper operation is confirmed, check the oil level.
1)
2) 608881
1) Good
2) Bad
10-31
CHAPTER 10 HYDRAULIC SYSTEM
9.
Removing Tilt Cylinders
9.1
Removal Sequence
2
•
4 1 3 1. 2.
Tilt cylinder pin Hoses
9.2
3. 4.
608882
Tilt cylinder pin Tilt cylinder
Preparation
(1) Lower the forks to the bottom, and tilt the mast fully FORWARD. (2) Attach a sling on the top crossmember of outer mast, and support the weight of the mast with a hoist.
608883
9.3
Suggestions for Removal
Retracting piston rod Remove tilt cylinder pin 1. Turn ON the engine, retract the piston rod to the full stroke, and then turn the engine OFF. Disconnecting hoses Disconnect hoses 2 from the cylinder at the connectors. Catch oil that is flowing out of the cylinder in a drip pan. Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of the cylinder when the cylinder is removed.
10-32
CHAPTER 10 HYDRAULIC SYSTEM
10. Disassembling Gear Pump 10.1 Disassembly Sequence
7
* 16 18
17
9
12
8
15 13
6
15
10
11
4
5
3 15
15 14 1
2
608884
1. 2. 3. 4. 5. 6. 7. 8. 9.
Bolt Rear cover Gasket Gasket Backup strip Front cover Gasket Gasket Backup strip
10. 11. 12. 13. 14. 15. 16. 17. 18.
Body Side plate Side plate Drive gear Driven gear Bushing Snapring Oil seal Snapring*
Note: (1) The gear pump should be overhauled by the manufacturer. Where it has to be overhauled in the field, BE SURE to follow the suggestions for disassembly. Remember, field overhauling will release the manufacturer from any guarantee. (2) Do not remove oil seal 17 and bushing 15 unless they are defective. Start by: Remove the fan drive pulley, and then remove snapring 18*.
10.2 Suggestions for Disassembly (1) If gears 13 and14 and side plates 11 and 12 are separated from body 10, it might be difficult to restore them to the original state, resulting in defective pump performance. For this reason, remove the gears, side plates, and body as a set for replacement of the gaskets 3 and 7. (2) Front cover 6 and cover 2 are made of aluminum alloy which is easy to damage; do not use a hammer or pry bar.
10-33
CHAPTER 10 HYDRAULIC SYSTEM
11. Inspection After Disassembling Gear Pump 11.1 Drive and Driven Gears (1) Inspect the gear teeth for wear, chipping, or other defects. Also, inspect the journals and splines for wear, chipping, or other defects. (2) Check the end faces of the gear for wear or damage. (3) Check the journals and splines of the shaft for wear or damage.
608885
11.2 Pump Covers, Body, and Bushings Inspect pump covers, body, and bushing for wear and damage.
10-34
CHAPTER 10 HYDRAULIC SYSTEM
12. Assembling Gear Pump 12.1 Assembly Sequence
4
1 6, 7
13 10
9
8
18
14 2
15
3 4
5
1. 2. 3. 4. 5. 6. 7.
Front cover Oil seal Snapring Bushing Gasket Gasket Backup strip (Assemble 1 through 7 to make a subassembly) 8. Rear cover 9. Bushing 10. Gasket
6 17
11, 12
9
608886
11. Gasket 12. Backup strip (Assemble 8 through 12 to make a subassembly) 13. Body 14. Driven gear 15. Drive gear 16. Side plate 17. Side plate (Install 13 through 17) 18. Bolt (Install front cover subassembly 1 and rear cover subassembly 8 in body 13)
12.2 Suggestions for Assembly (1) (2) (3) (4) (5) (6)
Position rear cover 8 correctly. Clean the mating faces of covers 1, 8, and body 13, making sure that they are free from any oil or grease. Put grease on the lip of oil seal 2. Lubricate bearings, gears, and shafts with clean hydraulic oil before assembling. Make sure not to damage the lip of oil seal by the splines of drive gear 15. Tighten all bolts evenly and progressively. Item
Bolts
Tightening torque 98 to 108 N·m (10 to 11 kgf·m) [72 to 80 lbf·ft]
10-35
CHAPTER 10 HYDRAULIC SYSTEM
13. Inspection After Disassembling Control Valve 13.1 Sections, Spools, and Return Springs (1) Check each sliding surface for cracks and defects. Also, check the check-valve seat for wear. (2) Check the spool for burn and distortion. Also, check for operating force. Item Spool operating force
Value 177 to 216N (18 to 22 kgf) [40 to 49 lbf]
(3) Check the tilt lock valve for damaged or sticking valve.
1
608889 1. Tilt lock valve
10-36
CHAPTER 10 HYDRAULIC SYSTEM
14. Assembling Control Valve To assemble, follow the reverse of disassembly sequence, and follow the Steps below: (1) Clean the disassembled parts with high flash-point solvent. Dry all parts (excluding rubber parts) with compressed air. (2) Apply hydraulic oil on the spools when inserting them into the valve blocks. (3) Position the poppet (tilt lock valve) correctly. (4) Apply grease on the O-rings when fitting them between the valve housings to prevent them from twisting. (5) Do not use any type of sealant. (6) Tighten the tie bolts (that hold the valve housings) as evenly as possible to prevent distortion of the housings. Note: Remember, a failure to follow this precaution will result in sluggish movement of the spools.
6.56 (141.3)
1)
2) 608890
Ref.
Item
Tightening torque
1)
bolts
65 N·m (6.6 kgf·m) [48 lbf·ft]
2)
bolt
101 N·m (10.3 kgf·m) [74 lbf·ft]
10-37
CHAPTER 10 HYDRAULIC SYSTEM
15. Disassembling Lift Cylinders (Simplex Mast) 15.1 Disassembly Sequence (A40A)
* 1
2
4 * 7
* 6 5
*
3
* 608891
1. 2. 3. 4.
Cylinder head Wiper ring, U-ring, O-ring Collar Piston rod
5. 6. 7.
U-ring, Backup ring, Bushing Bushing Cylinder tube
Note: -
Parts marked with * are included in the seal kit. Do not remove bushing 6 from cylinder head 1 unless they are defective.
15.2 Suggestions for Disassembly Removing cylinder head To remove the cylinder head, wrap the cylinder tube in cloth and hold it with a vise. Remove the cylinder head using the special tool.
608892
Special tool needed Wrench
10-38
05312-20850
CHAPTER 10 HYDRAULIC SYSTEM 15.3 Disassembly Sequence (A45A, A55A, and A70A)
4
* 1
6
7
* 2
* 5 *
3 608895
1. 2. 3. 4.
Holder, Wiper ring Cylinder head, U-ring, O-ring Collar Piston rod
5. 6. 7.
Piston ring, U-ring, Holder, Stopper Bushing Cylinder tube
Note: -
Parts marked with * are included in the seal kit. Do not remove bushing 6 from cylinder head 2 unless they are defective.
15.4 Suggestions for Disassembly Removing holder To remove the holder from the A70A cylinder, wrap the cylinder in cloth and hold it with a vice. Remove the holder using the special tool. Special tool needed Wrench
05312-10600
Remove the holder from the A45A and A55A cylinders using the spanner. Item Spanner
Value width across flats 85 mm (3.35 in.)
10-39
CHAPTER 10 HYDRAULIC SYSTEM
16. Inspection After Disassembling Lift Cylinders (Simplex Mast) 16.1 Cylinder Tube (1) Check the inner wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
16.2 Piston Rod (1) Place the rod on V-blocks and check for deflection with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
16.3 Packings and Rings Replace all parts contained in the seal kit once disturbed.
17. Assembling Lift Cylinders (Simplex Mast) 17.1 Assembly Sequence
1
6
5
4
3
2
608894
A45A, A55A, and A70A 1. 2. 3.
Piston rod Piston ring, U-ring, Holder, Stopper Collar
4. 5. 6.
Cylinder tube Cylinder head, bushing, U-ring, O-ring Holder, Wiper ring
4. 5.
Cylinder tube Cylinder head, Wiper ring, U-ring, Bushing, O-ring
A40A 1. 2. 3.
Piston rod Bushing, Backup ring, U-ring Collar
10-40
CHAPTER 10 HYDRAULIC SYSTEM 17.2 Suggestions for Assembly (1) (2) (3) (4) (5)
Clean parts completely before assembly, and make sure that parts are free of dust and other particles. To assemble, use new seal kit parts. Apply oil on the U-ring, piston ring, O-ring, bushing, wiper ring, and the cylinder bore before assembly. When holding the cylinder with a vise, be careful not to deform the cylinder by overtightening. Before tightening the cylinder head and the holder, apply liquid gasket (ThreeBond® 1901) on the threads. Tightening torque Item
Cylinder head and the holder
A40A
A45A, A55A
A70A
304 N·m (31 kgf·m) [224 lbf·ft]
422 N·m (43 kgf·m) [311 lbf·ft]
490 N·m (50 kgf·m) [362 lbf·ft]
10-41
CHAPTER 10 HYDRAULIC SYSTEM
18. Disassembling Lift Cylinders (Duplex and Triplex Masts) 18.1 Disassembly Sequence for First Lift Cylinders (B55A and C40A Through C70A)
1 *
4
2
*3
7 8 *6 5
608896
1. 2. 3. 4.
Plug, Gasket Cylinder head U-ring, Wiper ring, O-ring, O-ring Piston rod
5. 6. 7. 8.
Check valve, Snapring Slide ring, Seal ring Bushing Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 7 from cylinder head 2 unless they are defective.
18.2 Suggestions for Disassembly Removing cylinder head To remove the cylinder head, hold the lift chain mounting area with a vise. Remove the cylinder head using the wrench. Special tool needed Wrench
10-42
05312-10800 (B40A, C40A) 05312-11000 (B45A, B55A, C45A through C70A)
CHAPTER 10 HYDRAULIC SYSTEM 18.3 Disassembly Sequence for Second Lift Cylinders (B40A)
1 2 6
9
*4
5
10 7
8
3 608897
1. 2. 3. 4. 5.
Valve, Steel ball Holder Cylinder head Wiper ring, U-ring, Backup ring, O-ring Piston rod
6. 7. 8. 9. 10.
Slide ring, Set screw, Piston Snapring, Check valve, Spring, Cushion spool Bushing Steel ball, Screw Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 8 from cylinder head 3 unless they are defective.
18.4 Suggestions for Disassembly Removing holder To remove the holder, wrap the cylinder tube in cloth and hold it with a vice. Remove the holder using the spanner. Item Spanner
Value width across flats 65 mm (2.56 in.)
10-43
CHAPTER 10 HYDRAULIC SYSTEM 18.5 Disassembly Sequence for Second Lift Cylinders (B45A and B55A)
1
6
7
5
10
2 9
*4
8 3
608898
1. 2. 3. 4. 5.
Valve, Steel ball Cylinder head Spacer U-ring, Wiper ring, O-ring Piston rod
6. 7. 8. 9. 10.
Spacer, Snapring Slide ring, Set screw, Piston Snapring, Check valve, Spring, Cushion spool Bushing Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 9 from cylinder head 2 unless they are defective.
18.6 Suggestions for Disassembly Removing cylinder head To remove the cylinder head, hold the mast fitting area of the cylinder tube with a vice. Remove the cylinder head using the wrench.
Special tool needed Wrench
10-44
05312-11000
CHAPTER 10 HYDRAULIC SYSTEM
19. Inspection After Disassembling Lift Cylinders (Duplex and Triplex Masts) 19.1 Cylinder Tube (1) Check the bore wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
19.2 Piston rod (1) Place the rod on V-blocks and check for deflection with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
19.3 Packings and rings Replace all parts contained in the seal kit once disturbed.
20. Assembling Lift Cylinders (Duplex and Triplex Masts) 20.1 First Lift Cylinder (B40A Through B55A, and C40A Through C70A) Assembly sequence
7
6 *
4
1
*
3
2 *
5 1. 2. 3. 4.
Piston rod Check valve, Snapring Slid ring, Seal ring Cylinder tube
608899
5. 6. 7.
Cylinder head, Bushing (Install parts 6 to part 5) U-ring, Wiper ring, O-ring Plug, Gasket
Note: Parts marked with * are included in the seal kit.
10-45
CHAPTER 10 HYDRAULIC SYSTEM 20.2 Second Lift Cylinders (B40A) Assembly sequence
6 1. 2. 3. 4.
1
8
7 *
3
4
5
2
Piston rod Cushion spool, Spring, Check valve, Snapring Piston, Set screw, Slid ring Cylinder tube
5. 6. 7. 8.
608900
Cylinder head, Bushing Holder (Install parts 7 to part 6) Backup ring, U-ring, Wiper ring, O-ring Steel ball, Screw
Note: Parts marked with * are included in the seal kit.
20.3 Second Lift Cylinders (B45A and B55A) Assembly sequence
9 *
10 1. 2. 3. 4. 5.
7
6
5
8
Piston rod Cushion spool, Spring, Check valve, Snapring Piston, Set screw, Slid ring Spacer, Snapring Cylinder tube
Note: Parts marked with * are included in the seal kit.
10-46
1
4
3
2 6. 7. 8. 9. 10.
Spacer Cylinder head (Install parts 8 and 9 to part 7) Bushing U-ring, Wiper ring, O-ring Steel ball, Valve
608901
CHAPTER 10 HYDRAULIC SYSTEM Suggestions for assembly (1) Clean parts completely before assembly, and make sure that parts are free of dust and other particles. (2) Use new seal kit parts and repair kit parts. (3) Apply oil on the seal kit parts such as U-ring, wiper ring, seal ring, and O-ring. Also apply oil on the slide ring and bushing before assembly. Apply oil on the cylinder bore before assembly. (4) When holding the cylinder with a vice, be careful not to deform the cylinder by overtightening. (5) Tighten parts such as the cylinder head, holder, piston, set screw, and the valve to the specified torque. See “Service Data”. (6) Before tightening the cylinder head and the holder, apply liquid gasket (ThreeBond 1901) on the threads. (7) After assembling the first lift cylinder, fill the rod chamber with hydraulic oil. Supply hydraulic oil from the plug, and tighten the plug to the specified torque.
1
2
608902 1. Plug
2. Rod chamber
Specified torque Item
Amount of hydraulic oil
A40A
A45A, A55A
A70A
160 to 180 cc (9.76 to 10.98 cu. in.)
190 to 210 cc (11.59 to 12.81 cu. in.)
260 to 290 cc (15.86 to 17.69 cu. in.)
10-47
CHAPTER 10 HYDRAULIC SYSTEM
21. Disassembling Lift Cylinders (Triplex Masts) 21.1 Second Lift Cylinders (C40A) Disassembly sequence
* 7
* 2
*
*
1
5 6
* 3
4 8
608903
1. 2. 3. 4.
Cylinder head, Bushing Wiper ring, U-ring, O-ring Spacer Piston rod
5. 6. 7. 8.
Snapring, Pin Spring guide, Spring, Cushion spool U-ring, Backup ring, Bushing Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 1 from cylinder head 1 unless they are defective.
10-48
CHAPTER 10 HYDRAULIC SYSTEM 21.2 Second Lift Cylinders (C45A and C55A) Disassembly sequence
* 1
7
*
5
2
6
* 3 8 4
608904
1. 2. 3. 4.
Holder, Wiper ring Cylinder head, U-ring, Bushing, O-ring Spacer Piston rod
5. 6. 7. 8.
Holder, Stopper, Springpin Spring guide, Spring, Cushion rod U-ring assembly, Piston ring Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 2 from cylinder head 2 unless they are defective.
10-49
CHAPTER 10 HYDRAULIC SYSTEM 21.3 Second Lift Cylinders (C70A) Disassembly sequence
* 5
1
* *
*
2
7 *
3
4
8
6
608905
1. 2. 3. 4.
Holder, Wiper ring Cylinder head, U-ring, Bushing, O-ring Spacer Piston rod
5. 6. 7. 8.
Holder, Stopper, U-ring assembly, Piston ring Set screw, Piston, O-ring Spring guide, Spring, Cushion rod Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 2 from cylinder head 2 unless they are defective.
10-50
CHAPTER 10 HYDRAULIC SYSTEM Suggestions for disassembly (1) Removing cylinder head or holder To remove the cylinder head or holder, wrap the cylinder tube in cloth and hold it with a vice.
608892
(2) Remove the cylinder head or holder using the wrench or the spanner. Special tool needed Item
C40A
Wrench
05312-10800
Item
C70A
Wrench
05312-11000
Item Spanner
C45A, C55A Width across flats 85 mm (3.35 in.)
22. Inspection After Disassembling Lift Cylinders (Triplex Masts) 22.1 Cylinder Tube (1) Check the inner wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
22.2 Piston Rod (1) Place the rod on V-blocks and check for deflection with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
22.3 Packings and Rings Replace all parts contained in the seal kit once disturbed.
10-51
CHAPTER 10 HYDRAULIC SYSTEM
23. Assembling Lift Cylinders (Triplex Masts) 23.1 Second Lift Cylinder (C40A) Assembly sequence
14 13 12 15
1
11
10
5
6
2 3
4
9
8
7
608906
1. 2. 3. 4. 5. 6. 7. 8.
Piston rod (Install parts 2 through 9 to part 1) Bushing Backup ring U-ring Spring seat Spring Cushion spool Pin
9. 10. 11. 12.
Snapring Spacer Cylinder tube Cylinder head kit (Install parts 13 through 15 to part 12) 13. U-ring 14. Wiper ring 15. O-ring
23.2 Second Lift Cylinders (C45A and C55A) Assembly sequence
17 14 16 13 12 15
1
11
10 4
5
2
3
9 8
7
6
608907
1. 2. 3. 4. 5. 6. 7. 8. 9.
Piston rod (Install parts 2 through 9 to part 1) Piston ring U-ring assembly Spring guide Spring Cushion rod Springpin Stopper Holder
10-52
10. Spacer 11. Cylinder tube 12. Cylinder head (Install parts 13 through 15 to part 12) 13. Bushing 14. U-ring 15. O-ring 16. Holder 17. Wiper ring
CHAPTER 10 HYDRAULIC SYSTEM 23.3 Second Lift Cylinders (C70A) Assembly sequence
19 16 18 17 15 14
1
13
12 2 3 4 7 6 5 8 9 11 10
608908
1.
Piston rod (Install parts 2 through 11 to part 1) 2. Spring seat 3. Spring 4. Cushion rod 5. O-ring 6. Piston 7. Set screw 8. Piston ring 9. U-ring assembly 10. Stopper
11. 12. 13. 14. 15. 16. 17. 18. 19.
Holder Spacer Cylinder tube Holder (Install parts 15 through 17 to part 14) Bushing U-ring O-ring Holder Wiper ring
Suggestions for assembly (1) Clean parts completely before assembly, and make sure that parts are free of dust and other particles. (2) Use new seal kit parts and repair kit parts. (3) Apply oil on the seal kit parts such as U-ring, wiper ring, seal ring, and O-ring. Also apply oil on the slide ring and bushing before assembly. Apply oil on the cylinder bore before assembly. (4) When holding the cylinder with a vise, be careful not to deform the cylinder by overtightening. (5) Tighten parts such as the cylinder head, holder, piston, set screw, and valve to the specified torque. See “Service Data”. (6) Before tightening the cylinder head and holder, apply liquid gasket (ThreeBond 1901) on the threads.
10-53
CHAPTER 10 HYDRAULIC SYSTEM
24. Disassembling Tilt Cylinders 24.1 Disassembly Sequence
12 8 7
4 2
5
* *
6
3
*
*
1
13
11
9 1)
10
608909
1. 2. 3. 4. 5. 6. 7.
Bolt, Spring washer Socket (Remove 3 through 7 as a subassembly.) Guide bushing Dust seal Packing Buffer ring O-ring
8. 9. 10. 11. 12. 13. 1)
Piston rod Self-locknut Piston Piston seal Collar Cylinder tube Tilt cylinders for 6.0 to 7.0 ton.
Note: Parts marked with * are included in the seal kit. (1) The illustration shows tilt cylinder for 3.5 to 5.5 ton models. The frame fitting for 6.0 to 7.0 ton models have a different form. (2) Do not disassemble piston 10 unless defective. (3) Collar 12 is for forward tilt angle of 3 degrees. Tilt cylinders with Weber hydraulic stamped into the cylinder are assembled using thread locking compound. The gland nut must be heated to 300 °C (572 °F) before disassembling the cylinders. Use LOCTITE 270 when assembling.
10-54
CHAPTER 10 HYDRAULIC SYSTEM 24.2 Suggestions for Disassembly Removing guide bushing To remove the guide bushing, wrap the tilt cylinder in cloth and hold it with a vise. Remove the guide bushing using the wrench.
608892
Special tool needed Item Wrench
3.5 to 5.5 ton
6.0 to 7.0 ton
05312-10800
05312-11000
Weber hydraulic type cylinders Loosen LOCTITE material by heating up the thread zone (rod guide cylinder barrel) to 300°C (572°F) or higher and loosen the rod guide with a fitting spanner.
25. Inspection After Disassembling Tilt Cylinders 25.1 Cylinder Tube (1) Check the inner wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
25.2 Piston Rod (1) Check for deflection as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
10-55
CHAPTER 10 HYDRAULIC SYSTEM 25.3 Packings and Rings Replace all parts contained in the seal kit once disturbed. Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
1
Inside diameter of cylinder tube
Standard
100 mm (3.937 in.)
110 mm (4.33 in.)
2
[Guide bushing] Standard Diameter of piston rod
40 mm (1.574 in.)
50 mm (1.968 in.)
3
Inside diameter of tilt Standard socket bushing (fitted)
40 +0.05 mm (1.574 +0.002 in.)
4
Inside diameter of cylinder tube head bushing (fitted)
Standard
5
[Guide bushing] Thread diameter
Standard
5
Guide bushing
Tightening torque
6
[Tilt socket] Thread diameter
Standard
7
Tilt socket bolt
8
Self-locking nut
+0.10
50
+0.004
+0.039 +0.0015 0 mm (1.574 0 in.)
696 ± 69 N·m (71 ± 7 kgf·m) [513 ± 50 lbf·ft]
+0.11 +0.043 0 mm (1.968 0 in.)
785
+98 +10 +7.28 0 N·m (80 0 kgf·m) [578 0 lbf·ft]
M38 × 1.5
M38 × 1.5
Tightening torque
262 ± 13 N·m (27 ± 1.4 kgf·m) [195 ± 10.1 lbf·ft]
262 ± 13 N·m (27 ± 1.4 kgf·m) [195 ± 10.1 lbf·ft]
Tightening torque
588 ± 29 N·m (60 ± 29 kgf·m) [434 ± 21.7 lbf·ft]
981
+98 +10 +72.3 0 N·m (100 0 kgf·m) [723.3 0 lbf·ft]
8 4
2
10-56
+0.004
M115 × 2.0
6
7
50
M105 × 2.0
5 3
+0.10
45 +0.05 mm (1.77 +0.002 in.)
1
608910
CHAPTER 10 HYDRAULIC SYSTEM
26. Assembling Tilt Cylinders Follow the disassembly sequence in reverse.
26.1 Suggestions for Assembly (1) Carefully clean all parts to remove any gritty particle. (2) Assemble the cylinder in the reverse sequence of the disassembling, apply hydraulic oil on the bore wall of the cylinder tube, and also on sealing parts (O-rings, Urings, wiper rings, nylon heels, piston seals, dust seals, and packings) so that they will smoothly slide into the bore. (3) When clamping the cylinder tube in the vise in order to run the head into the cylinder tube, be careful not to distort the tube. 608911
(4) Before fitting the piston seal to the tilt cylinder piston, squeeze the seal by hand 5 or 6 times to soften it. Hold the piston steady by clamping the rod in the vise; apply a small amount of hydraulic oil on the seal; fit a portion of the seal to the groove; and push the other portions just a little at a time into the groove. For Weber hydraulic cylinders, use LOCTITE 270 when installing the rod guide bushing.
608912
Item Rod guide bushing
Tightening torque 400±40 N·m (41±5Kgf·m) [295±29lbf·ft)
10-57
CHAPTER 10 HYDRAULIC SYSTEM
27. Disassembling Flow Regulator Valve 27.1 Flow Regulator Valve (3.5 to 5.5 Ton) Disassembly sequence
3
11
2 1
6
10
9
5
8
7 4
1. 2. 3. 4. 5. 6.
Locknut Plug, O-ring Spring Piston Snapring Springpin
7. 8. 9. 10. 11.
Washer Spring Plate Valve Body
28. Inspection After Disassembling Flow Regulator Valve (1) Check the springs for fatigue. (2) Check seat and sliding faces of valve and piston. (3) Check the sliding surfaces of the piston and valve body for damage. Note: Replace the flow regulator valve as an assembly if any part is defective.
10-58
608913
CHAPTER 10 HYDRAULIC SYSTEM
29. Assembling Flow Regulator Valve 29.1 Flow Regulator Valve Disassembly sequence
10
4
9
5
11 12
6 1 2 3 8 1. 2. 3. 4. 5. 6.
7
Nut Plug, O-ring Spring Piston Snap spring Pin
608915
7. 8. 9. 10. 11. 12.
Stopper Disc spring Plate Valve Body Elbow
30. Inspection After Disassembling Flow Regulator Valve (1) Check the springs for fatigue. (2) Check seat and sliding faces of valve and piston. (3) Check the sliding surfaces of the piston and valve body for damage. Note: Replace the flow regulator valve as an assembly if any part is defective.
31. Assembling Flow Regulator Valve Follow the disassembly sequence in reverse. Item Control flow rate
Value 165 liter/min (43.6 U.S.gal)
10-59
CHAPTER 10 HYDRAULIC SYSTEM
32. Inspection and Adjustment 32.1 Hydraulic Oil Level
295 mm (11.6 in.)
H N
33 (1.3) 50 (1.97)
L 120 (4.72) 608916
Item
3.5 to 4.5 ton
5.5 ton
6.0 to 7.0 ton
Hydraulic oil level
46 liter (12.1 U.S.gal)
52 liter (13.7 U.S.gal)
69 liter (18.2 U.S.gal)
Level gauge scale
H
N
450 mm (17.72 in.)
415 mm (16.34 in.)
Oil level (from the bottom of tank)
Note: Use level gauge scale N or H to check the oil level. Hydraulic tank (1) Hydraulic oil Check the hydraulic oil in the tank for cleanliness. Oil showing discoloring must be changed (slightly whitish color is allowed as it always appears after the operation). (2) Refill capacities and the amount of oil required. (3) Suction strainer and return filter Check for clogging or damage, and clean or replace the strainer and filter.
10-60
CHAPTER 10 HYDRAULIC SYSTEM 32.2 Test-run of Gear Pump The purpose of a test-run is to break-in the overhauled pump and verify its performance. The use of pump testing equipment, specifically designed as such and commonly used in the service shop is recommended but is not mandatory. The following procedure, however, assumes that the pump is installed on the forklift truck. (1) Install a hydraulic pressure gauge with a range of 0 to 35200 kPa (0 to 352 kgf/cm2) [0 to 5000 psi].
1
1)
Installing hydraulic pressure gauge: Remove the plug from the delivery at the hose connector, and install the following tools:
4
3 2 608917 1) R2 PORT
Ref.
Item
1
Connector
2
Hose
3
Connector
4
Gauge
Special tools needed Threaded section (G3/4 MALE O-RING PORT to G3/8 MALE HOSE PORT) 64309-17722 64309-17731 (for gauge mounting) 64309-17712 0 to 35200 kPa (0 to 352 kgf/cm2) [0 to 5000 psi]
Note: Parts 2 through 4 are included in gauge kit 64309-17701. (2) Set the operating control lever in the NEUTRAL position, and run the engine at 500 to 1000 min-1. The hydraulic gauge reading under NEUTRAL condition should become 981 kPa (10 kgf/cm2) [142 psi] or less. Run the pump for 10 minutes and check the pump for abnormal noise. (3) Gradually increase the engine speed to 1500 to 2000 min-1, and run the pump for another 10 minutes under no load. (4) Under the condition of Step (3), loosen the adjusting screw of relief valve, and switch the operating control lever to operating condition. Adjust the adjusting screw and run the pump for 5 minutes with the pressure of 2942 kPa (30 kgf/cm2) [427 psi]. Increase the pressure by 1961 kPa (20 kgf/cm2) [284 psi] and run the pump for 5 minutes. Repeat the 5-minute run while increasing the pressure by the same amount for each run until the pressure reaches the set pressure of relief valve. (5) While increasing the pressure, check the pump surface temperature of the pump and for abnormal noise. If oil and pump are abnormally heated, continue the testrun under no load after lowering the temperature, or disassemble and inspect the pump. (6) After Steps (2) through (5) are completed, adjust the relief valve to the specified set pressure, and make sure that the operation speed is normal.
1 1. Spanner
2
608918 2. Allen wrench
10-61
CHAPTER 10 HYDRAULIC SYSTEM 32.3 Control Valve External oil leaks (1) Check the O-ring between housings for oil leakage. (2) Check the scraper and O-ring for oil leakage. (3) Check the thread connection for oil leakage. Oil leakage It is difficult to carry out an oil leakage check for the control valve individually. Therefore follow the procedures for inspection of cylinders before and after connecting as is described in (1) through (3) below: Measurement indicates the total leakage from the lift spool, tilt spool, tilt lock valve, and the check valves. Oil temperature: approx. 50°C (122°F) (1) Raise the forks with a rated load to approx. 1 m (40 in.). Tilt the mast FORWARD from the vertical position by approx. 3 to 4 degrees, then turn the engine OFF.
3° to 4°
Approx. 1 m (40 in.) 608919
(2) Immediately remove the oil return hose and collect oil from the hose.
608920
Item Standard oil discharge in 15 min.
500 cc (30.5 cu. in.)
(3) If the lift cylinders or tilt cylinders drift (the mast tilts forward or the fork lowers) excessively in spite of that the amount of oil collected for 15 minutes is less than 500 cc (30.5 cu.in.), measure the internal leakage of each cylinder. (The measurement is the assembly standard and not the secure limit).
10-62
CHAPTER 10 HYDRAULIC SYSTEM 32.4 Main Relief Valve Adjustment (1) Install a hydraulic gauge of 35200 kPa (352 kgf/cm2) [5000 psi] to R2 port. Use the same gauge, connector, and the hose used for the test-run of the gear pump. (2) Start the engine, and operate the tilt lever to the BACKWARD position at the maximum engine speed. When the tilt cylinder reaches the maximum BACKWARD position, check the pressure gauge. The main relief valve is in good condition if the oil pressure is relieved and the gauge reading is +0.5
+5.1
+72
19.4 0 MPa (197.8 0 kgf/cm2) [2814 0 psi]. (3) If the relief pressure is incorrect, loosen the relief valve locknut, and while observing the hydraulic gauge, adjust the pressure using the adjusting screw. (4) While pressing the adjusting screw, tighten the locknut to secure. (5) After tightening, check the relief valve set pressure again.
1 1. Spanner
2
608918 2. Allen wrench
Item Main relief valve set pressure
19.4
+0.5 +5.1 +72 2 0 MPa (197.8 0 kgf/cm ) [2814 0 psi]
32.5 Attachment Relief Valve Adjustment (1) Install a hydraulic gauge of 35200 kPa (352 kgf/cm2) [5000 psi] to R2 port. Note: Use the same equipment and tools as used for adjusting the main relief valve. (2) Turn ON the engine, and operate the attachment lever FORWARD or BACKWARD at the maximum engine speed. When the hydraulic pressure of actuator reaches the limit, check the pressure gauge. The secondary relief valve is in good condition if the oil pressure is relieved and the gauge reading becomes the specified value. (3) If the relief pressure is defective, loosen the relief valve locknut, and while observing the hydraulic gauge, adjust the pressure using the adjusting screw. (4) While pressing the adjusting screw, tighten the locknut to secure. (5) After tightening, check the relief valve set pressure again.
608921
10-63
CHAPTER 10 HYDRAULIC SYSTEM 32.6 Priority Relief Valve Function Check (1) Install a hydraulic pressure gauge to the position indicated in the figure to the right.
3 2
1 Ref.
Item
1
Connector
2
Hose
3
Gauge
608922
Special tools needed G3/8 FEMALE O-ring port to G3/8 MALE hose port 64309-17722 64309-17712 35200 kPa (352 kgf/cm2) [5000 psi]
Note: -
Tools 1 through 3 are included in gauge kit. It is desirable to use a hydraulic gauge with a double capacity of the pressure to be measured.
32.7 Flow Regulator Valve Adjustment Measure the lowering speed under rated load. If the speed is not the standard value, loosen the locknut of set bolt and turn the set bolt in either direction.
608925
Lowering speed
3.5 to 5.5 ton
4.5 to 5.5 ton
6.0 to 7.0 ton
Loaded
550 mm/sec (108 fpm)
440 mm/sec (86.6 fpm)
540 mm/sec (106 fpm)
No load
500 mm/sec (98.4 fpm)
410 mm/sec (81 fpm)
390 mm/sec (77 fpm)
10-64
CHAPTER 10 HYDRAULIC SYSTEM 32.8 Lift and Tilt Cylinders Adjusting mast tilt angle (simplex and duplex) (1) Place the forks on a level and hard surface. (2) Tilt the mast BACKWARD to the maximum tilt position for the mast without tilt cylinder spacers, then turn the engine OFF. (3) Measure the BACKWARD angle of the mast at both sides. (4) Loosen the tightening bolt of tilt cylinder socket, rotate the tilt cylinder rod and adjust the cylinder stroke until the right and left masts are tilted at the same angle. Note: It is unnecessary to adjust the forward tilt angle, provided that the backward tilt angle is properly adjusted on the mast without spacers.
608926
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Simplex Forward tilt - Backward tilt degrees
5° to 10°
6° to 9°
Adjusting mast tilt angle (triplex) (1) (2) (3) (4) (5)
Place the forks on a level and hard surface. Raise the forks up so when mast is tilted FORWARD to the maximum tilt position the forks will not hit the floor. Measure the forward tilt angle of the mast at both sides. Loosen the tightening bolt of tilt cylinder socket, rotate the tilt cylinder rod and adjust the tilt angle. Tilt mast BACKWARD and then slowly tilt the mast FORWARD, and observe the stopping of piston rod, right and left, at the moment the tilt cylinder reaches its maximum backward tilt. (6) If right to left piston rods stops before and mast cocks, adjust cylinder rod so that right and left stops at the same time. (7) Slowly tilt the mast BACKWARD observing the stopping point at tilt cylinder spacers. (8) Add shims between tilt cylinder socket and spacer, tighten to specified torque. Item
All model
Triplex Forward tilt - Backward tilt degrees
6° to 5°
Lift cylinder stroke adjustment (1) Slowly raise the inner mast, and observe the stopping of piston rod, right and left, at the moment the inner mast reaches its maximum lift height. (2) If the top of mast rolls at that moment, it should be adjusted with shims. Abnormal condition can be detected by a little time lag in stopping between right hand and left hand piston rods and rolling of the rod with a longer cylinder stroke. 608927
10-65
CHAPTER 10 HYDRAULIC SYSTEM Adjusting method (1) Raise the inner mast, tie blocks under the right and left sides of the mast, and lower the mast until it rests on the blocks. (2) Remove the stopper bolt at the top of lift cylinder which stopped first, retract the piston rod, and insert shims at the top of piston rod end.
608873
Note: To retract the piston rod, move the lift lever to the lowering position to let the oil escape from the lift cylinder. (3) Extend the piston rod, and tighten the cylinder stopper bolt. Remove the blocks from under the inner mast. (4) Slowly lower the inner mast to the bottom to ensure the piston rods move smoothly.
1
608928 1. Shims
10-66
CHAPTER 10 HYDRAULIC SYSTEM 32.9 Tests Descent by internal leakages (leakdown) (1) Position the mast VERTICAL with rated load, raise the forks approx. 1 m [40 in.], then turn the engine OFF. (2) Draw a reference line on the mast, and measure the distance of fork lowering after 15 minutes.
608929
Item Load descent test (rated load)
3.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (1.97 in.)
70 mm (2.76 in.)
Forward tilt by internal leakages (leakdown) (1) Position the mast VERTICAL with rated load, raise the forks approx. 50 cm (20 in.), then turn the engine OFF. (2) Measure the amount of tilt cylinder extension after 15 minutes.
608930
Item Load descent test (rated load)
3.5 to 5.5 ton
6.0 to 7.0 ton
30 mm (1.18 in.)
40 mm (1.57 in.)
10-67
CHAPTER 10 HYDRAULIC SYSTEM
33. Hydraulic Circuit Diagram 1 11 2
LS T P
R
L
10
9 4
P2 PF
A1
B2
A2
B3
A3
B4
8
A4
T1
P1
T2 LS
3
5
7
6 608931
1. 2. 3. 4. 5. 6.
Engine Gear pump Main relief valve PF relief valve Lift cylinder Flow regulator valve
10-68
7. 8. 9. 10. 11.
Tilt cylinder Control valve ATT relief valve Steering control valve Steering cylinder
CHAPTER 10 HYDRAULIC SYSTEM
34. Troubleshooting Item
Condition
Possible cause Oil low level
Actions Refill
Relief valve out of order, because of: Will not lift or tilt
(1) Main valve seized
Replace
(2) Valve spring broken
Replace
Oil pump defective
Replace
Relief valve out of order, because of:
Will not lift rated load
Lift speed is too slow Lift and tilt cylinders Lowering speed is too slow
Cylinder vibrates when actuated
Load descends too fast (drift)
Mast tilts forward (drift)
(1) Relief pressure setting too low
Adjust
(2) Plunger or poppet seat defective
Replace
(3) Spring fatigued
Replace
(4) O-ring in valve case damaged
Replace O-ring
Oil pump defective
Replace
Piston seals worn or damaged
Replace
Engine idle speed too low
Tune up engine
Operating control lever installed loosely, resulting in short spool stroke
Repair or replace
Tank strainer clogged
Clean or replace
Pump not delivering enough oil
Repair or replace
Sleeve seized in flow regulator valve
Repair
Dirt in flow regulator valve
Clean, repair system and replace defective hose
Abnormal resistance to flow due to deformation or partial clogging of hose
Replace hose
Piston rod distorted
Repair or replace
Air in oil circuit
Bleed air by operating cylinders through full strokes
Not enough oil in hydraulic tank
Refill
Control valve spool internally leaking
Replace
Sliding (inside) surface of cylinder tube slightly grooved
Repair or replace cylinder assembly
Sliding (inside) surface of cylinder tube badly grooved
Replace cylinder assembly
Piston seals broken or distorted
Replace seal kit
Oil leakage from piping
Repair or replace
Control valve spool internally leaking
Replace
Foreign particles lodged between packing
Replace packing
10-69
CHAPTER 10 HYDRAULIC SYSTEM Item
Lift and tilt cylinders
Condition
Bushing leaks
Hydraulic tank heats excessively
Actions
Foreign particles lodged between sealing members such as oil seals and dust seals
Replace
Oil seals and dust seals defective
Replace
O-rings damaged
Replace
Cylinder distorted
Repair or replace
Oil viscosity incorrect
Change oil
Overload
Check working conditions and, if overloaded, advise the operator to stay within the load limit
Local overheating of oil line due to a large restriction to flow
Repair or replace Adjust pressure setting
Relief valve adjustment incorrect 19.12
Hydraulic tank
Cylinders move too slow
Cylinders move too slow
Gear pump
Noise
10-70
Possible cause
+0.5 +0.5 +70 2 0 MPa (195 0 kgf/cm ) [2773 0 psi]
Pressure drop due to fatigued or broken springs
Repair or replace and adjust
Gear pump worn
Replace
Outlet pipe or tube deformed, or restricted
Repair or replace
Shortage of oil due to a natural loss
Refill
Oil leakage due to damaged oil line seals
Repair or replace
Oil viscosity too higher
Change oil
Gear pump defective
Check pump and piping; repair or replace
Oil leakage from oil line
Check oil for level and condition; add or change oil
Abnormal oil temperature rise
Check control valve spools for misalignment; repair or replace
Gear pump internally leaking
Replace pump
Poor pumping
Refill Check suction pipe for any flat portion (1) or loose connection; retighten or replace
Cavitation
(2)
Check that shaft oil seal is airtight; replace pump
(3)
Check pump case for any outside interference; repair
CHAPTER 10 HYDRAULIC SYSTEM Item
Condition
Possible cause Pressure too high
Pump case, drive gear and pump port flange damaged
Actions Replace pump Check to see if relief valve setting is correct Replace pump
Distortion or damage due to external strain or stress
(1) Check to see if return line is restricted Check to see if pipe connections have been externally stressed
(2)
Gear pump
Oil leakage from
Oil leakage past oil seal
Replace oil seal
Oil leakage past sliding surfaces of drive shaft
Replace whole pump assembly
Pump securing bolts loose
Retighten
Excessive internal leakage
Replace O-ring Adjust
Relief pressure setting too low 19.12 Slow or no motion of lift and tilt cylinders
Control valve Load descends or mast tilts forward (drifts) with operating control lever in neutral Oil leakage
+0.5 +0.5 +70 0 MPa (195 0 kgf/cm2) [2773 0 psi]
Relief valve piston seizure
Clean piston and check to see if it moves smoothly; or replace whole relief valve assembly
O-ring on relief valve body damaged
Replace O-ring
Operating control lever installed loosely, resulting in short spool stroke
Adjust
Control valve internally leaking
Adjust the tilt relief valve to the full closed position or replace the tilt relief valve.
Oil leakage from spool ring cap
Replace O-ring; check spool for flaws and if any, repair or replace a leaky block assembly
Loose plugs
Retighten
10-71
CHAPTER 10 HYDRAULIC SYSTEM
35. Service Data
Simplex mast
Item
3.5 to 4.0 ton
4.5 to 5.5 ton
60 to 7.0 ton
Lift speed (rated load/no load) mm (ft)/sec
Standard
540/570 (106.0/112.0)
390/420 (78.0/82.5)
360/390 (71.0/76.0)
Lowering speed (rated load)
Standard
550 (108)
440 (86.5)
540 (106.0)
Forward tilt angle
Standard
5°
6°
Backward tilt angle
Standard
10°
9°
Lift cylinder rod drift (rated load) Oil temperature: 45°C (113°F)
Standard
50 mm (1.97 in.)/15 min.
70 mm (2.76 in.)/15 min.
Tilt cylinder rod drift (forward) (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/15 min.
40 mm (1.57 in.)/15 min.
+0.5 2 0 kPa (197.6 kgf/cm ) [2810 psi]
Standard
Priority relief valve setting
Standard
11713 kPa (120 kgf/cm2) [1700 psi]
14641 kPa (150 kgf/cm2) [2125 psi]
Capacity
Standard
98 liter (25.89 U.S.gal)/2450 min
117.6 liter (31.07 U.S.gal) /2450 min
Flow rate (no load)
Standard
Flow regulator valve Gear pump
Main relief valve setting
Control valve Duplex mast
115 liter (30.38 U.S.gal)/ min
100 liter (26.42 U.S.gal)/ min
165 liter (43.59 U.S.gal)/ min
Tightening torque
49 N·m (5 kgf·m) [36 lbf·ft]
Tie bolts 7/16 inch
Tightening torque
65 N·m (6.6 kgf·m) [48 lbf·ft]
Tie bolts 1/2 inch
Tightening torque
101 N·m (10.3 kgf·m) [74 lbf·ft]
Return filter
10-72
19361
Lift speed (rated load/no load) mm (ft)/sec
Standard
510/540 (100/106)
350/370 (69/73)
-
Lowering speed (rated load)
Standard
560 (110)
440 (86.5)
-
Forward tilt angle
Standard
5°
6°
Backward tilt angle
Standard
10°
10°
Lift cylinder rod drift (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/15 min.
40 mm (1.57 in.)/15 min.
Tilt cylinder rod drift (forward) (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/15 min.
40 mm (1.57 in.)/15 min.
CHAPTER 10 HYDRAULIC SYSTEM
Triplex mast
Item
3.5 to 4.0 ton
4.5 to 5.5 ton
60 to 7.0 ton
Lift speed (rated load/no load) mm (ft)/sec
Standard
510/550 (100/106)
360/390 (70/77)
330/360 (70/77)
Lowering speed (rated load)
Standard
560 (110)
460 (91)
510 (100)
Forward tilt angle
Standard
6°
Backward tilt angle
Standard
5°
Lift cylinder rod drift (rated load) Oil temperature: 45°C (113°F)
Standard
50 mm (1.97 in.)/ 15 min/70 mm (2.76 in.)/15 min
Tilt cylinder rod drift (forward) (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/ 15 min/40 mm (1.5 in.)/15 min
35.1 Lift Cylinder (Simplex Mast) A40A
A45A A55A
A70A
Standard
60 mm (2.36 in.)
70 mm (2.75 in.)
80 mm (3.15 in.)
Diameter of piston rod
Standard
45 mm (1.77 in.)
50 mm (1.97 in.)
*60 mm (2.36 in.)
3
Holder thread diameter
Standard
M64 × 1.5
M79 × 2.0
M90 × 2.0
4
Width across flat
Standard
-
85 mm (3.35 in.)
-
4
Cylinder head
Tightening torque
304 N·m (31 kgf·m) [224 lbf·ft]
422 N·m (43 kgf·m) [311 lbf·ft]
490 N·m (50 kgf·m) [362 lbf·ft]
Ref.
Item
1
Inside diameter of cylinder tube (Piston)
2
Value marked with * becomes 65 (2.56) for the mast size of 6.5 to 7.0 m (256 to 276 in.).
4
2
3
1
608932
10-73
CHAPTER 10 HYDRAULIC SYSTEM 35.2 Second Lift Cylinders (Duplex Mast Second Cylinders) Ref.
Item
B40A
B45A B55A
1
Inside diameter of cylinder tube (Piston)
Standard
55 mm (2.165 in.)
60 mm (2.362 in.)
2
Diameter of piston rod
Standard
42 mm (1.653 in.)
50 mm (1.968 in.)
3
Holder thread diameter
Standard
M63 x 2
M70 x 2
4
Holder or cylinder head
Tightening torque
304 ± 70.6 N·m (31 ± 7.2 kgf·m) [224 ± 52 lbf·ft]
343 ± 78.5 N·m (35 ± 8.0 kgf·m) [253 ± 57.8 lbf·ft]
5
Piston
Tightening torque
245 ± 44.1 N·m (25 ± 4.5 kgf·m) [180 ± 32.5 lbf·ft]
394 ± 52.9 N·m (30 ± 5.4 kgf·m) [217 ± 39 lbf·ft]
6
Set screw
Tightening torque
3.92 ± 0.98 N·m (0.4 ± 0.1 kgf·m) [2.9 ± 0.7 lbf·ft]
7
Valve
Tightening torque
19.6 ± 4.9 N·m (2 ± 0.5 kgf·m) [14.4 ± 3.6 lbf·ft]
8
Set screw
Tightening torque
B45A, B55A
4
3.92 ± 0.98 N·m (0.4 ± 0.1 kgf·m) [2.9 ± 0.7 lbf·ft]
3
6
2
-
5
1
7 8 B40A
608933
10-74
CHAPTER 10 HYDRAULIC SYSTEM 35.3 First Lift Cylinders (Duplex Mast, Triplex Mast First Cylinder) Ref.
Item
B40A C40A
B45A, B55A C45A, B55A
C70A
1
Inside diameter of cylinder tube (Piston)
Standard
90 mm (3.546 in.)
110 mm (4.33 in.)
125 mm (4.92 in.)
2
Diameter of piston rod
Standard
65 mm (2.56 in.)
75 mm (2.92 in.)
80 mm (3.15 in.)
3
Cylinder head thread diameter
Standard
M95 × 2
M115 × 2
M130 × 2
4
Holder or cylinder head
Tightening torque
530 ± 122 N·m (54 ± 12.4 kgf·m) [390 ± 89.7lbf·ft]
834 ± 191 N·m (85 ± 19.5 kgf·m) [614.8 ± 141 lbf·ft]
1120 ± 275 N·m (123 ± 28 kgf·m) [890 ± 203 lbf·ft]
5
Screw
Tightening torque
3
3.92 ± 0.78 N·m (0.4 ± 0.08 kgf·m) [28.9 ± 0.57 lbf·ft]
5
4
2
1
608934
10-75
CHAPTER 10 HYDRAULIC SYSTEM 35.4 Second Lift Cylinders (Triplex Mast) Ref.
Item
C40A
C45A C55A
C70A
1
Inside diameter of cylinder tube
Standard
60 mm (2.36 in.)
70 mm (2.76 in.)
80 mm (3.15 in.)
2
Diameter of piston rod
Standard
45 mm (1.77 in.)
50 mm (1.97 in.)
60 mm (2.36 in.)
3
Cylinder head or holder thread diameter
Standard
M64 × 1.5
M70 × 2.0
M90 × 2.0
4
Width across flat
Standard
-
85 mm (3.35 in.)
-
5
Holder or cylinder head
Tightening torque
304 ± 70.6 N·m (31 ± 7.2 kgf·m) [224 ± 52.0 lbf·ft]
422 N·m (43 kgf·m) [311 lbf·ft]
490 N·m (50 kgf·m) [362 lbf·ft]
6
Piston
Tightening torque
-
-
294 N·m (30 kgf·m) [217 lbf·ft]
7
Set screw
Tightening torque
-
-
6.86 N·m (0.7 kgf·m) [5.06 lbf·ft]
3
5 C40A
1
2
3
5 C45A, C55A
4
5
2
1
3
7
6
C70A
2
1
608935
10-76
CHAPTER 10 HYDRAULIC SYSTEM 35.5 Tilt Cylinders
Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
1
Inside diameter of cylinder tube
Standard value
100 mm (3.937 in.)
110 mm (4.33 in.)
2
Diameter of piston rod (Guide bushing)
Standard value
40 mm (1.574 in.)
50 mm (1.968 in.)
3
Inside diameter of tilt socket bushing (fitted)
Standard value
40+0.05 mm (1.574+0.002 in.)
4
Inside diameter of cylinder tube head bushing (fitted)
Standard value
5
Thread diameter (Guide bushing)
5
Guide bushing
6
Thread diameter (Tilt socket)
7
8
+0.10
+0.004
+0.10
+0.004
45+0.05 mm (1.574+0.002 in.)
+0.039 +0.0015 0 mm (1.968 0 in.)
50
Standard value
M105 x 2.0
Tightening torque
696 ± 69 N·m (71 ± 7 kgf·m) [513 ± 50 lbf·ft]
M115 x 2.0
+98 +10 +72.3 0 N·m (80 0 kgf·m) [578 0 lbf·ft]
785
Standard value
M38 x 1.5
Socket bolt
Tightening torque
262 ± 13N·m (27 ± 1.4 kgf·m) [195 ± 10.1 lbf·ft]
Self-locking nut
Tightening torque
3
6
588 ± 29 N·m (60 ± 3 kgf·m) [434 ± 21.7 lbf·ft]
+98 +10 +72.3 0 N·m (100 0 kgf·m) [723.3 0 lbf·ft]
981
8
5
2
4
1
8 608936
10-77
CHAPTER 11 MAST AND FORKS
Chapter 11 MAST AND FORKS 1.
Simplex Mast
1.1
Mast System
The following table shows a combination of truck and mast models: Lift Truck models
Mast
3.5 to 4.0 ton
A40A cc
4.5C ton
A40A cc
4.5 to 5.5 ton
A40A cc
6.0 to 7.0 ton
A40A cc
Note: cc represents maximum lift height. Example: 30 = 3,000 mm (157.5 in.) lift height Mast type and code Code
Mast
A
Simplex mast
Mast serial number location
609227
How to read mast model code
A
40
A
30 4 3 2 1 609228
1. 2.
Indicates the mast type Applicable forklift truck class (Example: 4.0 ton)
3. 4.
Mast generation (A6B6C···Z) Maximum lifting height (30: 3000 mm[118.11 in.])
11-1
CHAPTER 11 MAST AND FORKS 1.2
Structure and Functions C
5
C
4
•
15
1 2
9
•
6
B
B
13
12
11
A
A
12
11
16
10 14
•
3 7
10
9
D
8
D
Section A-A
1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Section B-B
2)
Outer mast Inner mast Lift bracket Lift cylinder Lift chain Load backrest extension Forks Mast strip Outer mast main roller Lift bracket upper roller Inner mast main roller
Section C-C
3) 12. 13. 14. 15. 16. 1) 2) 3) 4)
Section D-D
4)
609229
Lift bracket lower roller Lift bracket middle roller Side roller Chain wheel Tilt cylinder Detail of lift bracket lower rollers and inner mast main rollers Detail of outer mast main rollers Detail of lift bracket upper rollers Detail of mast strip
Note: For hydraulic lines, see 11-19 "Installing Hydraulic Lines". The simplex mast provides good visibility by placing both lift cylinders behind the outer mast columns. Mast strips are installed at the top end of outer mast in order to support the inner mast when the mast is tilted BACKWARD. All lift cylinders are equipped with a cushion mechanism. For mast operation, see 11-3 "Mast operation".
11-2
CHAPTER 11 MAST AND FORKS Mast operation The forks can reach the maximum free-lift height when the lift cylinders are extended. Further extension of the lift cylinders causes the inner mast to lift at the same speed as the cylinder rods, which causes the forks to lift twice as fast as the inner mast at the same time. See “HYDRAULIC SYSTEM”. Maximum free lift Maximum free lift means the maximum elevation of the forks without raising the mast.
2 3
1 4
4) 1) 1. 2. 3. 4.
Lift cylinder Lift chain Inner mast Outer mast
2) 1) 2) 3) 4)
3)
502138
Forks on the ground Maximum free lift Maximum lift Free lift height
11-3
CHAPTER 11 MAST AND FORKS 1.3
Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the forklift truck, see 11-21 "Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck" .
2 5
3
4 6
7 1 1. 2. 3.
1.4
609230
Nut Load backrest extension, Lift bracket, Forks Return hose [4.5 m (14.8 ft.) maximum lift height or above]
4. 5. 6. 7.
High-pressure hose Tilt socket pin Mast support cap, Bushing Inner mast, Outer mast, Lift cylinder
Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly (1) Tilt the mast FORWARD and lower the inner mast to the bottom so that the lift chain is slack. Then remove the nuts 1 from the lift chains. (2) Tilt the mast BACKWARD to the VERTICAL position and lift the inner mast until the lift bracket 2 becomes free. Then, slowly move the forklift truck away from the lift bracket. Note: Before overhauling the mast assembly, BE SURE to measure the clearance between the mast and the rollers. This helps to improve work efficiency by understanding which roller is to be replaced or the necessity of shim adjustment. See 11-98 "Adjusting Mast Roller Clearance".
2 1 609231
R CAUTION After the lift bracket is removed from the forklift truck, place wood blocks under the lift bracket to prevent it from falling down.
11-4
CHAPTER 11 MAST AND FORKS Disconnecting lift cylinder return hose (1) Turn the engine OFF and disconnect hose at the hose clamp on the return connector side (indicated by the arrow in the figure). (2) Lower the mast.
1)
2
1
2)
3) 502141
1. Return hose 2. Return connector
1) To right lift cylinder 2) To left lift cylinder 3) To tank
Disconnecting lift cylinder high-pressure hoses Lower the mast to the bottom, and then disconnect hose at the location indicated by the arrow.
505780
11-5
CHAPTER 11 MAST AND FORKS Separating tilt cylinders (1) Attach a sling on the rings on the crossmember at the top of the outer mast, then lift the outer mast with a hoist.
609232
R CAUTION When removing and installing the mast assembly with a hoist, BE SURE to use a hoist with enough lift capacity. (2) Place wood blocks under the tilt cylinder mounting section and remove the tilt socket pins, and separate the mast from the tilt cylinders. (3) Start the engine, and retract the tilt cylinder rods with the tilt lever.
609233
R CAUTION -
DO NOT touch any levers except the tilt lever while the engine is running. DO NOT loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps (1) Put a matchmark on each cap. (2) Remove cap mounting bolts from the mast and disconnect the mast assembly from the forklift truck by hoisting. Lay the mast assembly horizontally on a level and hard surface with the lift bracket side facing up. Note: Lay the mast assembly in a space large enough for disassembly work.
1) 609234 1) Matchmark
11-6
CHAPTER 11 MAST AND FORKS 1.5
Suggestions for Installing Mast and Lift Bracket Assembly
For installation, follow the removal sequence in reverse and observe the instructions below: Mast support (1) Apply a thick coat of grease on the inner surface of the caps and the mast support bushings. (2) Install the mast supports in the same direction as they were removed. (3) For greasing, place wood blocks under the mast so that the mast is off the ground. (4) Tighten the mast support bolts to the specified torque.
1 2
1) 2) 1. Bushing 2. Cap
Item Mast support bolt
505774
1) Bushing internal view 2) Cap internal view
Tightening torque 290 N·m (29.6 kgf·m) [214 lbf·ft]
Adjusting chain tension For chain tension adjustment, see 11-24 "Chain tension inspection and adjustment". Bleeding lift cylinders Move the lift bracket up and down several times to bleed air trapped in the piston end of the lift cylinder. After the proper operation of the forklift truck is confirmed, check the oil level in the hydraulic tank.
11-7
CHAPTER 11 MAST AND FORKS 1.6
Removal Sequence of Mast and Lift Bracket
3
16
9
13 8
5 2
16
6 1
5. 6. 7. 8.
1.7
10
11
2
1. 2. 3. 4.
12
15
10 17
7
14
4
Nut Forks, Lift bracket Load backrest extension Lift bracket middle rollers and lower rollers, Shims Lift bracket upper rollers, Snaprings Lift bracket side rollers, Brackets, Shims Lift hose (for high pressure), Rubber hose, T-joint, Down safety valve Return hose (for maximum lift height of 4.5 m [177.165 in.] or more)
609235
9. Snapring, Chain wheel 10. Cylinder clamps, Seats, Shims, Cushion, Collar, Clamp bolt 11. Set bolt, Shims, Washer 12. Mast strip, Shims 13. Outer mast main rollers, Shims 14. Inner mast main rollers, Shims 15. Inner mast 16. Lift cylinder 17. Outer mast, Grease nipple
Suggestions for Disassembling Mast and Lift Bracket
Removing mast strips and main rollers Remove the clamp bolt and set bolt to free the lift cylinders, then cross the two lift cylinders at the top. Slide the inner mast down from the outer mast, and remove the main rollers and the mast strips. Removing inner mast After removing the main rollers from the mast, attach a sling on the crossmember of the inner mast and slide the inner mast upward from the outer mast. Attach a sling on the inner mast again and gently pull out the inner mast from the outer mast by clearing the outer mast roller shafts.
609236
11-8
CHAPTER 11 MAST AND FORKS 1.8
Inspecting Mast and Lift Bracket
Mast (1) Check each roller for binding, wear, and cracks. (2) Check each roller on rolling surface for pitting or other defects. (3) Make sure that rollers rotate smoothly on the rolling face. (4) Check welded joints of mast member, crossmembers, shafts, supports, and tilt brackets for cracks. (5) Check the mast support bushings for wear or other defects. 609237
Lift bracket (1) Check the main rollers and side rollers for binding, wear, and cracks. (2) Check the welded areas of lift bracket for cracks. (3) Check the finger bar for bend or distortion.
1 609238 1. Straight edge
Item Distortion of finger bar
Standard value 5 mm (0.20 in.) or less
Lift chains, chain wheels, and chain wheel supports (1) Measure the length of each chain to make sure that the two chains are equal in length. Also check the chains for wear, indication of breakage and link binding and twisting. (2) Check each chain anchor bolt for cracks or thread damage. (3) Check the chain wheel support and the chain wheel for cracks, wear, and binding. (4) Measure chain length to check for elongation. See 1125 "Checking Chain Elongation". Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20 in.)
523 mm (20.6 in.)
4.5 to 7.0 ton
635 mm (25 in.)
654 mm (25.7 in.)
Mast strip Check for damage, scoring or distortion. See “HYDRAULIC SYSTEM”.
11-9
CHAPTER 11 MAST AND FORKS 1.9
Assembly Sequence of Lift Bracket Roller
1
2
1
6 1)
6)
2
1)
1
9)
3 6
8)
8)
2)
10) 5)
5)
5 3 6)
6 1)
1
3)
4
1
5
5) 4)
6) 5) 1. 2. 3. 4. 5. 6.
4
Lift bracket Lift bracket upper roller Lift bracket middle roller Lift bracket lower roller Side roller Inner mast
1.10 Adjusting Lift Bracket Clearance The lift bracket has three main roller bearings on one side and side rollers on both sides as shown in the illustration. The clearances are necessary so that the lift bracket can move up and down smoothly along the inner mast.
11-10
7)
6) 1)
505770
Clearance between main roller rolling face and mast 2) Clearance between middle roller side face and mast thrust plate 3) Clearance between lower roller side face and mast thrust face 4) Clearance between side roller rolling face and mast 5) Shim (a) 6) Shim (b) 7) Shim (c) 8) Thrust plate 9) No shim required 10) Minimum clearance
inner inner inner inner
CHAPTER 11 MAST AND FORKS Clearances between middle roller side face and thrust plate and between lower roller side face and inner mast The clearance between the side roller face and the inner mast thrust face (right-to-left clearance): Clearance 2) is used to determine the correct amount of shims at the bearing seat. Move the lift bracket to the top of the inner mast and slide the lift bracket to either the left-most or the right-most position. Measure the clearance 2) between the roller side face and the inner mast thrust face on the opposite side. Note: Shim adjustment for clearance 2) is not required for the lift bracket upper rollers. Adjust clearance G to the specified values with shims (a) and (b) for the middle and the lower rollers. Item
Standard value
Clearance between middle roller side face and inner mast thrust plate Clearance between lower roller side face and inner mast thrust face
0.1 to 0.5 mm (0.004 to 0.020 in.)
Clearance between main roller rolling face and inner mast Clearance between roller circumference and inner mast thrust face (back-to-front play): Clearance 1) is used for determining the proper size of the rollers. Select a roller of correct diameter so that the clearance meets the specified value. Check that the rollers rotate smoothly when installed. Item
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Clearance between side roller rolling face and inner mast To determine the clearance between side roller circumference and inner mast side roller thrust face: Move the side roller to the upper end of the inner mast and slide the lift bracket to either the left-most or right-most position. Measure G1 clearance between the roller circumference and inner mast on the opposite side. Adjust the number of shims (c) so that the clearance meets the specified value. Item Clearance between side roller rolling face and inner mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-11
CHAPTER 11 MAST AND FORKS Selecting roller of correct outer diameter Measure the clearance between the upper and lower rollers' rolling faces and the mast. If the measured clearances does not meet the standard value shown in the table replace the roller with a roller of the correct diameter. Use the same sized roller for the upper and the lower rollers and use one size smaller for the middle rollers. Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". Make sure that the rollers rotate smoothly when installed. Specifications Item
Roller size (external diameter)
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
Adjusting clearance between middle roller side face and thrust plate
1
2
Note: The following adjustment is not required for the upper rollers.
4
2)
Measure the clearance between middle roller side face and thrust plate. If the measured clearance does not meet the standard value, adjust the clearance as follows:
3)
3
Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) 1. 2. 3. 4.
1
2)
Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
11-12
1)
2
Measure the clearance between the lower roller side face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows:
(1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) Clearance between middle roller side face and inner mast thrust plate 2) Shim (a) 3) Shim (b)
Inner mast Lift bracket Thrust plate Roller stopper
Clearance between lower roller side face and inner mast thrust face
502152
3) 502153 1. Inner mast 2. Lift bracket
1) Clearance between lower roller side face and inner mast thrust face 2) Shim (a) 3) Shim (b)
CHAPTER 11 MAST AND FORKS Installing rollers To install main rollers on shafts, use a driving tool, and be careful not to strike the outer roller surface with the driving tool. The side of the roller with larger chamfering must face toward the outside. Make sure the rollers rotate smoothly when installed.
502154
Adjusting the clearance between side roller rolling face and inner mast
3
1
2
Measure the clearance between side roller rolling face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows: Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
4 1)
(1) If the clearance is too large, increase the number of shims (c) as required. Shim (c) is available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.)
2) 1. 2. 3. 4.
Side roller Inner mast Lift bracket Roller mounting bolt
505788 5. Lift bracket 1) Clearance between side roller rolling face and inner mast 2) Shim (c)
11-13
CHAPTER 11 MAST AND FORKS 1.11 Installing Outer/Inner Mast Rollers Mast rollers have the same shape and size as the lift bracket middle roller and the lower roller, and the mast rollers have the same standard value for clearances between the rollers and the masts.
2) 1) 3
6
2
1 2)
4
1) 7
3 5
1. 2. 3. 4. 5.
Outer mast Inner mast Shim (a) Lift bracket lower roller Lift bracket
Item
Standard value
1)
Clearance between main roller rolling face and mast
2)
Clearance between main roller side face and mast
1 mm (0.04 in.) or less 0.1 to 0.5 mm (0.004 to 0.02 in.)
Measuring the clearance between main roller rolling face and mast If the measured clearances do not meet the standard value given in the table below, replace the roller with a roller of the correct diameter. Note: For measurement, see 11-28 "Adjusting Mast Roller Clearance". Specifications Item
Roller size (external diameter)
11-14
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
502156 6. Mast upper side 7. Mast lower side 1) Clearance between main roller rolling face and mast 2) Clearance between main roller side face and mast
CHAPTER 11 MAST AND FORKS Installing rollers Installation of the mast rollers is exactly the same as for the lift bracket rollers. See “Installing Lift Bracket Rollers”. Measuring the clearance between main roller rolling face and mast If measured clearance is larger than the standard value, adjust the clearance by increasing the number of shims (a) and shims (b) under the roller seats. Note: For measurement, see 11-28 "Adjusting Mast Roller Clearance". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1.12 Installing Mast Strips
4
Adjusting the clearance between mast and mast strip Measure the clearance by inserting a feeler gauge between mast and mast strip. Adjust the number of shims (d) so that the clearance is within the range of 0.1 to 0.5 mm (0.004 to 0.02 in.).
1) 2
1 1. Inner mast 2. Mast strip 3. Outer mast
Item 1)
Clearance between mast and mast strip
3
4
502157
4. Shim (d) 1) Clearance between mast and mast strip
Standard value 0.1 to 0.5 mm (0.004 to 0.02 in.)
(1) If the clearance is too large, increase the number of shims (c) as required. (2) After the shim adjustment, slowly move the lift bracket up and down to check for the smooth movement.
11-15
CHAPTER 11 MAST AND FORKS 1.13 Installing Lift Cylinders (1) Install the cylinder brackets on the lift cylinders. (2) Place the lift cylinders between the outer and inner masts. (3) Install each lift cylinder in the mounting hole of the outer mast by aligning the cylinder end with the springpin.
1
502158
1. Springpin
(4) Install the lift cylinder rods on the inner mast as shown in the illustration on the right. Do not forget to install shims if they were installed. Normally shims are not installed. Note: BE SURE to tighten the set bolt securely on the cylinder rod.
3 2 4 1 502159 1. Cylinder bracket 2. Inner mast
(5) Measure the clearance after fully retracting the cylinder rods and placing the cylinders vertically. Add or remove shims (m) so that the clearance is 1.6 mm (0.063 in.) or less. If the clearance is too large, increase the number of shims (m). Normally shims are not installed. If the clearance is 3.2 mm (0.126 in.) or more, BE SURE to insert a 3.2 mm (0.126 in.) thick seat in the shim pack.
3. Set bolt 4. Shim
1 1 1) 1. Seat 2. Shim (m)
Item 1)
Clearance between cylinder bracket and seat
Standard value 1.6 mm (0.063 in.) or less
(6) After assembly, check both lift cylinders for smooth stroke movement, and adjust the stroke as required. See 11-31 "Inspecting and Adjusting Right and Left Lift Cylinder Stroke".
11-16
2
502160
1) Clearance between cylinder bracket and seat
CHAPTER 11 MAST AND FORKS 1.14 Connecting Chains Assemble each chain on the lift bracket as shown in the illustration. Installing chain on lift bracket (A40A mast) Install the chain as shown in the illustration.
5 4 1)
2 3
1 502161 4. Split pin 5. Link 1) Engraved mark
1. Lift bracket 2. Center plate (No engraved mark) 3. Link plate
R CAUTION DO NOT use a center plate without mark on the outer side. Installing chain on lift bracket (A45A to A70A masts)
6
5
(1) When installing the anchor bolt on the lift bracket, maintain a clearance of 1 to 5 mm (0.04 to 0.2 in.) between the lift bracket and the anchor bolt as shown in the illustration on the right. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2) 1) 4
3 2 7
1 7, 8
8
2
502162
1. Lift bracket 2. Anchor bolt 3. Center plate (No engraved mark) 4. Link plate (With engraved mark) 5. Split pin
6. 7. 8. 1) 2)
Link Double nut (upper) Double nut (lower) Engraved mark Clearance for lift chain when installed
R CAUTION DO NOT use a center plate without mark on the outer side. Item 2)
Clearance for lift chain when installed
Standard value
Item
Tightening torque
1 to 5 mm (0.04 to 0.2 in.)
Double nut
290 ± 29 N·m (29.57 ± 2.96 kgf·m) [213.89 ± 21.39 lbf·ft]
11-17
CHAPTER 11 MAST AND FORKS Installing chain to outer mast side
1
(1) Hold the anchor bolt with a spanner wrench, secure the bolt and secure the clip. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2 3 4 1. Anchor bolt 2. Upper nut
Item Double nut (upper and lower)
11-18
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.89 lbf·ft]
4.5C to 7.0 ton
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
3. Double nut (upper) 4. Double nut (lower)
609239
CHAPTER 11 MAST AND FORKS 1.15 Installing Hydraulic Lines General precautions -
Use care not to let abrasive dust or dirt to enter the hydraulic system during installation. Apply hydraulic oil on O-rings before installation. When assembling an elbow connector 6 (connection with straight thread and O-ring), follow the instructions in the “Installation using straight thread and O-ring” on the next page.
-
3) 2) 3 1 2 3 6
1)
2 1 4
1)
5 502165
1) 2)
Lift cylinder Return connector
Item
3)
Return hose (for Masts having 4.5 m (177.165 in.) or above lifting height)
Tightening torque
1
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
2
Nut
118 ± 11.8 N·m (12.03 ± 1.2 kgf·m) [87.03 ± 8.70 lbf·ft]
3
Nut
4
Nut
5
Nut
6
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
11-19
CHAPTER 11 MAST AND FORKS Installation using straight thread and O-ring (1) Apply grease or hydraulic oil on O-ring and O-ring seat on the housing side. (2) Turn locknut so that it moves up against the body of the fitting. Move the backup washer and O-ring up against the locknut. (3) Tighten the fitting by hand. Once O-ring is placed in the correct position of housing and the backup washer comes in contact with the surface of housing, turn it back to adjust the mounting direction. Do not loosen the body fitting more than one turn. (4) Tighten the locknut to the specified torque.
1)
1 3 5
4 6 502164
1. End of fitting body (for hose connection) 2. Fitting body 3. Locknut 4. O-ring seat
11-20
2
5. O-ring 6. Threaded portion to the housing 1) Shape varies by fitting type
CHAPTER 11 MAST AND FORKS 1.16 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck The mast rollers and strips can only be removed or installed when the inner mast is positioned lower than the outer mast. This can be achieved as follows:
1
(1) Disconnect the lift bracket assembly from the mast. (2) Lift the front side of the forklift truck by 15 to 20 cm (5.9 to 7.87 in.) and place wood blocks underneath. Keep the front side of the forklift truck off the ground in preparation to lower the inner mast with a hoist.
502166 1. Mast strip
(3) Remove the set bolts located on the top of the lift cylinders. Attach a sling on the inner mast, and lift the inner mast with a hoist to separate the lift cylinder piston rods from the inner mast.
1 4
7
5
3 7
3 6 1. 2. 3. 4.
Lift cylinder set bolt Clamp bolt Cylinder clamp part Cylinder bracket
2
502167
5. Lift cylinder 6. Mast strip 7. Shim
11-21
CHAPTER 11 MAST AND FORKS (4) Remove the lift cylinder clamp bolts, and separate the lift cylinders from the outer mast. Pull out the lift cylinders from the mounting seats at the bottom of the outer mast. Tilt the cylinder tops inward until they rest on the outer mast crossmember. Using a rope, fix the cylinders onto the crossmember. (5) Using the hoist, slowly lower the inner mast until the inner mast contacts the lift cylinders. (6) The main rollers of the inner and outer masts can now be removed. Before attempting to remove the main rollers, remove the mast strips and shims first as they tend to drop easily. (7) Adjust the number of shims for the main rollers and the mast strips as required. Note: To assemble, follow the disassembly sequence in reverse.
11-22
502168
CHAPTER 11 MAST AND FORKS 1.17 Inspection and Adjustment This section covers the inspection/adjustment that does not involve removal or disassembly. Conduct this inspection and adjustment whenever a defect is suspected.
1.18 Inspecting Forks (1) Check the forks for cracks or damage. Special attention should be given to the heel section 1) as well as all weld areas 2). Do not use a fork that has cracks. Magnetic particle inspection which features subsurface detection capability is recommended to check the root of the forks because most of the load weight rests on the root. Liquid penetration inspection is also recommended, however, it is less effective unless the paint on the inspection area is removed.
1)
2)
502169
(2) Check both forks for height 3) difference between the forktips and for any differences in shape. A slight difference between forktips may cause difficulty in inserting the forks into a pallet, which results in load imbalance. The maximum allowable difference in fork tip elevation 3) is 5 mm (0.2 in.) for pallet forks. Replace both forks when the difference in fork tip height exceeds the maximum allowable difference.
3)
502170
(3) Check fork blade thickness 4). If thickness 4) is worn down and exceeds the service limit, do not use.
4)
502171
Item Fork thickness
Standard Limit
3.5 to 4.5C ton
4.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (2 in.)
60 mm (2.4 in.)
65 mm (2.56 in.)
45 mm (1.77 in.)
51 mm (2.00 in.)
58 mm (2.28 in.)
11-23
CHAPTER 11 MAST AND FORKS 1.19 Inspecting and Adjusting Chain Tension R CAUTION -
BE SURE to turn the key switch to the OFF position before inspecting or adjusting lift chains, anchor bolts and nuts in order to prevent serious injury or death caused by a sudden movement of the mast and the lift bracket. BE SURE to place wood blocks under the forks in order to prevent serous injury or death caused by a sudden movement of the forks when they are raised.
Chain tension inspection and adjustment (1) Lower the forks to the ground. Tilt the mast FORWARD to create the slack in the chain. (2) Turn the engine OFF. (3) Loosen the lower nut. Move the upper nut upward. (4) Adjust the chain tension by turning the lower nut. (5) Park the forklift truck on a level and hard surface and place the mast in a VERTICAL position. Then lower the forks to the ground. Make sure that the lift cylinders are fully retracted. 502172
(6) Raise the forks approximately 100 mm (3.94 in.) off the ground. (7) Turn the key switch to the OFF position. (8) Place wood blocks with the height of approximately 90 mm (3.54 in.) under forks. (9) Push both chains at the midpoint between the chain wheel and the fixed chain end on the lift bracket. Make sure the tension in the right and left chains are the same. If the tension is uneven, adjust the chain tension.
3 2
1 1. Lower nut 2. Upper nut
Item
Tightening torque
3.5 to 4.0 ton Double nut (upper and lower) 4.5C to 7.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
11-24
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
3. Anchor bolt
505815
CHAPTER 11 MAST AND FORKS R CAUTION After adjustment, raise and lower the lift bracket several times. With the mast being tilted BACKWARD and fully retracted, check the position of the lift bracket lower roller. The protrusion of each lower roller must not exceed 40% of the roller diameter from the bottom of inner mast. If it exceeds 40%, elongation of chains is suspected.
2 1
1) 1. Lift bracket lower roller 2. Inner mast
502174
1) 40% or less of roller diameter
Tightening nuts after adjustment (1) Hold the anchor bolt with a spanner wrench, secure the bolt and lower the clip to the anchor. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
1.20 Checking Chain Elongation (1) Pull the chains taut by weighing a load close to the maximum load evenly on both forks. (2) Measure 20 links of chain length. If the length exceeds the limit, replace the chain with a new one.
1) 2)
505791 1) Link
Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 7.0 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
2) 20 links
11-25
CHAPTER 11 MAST AND FORKS 1.21 Adjusting Clearance Between Lift Bracket Roller and Inner Mast Measuring back-to-front clearance on lift bracket main rollers
1)
(1) Slightly lift the forks off the ground. (2) Insert a claw bar between the upper part of the lift bracket and the inner mast, push the inner mast to either side. Measure the clearance between the main roller and the inner mast on the opposite side with a feeler gauge. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-10 "Assembly Sequence of Lift Bracket Roller". Item 1)
1)
502176
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on lift bracket main rollers and side rollers
R CAUTION Place wood blocks under the lift bracket to prevent it from falling. (1) Raise the lift bracket to the inner mast uppermost position. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go over to the opposite side of the mast, and slide the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a claw bar between the inner mast and lift bracket on the dial indicator side, and push the lift bracket to the opposite side. 502177
(5) Measure the clearance between the lift bracket middle roller and the thrust plate. Adjust the number of shims as required. Note: The upper rollers do not require any measurement and adjustment.
1
1 1)
For adjustment, see 11-10 "Adjusting Lift Bracket Clearance".
2
2
502178 1. Upper roller
Item 1)
11-26
Clearance between middle roller side face and inner mast thrust plate
2. Thrust plate
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
CHAPTER 11 MAST AND FORKS (6) Lower the lift bracket slightly from the top so that the side roller comes in contact with the inner mast. Measure the clearance between the side roller and the inner mast. Adjust the number of shims as required. For adjustment, see “Installing Lift Bracket Rollers” .
2) 1
1
502179 1. Side roller
Item 2)
Clearance between side roller rolling face and inner mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
(7) Raise the lift bracket to the top of the inner mast, and measure the clearance between the lower roller and inner mast. Adjust the number of shims as required. For adjustment, see “Installing Lift Bracket Rollers”.
1 3)
502180
1. Lower roller
Item 3)
Clearance between lower roller side face and inner mast thrust face
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-27
CHAPTER 11 MAST AND FORKS 1.22 Adjusting Mast Roller Clearance Measuring back-to-front clearance on mast main rollers (1) Tilt the mast fully BACKWARD. (2) Measure the clearance between the inner mast lower roller and the outer mast's rolling contact face. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-14 "Installing Outer/Inner Mast Rollers".
1)
502181
Item 1)
Standard value
Clearance between main roller rolling face and mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on inner mast main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the inner mast to prevent it from falling. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the inner mast roller against the outer mast's rolling surface. Then go over to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502182
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-14 "Installing Outer/Inner Mast Rollers".
1) Item 1)
11-28
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502183
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on outer mast main rollers (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the outer main roller against the inner mast's rolling surface. Then go to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502184
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-14 "Installing Outer/Inner Mast Rollers".
1)
502185
Item 1)
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-29
CHAPTER 11 MAST AND FORKS 1.23 Inspecting and Adjusting Mast Strip Clearance (1) Measure the clearance with the clearance between the outer mast rollers and the inner mast rolling face adjusted to 0 mm (0 in.) at the maximum lift position. (2) If mast strip clearance deviates from the specified value, adjust the clearance with shims. For adjustment, see 11-15 "Installing Mast Strips".
1)
502186
Item 1)
Standard value
Clearance between mast and mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
(3) After all clearances are adjusted, move the mast and lift bracket slowly, and check whether the full stroke movement is smooth.
1.24 Adjusting Mast Tilt Angle (1) Adjust the tire air pressure and park the forklift truck on a level and hard surface. (2) Tilt the mast fully backward and turn the engine OFF. (3) Measure the BACKWARD tilt angle of the right and left masts. (4) Adjust the cylinder stroke by loosening the tilt cylinder socket bolt 1 and then turn the tilt cylinder rod so that the backward tilt angle of the mast on each side is the same. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Slowly tilt the mast BACKWARD, and adjust the rod so that both cylinders simultaneously move into their stroke end positions. Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Standard tilt angle
5 ° to 10 °
6 ° to 10 °
1 505772 1. Socket bolt
(5) After tilt angle adjustment, tighten the tilt cylinder socket bolts to the specified torque. Item
Tightening torque
Tilt cylinder socket bolt
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
11-30
CHAPTER 11 MAST AND FORKS 1.25 Inspecting and Adjusting Right and Left Lift Cylinder Stroke Inspection (1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. (2) If the top of the inner mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and shaking of the rod with a longer cylinder stroke. 502188
Adjustment (1) Raise the inner mast, place wood blocks under the right and left sides of the inner mast, and lower the mast until it rests on the wood blocks. (2) Remove the set bolt at the top of lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of piston rod end. Note: When retracting the piston rod, push the lift lever to lowering direction to release the hydraulic oil from the cylinders. 501408
(3) Extend the piston rod, and tighten the lift cylinder set bolt. Remove the wood blocks under the inner mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the inner mast to the bottom. Also check that the left and right lift cylinders come to the end of stroke simultaneously at the maximum lift position of the inner mast.
1
505773 1. Shim
11-31
CHAPTER 11 MAST AND FORKS 1.26 Troubleshooting Condition
Possible cause
Action
Clearance between lift rollers and side rollers is incorrect
Adjust forward/backward and right/ left clearances
Defective roller rotation
Lubricate side rollers and replace other rollers
Incorrect clearance on mast strip
Adjust using shims
Excessive clearance on side roller
Increase shim stack thickness
Uneven tension between chains on right and left side
Adjust chain tension
Shim adjustments are unequal between left and right lift cylinders (at the maximum height)
Adjust shim stack thickness
Defective roller rotation
Adjust or replace rollers after inspection
Lift cylinder packing is damaged
Replace
Sliding (inside) surface of lift cylinder tube is damaged
Replace
Whole mast shakes
Mast support bushing is worn out
Retighten or replace bushing
Mast is distorted
Off-center load or overload
Replace mast assembly
Lift bracket and inner mast do not move smoothly
Lift bracket or inner mast is tilted
Mast makes noise Drift (natural descent) of lift cylinders
Distortion of finger bar Forktips are different in height
Distortion of forks Uneven loading
11-32
Repair or replace
CHAPTER 11 MAST AND FORKS 1.27 Service Data Item
3.5 to 4.0 ton
6.0C to 7.0 ton
Standard
508 mm (20.00 in.)
635 mm (25.00 in.)
Limit
523 mm (20.59 in.)
654 mm (25.75 in.)
S
Standard
117 mm (4.60 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
Standard
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
Standard
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
Standard
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
Chain length (20 links)
Main roller outside diameter
4.5C to 5.5 ton
Side roller external diameter
Standard
52 mm (2.05 in.)
58 mm (2.28 in.)
680 mm(26.77 in.)
800 mm (31.50 in.)
1
Width of outer mast
Standard
2
Width of inner mast
Standard
566 mm (22.28 in.) 556 mm (21.89 in.) 662 mm (20.06 in.)
3
Width of lift bracket
Standard
434 mm (17.09 in.) 422 mm (16.61 in.) 510 mm (20.08 in.)
4
Clearance between main roller rolling face and mast
Standard
1 mm (0.04 in.) or less
5
Clearance between main roller side face and mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
6
Clearance between mast and Standard mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
4
Clearance between main roller rolling face and inner mast
Standard
1 mm (0.04 in.) or less
5
Clearance between middle roller side face and inner mast thrust plate
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
5
Clearance between lower roller side face and inner mast thrust face
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
7
Clearance between side roller rolling face and inner mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
Distortion of finger bar
Standard
5 mm (0.2 in.) or less
Mast support bolt
Tightening torque
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
Tilt cylinder socket bolt
Tightening torque
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
Lift chain nut
Tightening torque
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
Simplex mast size (reference)
Mast
Lift bracket
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
11-33
CHAPTER 11 MAST AND FORKS
4
6
5
5 4
7
4 5
5
2 3
1 502190
Note: The mast is slightly wider at the lower side than at the upper side. Always measure the clearance at the upper side of the mast.
11-34
CHAPTER 11 MAST AND FORKS
2.
Duplex Mast
2.1
Mast System
The following table shows a combination of forklift truck and mast models,: Lift Truck models
Mast
3.5 to 4.0 ton
B40A cc
4.5C ton
B45A cc
4.5 to 5.5 ton
B55A cc
Note: cc represents maximum lift height. Example: 30 = 3,000 mm (157.5 in.) lift height Mast type and code Code
Mast
B
Duplex mast
Mast serial number location
505775
How to read mast model code
B
40
A
30 4 3 2 1 505776
1. 2.
Indicates the mast type Applicable truck class (Example: 4.0 ton)
3. 4.
Mast generation (A6B6C···Z) Maximum lifting height (30: 3000 mm [118.11 in.])
11-35
CHAPTER 11 MAST AND FORKS 2.2
Structure and Functions C
C
5 2 1 6 4 7 B
A
14
15
Section A-A
1)
3
B
13
8
A
12 10
Section B-B
Section C-C
2)
3)
1. Outer mast 2. Inner mast 3. Lift bracket 4. First lift cylinder (single) 5. Second lift cylinder 6. Lift chain 7. Load backrest extension 8. Forks 9. Side roller 10. Mast strip Note: For hydraulic lines, see 11-55 "Installing Hydraulic Lines".
11-36
11
3 11. 12. 13. 14. 15. 1) 2) 3) 4)
9 Side roller detail 4)
Lift bracket upper roller Outer mast main roller Lift bracket middle roller Lift bracket lower roller Inner mast main roller Detail of lift bracket lower rollers Detail of lift bracket middle rollers Detail of outer mast main rollers Detail of side roller
505777
CHAPTER 11 MAST AND FORKS On the duplex mast, the first cylinder raises the forks without increasing the overall mast height (free-lift) until the upper edge of the load backrest extension exceeds the top of the mast. The mast assembly consists of inner mast, outer mast, lift bracket, first lift cylinder, and second lift cylinder. The first lift cylinder raises the lift bracket, while the second cylinders raise the inner mast. The first lift cylinder is the internal drain type, and the second lift cylinder is equipped with cushion mechanism. For mast operation, see 11-37 "Mast operation". Mast operation The first lift cylinder extends to raise the forks to the maximum free-lift height. When the first lift cylinder rod is fully extended, the second lift cylinders take over the role to bring the inner mast to the maximum lift height. The mast lowering mechanism is the reverse of lifting. See “HYDRAULIC SYSTEM”. Maximum free lift Maximum free lift means the maximum elevation of the forks without raising the mast.
2 4 1 3 5
4)
1) 1. 2. 3. 4. 5.
First lift cylinder Lift chain Second lift cylinder Inner mast Outer mast
2) 1) 2) 3) 4)
3)
502196
Forks on the ground Maximum free lift Maximum lift Free lift height
11-37
CHAPTER 11 MAST AND FORKS 2.3
Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the forklift truck, see 11-57 "Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck" .
8 1 2 1
5
6
7 1 1. 2. 3. 4.
505778
Chain guard, Bolt, Plug Clip Double nut Load backrest extension, Lift bracket, Forks
2.4
5. 6. 7. 8.
High-pressure hose Tilt socket pin Mast support cap, Bushing Inner mast, Outer mast, Lift cylinder
Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly (1) Lower the lift bracket, and place wood blocks under the lift bracket assembly. Tilt the mast FORWARD and lower the inner mast to the bottom to create slack in the lift chains. Then remove upper nut 2 and double nuts 3 from the lift chains. (2) Tilt the mast BACKWARD to the VERTICAL position and lift the inner mast until the lift bracket becomes free. Then, slowly move the forklift truck away from the lift bracket. Note: Before overhauling the mast assembly, BE SURE to measure the clearance between the mast and the rollers. This helps to improve work efficiency by understanding which roller is to be replaced or the necessity of shim adjustment. See 11-63 "Adjusting Mast Roller Clearance".
2
3 505779
R CAUTION After the lift bracket is removed from the forklift truck, place wood blocks under the lift bracket to prevent it from falling down.
11-38
CHAPTER 11 MAST AND FORKS Disconnecting lift cylinder high-pressure hoses Lower the mast to the bottom, and then disconnect hose at the location indicated by the arrow.
505780
Separating tilt cylinders (1) Attach a sling on the rings on the crossmember at the top of the outer mast, then lift the outer mast with a hoist.
505781
R CAUTION When removing and installing the mast assembly with a hoist, BE SURE to use a hoist with enough lift capacity. (2) Place wood blocks under the tilt cylinder mounting section and remove the tilt socket pins, and separate the mast from the tilt cylinders. (3) Start the engine, and pull back on the tilt lever to retract the tilt cylinder rods.
505782
R CAUTION -
DO NOT touch any levers except the tilt lever while the engine is running. DO NOT loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps (1) Put a matchmark on each cap. (2) Remove cap mounting bolts from the mast and disconnect the mast assembly from the lift truck by hoisting. Lay the mast assembly horizontally on a level and hard surface with the lift bracket side facing up. Note: Lay the mast assembly in a space large enough for disassembly work.
1) 505783 1) Matchmark
11-39
CHAPTER 11 MAST AND FORKS 2.5
Suggestions for Installing Mast and Lift Bracket Assembly
For installation, follow the removal sequence in reverse and observe the instructions below: Mast support (1) Apply a thick coat of grease on the inner surface of the caps and the mast support bushings. (2) Install the mast supports in the same direction as they were removed. (3) For greasing, place wood blocks under the mast so that the mast is off the ground. (4) Tighten the mast support bolts to the specified torque.
1 2
1) 2) 1. Bushing 2. Cap
Item Mast support bolt
505774
1) Bushing internal view 2) Cap internal view
Tightening torque 290 N·m (29.57 kgf·m) [213.89 lbf·ft]
Adjusting chain tension For chain tension adjustment, see 11-59 "Inspecting and Adjusting Chain Tension". Bleeding lift cylinders The duplex mast, unlike the other masts, has air bleeding plugs at the top of the second lift cylinders. Move the lift bracket up and down several times to bleed air trapped in the piston end of the lift cylinder. After the proper operation of the forklift truck is confirmed, check the oil level in the hydraulic tank.
1
1 502201 1. Air bleeding plug
11-40
CHAPTER 11 MAST AND FORKS 2.6
Removal Sequence of Mast and Lift Bracket
14 15
13 12
5
18
A
2
16
6 7
9
2
11 19
11
A
3
7 B
4
22 9
18 B
C
8
10
22
3
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
11
1 17 CA
21 20
14
18
13
Hose clamps, Bolts, Washers High-pressure hose, pipe (First lift cylinder) Bolt, Washer, Shim First lift cylinder Chain guard, Bolt Chain wheels, Snaprings Chain wheel supports, Bolts, Washers Down safety valve, O-ring High-pressure hose (Second lift cylinder), Connector Cushion, Collar, Shim, Clamp bolt, Washer, Clamp Set bolt, Washer, Shim
16
505784
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Mast strip, Shims Stopper, Shim, Bolt, Washer Main rollers, Shims Inner mast Second lift cylinder Down safety valve, O-ring Elbow, O-ring Cylinder bracket Mast cap, Bolt, Washer Bushing Outer mast, Grease nipple
Note: The lift bracket disassembly procedure is the same as that of the simplex mast.
2.7
Preparation for Disassembling Mast and Lift Bracket
Lay the mast assembly horizontally on wood blocks with the lift bracket side facing up. Place a wood block as a wedge to prevent the inner mast from sliding. Before disassembly, measure and record all clearances between each of the rollers and the lift bracket and between the main rollers and the mast. Recorded measurements will be helpful when replacing rollers or selecting shims to adjust clearances.
11-41
CHAPTER 11 MAST AND FORKS 2.8
Suggestions for Disassembling Mast and Lift Bracket
Removing first lift cylinders (1) Remove the first lift cylinder 4 mounting bolt 3. (2) Tie two slings securely to the first lift cylinder 4, and gently lift the cylinder.
3 505785
Removing main rollers and mast strips (1) Remove the clamp bolts from the second lift cylinders. (2) Remove the set bolts from the top of the second lift cylinder rods. Then place the cylinder rod ends on the outer mast. (3) Count and record the number and thickness of shims that were installed at the top of cylinder rods. (4) Lower the inner mast, then remove mast strips 12 and main rollers 14.
12
14 14 505786
Removing inner mast Attach a sling on the inner mast 15 and gently pull out the inner mast from the outer mast 22 by clearing the outer mast roller shafts.
22
11-42
15
505787
CHAPTER 11 MAST AND FORKS 2.9
Inspecting Mast and Lift Bracket
Mast (1) Check each roller for binding, wear, and cracks. (2) Check each roller on rolling surface for pitting or other defects. (3) Make sure that rollers rotate smoothly on the rolling face. (4) Check welded joints of mast member, crossmembers, shafts, supports, and tilt brackets for cracks. (5) Check the mast support bushings for wear or other defects. 502206
Lift bracket (1) Check the main rollers and side rollers for binding, wear, and cracks. (2) Check the welded areas of lift bracket for cracks. (3) Check the finger bar for bend or distortion.
1
502150
1. Straightedge
Item Distortion of finger bar
Standard value 5 mm (0.20 in.) or less
Lift chains, chain wheels and chain wheel supports (1) Measure the length of each chain to make sure that the two chains are equal in length. Also check the chains for wear, indication of breakage, link binding, and twisting. (2) Check each chain anchor bolt for cracks or thread damage. (3) Check the chain wheel support and the chain wheel for cracks, wear, and binding. (4) Measure chain length to check for elongation. See “Measuring Chain Elongation”. Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 5.5 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
Mast strip Check for damage, scoring or distortion. See “HYDRAULIC SYSTEM”.
11-43
CHAPTER 11 MAST AND FORKS 2.10 Assembly Sequence of Lift Bracket Roller
1
2
1
6 1)
6)
2
1)
1
9)
3 6
8)
8)
2)
10) 5)
5)
5 3 6)
6 1)
1
3)
4
1
5
5) 4)
6) 5) 1. 2. 3. 4. 5. 6.
4
Lift bracket Lift bracket upper roller Lift bracket middle roller Lift bracket lower roller Side roller Inner mast
11-44
7)
6) 1)
505770
Clearance between main roller rolling face and mast 2) Clearance between middle roller side face and mast thrust plate 3) Clearance between lower roller side face and mast thrust face 4) Clearance between side roller rolling face and mast 5) Shim (a) 6) Shim (b) 7) Shim (c) 8) Thrust plate 9) No shim required 10) Minimum clearance
inner inner inner inner
CHAPTER 11 MAST AND FORKS 2.11 Adjusting Lift Bracket Clearance The lift bracket has three main roller bearings on one side and side rollers on both sides as shown in the illustration. The clearances are necessary so that the lift bracket can move up and down smoothly along the inner mast. Clearances between middle roller side face and thrust plate and between lower roller side face and inner mast The clearance between the side roller face and the inner mast thrust face (right-to-left clearance): Clearance 2) is used to determine the correct amount of shims at the bearing seat. Move the lift bracket to the top of the inner mast and slide the lift bracket to either the left-most or the right-most position. Measure the clearance 2) between the roller side face and the inner mast thrust face on the opposite side. Note: Shim adjustment for clearance 2) is not required for the lift bracket upper rollers. Adjust clearance G to the specified values with shims (a) and (b) for the middle and the lower rollers. Item
Standard value
Clearance between middle roller side face and inner mast thrust plate Clearance between lower roller side face and inner mast thrust face
0.1 to 0.5 mm (0.004 to 0.020 in.)
Clearance between main roller rolling face and inner mast Clearance between roller circumference and inner mast thrust face (back-to-front play): Clearance 1) is used for determining the proper size of the rollers. Select a roller of correct diameter so that the clearance meets the specified value. Check that the rollers rotate smoothly when installed. Item Clearance between main roller rolling face and inner mast
Standard value 1 mm (0.04 in.) or less
11-45
CHAPTER 11 MAST AND FORKS Clearance between side roller rolling face and inner mast To determine the clearance between side roller circumference and inner mast side roller thrust face: Move the side roller to the upper end of the inner mast and slide the lift bracket to either the left-most or right-most position. Measure G1 clearance between the roller circumference and inner mast on the opposite side. Adjust the number of shims (c) so that the clearance meets the specified value. Item
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
Selecting roller of correct outer diameter Measure the clearance between the upper and lower rollers' rolling faces and the mast. If the measured clearances does not meet the standard value shown in the table replace the roller with a roller of the correct diameter. Use the same sized roller for the upper and the lower rollers and use one size smaller for the middle rollers. Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". Make sure that the rollers rotate smoothly when installed. Specifications Item
Roller size (external diameter)
11-46
3.5 to 4.0 ton
4.5C to 5.5 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
CHAPTER 11 MAST AND FORKS Adjusting clearance between middle roller side face and thrust plate
1
2
Note: The following adjustment is not required for the upper rollers.
4
2)
Measure the clearance between middle roller side face and thrust plate. If the measured clearance does not meet the standard value, adjust the clearance as follows:
3)
3
Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) 1. 2. 3. 4.
Clearance between lower roller side face and inner mast thrust face
1
2)
Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast" (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1)
2
Measure the clearance between the lower roller side face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows:
502152
1) Clearance between middle roller side face and inner mast thrust plate 2) Shim (a) 3) Shim (b)
Inner mast Lift bracket Thrust plate Roller stopper
3) 502153 1. Inner mast 2. Lift bracket
1) Clearance between lower roller side face and inner mast thrust face 2) Shim (a) 3) Shim (b)
11-47
CHAPTER 11 MAST AND FORKS Installing rollers To install main rollers on shafts, use a driving tool, and be careful not to strike the outer roller surface with the driving tool. The side of the roller with larger chamfering must face toward the outside. Make sure the rollers rotate smoothly when installed.
502154
Adjusting the clearance between side roller rolling face and inner mast
3
1
2
Measure the clearance between side roller rolling face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows: Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
4 1)
(1) If the clearance is too large, increase the number of shims (c) as required. Shim (c) is available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.)
2) 1. 2. 3. 4.
11-48
Side roller Inner mast Lift bracket Roller mounting bolt
505788 1) Clearance between side roller rolling face and inner mast 2) Shim (c)
CHAPTER 11 MAST AND FORKS 2.12 Installing Outer/Inner Mast Rollers Mast rollers have the same shape and size as the lift bracket middle roller and the lower roller, and the mast rollers have the same standard value for clearances between the rollers and the masts.
2) 1) 3
6
2
1 2)
4
1) 7
3 5
1. 2. 3. 4. 5.
Outer mast Inner mast Shim (a) Lift bracket lower roller Lift bracket
Item
502156 6. Mast upper side 7. Mast lower side 1) Clearance between main roller rolling face and mast 2) Clearance between main roller side face and mast
Standard value
1)
Clearance between main roller rolling face and mast
2)
Clearance between main roller side face and mast
1 mm (0.04 in.) or less 0.1 to 0.5 mm (0.004 to 0.020 in.)
Measuring the clearance between main roller rolling face and mast If the measured clearances does not meet the standard value given in the table below, replace the roller with a roller of the correct diameter. Note: For measurement, see 11-63 "Adjusting Mast Roller Clearance". Specifications Item
Roller size (external diameter)
3.5 to 4.0 ton
4.5C to 5.5 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
11-49
CHAPTER 11 MAST AND FORKS Installing rollers Installation of the mast rollers is exactly the same as for the lift bracket rollers. See 11-44 "Assembly Sequence of Lift Bracket Roller". Measuring the clearance between main roller rolling face and mast If measured clearance is larger than the standard value, adjust the clearance by increasing the number of shims (a) and shims (b) under the roller seats. Note: For measurement, see 11-63 "Adjusting Mast Roller Clearance". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
2.13 Installing Mast Strips
4
Adjusting the clearance between mast and mast strip Measure the clearance by inserting a feeler gauge between mast and mast strip. Adjust the number of shims (d) so that the clearance is within the range of 0.1 to 0.5 mm (0.004 to 0.02 in.).
1) 2
1 1. Inner mast 2. Mast strip 3. Outer mast
Item 1)
Clearance between mast and mast strip
Standard value 0.1 to 0.5 mm (0.004 to 0.02 in.)
(1) If the clearance is too large, increase the number of shims (c) as required. (2) After the shim adjustment, slowly move the lift bracket up and down to check for the smooth movement.
11-50
3
4
502157
4. Shim (d) 1) Clearance between mast and mast strip
CHAPTER 11 MAST AND FORKS 2.14 Installing Second Lift Cylinder (1) Install the cylinder brackets to the second lift cylinders. (2) Install the second lift cylinder between the outer and inner masts. (3) Install each lift cylinder to the mounting hole of the outer mast by aligning the cylinder end with the springpin. (4) Install the lift cylinder rods to the inner mast as shown in the illustration on the right. Do not forget to install shims if they were installed. Normally shims are not installed. Note: BE SURE to tighten the set bolt securely to the cylinder rod.
3 2 4
1 502207 1. Cylinder bracket 2. Inner mast
(5) Measure the clearance after fully retracting the cylinder rods and placing the cylinders vertically. Add or remove shims (m) so that the clearance is 1.6 mm (0.06 in.) or less. If the clearance is too large, increase the number of shims (m). Normally shims are not installed. If the clearance is 3.2 mm (0.13 in.) or more, BE SURE to insert a 3.2 mm (0.13 in.) thick seat in the shim pack.
3. Set bolt 4. Shim
1 1 1) 1. Seat 2. Shim (m)
Item 1)
Clearance between cylinder bracket and seat
2
502208
1) Clearance between cylinder bracket and seat
Standard value 1.6 mm (0.063 in.) or less
(6) After assembly, check both lift cylinders for smooth stroke movement, and adjust the stroke as required. See 11-66 "Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke".
11-51
CHAPTER 11 MAST AND FORKS 2.15 Installing First Lift Cylinder (1) With the mast positioned vertically and fully lowered, temporarily install the first lift cylinder to the inner mast with the original shims and mounting bolts. (2) Position the first lift cylinder vertically and measure the clearance between the cylinder brackets and the cylinder mounts on the inner mast. If there is clearance, remove the clearance by adding shims. - To check whether both sides of the cylinder (right-toleft) are vertical against each other, measure to check if the cylinder is parallel to the side face of the inner mast. The parallel difference at the top and the bottom should be plus or minus 1 mm (0.04 in.) - To check whether both sides of the cylinder (front-toback) are vertical against each other, visually check if the cylinder is parallel to the front face of the inner mast. The cylinder should not be inclined FORWARD, not even slightly. The cylinder slightly inclined BACKWARD is acceptable. - Thickness of each adjusting shim is 1 mm (0.04 in.). (3) After shim adjustment, tighten the mounting bolts.
3
2 1 502209 1. First lift cylinder 2. Shim (n)
Item
Tightening torque
First lift cylinder mounting bolt
233 ± 47 N·m (23.76 ± 4.79 kgf·m) [171.85 ± 34.66 lbf·ft]
11-52
3. Mounting bolt
CHAPTER 11 MAST AND FORKS 2.16 Connecting Chains Assemble each chain to the lift bracket as shown in the illustration.
4 5 1) 3
2 1
1. Anchor bolt 2. Center plate (No engraved mark) 3. Link plate
502210
4. Link 5. Split pin 1) Engraved mark
R CAUTION DO NOT use a center plate without mark on the outer side. Installing chain to lift bracket
1 3 4
2 502211 1. Chain 2. Lift bracket
Item
Tightening torque
3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
4.5C to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
Locknut 4.5C to 5.5 ton (double nut side)
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
Locknut (single nut side)
3. Locknut (single nut side) 4. Locknut (double nut side)
11-53
CHAPTER 11 MAST AND FORKS Installing on first lift cylinder side (1) Hold the anchor bolt with a spanner wrench, secure the bolt. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2 3 4 1 1. Anchor bolt 2. Nut
Item Double nut (upper and lower)
11-54
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
4.5C to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
3. Double nut (upper) 4. Double nut (lower)
505818
CHAPTER 11 MAST AND FORKS 2.17 Installing Hydraulic Lines General precautions -
Use care not to let abrasive dust or dirt to enter the hydraulic system during installation. Apply hydraulic oil on O-rings before installation. When assembling an elbow connector 6 (connection with straight thread and O-ring), follow the instructions in the “Installation using straight thread and O-ring” on the next page.
-
9 7 8
2)
5 2
1 A
6
1) B
A
B
1)
8 1) 2)
First lift cylinder Second lift cylinder Item 1
Nut
2
Nut
3
Nut
4
Nut
5
Nut
6
Nut
7
Nut
8
Nut
9
Nut
2)
3
4 3)
505790
Down safety valve
Tightening torque 118 ± 11.8 N·m (12.03 ± 1.2 kgf·m) [87.03 ± 8.70 lbf·ft]
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
11-55
CHAPTER 11 MAST AND FORKS Installation using straight thread and O-ring (1) Apply grease or hydraulic oil on O-ring and O-ring seat on the housing side. (2) Turn locknut so that it moves up against the body of the fitting. Move the backup washer and O-ring up against the locknut. (3) Tighten the fitting by hand. Once O-ring is placed in the correct position of housing and the backup washer comes in contact with the surface of housing, turn it back to adjust the mounting direction. Do not loosen the body fitting more than one turn. (4) Tighten the locknut to the specified torque.
1)
1 3 5
4 6 502164
1. End of fitting body (for hose connection) 2. Fitting body 3. Locknut 4. O-ring seat
11-56
2
5. O-ring 6. Threaded portion to the housing 1) Shape varies by fitting type
CHAPTER 11 MAST AND FORKS 2.18 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck Preparation (1) Disconnect the lift bracket assembly from the mast. (2) Disconnect the pipes from the first and the second lift cylinders. Removing first lift cylinders (1) Attach a sling on the first lift cylinder, and suspend it with a hoist.Tie the sling securely to the first lift cylinder to prevent the cylinder from slipping. (2) Remove the mounting bolts and slowly remove the first lift cylinder using a hoist.
502214
Place the inner mast lower than the outer mast.
1
(1) Lift the front side of the forklift truck by 15 to 20 cm (5.9 to 7.87 in.) and place wood blocks underneath. Keep the front side of the forklift truck off the ground in preparation to lower the inner mast with a hoist. (2) Remove the set bolts located on the top of the second lift cylinders. Attach a sling on the inner mast, and lift the inner mast with a hoist to separate the second lift cylinder piston rods from the inner mast.
502166 1. Mast strip
(3) Attach a sling on the inner mast, and lift the inner mast with a hoist to separate the second lift cylinder piston rods from the inner mast. Pull out the second lift cylinders from the mounting seats at the bottom of the outer mast. Tilt the cylinder tops inward until they rest on the outer mast crossmember. Using a rope, fix the cylinders onto the crossmember. (4) Using the hoist, slowly lower the inner mast until the inner mast contacts the second lift cylinders. (5) The main rollers of the inner and outer masts can now be removed. Before attempting to remove the main rollers, remove the mast strips and shims first as they tend to drop easily. (6) Adjust the number of shims for the main rollers and the mast strips as required. Note: To assemble, follow the disassembly sequence in reverse.
502168
11-57
CHAPTER 11 MAST AND FORKS 2.19 Inspection and Adjustment This section covers the inspection/adjustment that does not involve removal or disassembly. Conduct this inspection and adjustment whenever a defect is suspected.
2.20 Inspecting Forks (1) Check the forks for cracks or damage. Special attention should be given to the heel section 1) as well as all weld areas 2). Do not use a fork that has cracks. Magnetic particle inspection which features subsurface detection capability is recommended to check the root of the forks because most of the load weight rests on the root. Liquid penetration inspection is also recommended, however, it is less effective unless the paint on the inspection area is removed.
1)
2)
502169
(2) Check both forks for height 3) difference between the forktips and for any differences in shape. A slight difference between forktips may cause difficulty in inserting the forks into a pallet, which results in load imbalance. The maximum allowable difference in fork tip elevation 3) is 5 mm (0.2 in.) for pallet forks. Replace both forks when the difference in forktip height exceeds the maximum allowable difference.
3)
502170
(3) Check fork blade thickness 4). If thickness 4) is worn down and exceeds the service limit, do not use.
4)
502171
Item Fork thickness
11-58
Standard Limit
3.5 to 4.5C ton
4.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (2 in.)
60 mm (2.4 in.)
65 mm (2.56 in.)
45 mm (1.77 in.)
51 mm (2.00 in.)
58 mm (2.28 in.)
CHAPTER 11 MAST AND FORKS 2.21 Inspecting and Adjusting Chain Tension R CAUTION -
BE SURE to turn the key switch to the OFF position before inspecting or adjusting lift chains, anchor bolts and nuts in order to prevent serious injury or death caused by a sudden movement of the mast and the lift bracket. BE SURE to place wood blocks under the forks in order to prevent serous injury or death caused by a sudden movement of the forks when they are raised.
Chain tension inspection and adjustment (1) Lower the forks to the ground. Tilt the mast FORWARD to create the slack in the chain. (2) Turn the engine OFF. (3) Loosen the lower nut. Move the upper nut upward. (4) Adjust the chain tension by turning the lower nut. (5) Park the forklift truck on a level and hard surface and place the mast in a VERTICAL position. Then lower the forks to the ground. Make sure that the lift cylinders are fully retracted. 502215
(6) Raise the forks approximately 100 mm (3.94 in.) off the ground. (7) Turn the key switch to the OFF position. (8) Place wood blocks with the height of approximately 90 mm (3.54 in.) under forks. (9) Push both chains at the midpoint between the chain wheel and the fixed chain end on the lift bracket. Make sure the tension in the right and left chains are the same. If the tension is uneven, adjust the chain tension.
2 1
3 1. Lower nut 2. Upper nut
Item Double nut (upper and lower)
505789
3. Anchor bolt
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
4.5C to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
11-59
CHAPTER 11 MAST AND FORKS R CAUTION After adjustment, raise and lower the lift bracket several times. With the mast being tilted BACKWARD and fully retracted, check the position of the lift bracket lower roller. The protrusion of each lower roller must not exceed 40% of the roller diameter from the bottom of inner mast. If it exceeds 40%, elongation of chains is suspected.
2 1
1) 1. Lift bracket lower roller 2. Inner mast
502174
1) 40% or less of roller diameter
Tightening nuts after adjustment (1) Hold the anchor bolt with a spanner wrench, secure the bolt and lower the clip to the anchor. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2.22 Checking Chain Elongation (1) Pull the chains taut by weighing a load close to the maximum load evenly on both forks. (2) Measure 20 links of chain length. If the length exceeds the limit, replace the chain with a new one.
1) 2)
505791 1) Link
Item Chain length (20 links)
11-60
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 5.5 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
2) 20 links
CHAPTER 11 MAST AND FORKS 2.23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast Measuring back-to-front clearance on lift bracket main rollers
1)
(1) Slightly lift the forks off the ground. (2) Insert a claw bar between the upper part of the lift bracket and the inner mast, push the inner mast to either side. Measure the clearance between the main roller and the inner mast on the opposite side with a feeler gauge. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-44 "Assembly Sequence of Lift Bracket Roller". Item 1)
1)
502176
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on lift bracket main rollers and side rollers
R CAUTION Place wood blocks under the lift bracket to prevent it from falling. (1) Raise the lift bracket to the inner mast uppermost position. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go over to the opposite side of the mast, and slide the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a claw bar between the inner mast and lift bracket on the dial indicator side, and push the lift bracket to the opposite side. 502177
11-61
CHAPTER 11 MAST AND FORKS (5) Measure the clearance between the lift bracket middle roller and the thrust plate. Adjust the number of shims as required. Note: The upper rollers do not require any measurement and adjustment.
1
1 1)
For adjustment, see 11-45 "Adjusting Lift Bracket Clearance".
2
2
502178 1. Upper roller
2. Thrust plate
Item 1)
Standard value
Clearance between middle roller side face and inner mast thrust plate
0.1 to 0.5 mm (0.004 to 0.020 in.)
(6) Lower the lift bracket slightly from the top so that the side roller comes in contact with the inner mast. Measure the clearance between the side roller and the inner mast. Adjust the number of shims as required. For adjustment, see 11-45 "Adjusting Lift Bracket Clearance".
2) 1
1
502179 1. Side roller
Item 2)
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
(7) Raise the lift bracket to the top of the inner mast, and measure the clearance between the lower roller and inner mast. Adjust the number of shims as required. For adjustment, see 11-45 "Adjusting Lift Bracket Clearance".
1 3) 1. Lower roller
Item 3)
11-62
Clearance between lower roller side face and inner mast thrust face
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502180
CHAPTER 11 MAST AND FORKS 2.24 Adjusting Mast Roller Clearance Measuring back-to-front clearance on mast main rollers (1) Tilt the mast fully BACKWARD. (2) Measure the clearance between the inner mast lower roller and the outer mast's rolling contact face. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-49 "Installing Outer/Inner Mast Rollers".
1)
502181
Item 1)
Standard value
Clearance between main roller rolling face and mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on inner mast main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the inner mast to prevent it from falling. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the inner mast roller against the outer mast's rolling surface. Then go over to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502182
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-49 "Installing Outer/Inner Mast Rollers".
1) Item 1)
Clearance between main roller side face and mast
502183
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-63
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on outer mast main rollers
R CAUTION Place wood blocks under the outer mast to prevent it from falling. (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the outer main roller against the inner mast's rolling surface. Then go over to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502184
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-49 "Installing Outer/Inner Mast Rollers".
1)
502185
Item 1)
11-64
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
CHAPTER 11 MAST AND FORKS 2.25 Inspecting and Adjusting Mast Strip Clearance (1) Measure the clearance with the clearance between the outer mast rollers and the inner mast rolling face adjusted to 0 mm (0 in.) at the maximum lift position. (2) If mast strip clearance deviates from the specified value, adjust the clearance with shims. For adjustment, see 11-50 "Installing Mast Strips".
1)
502186
Item 1)
Standard value
Clearance between mast and mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
(3) After all clearances are adjusted, move the mast and lift bracket slowly, and check whether the full stroke movement is smooth.
2.26 Adjusting Mast Tilt Angle (1) Adjust the tire air pressure and park the forklift truck on a level and hard surface. (2) Tilt the mast fully BACKWARD and turn the engine OFF. (3) Measure the backward tilt angle of the right and left masts. (4) Adjust the cylinder stroke by loosening the tilt cylinder socket bolt 1 and then turn the tilt cylinder rod so that the backward tilt angle of the mast on each side is the same. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Slowly tilt the mast BACKWARD, and adjust the rod so that both cylinders simultaneously move into their stroke end positions.
Item
1 505772 1. Socket bolt
Forward tilt angle Backward tilt angle
Standard tilt angle
5°
10 °
(5) After tilt angle adjustment, tighten the tilt cylinder socket bolts to the specified torque. Item
Tightening torque
Tilt cylinder socket bolt
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
11-65
CHAPTER 11 MAST AND FORKS 2.27 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke Inspection (1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. (2) If the top of the inner mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and shaking of the rod with a longer second lift cylinder stroke. 502216
Adjustment (1) Raise the inner mast, place wood blocks under the right and left sides of the inner mast, and lower the mast until it rests on the wood blocks. (2) Remove the set bolt at the top of second lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of piston rod end. Note: When retracting the piston rod, push the lift lever to lowering direction to release the hydraulic oil from the second lift cylinders. 501408
(3) Raise the piston rod, and tighten the second lift cylinder set bolt. Remove the wood blocks under the inner mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the inner mast to the bottom. Also check that the left and right lift cylinders come to the end of stroke simultaneously at the maximum lift position of the inner mast.
1 2 4
3 502217 1. Set bolt 2. Inner mast
11-66
3. Cylinder bracket 4. Shim
CHAPTER 11 MAST AND FORKS 2.28 Troubleshooting Condition
Possible cause
Action
Clearance between lift rollers and side rollers is incorrect
Adjust forward/backward and right/ left clearances
Defective roller rotation
Lubricate side rollers and replace other rollers
Incorrect clearance on mast strip
Adjust using shims
Excessive clearance on side roller
Increase shim stack thickness
Uneven tension between chains on right and left side
Adjust chain tension
Shim adjustments are unequal between left and right lift cylinders (at the maximum height)
Adjust shim stack thickness
Defective roller rotation
Adjust or replace rollers after inspection
Lift cylinder packing is damaged
Replace
Sliding (inside) surface of lift cylinder tube is damaged
Replace
Whole mast shakes
Mast support bushing is worn out
Retighten or replace bushing
Mast is distorted
Off-center load or overload
Replace mast assembly
Lift bracket and inner mast do not move smoothly
Lift bracket or inner mast is tilted
Mast makes noise Drift (natural descent) of lift cylinders
Distortion of finger bar Forktips are different in height
Distortion of forks
Repair or replace
Uneven loading
11-67
CHAPTER 11 MAST AND FORKS 2.29 Service Data Item
3.5 to 4.0 ton
4.5C to 5.5 ton
Standard
508 mm (20.00 in.)
635 mm (25.00 in.)
Limit
523 mm (20.59 in.)
654 mm (25.75 in.)
S
Standard
117 mm (4.60 in.)
129 mm (5.08 in.)
M
Standard
118 mm (4.65 in.)
130 mm (5.12 in.)
L
Standard
119 mm (4.69 in.)
131 mm (5.16 in.)
LL
Standard
120 mm (4.72 in.)
132 mm (5.20 in.)
Chain length (20 links)
Main roller outside diameter
Side roller external diameter
Standard
52 mm (2.05 in.) 680 mm(26.77 in.)
1
Width of outer mast
Standard
2
Width of inner mast
Standard
566 mm (22.28 in.)
556 mm (21.89 in.)
3
Width of lift bracket
Standard
434 mm (17.09 in.)
422 mm (16.61 in.)
4
Clearance between main roller rolling face and mast
Standard
1 mm (0.04 in.) or less
5
Clearance between main roller side face and mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
6
Clearance between mast and mast strip
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
4
Clearance between main roller rolling face and inner mast
Standard
1 mm (0.04 in.) or less
5
Clearance between middle roller side Standard face and inner mast thrust plate
0.1 to 0.5 mm (0.004 to 0.020 in.)
5
Clearance between lower roller side face and inner mast thrust face
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
7
Clearance between side roller rolling face and inner mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
Distortion of finger bar
Standard
5 mm (0.2 in.) or less
Mast support bolt
Tightening torque
290 N·m (29.6 kgf·m) [213.89lbf·ft]
Tilt cylinder socket bolt
Tightening torque
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
Lift chain nut (single)
Tightening torque
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
290 N·m (29.6 kgf·m) [213.89lbf·ft]
Lift chain nut (double)
Tightening torque
-
290 N·m (29.6 kgf·m) [213.89lbf·ft]
Duplex mast size (reference)
Mast
Lift bracket
11-68
CHAPTER 11 MAST AND FORKS
4
6
5
5 4
7
4 5
5
2 3
1 502190
Note: The mast is slightly wider at the lower side than at the upper side. Always measure the clearance at the upper side of the mast.
11-69
CHAPTER 11 MAST AND FORKS
3.
Triplex Mast
3.1
Mast System
The following table shows a combination of truck and mast models. Lift Truck models
Mast
3.5 to 4.0 ton
C40A cc
4.5C ton
C45A cc
4.5 to 5.5 ton
C55A cc
6.0 to 7.0 ton
C70A cc
Note: cc represents maximum lift height. Example: 30 = 3,000 mm (157.5 in.) lift height Mast type and code Code
Mast
C
Triplex mast
Mast serial number location
505792
How to read mast model code
C
40
A
40 4 3 2 1 505793
1. 2.
Indicates the mast type Applicable truck class (example: 4.0 ton)
11-70
3. 4.
Mast generation (A6B6C···Z) Maximum lifting height (40: 4000 mm [157.48 in.])
CHAPTER 11 MAST AND FORKS 3.2
Structure and Functions C
C
6 3 2 1
7 8 5 B
A
4
B
9
A
11
15
16 17 18 Section A-A 1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
13 Section B-B 2)
Outer mast Middle mast Inner mast Lift bracket First lift cylinder Second lift cylinder Lift chain load backrest extension Forks Side roller Mast strip Lift bracket upper roller
12
14 Section C-C 3) 13. 14. 15. 16. 17. 18. 1) 2) 3) 4)
10 4
Side roller detail 4)
505794
Outer mast main roller Middle mast upper roller Lift bracket middle roller Lift bracket lower roller Inner mast main roller Middle mast lower roller Detail of lift bracket, middle mast lower rollers and inner mast main rollers Detail of lift bracket middle rollers Detail of outer mast main rollers and middle mast upper rollers Detail of side roller
Note: For hydraulic lines, see 11-89 "Installing Hydraulic Lines".
11-71
CHAPTER 11 MAST AND FORKS The triplex mast features both triple mast mechanism and full-free mast mechanism. The mast assembly consists of inner mast, middle mast, outer mast, lift bracket, first lift cylinder and second lift cylinder. The first lift cylinder raises the forks. The second cylinder extends the three-stage mast and raises the forks. The first lift cylinder is the internal drain type, and the second lift cylinder is equipped with cushion mechanism and has an internal drain. Therefore, the lift cylinder has no return hose. For mast operation, see 11-72 "Mast operation". Mast operation The first cylinder extends to raise the forks to the maximum free-lift height. When the first lift cylinder rod is fully extended, the second lift cylinder takes over the role to raise the middle mast, and also raise the forks, inner mast, and first lift cylinder as a unit using the second lift chain. The mast lowering mechanism is the reverse of lifting. See “HYDRAULIC SYSTEM”. Maximum free lift Maximum free lift means the maximum elevation of the forks without raising the mast.
3 5 1 6 4
2 4) 1) 1. 2. 3. 4. 5. 6. 7.
First lift cylinder Second lift cylinder First lift chain Second lift chain Inner mast Middle mast Outer mast
11-72
7 2) 1) 2) 3) 4)
3) Forks on the ground Maximum free lift Maximum lift Free lift height
502219
CHAPTER 11 MAST AND FORKS 3.3
Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the forklift truck, see 11-91 "Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck" .
3
4
1
7
5
6
2 505771
1. 2. 3. 4.
3.4
Nut Fork, Lift bracket assembly Tilt socket pin, Collar, Washer, Bolt Low-pressure hose
5. 6. 7.
High-pressure hose for lift cylinders Mast support cap Mast support bushing
Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly (1) Tilt the mast FORWARD and lower the inner mast to the bottom so that the lift chain is slack. Then remove nuts 1 from the lift chains. (2) Tilt the mast BACKWARD to the VERTICAL position and lift the inner mast until the lift bracket becomes free. Then, slowly move the forklift truck away from the lift bracket. Note: Before overhauling the mast assembly, BE SURE to measure the clearance between the mast and the rollers. This helps to improve work efficiency by understanding which roller is to be replaced or the necessity of shim adjustment. See 11-98 "Adjusting Mast Roller Clearance".
1 2 502221
R CAUTION After the lift bracket is removed from the forklift truck, place wood blocks under the lift bracket to prevent it from falling down.
11-73
CHAPTER 11 MAST AND FORKS Position the mast VERTICALLY. Raise the inner mast until main rollers 8 of the lift bracket become free. Then, slowly move the vehicle in reverse to separate from lift bracket 2.
8 2 505796
Separating tilt cylinders (1) Attach a sling on the crossmember at the top of the outer mast, then lift the outer mast with a hoist.
505797
R CAUTION When removing and installing the mast assembly with a hoist, BE SURE to use a hoist with enough lift capacity. (2) Place wooden blocks under the tilt cylinder mounting section and remove the tilt socket pins 1, and separate the mast from the tilt cylinders. (3) Start the engine, and pull back on the tilt lever to retract the tilt cylinder rods.
1
505798
R CAUTION -
DO NOT touch any levers except the tilt lever while the engine is running. DO NOT loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps (1) Put a matchmark on each cap. (2) Remove cap mounting bolts from the mast and disconnect the mast assembly from the forklift truck by hoisting. Lay the mast assembly horizontally on a level and hard surface with the lift bracket side facing up. Note: Lay the mast assembly in a space large enough for disassembly work.
1) 505799 1) Matchmark
11-74
CHAPTER 11 MAST AND FORKS 3.5
Suggestions for Installing Mast and Lift Bracket Assembly
For installation, follow the removal sequence in reverse and observe the instructions below: Mast support (1) Apply a thick coat of grease on the inner surface of the caps and the mast support bushings. (2) Install the mast supports in the same direction as they were removed. (3) For greasing, place wood blocks under the mast so that the mast is off the ground. (4) Tighten the mast support bolts to the specified torque.
1 2
1) 2) 1. Bushing 2. Cap
Item
505774
1) Bushing internal view 2) Cap internal view
Tightening torque 3.5 to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
6.0 to 7.0 ton
490 N·m (49.7 kgf·m) [361.40 lbf·ft]
Mast support bolt
Adjusting chain tension For chain tension adjustment, see 11-94 "Inspecting and Adjusting Chain Tension". Bleeding lift cylinders Move the lift bracket up and down several times to bleed air trapped in the piston end of the lift cylinder. After the proper operation of the lift truck is confirmed, check the oil level in the hydraulic tank.
11-75
CHAPTER 11 MAST AND FORKS 3.6
Removal Sequence of Mast and Lift Bracket
18
17
11 24
1
9
27
29 12 7
8
5 4
6
25 12
3
7
27
23
1
26 21
14 8
1
28 2 13
10 22 31
28 16
13
19
15
20
19 19
21
30 505800
1. First lift cylinder hose, Clamp, Bolt 2. Bolt, Washer 3. Shim 4. First lift cylinder 5. Bolt, Washer 6. Chain wheel support 7. Chain guard, Plug 8. Snapring, Chain wheel 9. Pulley bracket, Pulley, Bar, Bolt 10. Nut (for second lift cylinder chain) 11. Mast strip, Shims 12. Main roller, Shims 13. Main roller, Shims 14. Inner mast 15. Nut Note: The lift bracket disassembly procedure is the same as that of the simplex mast.
3.7
23. 24. 25. 26. 27. 28. 29. 30. 31.
Lift chain (for second lift cylinder) Chain guard, Bolt Snapring, Chain wheel Hose Joint, Connector, Bolt, Washer Hose, Clamp Cylinder clamps, Seats, Shims, Cushion, Collar, Clamp bolt Cushion, Shims, Bracket Set bolt, Washer, Shim Second lift cylinder Mast strip, Shims Main roller, Shims Main roller, Shims Middle mast Cap, Bolt, Washer Outer mast, Grease nipple
Preparation for Disassembling Mast and Lift Bracket
Lay the mast assembly horizontally on wood blocks with the lift bracket side facing up. Place a wood block so that it stops the inner and middle masts from falling down. Before disassembly, measure and record all clearances between each of the rollers and the lift bracket and between the main rollers and the mast. Recorded measurements will be helpful when replacing rollers or selecting shims to adjust clearances. See 11-98 "Adjusting Mast Roller Clearance".
11-76
16. 17. 18. 19. 20. 21. 22.
CHAPTER 11 MAST AND FORKS 3.8
Suggestions for Disassembling Mast and Lift Bracket
Removing first lift cylinders
4
(1) Remove the first lift cylinder 4 mounting bolt. (2) Tie two slings securely to the first lift cylinder 4, and gently lift the cylinder.
505801
14
Removing main rollers and mast strips Lower inner mast 14 until main rollers can be removed. Remove the middle mast rollers 12, 13, and mast strips 11.
13 11
12
505802
Removing inner mast Using a sling, slightly lift the inner mast 14 to clear the middle mast roller shafts, and separate the inner mast 14 from the middle mast.
14
505803
29
Removing main rollers and mast strips (outer race) Remove the set bolts from the top of the second lift cylinder rods 25. Then place the cylinder rod ends on the outer mast 31. Lower middle mast 29 until main rollers 28 can be removed. Then remove main rollers and mast strips from the outer mast.
28
25
31 27
505804
11-77
CHAPTER 11 MAST AND FORKS 3.9
Inspecting Mast and Lift Bracket
Mast (1) Check each roller for binding, wear, and cracks. (2) Check each roller on rolling surface for pitting or other defects. (3) Make sure that rollers rotate smoothly on the rolling face. (4) Check welded joints of mast member, crossmembers, shafts, supports, and tilt brackets for cracks. (5) Check the mast support bushings for wear or other defects. 505805
Lift bracket (1) Check the main rollers and side rollers for binding, wear, and cracks. (2) Check the welded areas of lift bracket for cracks. (3) Check the finger bar for bend or distortion.
1 505806 1. Straightedge
Item Distortion of finger bar
Standard value 5 mm (0.20 in.) or less
Lift chains, chain wheels and chain wheel supports (1) Measure the length of each chain to make sure that the two chains are equal in length. Also check the chains for wear, indication of breakage, link binding, and twisting. (2) Check each chain anchor bolt for cracks or thread damage. (3) Check the chain wheel support and the chain wheel for cracks, wear, and binding. (4) Measure chain length to check for elongation. See 1195 "Checking Chain Elongation". Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 7.0 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
Mast strip Check for damage, scoring, or distortion. See “HYDRAULIC SYSTEM”.
11-78
CHAPTER 11 MAST AND FORKS 3.10 Assembly Sequence of Lift Bracket Roller
1
2
1
6 1)
2
6)
1)
1
9)
3 6
8)
8)
2)
10) 5)
5)
5 3 6)
6 1)
1
3)
4
1
5
5) 4)
6) 5) 1. 2. 3. 4. 5. 6.
4
Lift bracket Lift bracket upper roller Lift bracket middle roller Lift bracket lower roller Side roller Inner mast
7)
6) 1)
505807
Clearance between main roller rolling face and mast 2) Clearance between middle roller side face and mast thrust plate 3) Clearance between lower roller side face and mast thrust face 4) Clearance between side roller rolling face and mast 5) Shim (a) 6) Shim (b) 7) Shim (c) 8) Thrust plate 9) No shim required 10) Minimum clearance
inner inner inner inner
11-79
CHAPTER 11 MAST AND FORKS 3.11 Adjusting Lift Bracket Clearance The lift bracket has three main roller bearings on one side and side rollers on both sides as shown in the illustration. The clearances are necessary so that the lift bracket can move up and down smoothly along the inner mast. Clearances between middle roller side face and thrust plate and between lower roller side face and inner mast The clearance between the side roller face and the inner mast thrust face (right-to-left clearance): Clearance 2) is used to determine the correct amount of shims at the bearing seat. Move the lift bracket to the top of the inner mast and slide the lift bracket to either the left-most or the right-most position. Measure the clearance 2) between the roller side face and the inner mast thrust face on the opposite side. Note: Shim adjustment for clearance 2) is not required for the lift bracket upper rollers. Adjust clearance G to the specified values with shims (a) and (b) for the middle and the lower rollers. Item
Standard value
Clearance between middle roller side face and inner mast thrust plate Clearance between lower roller side face and inner mast thrust face
0.1 to 0.5 mm (0.004 to 0.020 in.)
Clearance between main roller rolling face and inner mast Clearance between roller circumference and inner mast thrust face (back-to-front play): Clearance 1) is used for determining the proper size of the rollers. Select a roller of correct diameter so that the clearance meets the specified value. Check that the rollers rotate smoothly when installed. Item Clearance between main roller rolling face and inner mast
11-80
Standard value 1 mm (0.04 in.) or less
CHAPTER 11 MAST AND FORKS Clearance between side roller rolling face and inner mast To determine the clearance between side roller circumference and inner mast side roller thrust face: Move the side roller to the upper end of the inner mast and slide the lift bracket to either the left-most or right-most position. Measure G1 clearance between the roller circumference and inner mast on the opposite side. Adjust the number of shims (c) so that the clearance meets the specified value. Item
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
Selecting roller of correct outer diameter Measure the clearance between the upper and lower rollers' rolling faces and the mast. If the measured clearances do not meet the standard value shown in the table replace the roller with a roller of the correct diameter. Use the same sized roller for the upper and the lower rollers and use one size smaller for the middle rollers. Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". Make sure that the rollers rotate smoothly when installed. Specifications Item
Roller size (external diameter)
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
11-81
CHAPTER 11 MAST AND FORKS Adjusting clearance between middle roller side face and thrust plate
1
2
Note: The following adjustment is not required for the upper rollers.
4
2)
Measure the clearance between middle roller side face and thrust plate. If the measured clearance does not meet the standard value, adjust the clearance as follows:
3)
3
Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) 1. 2. 3. 4.
Clearance between lower roller side face and inner mast thrust face
11-82
1
2)
Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1)
2
Measure the clearance between the lower roller side face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows:
502152
1) Clearance between middle roller side face and inner mast thrust plate 2) Shim (a) 3) Shim (b)
Inner mast Lift bracket Thrust plate Roller stopper
3) 503981 1. Inner mast 2. Lift bracket
1) Clearance between lower roller side face and inner mast thrust face 2) Shim (a) 3) Shim (b)
CHAPTER 11 MAST AND FORKS Installing rollers To install main rollers on shafts, use a driving tool, and be careful not to strike the outer roller surface. The side of the roller with larger chamfering must face toward the outside. Make sure the rollers rotate smoothly when installed.
502154
Adjusting the clearance between side roller rolling face and inner mast
3
1
2
Measure the clearance between side roller rolling face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows: Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast"
4 1)
(1) If the clearance is too large, increase the number of shims (c) as required. Shim (c) is available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.)
2) 1. 2. 3. 4.
Side roller Inner mast Lift bracket Roller mounting bolt
505788 5. Lift bracket 1) Clearance between side roller rolling face and inner mast 2) Shim (c)
11-83
CHAPTER 11 MAST AND FORKS 3.12 Installing Outer/Inner Mast Rollers Mast rollers have the same shape and size as the lift bracket middle roller and the lower roller, and the mast rollers have the same standard value for clearances between the rollers and the masts.
2)
2)
6
1)
1) 4
4 3
2
1)
2)
1
2)
1) 4
7 4 5 1. 2. 3. 4. 5.
6. Mast upper side 7. Mast lower side 1) Clearance between main roller rolling face and mast 2) Clearance between main roller side face and mast
Outer mast Middle mast Inner mast Shim (a) Lift bracket
Item
Standard value
1)
Clearance between main roller rolling face and mast
2)
Clearance between main roller side face and mast
1 mm (0.04 in.) or less 0.1 to 0.5 mm (0.004 to 0.02 in.)
Measuring the clearance between main roller rolling face and mast If the measured clearances does not meet the standard value given in the table below, replace the roller with a roller of the correct diameter. Note: For measurement, see 11-98 "Adjusting Mast Roller Clearance". Specifications Item
Roller size (external diameter)
11-84
502231
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
CHAPTER 11 MAST AND FORKS Installing rollers Installation of the mast rollers is exactly the same as for the lift bracket rollers. See 11-79 "Assembly Sequence of Lift Bracket Roller". Measuring the clearance between main roller rolling face and mast If measured clearance is larger than the standard value, adjust the clearance by increasing the number of shims (a) and shims (b) under the roller seats. Note: For measurement, see 11-98 "Adjusting Mast Roller Clearance". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
3.13 Installing Mast Strips Adjusting the clearance between mast and mast strip Measure the clearance by inserting a feeler gauge between mast and mast strip. Adjust the number of shims (d) so that the clearance is within the range of 0.1 to 0.5 mm (0.004 to 0.02 in.).
2
5 1)
4 5
3
1 3 1. Mast strip 2. Inner mast 3. Middle mast
Item 1)
Clearance between mast and mast strip
4
5
502232
4. Outer mast 5. Shim (d) 1) Clearance between mast and mast strip
Standard value 0.1 to 0.5 mm (0.004 to 0.02 in.)
(1) If the clearance is too large, increase the number of shims (c) as required. (2) After the shim adjustment, slowly move the lift bracket up and down to check for the smooth movement.
11-85
CHAPTER 11 MAST AND FORKS 3.14 Installing Second Lift Cylinder (1) Install the cylinder brackets on the second lift cylinders. (2) Install the second lift cylinders between the outer and inner masts. (3) Install the lift cylinder rods on the middle mast as shown in the illustration on the right. Do not forget to install shims if they were installed. Normally shims are not installed. Note: BE SURE to tighten the set bolt securely on the cylinder rod.
2
1
3
505808 1. Middle mast 2. Set bolt
3. Shim
(4) Install each second lift cylinder on the mounting hole of the outer mast by aligning the cylinder end with the springpin.
1
502158
1. Springpin
(5) Measure the clearance after fully retracting the cylinder rods and placing the cylinders vertically. Add or remove shims (m) so that the clearance is 1.6 mm (0.063 in.) or less. If the clearance is too large, increase the number of shims (m). Normally shims are not installed. If the clearance is 3.2 mm (0.126 in.) or more, BE SURE to insert a 3.2 mm (0.126 in.) thick seat in the shim pack.
1 2
1 1) 1. Seat 2. Shim (m)
Item 1)
Clearance between cylinder bracket and seat
Standard value 1.6 mm (0.063 in.) or less
(6) After assembly, check both lift cylinders for smooth stroke movement, and adjust the stroke as required. See 11-103 "Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke".
11-86
502233
1) Clearance between cylinder bracket and seat
CHAPTER 11 MAST AND FORKS 3.15 Installing First Lift Cylinder (1) With the mast positioned VERTICALLY and fully lowered, temporarily install the first lift cylinder to the inner mast with the original shims and mounting bolts. (2) Position the first lift cylinder vertically and measure the clearance between the cylinder brackets and the cylinder mounts on the inner mast. If there is clearance, remove the clearance by adding shims. - To check whether both sides of the cylinder (right-toleft) are vertical against each other, measure to check if the cylinder is parallel to the side face of the inner mast. The parallel difference at the top and the bottom should be plus or minus 1 mm (0.04 in.) - To check whether both sides of the cylinder (front-toback) are vertical against each other, visually check if the cylinder is parallel to the front face of the inner mast. The cylinder should not be inclined FORWARD, not even slightly. The cylinder slightly inclined BACKWARD is acceptable. - Thickness of each adjusting shim is 1 mm (0.04 in.). (3) After shim adjustment, tighten the mounting bolts.
3
2 1 502209 1. First lift cylinder 2. Shim (n)
Item
Tightening torque
First lift cylinder mounting bolt
145 ± 15 N·m (14.8 ± 1.5 kgf·m) [106.94 ± 11.06 lbf·ft]
3. Mounting bolt
11-87
CHAPTER 11 MAST AND FORKS 3.16 Connecting Chains Assemble each chain on the lift bracket. For assembly, see 11-53 "Connecting Chains". After assembly is completed, maintain clearance between chains with locknuts in order to allow for chain tension.
505810
Ref.
Item
1
Locknut (upper)
2
Locknut (upper)
3
Locknut (lower)
4
Locknut (upper)
3.5 to 4.0 ton
4.5C ton
4.5 to 7.0 ton
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft] 290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
385 ± 39 N·m (39.3 ± 3.9 kgf·m) [289.96 ± 28.8 lbf·ft]
210 N·m (21.4 kgf·m) [154.89 lbf·ft]
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
7
4 1)
2 6
1)
8
2) 1
3
5
505809
1. 2. 3. 4. 5.
Locknut (upper) Locknut (upper) Locknut (lower) Locknut (upper) Inner mast
11-88
6. 7. 8. 1) 2)
First lift cylinder Middle mast chain wheel Outer mast 25 mm (0.98 in.) or more 5 mm (0.20 in.)
CHAPTER 11 MAST AND FORKS 3.17 Installing Hydraulic Lines General precautions -
Use care not to let abrasive dust or dirt to enter the hydraulic system during installation. Apply hydraulic oil on O-rings before installation. When assembling an elbow connector 6 (connection with straight thread and O-ring), follow the instructions in the “Installation using straight thread and O-ring” on the next page.
-
1
1) 2)
1
5
2) 6 6 3
2 3) 4 3
1) 2)
First lift cylinder Second lift cylinder Item
3)
505811
Down safety valve
Tightening torque
1
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
2
Nut
118 ± 11.8 N·m (12.03 ± 1.2 kgf·m) [87.03 ± 8.70 lbf·ft]
3
Nut
4
Nut
5
Nut
6
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
11-89
CHAPTER 11 MAST AND FORKS Installation using straight thread and O-ring (1) Apply grease or hydraulic oil on O-ring and O-ring seat on the housing side. (2) Turn locknut so that it moves up against the body of the fitting. Move the backup washer and O-ring up against the locknut. (3) Tighten the fitting by hand. Once the O-ring is placed in the correct position of housing and the backup washer comes in contact with the surface of housing, turn it back to adjust the mounting direction. Do not loosen the body fitting more than one turn. (4) Tighten the locknut to the specified torque.
1)
1 3 5
4 6 502164
1. End of fitting body (for hose connection) 2. Fitting body 3. Locknut 4. O-ring seat
11-90
2
5. O-ring 6. Threaded portion to the housing 1) Shape varies by fitting type
CHAPTER 11 MAST AND FORKS 3.18 Removing and Installing Mast Rollers and Strips Without Removing Mast From Forklift Truck Preparation (1) Disconnect the lift bracket assembly from the mast. (2) Disconnect the pipes from the first and the second lift cylinders. Removing first lift cylinders (1) Attach a sling on the first lift cylinder 1, and suspend it with a hoist. Tie the sling securely on the first lift cylinder to prevent the cylinder from slipping. (2) Remove the mounting bolts and slowly remove the first lift cylinder using a hoist.
1
505812
Removing inner mast main rollers and middle mast upper main rollers
1
(1) Lift the front side of the forklift truck by 15 to 20 cm (5.91 to 7.87 in.) and place jack stands underneath. Keep the front side of the forklift truck off the ground in preparation to lower the inner mast with a hoist.
502166 1. Mast strip
(2) Attach a sling on the crossmember of the inner mast and suspend the inner mast with a hoist. (3) Remove the chain guard from the second lift chain wheel. (4) Disconnect the second lift chain from the outer mast, and place the chain in front of the inner mast. (5) Lower the inner mast so that the mast rollers can be removed. (6) Support the inner mast with wood blocks. 505813
11-91
CHAPTER 11 MAST AND FORKS (7) The main rollers of the inner mast and upper main rollers of middle mast can now be removed. Before attempting to remove rollers, remove the mast strips and shims from the middle mast as they tend to drop easily. (8) Adjust the number of shims for the main rollers and the mast strips as required.
1 2 3 502239 1. Outer mast 2. Middle mast
3. Inner mast
Removing outer mast main rollers and middle mast lower rollers (1) Lift the inner mast member to the level of middle mast member, and support the inner mast with wood blocks. (2) Lift the middle and the inner masts. (3) Remove the set bolts from the top of the second lift cylinder, and lift the middle and the inner masts.
505814
(4) Remove the cylinder clamp bolts from the second lift cylinder, and secure the cylinder on the outer mast crossmember. (5) Lower the middle and the inner masts until the outer mast main rollers can be removed. (6) Support the middle and inner masts by placing wood blocks underneath. (7) Now that the main rollers of the outer mast and the lower rollers of the middle mast can be removed. Removing mast strips and shims of the outer mast is recommended at this stage because they tend to drop easily. (8) Adjust the number of shims for the main rollers and the mast strips as required.
1 2 3 502241
1. Outer mast 2. Middle mast
Note: To install, follow the removal sequence in reverse.
11-92
3. Inner mast
CHAPTER 11 MAST AND FORKS 3.19 Inspection and Adjustment This section covers the inspection/adjustment that does not involve removal or disassembly. Conduct this inspection and adjustment whenever a defect is suspected.
3.20 Inspecting Forks (1) Check the forks for cracks or damage. Special attention should be given to the heel section 1) as well as all weld areas 2). Do not use a fork that has cracks. Magnetic particle inspection which features subsurface detection capability is recommended to check the root of the forks because most of the load weight rests on the root. Liquid penetration inspection is also recommended, however, it is less effective unless the paint on the inspection area is removed.
1)
2)
502169
(2) Check both forks for height 3) difference between the forktips and for any differences in shape. A slight difference between forktips may cause difficulty in inserting the forks into a pallet, which results in load imbalance. The maximum allowable difference in fork tip elevation 3) is 5 mm (0.2 in.) for pallet forks. Replace both forks when the difference in forktip height exceeds the maximum allowable difference.
3)
502170
(3) Check fork blade thickness 4). If thickness 4) is worn down and exceeds the service limit, do not use.
4)
502171
Item Fork thickness
Standard Limit
3.5 to 4.5C ton
4.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (2 in.)
60 mm (2.4 in.)
65 mm (2.56 in.)
45 mm (1.77 in.)
51 mm (2.00 in.)
58 mm (2.28 in.)
11-93
CHAPTER 11 MAST AND FORKS 3.21 Inspecting and Adjusting Chain Tension R CAUTION -
BE SURE to turn the key switch to the OFF position before inspecting or adjusting lift chains, anchor bolts and nuts in order to prevent serious injury or death caused by a sudden movement of the mast and the lift bracket. BE SURE to place wood blocks under the forks in order to prevent serous injury or death caused by a sudden movement of the forks when they are raised.
Chain tension inspection and adjustment (1) Lower the forks to the ground. Tilt the mast FORWARD to create the slack in the chain. (2) Turn the engine OFF. (3) Loosen the lower nut. Move the upper nut upward. (4) Adjust the chain tension by turning the lower nut. (5) Park the forklift truck on a level and hard surface and place the mast in a VERTICAL position. Then lower the forks to the ground. Make sure that the lift cylinders are fully retracted. 505810
(6) Raise the forks approximately 100 mm (3.94 in.) off the ground. (7) Turn the key switch to the OFF position. (8) Place wood blocks with the height of approximately 90 mm (3.54 in.) under forks. (9) To check the first lift chain tension, push both chains at the midpoint between the chain wheel and the fixed chain end on the lift bracket. To check the tension of second lift chain, push both chains at the midpoint between the chain wheel and the fixed chain end on the inner mast. Make sure the tension in the right and left chains are the same. If the tension is uneven, adjust the chain tension.
Item
2
1 1. Lower nut 2. Upper nut
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.89 lbf·ft]
4.5C to 7.0 ton
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
Upper nut
11-94
3
3. Anchor bolt
505815
CHAPTER 11 MAST AND FORKS R CAUTION After adjustment, raise and lower the lift bracket several times. With the mast being tilted BACKWARD and fully retracted, check the position of the lift bracket lower roller. The protrusion of each lower roller must not exceed 40% of the roller diameter from the bottom of inner mast. If it exceeds 40%, elongation of chains is suspected.
2
1
1) 505816
1. Lift bracket lower roller 2. Inner mast
1) 40% or less of roller diameter
Tightening nuts after adjustment (1) Hold the anchor bolt with a spanner wrench, secure the bolt and lower the clip on the anchor. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
3.22 Checking Chain Elongation (1) Pull the chains taut by weighing a load close to the maximum load evenly on both forks. (2) Measure 20 links of chain length. If the length exceeds the limit, replace the chain with a new one.
1) 2)
505817 1) Link
Item
Standard value
Limit value
Chain length 3.5 to 4.0 ton (20 links) 4.5C to 7.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
635 mm (25.00 in.)
654 mm (25.75 in.)
2) 20 links
11-95
CHAPTER 11 MAST AND FORKS 3.23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast Measuring back-to-front clearance on lift bracket main rollers
1)
(1) Slightly lift the forks off the ground. (2) Insert a claw bar between the upper part of the lift bracket and the inner mast, push the inner mast to either side. Measure the clearance between the main roller and the inner mast on the opposite side with a feeler gauge. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-79 "Assembly Sequence of Lift Bracket Roller". Item 1)
1)
502176
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on lift bracket main rollers and side rollers
R CAUTION Place wood blocks under the lift bracket to prevent it from falling. (1) Raise the lift bracket to the inner mast uppermost position. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go to the opposite side of the mast, and slide the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a claw bar between the inner mast and lift bracket on the dial indicator side, and push the lift bracket to the opposite side.
502177
11-96
CHAPTER 11 MAST AND FORKS (5) Measure the clearance between the lift bracket middle roller and the thrust plate. Adjust the number of shims as required. Note: The upper rollers do not require any measurement and adjustment.
1
1 1)
For adjustment, see 11-80 "Adjusting Lift Bracket Clearance".
2
2
502178 1. Upper roller
2. Thrust plate
Item 1)
Standard value
Clearance between middle roller side face and inner mast thrust plate
(6) Lower the lift bracket slightly from the top so that the side roller comes in contact with the inner mast. Measure the clearance between the side roller and the inner mast. Adjust the number of shims as required. For adjustment, see 11-80 "Adjusting Lift Bracket Clearance".
0.1 to 0.5 mm (0.004 to 0.020 in.)
2) 1
1
502179 1. Side roller
Item 2)
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
(7) Raise the lift bracket to the top of the inner mast, and measure the clearance between the lower roller and inner mast. Adjust the number of shims as required. For adjustment, see 11-80 "Adjusting Lift Bracket Clearance".
1 3)
502180
1. Lower roller
Item 3)
Clearance between lower roller side face and inner mast thrust face
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-97
CHAPTER 11 MAST AND FORKS 3.24 Adjusting Mast Roller Clearance Measuring back-to-front clearance on mast main rollers
1)
(1) Tilt the mast fully BACKWARD. (2) Measure the clearance between the inner and middle mast lower roller and the mast rolling surface. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-84 "Installing Outer/Inner Mast Rollers".
502243
Item 1)
Standard value
Clearance between main roller rolling face and mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on inner mast main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the inner mast to prevent it from falling. (2) Set a dial indicator on the inside of the middle mast with its contact point rested on the inner mast. (3) Push the inner mast main roller against the middle mast rolling surface with a claw bar from the opposite side of the dial indicator, and set the dial indicator to zero. (4) Insert a claw bar between the middle mast with dial indicator and the inner mast, and push the middle mast to the opposite side.
1)
502182
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1) Item 1)
11-98
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502245
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on middle mast upper main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the middle mast to prevent it from falling. (2) Set a dial indicator on the middle mast with its contact point rested on the inner mast. (3) Push the inner mast main roller against the middle mast rolling surface with a claw bar from the opposite side of the dial indicator, and set the dial indicator to zero. (4) Insert a claw bar between the middle mast with dial indicator and the inner mast, and push the middle mast to the opposite side.
1)
502184
(5) Measure the clearance between the middle mast upper main roller and the inner mast. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1) Item 1)
Clearance between main roller side face and mast
502244
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-99
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on middle mast lower main rollers
R CAUTION Place wood blocks under the middle mast to prevent it from falling. (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the middle mast. (3) From opposite side of dial indicator, push the middle mast main roller against the outer mast's rolling surface with a claw bar, and set the dial indicator to zero. (4) Insert a claw bar between the outer mast with the dial indicator and middle mast, and push the middle mast to the opposite side.
1)
502182
(5) Measure the clearance between the middle mast lower main roller and the inner mast. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1) Item 1)
11-100
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502245
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on outer mast main rollers
R CAUTION Place wood blocks under the outer mast to prevent it from falling. (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the outer mast with its contact point rested on the middle mast. (3) From the opposite side of dial indicator, push the outer mast main roller against the middle mast rolling surface with a claw bar, and set the dial indicator to zero. (4) Insert a claw bar between the outer mast with the dial indicator and middle mast, and push the middle mast to the opposite side.
1)
502184
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1)
503983
Item 1)
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-101
CHAPTER 11 MAST AND FORKS 3.25 Inspecting and Adjusting Mast Strip Clearance (1) Measure the clearance with the clearance between the outer mast rollers and the inner mast rolling face adjusted to 0 mm (0 in.) at the maximum lift position. Measure the clearance between the outer mast main roller and the middle mast rolling surface in a similar manner. (2) If mast strip clearance deviates from the specified value, adjust the clearance with shims. For adjustment, see 11-85 "Installing Mast Strips".
1)
502186
Item 1)
Standard value
Clearance between mast and mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
(3) After all clearances are adjusted, move the mast and lift bracket slowly, and check whether the full stroke movement is smooth.
3.26 Adjusting Mast Tilt Angle (1) Adjust the tire air pressure and park the forklift truck on a level and hard surface. (2) Tilt the mast fully BACKWARD and turn the engine OFF. (3) Measure the backward tilt angle of the right and left masts. (4) Adjust the cylinder stroke by loosening the tilt cylinder socket bolt 1 and then turn the tilt cylinder rod so that the backward tilt angle of the mast on each side is the same. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Slowly tilt the mast BACKWARD, and adjust the rod so that both cylinders simultaneously move into their stroke end positions.
1 505772 1. Socket bolt
Item
Forward tilt angle
Backward tilt angle
Standard tilt angle
6°
5°
(5) After tilt angle adjustment, tighten the tilt cylinder socket bolts to the specified torque. Item
Tightening torque
Tilt cylinder socket bolt
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
11-102
CHAPTER 11 MAST AND FORKS 3.27 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke Inspection (1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the middle mast reaches its maximum height. (2) If the top of the middle mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and shaking of the rod with a longer second lift cylinder stroke. 502216
Adjustment (1) Raise the middle mast, place wood blocks under the right and left sides of the middle mast, and lower the mast until it rests on the wood blocks. (2) Remove the set bolt at the top of second lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of piston rod end. Note: When retracting the piston rod, push the lift lever to lowering direction to release the hydraulic oil from the second lift cylinders. 501408
(3) Raise the piston rod, and tighten the second lift cylinder set bolt. Remove the wood blocks under the middle mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the middle mast to the bottom. Also check that the left and right lift cylinders come to the end of stroke simultaneously at the maximum lift position of the middle mast.
1
2 3
505808 1. Set bolt 2. Middle mast
3. Shim
11-103
CHAPTER 11 MAST AND FORKS 3.28 Troubleshooting Condition
Possible cause
Action
Clearance between lift rollers and side rollers is incorrect
Adjust forward/backward and right/ left clearances
Defective roller rotation
Lubricate side rollers and replace other rollers
Incorrect clearance on mast strip
Adjust using shims
Excessive clearance on side roller
Increase shim stack thickness
Uneven tension between chains on right and left side
Adjust chain tension
Shim adjustments are unequal between left and right lift cylinders (at the maximum height)
Adjust shim stack thickness
Defective roller rotation
Adjust or replace rollers after inspection
Lift cylinder packing is damaged
Replace
Sliding (inside) surface of lift cylinder tube is damaged
Replace
Whole mast shakes
Mast support bushing is worn out
Retighten or replace bushing
Mast is distorted
Off-center load or overload
Replace mast assembly
Lift bracket and inner mast do not move smoothly
Lift bracket or inner mast is tilted
Mast makes noise Drift (natural descent) of lift cylinders
Distortion of finger bar Forktips are different in height
Distortion of forks Uneven loading
11-104
Repair or replace
CHAPTER 11 MAST AND FORKS 3.29 Service Data Item
3.5 to 4.0 ton
6.0C to 7.0 ton
Standard
508 mm (20.00 in.)
635 mm (25.00 in.)
Limit
523 mm (20.59 in.)
654 mm (25.75 in.)
S
Standard
117 mm (4.60 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
Standard
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
Standard
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
Standard
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
Chain length (20 links)
Main roller outside diameter
4.5C to 5.5 ton
Side roller external diameter
Standard
52 mm (2.05 in.)
58 mm (2.28 in.)
780 mm(26.77 in.)
800 mm (31.50 in.)
1
Width of outer mast
Standard
2
Width of middle mast
Standard
666 mm (26.22 in.) 656 mm (25.83 in.) 662 mm (20.06 in.)
3
Width of inner mast
Standard
554 mm (21.81 in.) 536 mm (21.10 in.) 534 mm (21.02 in.)
4
Width of lift bracket
Standard
422 mm (16.61 in.) 402 mm (15.83 in.) 382 mm (15.04 in.)
5
Clearance between main roller rolling face and mast
Standard
1 mm (0.04 in.) or less
6
Clearance between main roller side face and mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
7
Clearance between mast and Standard mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
5
Clearance between main roller rolling face and inner mast
Standard
1 mm (0.04 in.) or less
6
Clearance between middle roller side face and inner mast thrust plate
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
6
Clearance between lower roller side face and inner mast thrust face
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
8
Clearance between side roller rolling face and inner mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
Distortion of finger bar
Standard
5 mm (0.2 in.) or less
Mast support bolt
Tightening torque
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
Tilt cylinder socket bolt
Tightening torque
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
Lift chain nut
Tightening torque
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
Lift chain nut (C45A: inner mast)
Tightening torque
Triplex mast size (reference)
Mast
Lift bracket
-
490 N·m (49.7 kgf·m) [361.40 lbf·ft]
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft] 385 ± 39 N·m (39.3 ± 3.9 kgf·m) [283.96 ± 28.76 lbf·ft]
-
11-105
CHAPTER 11 MAST AND FORKS
6
7
5 6 8
5
6
6 6
5
6
3
2
4
1 502246
Note: The mast is slightly wider at the lower side than at the upper side. Always measure the clearance at the upper side of the mast.
11-106
CHAPTER 11 MAST AND FORKS
Model
4.0 ton
4.5 ton
Type
5 to 5.5 ton
Limit value
1
HX**** x 500 (Maker Symbol "HX")
50 x 125
45 mm (1.77 in.)
50 x 122
45 mm (1.77 in.)
2
T**** ("T" Mark)
50 x 122
45 mm (1.77 in.)
3
Without Mark **** or U**** or UQ****
50 x 125
45 mm (1.77 in.)
4
MSI-Fork
50 x 150
45 mm (1.77 in.)
1
HX**** x 500 (Maker Symbol "HX")
50 x 150
45 mm (1.77 in.)
3
5.00 ton
Blade side
50 x 150
45 mm (1.77 in.)
3
Without Mark **** or U**** or UQ****
55 x 150
50 mm (1.97 in.)
4
MSI-Fork
50 x 150
45 mm (1.77 in.)
1
HX**** x 500 (Maker Symbol "HX")
50 x 150
45 mm (1.77 in.)
3
Without Mark **** or U**** or UQ****
55 x 150
50 mm (1.97 in.)
4
MSI-Fork
60 x 150
55 mm (2.17 in.)
1
HX**** x 500 (Maker Symbol "HX")
60 x 150
55 mm (2.17 in.)
3
Without Mark **** or U**** or UQ****
65 x 150
1
2
3
4 Q00581
60 mm (2.36 in.)
11-107
CHAPTER 12 SERVICE DATA
Chapter 12 SERVICE DATA 1.
Maintenance Schedule
Note: Inspection and maintenance should be performed every specified period: months or service hour, whichever comes first.
Brake fluid level
R
Brake hose, pipes, and joints
9
Brake pedal free play
9
Parking brake
9
Brake and inching pedal rod (see Note 2)
L
Brake hose and tube
R
Brake wheel cylinder rubber parts
R
Brake booster rubber parts
R
Braking force, brake drum and shoe, and other devices
9
Backing plate, fitting cable, ratchet
9
Radiator fins (see Note 2)
Cooling
C
Cooling fan
9
Engine coolant level
9
Radiator filler cap
9
9
Rubber hose condition
9
9
V-belt (fan and alternator) tension Engine coolant (including reserve tank)
Others (see note 1)
9
Brake fluid
Brake (Dry)
Every 2400 hrs or 12 months
R: Replace Every 1200 hrs or 6 months
Check items
L: Lubricate,
Every 300 hrs or 6 weeks
D: Drain,
1st month (200 hrs)
System
C: Clean,
Every 50 hrs or weekly
9: Check,
Pre-start (daily/10 hours)
Abbreviation
9 R
12-1
Battery terminal loosen and damage
9
Driving interlock system
9
Electrical wires
9
Horn
9
Meter panel icons (including seat belt)
9
Mast interlock system
9 9
9 9
Voltage, current, other electrical system Backup light, stop lights (if equipped)
9
Turn-signal lights (if equipped)
9
Working and head lights (if equipped)
9 9
Warning devices, lights, and meter panel Engine (exhaust, noise, vibration)
9
Engine oil (dirt and level)
9 9
Positive crankcase ventilation valves and hoses Engine oil
R
R
Engine oil filter
R
R
Engine mounts
9
Compressing and injection pressure
9 9
Exhaust pipe and catalyst/muffler Assist grip
9 9
Loosen bolts and nuts Frame and Chassis
12-2
Overhead guard
9
Seat adjustment
9
Seat belt
9
Rear view mirror (if equipped)
9
Operator seat
9
Others (see note 1)
Every 2400 hrs or 12 months
9
Starter
Engine
Every 1200 hrs or 6 months 9
9
Battery electrolyte specific gravity (Not required if battery is maintenance free type)
Electrical
Every 300 hrs or 6 weeks
9
Alternator Battery electrolyte level (Not required if battery is maintenance free type)
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
Fuel
Tar in vaporizer (see Note 3)
9
LPG hose, pipes and joints (damage)
9
LPG level (fuel gauge) LPG filter replacement (see Note 3)
R
R
LPG hose (see Note 1)
***
Vaporizer rubber parts
R 9 9
Hydraulic hose, pipes, and joints Hydraulic oil (dirt and level)
9 9
Hydraulic pump (oil leakage) Hydraulic tank strainer
C
Hydraulic hose (high-pressure hose) (see Note 1)
*
Hydraulic oil
R
Hydraulic tank return oil filter
R
R 9
Cylinder, safety valve, solenoid valve, and other hydraulic system
Intake
Hydraulic system
9
Hydraulic pump drive shaft and U-joint
9
Air cleaner element (see Note 2) (Clean every 2 weeks if note 2 applies)
C
Air cleaner element replacement (see Note 2)
Mast and Forks
Others (see note 1)
9
Control valve
Hydraulic
Every 2400 hrs or 12 months
Every 1200 hrs or 6 months
Every 300 hrs or 6 weeks
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
R
Lift and tilt cylinder (oil leakage and damage)
9
Lift cylinder, tilt cylinder, and attachment functions
9
Lift cylinder mounting bolts
9
Mast, lift bracket, and forks
9
Lift bracket main rollers and side rollers (see Note 2)
9
L
L
Mast strip sliding surfaces (see Note 2)
9
L
L
Tilt cylinder socket bolts
9
Lift chains (see Note 1, 2)
9
Mast support bushings (see Note 2)
9
L
***
L
Tilt socket pins (see Note 2)
L
L
Tilt cylinder (see Note 2)
L
L 9
Fork lowering speed Load backrest extension
9
12-3
Steering and Axle
Front axle
9
Power steering cylinder
9
Rear axle
9
Steering column
9
Steering wheel
9
Rear axle mount bushings (see Note 2)
L
Knuckles (see Note 2)
L
L
Tie rod pins (see Note 2)
L
L
9
Power steering cylinder hoses and rubber parts (see Note 1)
**
Wheel bearings and other traveling devices
9
Wheel steering angle, rod, arm, and other operating devices
9
Accelerator pedal
9 9
Differential oil Inching pedal Transmission drive
General
R
9 9
Transmission gear and bearing Transmission strainer
9 C
Inching pedal bracket and cable
9
Transmission oil
9
R 9
Differential, and other power flow devices Wheel
Tire and rims
9
Wheel nuts
9
Oil, fuel, and coolant leak (walk around)
9
Hyd lines, tubes, and hoses (damage and oil leakage)
9
Grease nipples
L
Note 1: * = Replace every 1 to 2 years. ** = Replace every 2 years. *** = Replace every 2 to 4 years. Note 2: In corrosive or abrasive environments, more frequent cleaning, lubrication, changing/replacing are required. Note 3: If you have to use poor quality fuel, more frequent checking, draining, cleaning, and replacing are required.
12-4
Others (see note 1)
Every 2400 hrs or 12 months
Every 1200 hrs or 6 months
Every 300 hrs or 6 weeks
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
CHAPTER 12 SERVICE DATA
2.
Tightening Torques for Standard Bolts and Nuts
(1) The tables below show the tightening torque for general bolts and nuts. For the tightening torque of the bolts and nuts for specific use, see the torque specified in each section. (2) The table shows the standard value. Bolts and nuts should be tightened within ±10% range of the torque value in the table. When you use an impact wrench, tighten bolts and nuts within ±20% range if the value is 137 N·m (14.0 kgf) [30.80 lbf] or less, and tighten ±15% if the value is more than 137 N·m (14.0 kgf) [30.80 lbf]. (3) Threads and seating faces are in a dry condition.
2.1
Metric Fine Thread With spring washer
Nominal size mm (in.)
Pitch mm (in.)
500244
500245
500246
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
6 (0.24)
1 (0.04)
7.4
0.75
5.4
9.6
0.98
7.1
12.7
1.3
9.4
8 (0.32)
1.25 (0.05)
16.7
1.7
12.3
22.6
2.3
16.6
30.4
3.1
22.4
10 (0.39)
1.25 (0.05)
34.3
3.5
25.3
45.1
4.6
33.3
69.6
7.1
51.4
12 (0.47)
1.25 (0.05)
63.7
6.5
47.0
82.4
8.4
60.8
122.6
12.5
90.4
14 (0.55)
1.5 (0.06)
102.0
10.4
75.2
132.4
13.5
97.6
192.2
19.5
141.8
16 (0.63)
1.5 (0.06)
157.9
16.1
116.5
202.0
20.6
149.0
287.3
29.3
211.9
18 (0.71)
1.5 (0.06)
224.6
22.9
165.6
292.2
29.8
215.5
413.8
42.2
305.2
20 (0.79)
1.5 (0.06)
310.9
31.7
229.3
404.0
41.2
298.0
573.7
58.5
423.1
22 (0.87)
1.5 (0.06)
413.8
42.2
305.2
537.4
54.8
396.4
763.0
77.8
562.7
24 (0.95)
1.5 (0.06)
547.2
55.8
403.6
711.0
72.5
524.4
1006.2
102.6
742.1
27 (1.06)
1.5 (0.06)
794.3
81.0
585.9
1032.6
105.3
761.6
1451.1
148.0
1070.5
30 (1.18)
1.5 (0.06)
1100.3
112.2
811.5
1430.8
145.9
1055.3
2012.3
205.2
1484.2
33 (1.30)
1.5 (0.06)
1467.1
149.6
1082.1
1907.4
194.5
1406.8
2680.2
273.3
1976.8
36 (1.42)
1.5 (0.06)
1918.2
195.6
1414.8
2493.8
254.3
1839.4
3497.1
356.6
2579.3
39 (1.54)
1.5 (0.06)
2461.5
251.0
1815.5
3198.8
326.2
2359.4
4469.9
455.8
3296.8
12-5
CHAPTER 12 SERVICE DATA Without spring washer
Nominal size mm (in.)
Pitch mm (in.)
500244
500245
500246
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
6 (0.24)
1 (0.04)
8.6
0.88
6.4
10.8
1.1
8.0
14.7
1.5
10.8
8 (0.32)
1.25 (0.05)
19.6
2.0
14.5
26.5
2.7
19.5
36.6
3.7
26.8
10 (0.39)
1.25 (0.05)
41.2
4.2
30.4
53.0
5.4
39.1
81.4
8.3
60.0
12 (0.47)
1.25 (0.05)
74.5
7.6
55.0
97.1
9.9
71.6
144.2
14.7
106.3
14 (0.55)
1.5 (0.06)
119.6
12.2
88.2
155.9
15.9
115.0
226.5
23.1
167.1
16 (0.63)
1.5 (0.06)
182.4
18.6
134.5
237.3
24.2
175.0
338.3
34.5
249.5
18 (0.71)
1.5 (0.06)
263.8
26.9
194.6
343.2
35.0
253.2
487.4
49.7
359.5
20 (0.79)
1.5 (0.06)
365.8
37.3
269.8
475.6
48.5
350.8
674.7
68.8
497.6
22 (0.87)
1.5 (0.06)
486.4
49.6
358.8
632.5
64.5
466.5
897.3
91.5
661.8
24 (0.95)
1.5 (0.06)
643.3
65.6
474.5
836.5
85.3
617.0
1183.7
120.7
873.0
27 (1.06)
1.5 (0.06)
934.6
95.3
689.3
1216.0
123.9
896.9
1707.3
174.1
1259.3
30 (1.18)
1.5 (0.06)
1294.5
132.0
954.8
1682.8
171.6
1241.2
2367.3
241.4
1746.0
33 (1.30)
1.5 (0.06)
1726.0
176.0
1273.0
2243.8
228.8
1654.9
3153.8
321.6
2326.1
36 (1.42)
1.5 (0.06)
2256.5
230.1
1664.3
2934.1
299.2
2164.1
4114.0
419.6
3035.0
39 (1.54)
1.5 (0.06)
2896.0
295.3
2135.9
3763.8
383.8
2776.0
5258.3
536.2
3878.3
12-6
CHAPTER 12 SERVICE DATA 2.2
Metric Coarse Thread With spring washer
Nominal size mm (in.)
Pitch mm (in.)
500247
500248
500249
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
10 (0.39)
1.5 (0.06)
33.3
3.4
24.6
43.1
4.4
31.8
67.7
6.9
49.9
12 (0.47)
1.75 (0.07)
58.8
6.0
43.4
76.5
7.8
56.4
115.7
11.8
85.3
14 (0.55)
2 (0.08)
96.4
9.8
70.9
124.5
12.7
91.9
182.4
18.6
134.5
16 (0.63)
2 (0.08)
147.1
15.0
108.5
191.2
19.5
141.0
274.6
28.0
202.5
18 (0.71)
2.5 (0.10)
203.0
20.7
149.7
264.8
27.0
195.3
383.4
39.1
282.8
20 (0.79)
2.5 (0.10)
286.4
29.2
211.2
371.7
37.9
274.1
536.4
54.7
395.6
22 (0.87)
2.5 (0.10)
383.4
39.1
282.8
499.2
50.9
368.2
725.9
74.0
535.2
24 (0.95)
3 (0.12)
492.3
50.2
363.1
640.4
65.3
472.3
924.8
94.3
682.1
27 (1.06)
3 (0.12)
724.7
73.9
534.5
942.2
96.1
695.1
1350.4
137.7
996.0
30 (1.18)
3.5 (0.14)
969.9
98.9
715.3
1259.2
128.4
928.7
1843.7
188.0
1359.8
33 (1.30)
3.5 (0.14)
1328.8
135.5
980.1
1727.0
176.1
1273.7
2477.2
252.6
1827.1
36 (1.42)
4 (0.16)
1676.0
170.9
1236.1
2180.0
222.3
1607.9
3199.9
326.3
2360.1
39 (1.54)
4 (0.16)
2219.2
226.3
1636.8
2884.1
294.1
2127.2
4118.8
420.0
3037.9
42 (16.5)
4.5 (0.18)
2754.7
280.9
2031.8
3581.4
365.2
2641.5
5137.7
523.9
3789.4
12-7
CHAPTER 12 SERVICE DATA Without spring washer
Nominal size mm (in.)
Pitch mm (in.)
500247
500248
500249
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
10 (0.39)
1.5 (0.06)
39.2
4.0
28.9
51.0
5.2
37.6
79.4
8.1
58.6
12 (0.47)
1.75 (0.07)
69.6
7.1
51.4
90.2
9.2
66.5
135.3
13.8
99.8
14 (0.55)
2 (0.08)
112.8
11.5
83.2
146.1
14.9
107.8
215.7
22.0
159.1
16 (0.63)
2 (0.08)
172.6
17.6
127.3
224.6
22.9
165.6
323.6
33.0
238.7
18 (0.71)
2.5 (0.10)
239.3
24.4
176.5
311.9
31.8
230.0
451.1
46.0
332.7
20 (0.79)
2.5 (0.10)
336.4
34.3
248.1
437.4
44.6
322.6
630.6
64.3
465.1
22 (0.87)
2.5 (0.10)
392.3
40.0
289.3
587.4
59.9
433.3
842.4
85.9
621.3
24 (0.95)
3 (0.12)
578.6
59.0
426.7
753.2
76.8
555.5
1088.5
111.0
802.9
27 (1.06)
3 (0.12)
852.2
86.9
628.5
1108.2
113.0
817.3
1588.7
162.0
1771.7
30 (1.18)
3.5 (0.14)
1140.5
116.3
841.2
1481.8
151.1
1092.9
2168.3
221.1
1599.2
33 (1.30)
3.5 (0.14)
1563.2
159.4
1153.0
2031.9
207.2
1498.7
2915.5
297.3
2150.4
36 (1.42)
4 (0.16)
1972.1
201.1
1454.6
2564.4
261.5
1891.4
3765.8
384.0
2777.5
39 (1.54)
4 (0.16)
2610.5
266.2
1925.4
3393.1
3469.0
2502.6
4845.5
494.1
3573.8
42 (16.5)
4.5 (0.18)
3241.1
330.5
2390.5
4212.9
429.6
3107.3
6044.8
616.4
4458.4
12-8
CHAPTER 12 SERVICE DATA
3.
Periodic Replacement Parts
The important parts (marked with *) and elements for safe operation listed below must be replaced at every designated replacement period. Replacement period No.
Periodic replacement parts Year
Month
1
*
Brake booster rubber parts and hoses
1
2400
2
*
Rubber parts for brake wheel cylinder
1
2400
Brake hoses, tube, reserve tube
1
2400
1 to 2
2400 to 4800
3
Remark
Service hours
Week
4
*
High pressure hoses for loading/unloading operation
5
*
Rubber parts for power cylinder
2
4800
6
*
Power steering hose
2
4800
7
*
Lift chain
2 to 4
4800 to 9600
8
*
LPG hose
2 to 4
4800 to 9600
9
Engine oil filter element
6
300
Also 1 month after delivery
10
LPG filter element
6
300
Also 1 month after delivery
11
Hydraulic tank return filter
6
1200
Also 1 month after delivery
12
Air cleaner element
6
1200
Clean every 300 hrs
13
Engine cooling water
1
2400
Note: "*" indicates safety critical parts.
3.1
Safety Critical Parts
10 *7
*3 *8
*5 *4 *2
*6 *1
*4 *2
609259
12-9
CHAPTER 12 SERVICE DATA
4.
Lubrication Schedule
4.1
Lubrication Chart
1
2
4
3 6
5
7 8 7
9 507035
Ref.
Lubricating point
1
Lift chains (right and left)
2
Lift bracket main rollers and side rollers (right and left)
3
Mast strip sliding surfaces (right and left)
4
Tilt socket pins (right and left)
5
Tilt cylinder (right and left) * (if equipped)
6
Mast support bushings (right and left)
7
Rear axle mount bushings (front and rear)
8
Knuckles (2 places)
9
Tie rod pins (4 places)
12-10
Lubrication/ greasing Engine oil
Intervals Every 50 hours or weekly
Every 300 hours or 6 weeks, whichever comes first Multi-purpose grease
Every 50 hours or weekly Every 300 hours or 6 weeks, whichever comes first
CHAPTER 12 SERVICE DATA 4.2
Fuel and Lubricant Specifications Recommendation for Ambient Temperatures °C [°F] Fuel or Oil
Recommendation
-30 (-22)
-20 (-4)
Fuel
10 (50)
SAE10W or SAE10W-30
API service classification SJ, MIN.
Front axle oil
API service classification multi-purpose type GL-4
Powershift Transmission Oil
Dexron III
20 (68)
30 (86)
SAE30 SAE20
SAE80W
SAE90
Consult your authorized forklift truck dealer.
Hydraulic Oil
SAE5W F.M.V.S.S. No.116-DOT3 or DOT4 (SAE J1703)
Brake fluid
SAE10W
See Recommended Brands of Lubricants.
Wheel bearings
NLGI No.2 grade multipurpose type (lithium base), consistency: 265-295
Chassis
NLGI No.1 grade multipurpose type (lithium base), consistency: 310-340 Item
Antifreeze solution
0 (32)
Consult your authorized forklift truck dealer.
Engine oil
Grease
-10 (14)
Ambient temperature (°C [°F]) (Long Life Coolant) Concentration (%)
Value -45 (-49)
-39 (-38)
-30 (-22)
-25 (-13)
-20 (-4)
-15 (5)
-10 (14)
60
55
50
45
40
35
30
R CAUTION Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with one and the same brand at successive service intervals.
12-11
CHAPTER 12 SERVICE DATA 4.3
Adjustment Value and Oil Capacity
Note: The values in the table below are for the standard model. Class (ton) Item 3.5
4.0
4.5
Alternator drive belt deflectionwhen pushed inward with 98 N (10 kgf) [22 lbf] pressure
5.5
AC Delco AC R44LTS
Spark plug gap
0.77 mm (0.030 in.) 650 to 700 min-1
Engine idling speed Steering wheel free play (when measured at rim with engine idling)
15 to 30 mm (0.59 to 1.18 in.)
Brake pedal free play
5 mm (0.20 in.)
Parking brake lever effort
250 to 290 N (25 to 30 kgf) [55 to 65 lbf]
Front tire
22 × 9 × 16
22 × 12 × 16
22 × 12 × 22
Rear tire
18 × 7 × 12-1/8
18 × 8 × 121/8
22 × 8 × 16
Tightening torque of wheel nuts
Front tire
Lift chain elongation limit
551 N·m (56.2 kgf·m) [406.5 lbf·ft] 523 mm (20.6 in.)/20 links
Engine cooling system (0.65 liter [0.17 US gal.] reserve tank included)
Engine oil
654 mm (25.7 in.)/20 links 17 L (4.5 US gal.)
Crankcase
4.2 L (1.1 US gal.)
Oil filter
0.8 L (0.2 US gal.)
Total
5.0 L (1.3 US gal.)
Transmission oil
14 L (3.7 US gal.)
Differential (P/T) Hydraulic tank Brake fluid reserve tank Battery electrolyte specific gravity, corrected to 20°C (68°F)
12-12
7.0
11 to 13 mm (0.43 to 0.51 in.)
Spark plug type
Tire size
6.0
15 L (4.0 US gal.)
9.1 L (2.4 US gal.) 45.9 L (12.1 US gal.)
51.6 L (13.6 US gal.)
68.8 L (18.2 US gal.)
149 cc (9.1 cu in.) Consult your battery manufacturer for the specific gravity of your battery.
CHAPTER 12 SERVICE DATA
5. 5.1
No.
Special Tools Special Service Tools
Name
Part number
Forklift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
1
Wrench
93768-00100
Removal/installation of pulley
z
z
2
Wrench
91868-00100
Removal/installation of pulley (used with wrench 93768-00100)
z
z
z
z
3
Bolt Bolt set
F1035-10050 67284-15400
Pulling out the torque converter-drive transmission pump body and the direct-drive transmission shifter case
4
Bevel pinion puller
91868-02100
Pulling out the bevel pinion assembly
z
z
5
Wrench
91868-00300
Tightening the bevel pinion assembly
z
z
6
Installer
91868-02200
Driving in the oil seal of the transmission output shaft
-
z
7
Puller Plate Bolt Puller
91268-13810 91268-13820 F1035-10020 T24
Removing bearing from the torque-drive transmission (to be used in combination with 91268-13820 plate. F1035-10020 bolt and T24 puller) (Commercial)
z
z
12-13
CHAPTER 12 SERVICE DATA
No.
Name
Part number
Forklift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
8
Installer
91268-04100
Driving in the ball bearing of the torque-drive transmission
z
z
9
Piston tool Piston tool
92267-00300
Removal/installation of torque-drive transmission clutch return spring
z -
z
10
Ring puller
91268-00500
Removal/installation of torque converter-drive transmission snapring
z
z
11
Gauge kit
64309-17700
Measuring oil pressure of transmission and hydraulic system
z
z
z
z
12
Connector
92067-00300
Measuring oil pressure of torque converter-drive transmission (used with gauge kit)
13
Socket wrench 105 mm
03703-49000
Removal/installation of wheel hub nut
-
z
14
Socket wrench 100 mm
-
Removal/installation of front wheel hub nut
z
-
12-14
CHAPTER 12 SERVICE DATA
No.
Name
Part number
Forklift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
15
Spring remover 64309-15400
Removal of return spring
z
z
16
Spring retainer
91868-00600
Removal/installation of brake shoe
z
z
17
Spring hook
64309-15400
Installation of return spring
z
z
18
Puller
91268-10600
Removal of steering wheel
z
z
19
Puller
91268-03200
Removal of steering column needle roller bearing
z
z
91268-01700
Measuring main oil pressure of the steering system (used with gauge kit 64309-00300)
z
z
05312-20850
Removal/installation of tilt cylinder bushing Removal/installation of lift cylinder head (for A40A and B55A)
z
z
20
21
Connector
Hook wrench
12-15
CHAPTER 12 SERVICE DATA
No.
Name
Part number
Forklift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
22
Hook wrench
05312-10600
Removal/installation of lift cylinder holder (for A75A)
z
z
23
Hook wrench
05312-10800
Removal/installation of lift cylinder holder (for B40A)
z
z
24
Hook wrench
15312-11000
Removal/installation of lift cylinder holder (for B55A)
z
z
25
Hook wrench
-
Removal/installation of tilt cylinder guide bushing
z
-
26
Hook wrench
-
Removal/installation of tilt cylinder guide bushing
-
z
27
Wheel socket 41 mm
-
Removal/installation of drive wheels
z
z
64309-17722
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
28
12-16
Hose
CHAPTER 12 SERVICE DATA
No.
Name
29
Gauge, 0-5000 psi
30
Gauge, 0-3000 psi
31
Gauge, 0-100 psi
32
Connector
33
Banjo connector
Part number
Forklift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
64309-17712
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17713
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17714
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17714
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17733
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
-
z
Note: Special service tool 4 is a dedicated inspection connector for 91105-00700. Special service tools from 2 through 20 are dedicated inspection connectors and each of them is different in shape and has the different number of connector poles. They are supplied as a set, but individual supply is also available.
12-17
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
Chapter 13 HOW TO READ CIRCUIT DIAGRAMS 1.
Description of Circuit Diagrams
The circuit diagrams consist of the schematic diagrams and connector diagrams.
1.1
Circuit Diagrams
All circuits including the power supply and ground are divided into the power circuit, GND circuit and system circuits. Power circuit diagram The power circuit diagram indicates the power circuit including the battery, fuse, ignition switch, etc. GND circuit diagram The GND circuit diagram indicates the circuits from each electric component to the body ground or from each component to the battery negative terminal. System circuit diagrams The system circuit diagrams indicate the circuits of each system from fuse to GND (earth) excluding the above power supply and GND circuit portions.
1.2
Connector Diagrams
The connector shapes, terminal shapes and terminal arrangements of all connectors in the circuit diagrams are indicated.
13-1
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
2.
How to Read Circuit Diagrams
The circuit of each system from fuse to GND (earth) is indicated. The circuits indicate the direction of signal flow. In figures, it flows from top (positive) to bottom (negative).
1 2 3 4 10
5 6
7
11
15
8 12
16 17
9
13 14
18 19 501952
13-2
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
2.1
Departure equipment name Departure sheet number Cable diameter & color (Description(2)) Circuit number Boundary (Description(4)) Equipment name Terminal number of connector Connector number (Description(3)) Indicates connection with body GND Equipment number
11. 12. 13. 14. 15. 16. 17. 18. 19.
Used place of relay coil (Description(1)) Indicates same connector Indicates connection with GND circuit Sheet number of GND circuit Used place of relay contact (Description (1)) Destination sheet number Destination equipment name Indicates connection with Negative circuit Sheet number of Negative circuit
Symbols
Symbols are used in the figures for easy reading of circuit diagrams. General symbols (1) General use symbols Symbol
Name
Symbol
Name
Negative
GND (Harness)
GND (Body)
(2) Conductors and coupling parts Symbol
Name
Symbol
Name
Connector (Socket/Plug)
Twist wire
Terminal (Socket)
Shield wire
Terminal (Plug)
Branching
Terminal
13-3
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (3) Standard passive parts Symbol
Name
Symbol
Name
Variable resistor
Resistor
(4) Semiconductors and electronic tubes SYMBOL
NAME
SYMBOL
NAME Auto light sensor (Photo diode)
Diode
LED
(5) Generation and conversion of electric energy Symbol
Name
Generator
Three phase Induction motor
DC motor
13-4
Symbol
Name
Stepping motor
Battery
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (6) Switches, control, and protective devices Symbol
Name
Symbol
Name
Switch (N.O)
Oil pressure switch
Switch (N.C)
Magnetic contactor
Fuse
Two position switch
Thermistor
Emergency switch
Magnetic coil
Push button switch
Proximity sensor
Switch (Auto return)
(7) Indicators, lamps, and signal devices Symbol
Name
Lamp
Symbol
Name
Horn
Buzzer
13-5
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS Special symbols The following symbols are used when the representation by general symbols is difficult.
2
This diagram shows that No. 1 and No. 3 terminals are connected when the switch position is placed in N position.
1
F N R 501953
1. Switch position
2.2
2. Terminal
Sheet Symbol
A sheet symbol is provided in each circuit diagram sheet so that the relationship between diagrams can be clarified. The sheet symbol consists of "SH" and two digit numbers, for example, “SH-01" or “SH-02".
13-6
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS Connecting Lines
(1) There are two thicknesses of the line which connect between elements in the circuit diagram. Each line is used as follows: Thick line: Connecting lines for the electric wires size of 20 mm2 (0.78 in2) or above. Thin line: All other connecting lines except the above. (2) Connecting lines are represented by the circuit number, wire diameter and wire color. For the connecting lines of 0.5 mm2 (0.02 in2) wire size, the wire diameter is omitted.
1 2
101(1.25R)
2.3
3 4 501954
1. Wire diameter, wire color 2. Circuit number
3. Wire color 4. Wire diameter
(3) Here are two types of wires: the one having only one color and the one having a colored stripe (combination of two colors).
2 1
3 4
501955 1. Base color 2. Stripe color
3. Base color 4. Stripe color
Color codes Symbol
Color
Symbol
Color
Symbol
Color
B
Black
Br
Brown
P
Pink
W
White
L
Blue
Sb
Sky blue
R
Red
Lg
Light green
V
Purple
G
Green
O
Orange
Y
Yellow
Gr
Gray
13-7
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 2.4
Equipment
(1) Equipment is represented by a box. The symbol of connector that belongs to the equipment is indicated inside the box. (2) The items listed under the item category symbol have a specific symbol (equipment number) for classification of items and identification of identical items. Equipment number system
3
1
4
5
2 6 7 501956
1. 2. 3. 4.
Equipment name Box Connector for harness Connector belongs to equipment
5. 6. 7.
Equipment number Classification number (serial number) Item category symbol
Item category symbol
13-8
Symbol
Item
Symbol
Item
F
Fuse
MC
Contactor
SBF
Slow-blow fuse
R
Resistor
FLW
Fusible link
C
Capacitor
RY
Relay
D
Diode
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 2.5
Relay Contactor and Coil
(1) For the relay contactor, the sheet symbol in which its coil is represented is provided so that you can find its coil easily. However, when the coil is represented in the same sheet, the sheet symbol is omitted.
2 LAMP RELAY
1
3 501957
1. Equipment name 2. Equipment number
(2) For the relay coil (contactor coil), the sheet symbol in which its contact is represented is provided so that you can find the location of contacts. However, when the contact is represented in the same sheet, the sheet symbol is omitted.
3. Sheet symbol where coil is represented
2 LAMP RELAY
1
3 501958 1. Equipment name 2. Equipment number
2.6
3. Sheet symbol where the contact is represented
Connectors
(1) The connectors are represented by the connector number for identification. The connector number is enclosed with a box. (2) The same connector number is allocated to a plug connector (male connector) and its mating socket connector (female connector) as a pair. (3) The connector terminal number is indicated next to the connector symbol. However, for the terminals such as round shape terminal, plug terminal, and flat shape terminal, etc., the terminal number is indicated. (4) When the connectors located side by side are the identical but have a different number, the line between the connectors are indicated by a dotted line.
1
3 2
4
1. 2. 3.
Terminal number Connector number Terminal number
4. 5.
5
501959
Connector number Indicates that the connector is the same.
13-9
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 2.7
Indication of Connecting Line
(1) When a connecting wire crosses to another sheet, it is indicated by the arrow with the sheet symbol next to it. Also, the name of destination equipment is indicated for better understanding.
1 2 501960 1. Destination sheet symbol
2. Destination equipment name
(2) A connecting wire from another sheet is also indicated by the arrow with the sheet symbol next to it. Also, the name of sender equipment is indicated for better understanding.
1 2
501961 1. Sender equipment name
2.8
2. Sender sheet symbol
Indication of GND (Earth)
The GND (earth), depending on the connection type, is represented as shown below. (1) When connecting directly to the body.
1
2
501962 1. Terminal connector number
13-10
2. Graphic symbol
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (2) When connecting to body or battery negative terminal through GND circuit and negative circuit.
1
1
2 3
2 4 501963
4. This indicates the connection to 1. Graphic symbol negative circuit. 2. Destination sheet symbol 3. This indicates the connection to GND circuit
2.9
Indication of Another Specification
When there is another specification, the portion of circuit, for which another specification is available, is enclosed with an alternate long and two short dashes line, and the circuit of another specification is enclosed by a thick solid line.
1
2
501964
1.
The circuit portion which differs depending on the specification
2.
The circuit of another specification
13-11
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
3.
How to Read Connector Diagrams
For all connectors included in the circuit diagrams; the connector shapes, terminal arrangements, and terminal shapes (plug or socket) are indicated. Socket terminal (female terminal)
4
1
5
2 3
6 501965
1. 2. 3. 4.
Connector number Lock Terminal arrangement terminal number This indicates No.4 terminal of B-01 connector
5. 6.
Socket terminal Plug terminal
Plug terminal (male terminal)
1
502710
1.
Lock (Blackened)
(1) The connector diagram is a view from its mating face. (2) For the connectors that are connected to the equipment, only the wire harness side connector is indicated. (3) For intermediate connectors, the connector diagram of both plug terminal (male) and socket terminal (female) are indicated. (4) The lock portion of the plug terminal (male) is represented by blackening to distinguish from the socket terminal (female). 501966
13-12
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (5) Unused terminals are represented by the terminal number “-” Also, the terminal number marked with * indicates a gold-plated terminal.
2
1
501967 1. Gold-plated terminal
2. Unused terminal
(6) The terminal shapes are simplified as shown below.
Type
Round shape terminal
“U” shaped end terminal
Plug terminal (Plug)
Plug receptacle terminal (Socket)
Flat shape terminal
Actual shape
Simplified representation
13-13
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
4.
Abbreviation
Abbreviation used in this circuit diagrams are explained in the following table: List of abbreviations (Alphabetical order) Abbreviation COMBI
Explanation COMBINATION
DOC
DIESEL OXIDIZATION CATALYST
DPF
DIESEL PARTICULATE FILTER
ECM
ENGINE CONTROL MODULE
ENG
ENGINE
FC
FINGERTIP CONTROL
FDC
FOOT DIRECTION CONTROL
FNR
FORWARD-NEUTRAL-REVERSE
GND
GROUND
GSE
GROUND SUPPORT EQUIPMENT
HYD
HYDRAULIC
IGN
IGNITION
OCM
OPTION CONTROL MODULE
PS
POWER STEERING
SOL
SOLENOID
SW
SWITCH
TEMP
TEMPERATURE
T/M
TRANSMISSION
VCM
VEHICLE CONTROL MODULE
Different circuit for each market country is explained in the following abbreviations: Abbreviation of market countries
Abbreviation
13-14
Explanation
MCFA
North and South American market
MCFE
European market
SGM
Japanese market
CHAPTER 14 CIRCUIT DIAGRAM
Chapter 14 CIRCUIT DIAGRAM
14-1
㪘
㪙
㪚
㪛
㪜
㪝
㪈
㪉
㪊
㪇㪏
㪇㪎
㪇㪍
㪇㪌
㪇㪋
㪇㪊
㪇㪉
㪇㪈
㩷㪪㪫㪘㪩㪫㪜㪩
㩷㪟㪦㪩㪥㩷㩽㩷㪮㪘㪩㪥㪠㪥㪞㩷㪙㪬㪱㪱㪜㪩
㩷㪫㪬㪩㪥㩷㪪㪠㪞㪥㪘㪣
㩷㪣㪘㪤㪧
㩷㪣㪘㪤㪧
㩷㪞㪥㪛
㩷㪞㪥㪛
㩷㪚㪟㪘㪩㪞㪠㪥㪞
㩷㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩㩷㪪㪬㪧㪧㪣㪰
㩷㪈㪉㪭㩷㪧㪦㪮㪜㪩㩷㪪㪬㪧㪧㪣㪰
㪉㪊
㪉㪉
㪉㪈
㪉㪇
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪋
㪋
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪌
㪌
㪚㪠㪩㪚㪬㪠㪫㩷㪛㪠㪘㪞㪩㪘㪤
㪇㪐
㩷㪭㪜㪟㪠㪚㪣㪜㩷㪚㪦㪥㪫㪩㪦㪣
㪪㪟
㪈㪇
㩷㪭㪜㪟㪠㪚㪣㪜㩷㪚㪦㪥㪫㪩㪦㪣
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪈㪈
㩷㪭㪜㪟㪠㪚㪣㪜㩷㪚㪦㪥㪫㪩㪦㪣
㪪㪟
㪈㪉
㩷㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣
㩷㪝㪦㪦㪫㩷㪛㪠㪩㪜㪚㪫㪠㪦㪥
㪈㪊
㩷㪝㪬㪪㪜㩷㪙㪦㪯
㩷㪮㪘㪩㪥㪠㪥㪞㩷㪣㪘㪤㪧
㪈㪍
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪈㪋
㪈㪎
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㩷㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪊
㪈㪌
㪈㪏
㪉
㪈㪋㪘
㪈㪐
㪈
㪪㪟
㪍
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪚㪦㪥㪫㪜㪥㪫㪪
㪎
㪏
㪏
㪪㪟
㪘㪈
㪘
㪙
㪚
㪛
㪜
㪝
14-2
㪈
㪉
㪊
㪋
㪌
㪪㪟㪄㪇㪊
㪘㪣㪫㪜㪩㪥㪘㪫㪦㪩
㪍
㪣㪠㪞㪟㪫㩷㪪㪮
㪪㪟㪄㪇㪍
㪝㪈㩷㪈㪌㪘
㪘
㪍㪇㪘
㪪㪟㪄㪇㪉
㪪㪫㪘㪩㪫㪜㪩
㪪㪟㪄㪈㪇
㪘㪄㪇㪋
㪠㪞㪥㩷㪪㪮
㪌
㪘㪄㪇㪍
㪝㪬㪪㪜㩷㪙㪦㪯 㪘㪄㪇㪌
㪟㪦㪩㪥
㪪㪟㪄㪇㪐
㪉㪇㪉㩷㩿㪈㪅㪉㪌㪮㪆㪞㪀 㪪㪟㪄㪇㪎 㪪㪜㪩㪭㪠㪚㪜㩷 㪙㪩㪘㪢㪜㩷㪪㪮
㪉㪇㪊㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀
㪚㪄㪉㪎
㪪㪟㪄㪇㪉
㪍
㪝㪊㩷㪈㪇㪘
㪌
㪈㪋
㩿㪏㪮㪀
㪞㪄㪍㪈
㪚㪄㪉㪏
㪝㪣㪮㪈 㪇㪅㪌㫄㫄㪉 㪠㪞㪥㩷㪩㪜㪣㪘㪰
㪋
㪉㪇㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀
㪞㪄㪌㪌
㪞㪄㪌㪏
㪊
㩿㪊㪇㪙㪀
㪝㪉㩷㪈㪇㪘
㪈㪉㪭 㪞㪄㪌㪎
㪙㪦㪛㪰 㪞㪥㪛
㪉
㩿㪪㪟㪄㪇㪉㪀 㪍
㪉 㪉㪈㩷㩿㪇㪅㪏㪌㪮㪆㪙㪀
㪙
㪚
㪛
㪜
㪝
㪈
㪈 㪈 㪈㩷㩿㪌㪮㪀
㩿㪊㪇㪙㪀 㩿㪊㪇㪙㪀 㩿㪊㪇㪙㪀
㪉㪇㪈㩷㩿㪊㪮㪀
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪈㪉㪭㩷㪧㪦㪮㪜㪩㩷㪪㪬㪧㪧㪣㪰
㪎
㪏
㪏
㪪㪟
㪇㪈
㪘
㪙
㪚
㪛
㪜
㪝
14-3
㪘
㪙
㪚
㪛
㪜
㪝
㪥㪦㪫㪜
㪠㪞㪥㩷㪪㪮
㪦㪥
㪊
㪉㪋㩷㩿㪈㪅㪉㪌㪞㪆㪩㪀
㪉
㪋
㪈
㪈㩷㩿㪌㪮㪀
㪝㪥㪩㩷㪣㪘㪭㪜㪩
㪪㪟㪄㪈㪇
㪪㪜㪘㪫㩷㪪㪮
㪪㪟㪄㪈㪉
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪈㪊
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪊
㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪪㪟㪄㪈㪌
㪈
㪝㪈㪈㩷㪈㪇㪘
㪊
㪝㪈㪉㩷㪈㪌㪘
㪉
㪝㪈㪊㩷㪈㪇㪘
㪊
㪪㪟㪄㪈㪉
㪎
㪉㪇㪍㩷㩿㪊㪮㪆㪩㪀
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪩㪜㪣㪘㪰
㪈㪈㪸㩷㩿㪈㪅㪉㪌㪩㪀
㪈
㪏㪎㩷㩿㪈㪅㪉㪌㪩㪀
㪏㪍㩷㩿㪩㪀
㪋
㪋
㪪㪟㪄㪈㪉
㪝㪈㪇㩷㪈㪇㪘
㪘㪄㪇㪍
㪝㪬㪪㪜㩷㪙㪦㪯
㪘㪄㪇㪋
㪊 㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪉㪇㪊㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀
㪝㪣㪮㪈 㪈㪉㪭㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪈
㪪㪟㪄㪈㪇 㪪㪫㪘㪩㪫㩷㪪㪘㪝㪜㪫㪰㩷 㪩㪜㪣㪘㪰
㪉㪇㪍㩷㩿㪊㪮㪆㪩㪀
㪉
㪝㪬㪪㪜㩷㩿㪝㪊㪀 㪈㪉㪭㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪈
㪋
㪚㪄㪉㪉
㪞 㪙 㪤 㪪㪫
㪉㪇㪌㩷㩿㪞㪀
㪉
㪈
㪦㪝㪝
㪪㪫㪘㪩㪫
㪚㪄㪉㪉
㪊
㪩㪰㪈
㪉㪎㪇㩷㩿㪈㪅㪉㪌㪙㪀
㪚㪄㪉㪍
㪚㪄㪉㪍
㪪㪟㪄㪇㪌
㪞㪥㪛
㪉
㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪫㪩㪬㪚㪢㩷㪫㪰㪧㪜㪅
㪈
㪠㪞㪥㩷㪩㪜㪣㪘㪰
㪫㪆㪤㩷㪚㪟㪘㪥㪞㪜㩷㪪㪦㪣㪜㪥㪦㪠㪛㩷㪩㪜㪣㪘㪰
㪉㪇㪐㩷㩿㪇㪅㪏㪌㪩㪀
㪊㪉㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀
㪌
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪉㪇㪎㩷㩿㪈㪅㪉㪌㪩㪀
㪘㪄㪇㪌
㪌
㪜㪥㪞㪠㪥㪜㩷㪚㪟㪜㪚㪢㩷㪣㪘㪤㪧 㪪㪟㪄㪈㪋㪘
㪈㪇㪈㩷㩿㪩㪀
㪊㪉㪸㩷㩿㪇㪅㪏㪌㪩㪆㪮㪀
㪍㪅㪇㩷㫋㫆㩷㪎㪅㪇㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊 㪪㪟㪄㪈㪈
㪈㪈㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪍
㪍 㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪊㪅㪌㩷㫋㫆㩷㪌㪅㪌㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊 㪪㪟㪄㪇㪎
㪙㪘㪚㪢㪄㪬㪧㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪇㪎
㪝㪣㪘㪪㪟㪜㪩㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪇㪏
㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣
㪪㪟㪄㪈㪋
㪫㪆㪤㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪈㪈
㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪌
㪈㪈㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪉㪈㪌㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪉㪐㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩㩷㪪㪬㪧㪧㪣㪰
㪎
㪪㪫㪩㪦㪙㪜㩷㪣㪘㪤㪧
㪉㪈㪇㩷㩿㪈㪅㪉㪌㪩㪆㪞㪀
㩿㪪㪟㪄㪇㪈㪀 㪍㪏㩷㩿㪈㪅㪉㪌㪩㪆㪞㪀
㪈㪊㪎㩷㩿㪩㪆㪞㪀
㪏
㪏 㪛㪬㪪㪫㩷㪠㪥㪛㪠㪚㪘㪫㪦㪩㩷㪣㪘㪤㪧 㪪㪟㪄㪈㪋㪘
㪉㪈㪉㩷㩿㪩㪆㪞㪀
㪪㪟
㪇㪉
㪘
㪙
㪚
㪛
㪜
㪝
14-4
㪘
㪙
㪚
㪛
㪈
㪉
㪘㪣㪫㪜㪩㪥㪘㪫㪦㪩
㪊
㪠㪚 㪩㪜㪞㪬㪣㪘㪫㪦㪩
㪜
㪣
㪪 㪙
㪋
㪪㪟㪄㪇㪈 㪝㪬㪪㪜㩷㩿㪍㪇㪘㪀
㪌
㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪌
㪍
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪏
㪏
㪎
㩷㪚㪟㪘㪩㪞㪠㪥㪞
㪪㪟
㪇㪊
㪘
㪙
㪚
㪛
㪜
㪋
㪜
㪊
㪝
㪉
㪝
㪈
14-5
㪘
㪙
㪚
㪛
㪜
㪝
㪥㪦㪫㪜 㪈
㪞㪄㪇㪉
㪞㪄㪍㪋
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫
㪉
㪌㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪌㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪪㪟㪄㪇㪍 㪪㪟㪄㪇㪎 㪪㪟㪄㪇㪏
㪩㪜㪘㪩㩷㪚㪦㪤㪙㪠㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫 㩿㪫㪘㪠㪣㪃㩷㪪㪫㪦㪧㪃㩷㪙㪘㪚㪢㪃㩷㪫㪬㪩㪥㪀
㪌㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪪㪟㪄㪇㪍 㪪㪟㪄㪇㪎 㪪㪟㪄㪇㪏
㪩㪜㪘㪩㩷㪚㪦㪤㪙㪠㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫 㩿㪫㪘㪠㪣㪃㩷㪪㪫㪦㪧㪃㩷㪙㪘㪚㪢㪃㩷㪫㪬㪩㪥㪀
㪪㪟㪄㪇㪍
㪩㪜㪘㪩㩷㪮㪦㪩㪢㪠㪥㪞㩷㪣㪘㪤㪧
㪪㪟㪄㪇㪎
㪪㪫㪩㪦㪙㪜㩷㪣㪘㪤㪧
㪪㪟㪄㪇㪎
㪙㪘㪚㪢㪄㪬㪧㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪇
㪪㪫㪘㪩㪫㩷㪪㪘㪝㪜㪫㪰㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪈
㪫㪆㪤㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪈㪈
㪫㪆㪤㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪈㪋
㪣㪧㪞㩷㪧㪩㪜㪪㪪㪬㪩㪜㩷㪪㪮
㪪㪟㪄㪈㪋
㪙㪩㪘㪢㪜㩷㪝㪬㪣㪠㪛㩷㪪㪜㪥㪪㪦㪩
㪪㪟㪄㪈㪋
㪛㪬㪪㪫㩷㪠㪥㪛㪠㪚㪘㪫㪦㪩
㪪㪟㪄㪈㪌
㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪋
㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣
㪪㪟㪄㪇㪍 㪪㪟㪄㪇㪏
㪝㪩㪦㪥㪫㩷㪚㪦㪤㪙㪠㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫 㩿㪧㪘㪩㪢㪃㩷㪫㪬㪩㪥㪀
㪪㪟㪄㪇㪍
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫
㪪㪟㪄㪇㪍 㪪㪟㪄㪇㪏
㪝㪩㪦㪥㪫㩷㪚㪦㪤㪙㪠㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫 㩿㪧㪘㪩㪢㪃㩷㪫㪬㪩㪥㪀
㪪㪟㪄㪇㪍
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫
㪪㪟㪄㪈㪈
㪫㪆㪤㩷㪚㪟㪘㪥㪞㪜㩷㪪㪦㪣㪜㪥㪦㪠㪛㩷 㪩㪜㪣㪘㪰
㪪㪟㪄㪇㪍
㪩㪜㪘㪩㩷㪮㪦㪩㪢㪠㪥㪞㩷㪣㪘㪤㪧
㪪㪟㪄㪇㪎
㪪㪫㪩㪦㪙㪜㩷㪣㪘㪤㪧
㪉㪏㩷㩿㪈㪅㪉㪌㪙㪀 㪞㪄㪊㪌
㪍㪇㩷㩿㪈㪅㪉㪌㪙㪀
㪉
㪚㪄㪇㪏 㪉㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪈㪊㪸㩷㩿㪙㪀
㪍㪐㩷㩿㪈㪅㪉㪌㪙㪀
㪊
㪊 㪈㪊㩷㩿㪈㪅㪉㪌㪙㪀
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪉㪀
㪪㪟㪄㪇㪍
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪌㪈㩷㩿㪈㪅㪉㪌㪙㪀
㪊㪅㪌㩷㫋㫆㩷㪌㪅㪌㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫
㪞㪄㪇㪋
㪪㪟㪄㪇㪍
㪪㪫㪘㪥㪛㪘㪩㪛
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪙㪦㪛㪰 㪞㪥㪛㩷㪈
㪉
㩿㪉㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪫㪩㪬㪚㪢㩷㪫㪰㪧㪜㪅 㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪣㪘㪤㪧㩷㪪㪧㪜㪚㪠㪝㪠㪚㪘㪫㪠㪦㪥㪅
㪈
㪌㪇㩷㩿㪉㪙㪀
㪋
㪋 㪍㪍㩷㩿㪈㪅㪉㪌㪙㪆㪰㪀
㪈㪊㪈㩷㩿㪙㪀
㪊㪌㩷㩿㪙㪀
㪈㪊㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪉㪎㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪌
㪌
㪊㪍㩷㩿㪙㪀
㪍
㪍 㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪎㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪞㪄㪋㪐
㪪㪟
㪇㪋
㪘
㪙
㪚
㪛
㪜
㪝
14-6
㪏
㪏 㪍㪇㩷㩿㪈㪅㪉㪌㪙㪀
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪉㪀
㪉㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪍㪅㪇㩷㫋㫆㩷㪎㪅㪇㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊
㪞㪄㪊㪌
㪎㪏㪹㩷㩿㪈㪅㪉㪌㪙㪀
㪎
㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪚㪄㪈㪍
㪞㪄㪇㪋
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪞㪥㪛
㪎
㪊
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪮㪠㪫㪟㩷㪫㪬㪩㪥㩷㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧
㪞㪄㪇㪉 㪌㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪊 㪚㪄㪈㪎
㪌㪋㩷㩿㪈㪅㪉㪌㪙㪀
㪘
㪙
㪚
㪛
㪜
㪝
㪈
㪈 㪞㪄㪍㪋 㪙㪦㪛㪰 㪞㪥㪛㩷㪉
㪉㪎㪇㩷㩿㪈㪅㪉㪌㪙㪀
㪠㪞㪥㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪉
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪈㪉
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪊
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪈㪊
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪋
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪣㪘㪤㪧
㪪㪟㪄㪈㪉
㪫㪆㪤㩷㪪㪦㪣㪜㪥㪦㪠㪛
㪪㪟㪄㪈㪊
㪣㪠㪝㪫㩷㪣㪦㪚㪢㩷㪪㪦㪣㪜㪥㪦㪠㪛
㪪㪟㪄㪈㪊
㪬㪥㪣㪦㪘㪛㩷㪪㪦㪣㪜㪥㪦㪠㪛
㪪㪟㪄㪈㪋
㪠㪥㪫㪜㪩㩷㪣㪦㪚㪢㩷㪣㪘㪤㪧㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪋
㪠㪥㪫㪜㪩㩷㪣㪦㪚㪢㩷㪣㪘㪤㪧㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪍
㪝㪮㪛㩷㪩㪜㪣㪘㪰㩷㪉
㪉
㪉
㪪㪟㪄㪇㪉
㪈㪊㪹㩷㩿㪈㪅㪉㪌㪙㪀
㪈㪊㪺㩷㩿㪙㪀
㪉㪎㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪈㪊㪻㩷㩿㪙㪀
㪐㪊㩷㩿㪈㪅㪉㪌㪙㪀
㪉㪎㪋㩷㩿㪇㪅㪏㪌㪙㪀
㪊
㪊
㪉㪎㪊㩷㩿㪙㪀
㪋
㪋 㪉㪎㪌㩷㩿㪇㪅㪏㪌㪙㪀
㪉㪏㪌㩷㩿㪙㪀
㪉㪏㪍㩷㩿㪙㪀
㪌
㪌 㪞㪄㪌㪋
㪍
㪙㪦㪛㪰 㪞㪥㪛㩷㪊
㪍
㪊㪈㪊㩷㩿㪈㪅㪉㪌㪙㪀
㪞㪄㪌㪐
㪞㪄㪍㪇
㪎
㪙㪦㪛㪰 㪞㪥㪛㩷㪋
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪎
㩷㪞㪥㪛
㩿㪊㪇㪙㪀
㪫㪆㪤㩷㪚㪘㪪㪜
㪏
㪏 㪪㪟
㪇㪌
㪘
㪙
㪚
㪛
㪜
㪝
14-7
㪘
㪙
㪚
㪛
㪜
㪝
㪣㪠㪞㪟㪫㩷㪪㪮㪠㪫㪚㪟
㪈
㪈 㪈
㪋
㪈㪏㩷㩿㪇㪅㪏㪌㪞㪆㪙㪀
㪉
㪈㪏㩷㩿㪇㪅㪏㪌㪞㪆㪙㪀
㪎
㪉㪇㪉㩷㩿㪈㪅㪉㪌㪮㪆㪞㪀
㪉
㪈
㪝㪬㪪㪜㩷㩿㪝㪈㪀 㪈㪉㪭㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪈
㪘㪄㪇㪈
㪦㪝㪝
㪟㪜㪘㪛
㪪㪤㪘㪣㪣
㪘㪄㪇㪈
㪫㪘㪠㪣㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫 㪉
㪚㪄㪇㪏
㪚㪄㪈㪌
㪚㪄㪈㪌
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪊
㪍
㪊
㪊㩷㩿㪇㪅㪏㪌㪩㪆㪮㪀
㪋
㪉
㪋
㪉㪈㪎㩷㩿㪇㪅㪏㪌㪞㪆㪙㪀
㪊㩷㩿㪇㪅㪏㪌㪩㪆㪮㪀
㪉㪈㪎㩷㩿㪇㪅㪏㪌㪞㪆㪙㪀 㪉㪈㪏㩷㩿㪇㪅㪏㪌㪞㪆㪙㪀
㪚㪄㪈㪏
㪧㪘㪩㪢㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫 㪉
㪞㪄㪍㪊
㪚㪄㪈㪐
㪊
㪚㪄㪈㪍
㪪㪟㪄㪇㪋
㪧㪘㪩㪢㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫 㪉
㪋㪏㩷㩿㪇㪅㪏㪌㪞㪆㪙㪀
㪚㪄㪈㪎
㪪㪟㪄㪇㪋
㪞㪥㪛
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪈
㪚㪄㪈㪏
㪪㪟㪄㪇㪋
㪞㪥㪛
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪫㪘㪠㪣㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫 㪉
㪚㪄㪈㪐
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪚㪄㪈㪋
㪚㪄㪈㪋
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪉
㪞㪥㪛
㪌㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪊
㪊
㪞㪄㪇㪈
㪞㪄㪇㪌
㪞㪄㪇㪎
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫
㪈㩷㩿㪈㪅㪉㪌㪮㪆㪩㪀
㪞㪄㪇㪊
㪞㪄㪇㪍
㪞㪄㪇㪏
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫
㪈㪎㩷㩿㪈㪅㪉㪌㪞㪆㪰㪀
㪋
㪋
㪋㪎㩷㩿㪈㪅㪉㪌㪞㪆㪰㪀
㪈㩷㩿㪈㪅㪉㪌㪮㪆㪩㪀
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀 㪪㪫㪘㪥㪛㪘㪩㪛 㪞㪄㪊㪋
㪪㪟㪄㪇㪋
㪞㪥㪛
㪉㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪞㪄㪊㪎
㪞㪄㪊㪐
㪩㪜㪘㪩㩷㪮㪦㪩㪢㪠㪥㪞㩷 㪣㪘㪤㪧
㪈㪐㩷㩿㪇㪅㪏㪌㪙㪀
㪈㪐㩷㩿㪇㪅㪏㪌㪞㪆㪰㪀
㪌
㪌 㪥㪦㪫㪜 㪞㪄㪇㪈
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫
㪚㪄㪈㪎
㪈㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀
㪌
㪈㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀
㪌
㪈㪎㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀
㪍
㪞㪥㪛
㪪㪟㪄㪇㪋
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪞㪄㪇㪌
㪞㪄㪇㪎
㪞㪥㪛
㪪㪟㪄㪇㪋
㪞㪄㪇㪊
㪚㪄㪈㪍
㪟㪜㪘㪛㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫
㪞㪄㪇㪍
㪞㪄㪇㪏
㪊㪏㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀 㪮㪠㪫㪟㩷㪫㪬㪩㪥㩷㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪣㪘㪤㪧
㪎
㪎
㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪣㪘㪤㪧㩷㪪㪧㪜㪚㪠㪝㪠㪚㪘㪫㪠㪦㪥㪅
㪍
㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪏
㪏 㪪㪟
㪇㪍
㪘
㪙
㪚
㪛
㪜
㪝
14-8
㪘
㪙
㪚
㪛
㪜
㪝
㪥㪦㪫㪜 㪈 㪝㪬㪪㪜㩷㩿㪝㪉㪀 㪈㪉㪭㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪈
㪚㪄㪇㪏
㪞㪄㪋㪇
㪉㪈㩷㩿㪇㪅㪏㪌㪮㪆㪙㪀
㪉
㪋㪌㩷㩿㪇㪅㪏㪌㪞㪀
㪙㪘㪚㪢㪄㪬㪧㩷㪩㪜㪣㪘㪰
㪚㪄㪈㪋
㪉㪈㪌㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪙㪘㪚㪢㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫㩷 㪌
㪊
㪈
㪏㪊㩷㩿㪈㪅㪉㪌㪙㫉㪀
㪌㪉㩷㩿㪇㪅㪏㪌㪞㪆㪣㪀
㪉㪊㪇㩷㩿㪈㪅㪉㪌㪞㪆㪣㪀
㪝㪥㪩㩷㪣㪜㪭㪜㪩
㪪㪟㪄㪈㪉
㪈㪊㩷㩿㪈㪅㪉㪌㪙㪀
㪩㪰㪉
㪪㪟㪄㪇㪋
㪞㪥㪛
㪉
㪋
㪪㪟㪄㪇㪐 㪙㪘㪚㪢㩷 㪙㪬㪱㪱㪜㪩
㪋
㪋
㪊
㪉㪊㩷㩿㪈㪅㪉㪌㪞㪆㪣㪀
㪝㪬㪪㪜㩷㩿㪝㪈㪉㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪈
㪚㪄㪉㪌
㪉㪊㩷㩿㪇㪅㪏㪌㪞㪆㪣㪀
㪚㪄㪉㪌
㪌
㪚㪄㪇㪏
㪚㪄㪈㪌
㪊
㪙㪘㪚㪢㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫
㪉
㪞㪄㪋㪈
㪋
㪉
㪊
㪉㪈㩷㩿㪇㪅㪏㪌㪞㪆㪮㪀
㪚㪄㪈㪋
㪪㪟㪄㪇㪋
㪪㪫㪦㪧㩷㪣㪘㪤㪧㩷㪣㪜㪝㪫 㪉
㪋㪋㩷㩿㪇㪅㪏㪌㪞㪀
㪚㪄㪈㪌
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪋
㪪㪜㪩㪭㪠㪚㪜㩷㪙㪩㪘㪢㪜㩷 㪪㪮㪠㪫㪚㪟
㪚㪄㪈㪌
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪉
㪚㪄㪈㪌
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪚㪄㪈㪋
㪚㪄㪈㪋
㪞㪥㪛
㪉
㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪫㪩㪬㪚㪢㩷㪫㪰㪧㪜㪅
㪈
㪌㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪪㪫㪦㪧㩷㪣㪘㪤㪧㩷㪩㪠㪞㪟㪫㩷
㪌
㪌 㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀 㪊㪅㪌㩷㫋㫆㩷㪌㪅㪌㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊
㪍
㪍 㪞㪥㪛
㪪㪟㪄㪇㪋
㪍㪈㩷㩿㪇㪅㪏㪌㪰㪀
㪝㪬㪪㪜㩷㩿㪝㪈㪉㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪞㪄㪊㪊
㪞㪄㪊㪍
㪞㪄㪊㪏
㪪㪫㪩㪦㪙㪜㩷㪣㪘㪤㪧
㪍㪇㩷㩿㪈㪅㪉㪌㪙㪀
㪈㪈㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪞㪄㪋㪎 㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪎
㪍㪅㪇㩷㫋㫆㩷㪎㪅㪇㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊 㪝㪬㪪㪜㩷㩿㪝㪈㪉㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪈㪈
㪞㪄㪋㪏
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪣㪘㪤㪧
㪎
㪪㪧㪘㪩㪜㩷㪧㪦㪮㪜㪩㩷 㪪㪬㪧㪧㪣㪰
㪈㪈㩷㩿㪈㪅㪉㪌㪰㪀
㪉㪉㪸㩷㩿㪈㪅㪉㪌㪙㪆㪰㪀
㪏
㪏 㪪㪟
㪇㪎
㪘
㪙
㪚
㪛
㪜
㪝
14-9
㪘
㪙
㪚
㪛
㪜
㪝
㪉㪐㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪣㪠㪞㪟㪫
㪈
㪞㪄㪋㪋
㪈㩷㩿㪈㪅㪉㪌㪩㪀
㪙㪘㪫㪫㪜㪩㪰
㪝㪬㪪㪜㩷㩿㪝㪈㪉㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪞㪄㪋㪉
㪞㪄㪋㪊
㪈
㪝㪣㪘㪪㪟㪜㪩㩷㪩㪜㪣㪘㪰
㪩㪰㪋
㪚㪄㪊㪎
㪉
㪉 㪈㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪊
㪈㪌㩷㩿㪈㪅㪉㪌㪰㪆㪩㪀
㪫㪬㪩㪥㩷㪪㪮㪠㪫㪚㪟 㪘㪄㪇㪈
㪣
㪥
㪩
㪘㪄㪇㪈
㪚㪄㪈㪍
㪚㪄㪈㪏
㪚㪄㪈㪏
㪝㪩㪦㪥㪫㩷㪫㪬㪩㪥 㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧 㪩㪠㪞㪟㪫
㪈
㪈
㪉
㪋㩷㩿㪈㪅㪉㪌㪞㪆㪩㪀
㪉
㪈
㪋㪈㩷㩿㪈㪅㪉㪌㪮㪀
㪊 㪋
㪉
㪊㪐㪘㩷㩿㪇㪅㪏㪌㪮㪆㪣㪀
㪊
㪊㪐㪘㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀
㪚㪄㪈㪊
㪪㪟㪄㪇㪋
㪞㪥㪛
㪊
㪊
㪚㪄㪈㪎
㪋㩷㩿㪈㪅㪉㪌㪞㪆㪩㪀
㪚㪄㪈㪌
㪚㪄㪈㪌
㪩㪜㪘㪩㩷㪫㪬㪩㪥 㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧 㪣㪜㪝㪫
㪊
㪚㪄㪈㪊
㪈
㪉
㪉
㪋㪈㪘㩷㩿㪇㪅㪏㪌㪮㪆㪩㪀
㪚㪄㪈㪐
㪝㪩㪦㪥㪫㩷㪫㪬㪩㪥 㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧 㪣㪜㪝㪫
㪚㪄㪈㪐
㪪㪟㪄㪇㪋
㪞㪥㪛
㪋
㪌㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪊
㪉
㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪚㪄㪈㪋
㪚㪄㪈㪋
㪪㪟㪄㪇㪋
㪞㪥㪛
㪉
㪋
㪋㪈㪘㩷㩿㪈㪅㪉㪌㪮㪆㪩㪀
㪊
㪉
㪌㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪏
㪊㪐㩷㩿㪈㪅㪉㪌㪰㪆㪙㪀
㪊㪐㩷㩿㪈㪅㪉㪌㪮㪀
㪩㪜㪘㪩㩷㪫㪬㪩㪥 㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧 㪩㪠㪞㪟㪫
㪋㪈㩷㩿㪈㪅㪉㪌㪰㪀
㪉
㪪㪟㪄㪇㪋
㪞㪥㪛
㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪌
㪌
㪍
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪫㪬㪩㪥㩷㪪㪠㪞㪥㪘㪣
㪎
㪏
㪏 㪪㪟
㪇㪏
㪘
㪙
㪚
㪛
㪜
㪝
14-10
㪘
㪙
㪚
㪈
㪉
㪉
㪝㪬㪪㪜㩷㩿㪝㪊㪀 㪈㪉㪭㩷㪧㪦㪮㪜㪩㩷 㪪㪟㪄㪇㪈
㪜㪄㪇㪊
㪜㪄㪇㪋
㪘㪄㪇㪊
㪙㪦㪛㪰 㪞㪥㪛
㪊
㪊
㪙㪦㪛㪰 㪞㪥㪛
㪌
㪌
㪍
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪎
㩷㪟㪦㪩㪥㩷㩽㩷㪮㪘㪩㪥㪠㪥㪞㩷㪙㪬㪱㪱㪜㪩
㪏
㪏
㪪㪟
㪇㪐
㪘
㪙
㪚
㪛
㪜
㪝
14-11
㪋
㪋
㪙㪘㪚㪢㪄㪬㪧 㪩㪜㪣㪘㪰㩷 㪪㪟㪄㪇㪎
㪚㪄㪉㪊
㪚㪄㪉㪊
㪞㪄㪊㪈
㪞㪄㪊㪉
㪉㪊㪇㩷㩿㪈㪅㪉㪌㪞㪆㪣㪀 㪉 㪈 㪌㪋㩷㩿㪈㪅㪉㪌㪞㪆㪮㪀 㪌㪋㩷㩿㪈㪅㪉㪌㪞㪆㪣㪀
㪝㪉㪇 㪌㪘 㪙㪘㪚㪢㩷㪙㪬㪱㪱㪜㪩
㪟㪦㪩㪥
㪉㪇㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀 㪈 㪈 㪌㪊㩷㩿㪈㪅㪉㪌㪞㪀 㪈
㪛
㪜
㪝
㪈
㪟㪦㪩㪥㩷㪪㪮
㪈
㪉
㪩㪰㪎
㪌
㪪㪟㪄㪈㪉 㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪪㪟㪄㪇㪉
㪋
㪋
㪪㪫㪘㪥㪛㪘㪩㪛
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪊
㪊
㪠㪞㪥㩷㪪㪮
㪈
㪉
㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪘㪄㪇㪉
㪝 㪩
㪥
㪘㪄㪇㪉
㪚㪄㪇㪎
㪚㪄㪇㪎
㪞㪥㪛
㪪㪟㪄㪇㪋
㪊
㪪㪟㪄㪈㪌 㪜㪥㪞㪠㪥㪜㩷 㪟㪘㪩㪥㪜㪪㪪
㪋
㪌
㪌
㪍
㪜㪥㪞㪠㪥㪜 㪟㪘㪩㪥㪜㪪㪪
㪪
㪍
㪞㪄㪌㪍
㪙㪘㪫㪫㪜㪩㪰 㪪㪟㪄㪇㪈
㪙㪄
㪙㪂
㩿㪊㪇㪙㪀
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀 㪝㪦㪦㪫㩷㪛㪠㪩㪜㪚㪫㪠㪦㪥
㪘㪄㪇㪉
㪟㪄㪇㪋
㪪㪟㪄㪈㪍 㪥㪜㪬㪫㪩㪘㪣㩷 㪩㪜㪪㪜㪫㩷㪪㪮
㪥㪜㪬㪫㪩㪘㪣㩷 㪩㪜㪪㪜㪫㩷㪪㪮 㪪㪟㪄㪈㪍
㪟㪄㪇㪋
㪘㪄㪇㪉
㪝㪥㪩㩷㪣㪜㪭㪜㪩
㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪛㪠㪩㪚㪫㪠㪦㪥㩷㪫㪰㪧㪜㪅 㪉
㪏㪌㪹㩷㩿㪰㪀
㪘
㪙
㪚
㪛
㪜
㪝
㪥㪦㪫㪜
㪈
㪏
㪪㪟
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪈㪇
㪏
㩷㪪㪫㪘㪩㪫㪜㪩
㪎
㪘
㪙
㪚
㪛
㪜
㪝
14-12
㪉㪋㩷㩿㪈㪅㪉㪌㪞㪆㪩㪀 㪉 㪋 㪉㪋㪸㩷㩿㪈㪅㪉㪌㪞㪆㪰㪀
㪉 㪏㪌㩷㩿㪰㪀 㪈 㪊 㪈㪊㪸㩷㩿㪙㪀
㪏㪍㩷㩿㪩㪀 㪍 㪪㪫㪘㪩㪫㩷㪪㪘㪝㪜㪫㪰㩷 㪩㪜㪣㪘㪰
㪏㪍㩷㩿㪩㪀 㪍 㪏㪍㩷㩿㪩㪀 㪋 㪏㪍㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀 㪏㪌㩷㩿㪈㪅㪉㪌㪙㪆㪩㪀 㪉 㪏㪌㩷㩿㪰㪀 㪉 㪏㪌㩷㩿㪰㪀
㪪㪫㪘㪩㪫㪜㪩㩷㪤㪦㪫㪦㪩
㪉
㪝㪬㪪㪜㩷㩿㪝㪈㪊㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪚㪄㪉㪈 㪍㪏㩷㩿㪈㪅㪉㪌㪩㪆㪰㪀
㪈
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩
䇼㪊㪅㪌㩷㫋㫆㩷㪌㪅㪌㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊䇽
㪝㪄㪇㪈 㪉
㪚㪄㪇㪐
㪚㪄㪉㪇
㪩㪘㪙㪙㪠㪫
㪍㪈㩷㩿㪇㪅㪏㪌㪮㪆㪩㪀
㪊
㪍㪈㩷㩿㪇㪅㪏㪌㪮㪆㪩㪀
㪈
㪍㪉㩷㩿㪇㪅㪏㪌㪙㪆㪮㪀
㪉
㪍㪉㩷㩿㪇㪅㪏㪌㪙㪆㪮㪀
㪉
㪪㪧㪜㪜㪛㩷㪪㪜㪣㪜㪚㪫㪦㪩
㪊
㪊
㪞 㪩 㪰
㪈
㪍㪋㩷㩿㪈㪅㪉㪌㪮㪆㪙㪀
㪏
㪂㪉㪋㪭
㪫㪦㪩㪫㪦㪠㪪㪜
㪚㪄㪉㪇 㪊
㪈
㪎
㪂㪈㪉㪭
㪫㪆㪤㩷㪪㪟㪠㪝㪫㩷㪤㪦㪛㪜㩷 㪪㪮㪠㪫㪚㪟
㪪㪟㪄㪈㪌
㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪚㪄㪉㪈
㪞㪥㪛
㪉
㪪㪟㪄㪇㪋
㪞㪥㪛
㪘
㪙
㪚
㪛
㪜
㪝
㪈 㪉㩷㪪㪧㪜㪜㪛 㪫㪆㪤㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩 㪐
㪍㪐㩷㩿㪈㪅㪉㪌㪙㪀
㪍㪊㩷㩿㪈㪅㪉㪌㪮㪀
㪪㪠㪞㩷㪞㪥㪛 㪝㪄㪇㪈
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩㩷㪄
㪍
㪍㪊㩷㩿㪈㪅㪉㪌㪮㪀
㪈
㪊
㪍㪋㩷㩿㪈㪅㪉㪌㪮㪆㪙㪀
㪉
㪌
㩿㪈㪅㪉㪌㪮㪆㪙㪀
㪫㪆㪤㩷㪪㪧㪜㪜㪛㩷㪧㪬㪣㪪㪜
㪥㪦㪫㪜
㪪㪦㪣㪜㪥㪦㪠㪛
㪚㪟㪘㪥㪞㪜㩷㪧㪦㪠㪥㪫㩷㪪㪮
㪈㪉
㪚㪟㪘㪥㪞㪜㩷㪧㪦㪠㪥㪫㩷㪪㪮
㪍
㪍
㪩㪈 㪉㪌㱅
㪎㪏㪸㩷㩿㪈㪅㪉㪌㪙㪀
㪍㪌㪹㩷㩿㪈㪅㪉㪌㪩㪆㪰㪀
㪍㪌 㩿㪈㪅㪉㪌㪩㪆㪰㪀
㪍㪌㪸
㪏㪎
㪊㪇
㩿㪈㪅㪉㪌㪙㪆㪩㪀
㪉㪉
㪈㪈
㩿㪈㪅㪉㪌㪙㪆㪰㪀
㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪉㪉㪸㩷㩿㪈㪅㪉㪌㪙㪆㪰㪀
㪘
㪙
㪚
㪛
㪜
㪝
14-13
㪏
㪪㪟㪄㪇㪎
㪪㪟
㪈㪈
㪪㪫㪩㪦㪙㪜㩷㪣㪘㪤㪧
㪏
㪝㪬㪪㪜㩷㩿㪝㪈㪉㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪞㪄㪊㪊
㪙㪦㪛㪰 㪞㪥㪛
㩿㪈㪅㪉㪌㪙㫉㪀
㪎
㪞㪄㪈㪎
㪩㪰㪏
㪏㪌
㪞㪄㪈㪏
㪞㪄㪈㪐
㪫㪆㪤㩷㪚㪟㪘㪥㪞㪜㩷 㪪㪦㪣㪜㪥㪦㪠㪛
㪟㪄㪇㪊
㪟㪄㪇㪊
㪞㪥㪛
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪭㪜㪟㪠㪚㪣㪜㩷㪚㪦㪥㪫㪩㪦㪣
㪎
㪏㪍
㪎㪏㩷㩿㪈㪅㪉㪌㪙㪀
㪍㪌㩷㩿㪈㪅㪉㪌㪩㪆㪰㪀
㪫㪆㪤㩷㪚㪟㪘㪥㪞㪜㩷 㪪㪦㪣㪜㪥㪦㪠㪛㩷㪩㪜㪣㪘㪰
㪪㪟㪄㪇㪋
㩿㪈㪀㩷㪉㩷㪪㪧㪜㪜㪛㩷㪚㪦㪥㪫㪩㪦㪣㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪝㪦㪩㩷㪍㪅㪇㩷㫋㫆㩷㪎㪅㪇㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊㪅
㪈㪈
㪌
㪋
㪍㪋㪸
䇼㪍㪅㪇㩷㫋㫆㩷㪎㪅㪇㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊䇽
㪍㪌㩷㩿㪈㪅㪉㪌㪩㪆㪰㪀
㪪㪟㪄㪈㪌
㪪㪟㪄㪈㪌 㪜㪥㪞㪠㪥㪜㩷 㪟㪘㪩㪥㪜㪪㪪
㪈㪇
㪪㪦㪣㪜㪥㪦㪠㪛㩷㪞㪥㪛
㪌
㪎㪇㩷㩿㪈㪅㪉㪌㪣㪀
㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪞㪥㪛
㪪㪟㪄㪇㪋
㪍㪍㩷㩿㪈㪅㪉㪌㪙㪆㪰㪀
㪋
㪋
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩㩷㪂
㪈
㪪㪟㪄㪈㪇
㪝㪥㪩㩷㪣㪜㪭㪜㪩
㪉 㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪊
㪋 㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪚㪄㪇㪊
㪚㪄㪇㪊
㪌
㪝 㪥 㪩
㪈
㪞㪄㪈㪋
㪞㪄㪈㪈
㪘㪄㪇㪉
㪘㪄㪇㪉
㪏㪎㪸㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪌
㪞㪄㪈㪍
㪞㪄㪈㪊
㪉
㪊
㪞㪥㪛
㪌
㪪㪫㪘㪥㪛㪘㪩㪛
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪋
㪪㪟㪄㪇㪌
㪎
㪚㪄㪈㪉
㪉㪊㪈㩷㩿㪣㪀
㪩㪰㪍
㪝㪥㪩㩷㪣㪜㪭㪜㪩
㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪚㪄㪇㪈
㪚㪄㪈㪉
㪚㪄㪇㪍
㪚㪄㪇㪍
㪞㪥㪛
㪪㪟㪄㪇㪌
㪋
㩿㪈㪅㪉㪌㪣㪾㪆㪩㪀
㪍
㪏㪊㩷㩿㪈㪅㪉㪌㪙㫉㪀
㪞㪄㪈㪉
㪞㪄㪈㪌
㪍
㪚㪄㪇㪋
㪚㪄㪇㪋
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪪㪟㪄㪇㪎 㪙㪘㪚㪢㪄㪬㪧㩷 㪩㪜㪣㪘㪰
㪏㪊㩷㩿㪈㪅㪉㪌㪙㫉㪀
㪏
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀
㪝㪦㪦㪫㩷㪛㪠㪩㪜㪚㪫㪠㪦㪥
㪘㪄㪇㪉
㪟㪄㪇㪋
㪏
㪝㪮㪛 㪩㪜㪭 㪩㪜㪣㪘㪰㩷㪈 㪩㪜㪣㪘㪰㩷㪈 㪪㪟㪄㪈㪍 㪪㪟㪄㪈㪍
㪪㪟㪄㪈㪍 㪥㪜㪬㪫㪩㪘㪣㩷 㪩㪜㪪㪜㪫㩷㪪㪮
㪟㪄㪇㪋
㪘㪄㪇㪉
㩷㪭㪜㪟㪠㪚㪣㪜㩷㪚㪦㪥㪫㪩㪦㪣
㪎
㪏㪎㪸㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㪈
㪏㪎㪸
㪌
㪘
㪙 㪚㪄㪇㪈
㪪㪟㪄㪈㪊 㪤㪘㪪㪫㩷㪣㪦㪚㪢 㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪩㪜㪣㪘㪰 㪪㪟㪄㪈㪋㪘 㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪣㪘㪤㪧
㪊
㩿㪈㪅㪉㪌㪙㫉㪀
㪏㪏 㩿㪈㪅㪉㪌㪙㫉㪀
㪏㪎㩷㩿㪈㪅㪉㪌㪞㪆㪮㪀
㪏㪋㩷㩿㪈㪅㪉㪌㪣㪾㪆㪩㪀
㪟㪄㪇㪈
㪟㪄㪇㪈
㪞㪥㪛
㪪㪟㪄㪇㪌
㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪛㪠㪩㪚㪫㪠㪦㪥㩷㪫㪰㪧㪜㪅 㪉
㪛㪊
㩿㪪㪟㪄㪁㪁㪀 㪩㪜㪭㪜㪩㪪㪜
㪌
㪈 㪝㪦㪩㪮㪘㪩㪛
㩿㪈㪅㪉㪌㪩㪆㪙㪀
㩿㪈㪅㪉㪌㪣㪾㪆㪩㪀
㪚
㪛
㪜
㪝
㪥㪦㪫㪜
㪈
㪪㪟
㪈㪉
㪘
㪙
㪚
㪛
㪜
㪝
14-14
㪏㪊㩷㩿㪈㪅㪉㪌㪙㫉㪀
㪊
㪏㪊
㪎
㪏㪊㩷㩿㪈㪅㪉㪌㪙㫉㪀
㪫㪆㪤㩷㪪㪦㪣㪜㪥㪦㪠㪛
㪐㪈㩷㩿㪈㪅㪉㪌㪙㫉㪀 㪉 㪈 㪐㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪛㪉
㪏㪐㩷㩿㪈㪅㪉㪌㪣㪾㪆㪩㪀 㪉 㪈 㪐㪇㩷㩿㪈㪅㪉㪌㪙㪀
㪏㪋 㩿㪈㪅㪉㪌㪙㫉㪀 㩿㪈㪅㪉㪌㪙㪀 㪐㪊㩷㩿㪈㪅㪉㪌㪙㪀
㪈
㪏㪋
㪌
㪏㪋㩷㩿㪈㪅㪉㪌㪣㪾㪆㪩㪀
㪏㪎㩷㩿㪈㪅㪉㪌㪩㪀 㪉 㪋
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪦㪬㪫 㪉 㪏㪌㪺㩷㩿㪞㪆㪮㪀 㪈 㪊 㪈㪊㪺㩷㩿㪙㪀
㪠㪥㪫㪜㪩㪣㪦㪚㪢㩷㪣㪘㪤㪧 㪍 㪈㪇㪌㩷㩿㪞㪀
㪪㪜㪘㪫㩷㪪㪮㪠㪫㪚㪟
㪈㪇㪈㩷㩿㪩㪀 㪈 㪉 㪈㪇㪉㩷㩿㪣㪀 㪋 㪪㪜㪘㪫㩷㪪㪮㪠㪫㪚㪟
㪏㪌㪹㩷㩿㪰㪀 㪌 㪥㪜㪬㪫㪩㪘㪣
㪈㪈㪸㩷㩿㪈㪅㪉㪌㪩㪀 㪈 㪉 㪈㪈㪹㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀 㪈 㪧㪦㪮㪜㪩 㪞㪥㪛 㪊 㪈㪊㪹㩷㩿㪈㪅㪉㪌㪙㪀
㪝㪈㪏 㪌㪘 㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪏㪎㪸㩷㩿㪈㪅㪉㪌㪩㪆㪙㪀
㩿㪈㪅㪉㪌㪙㫉㪀
㪉
㪈
㪪㪟㪄㪈㪉
㪉㪊㪈㩷㩿㪣㪀
㪪㪜㪘㪫㩷㪪㪮
㪋
㪉㪇㪎㩷㩿㪈㪅㪉㪌㪩㪀
㪈
㪉㪇㪏㩷㩿㪈㪅㪉㪌㪩㪆㪰㪀
㪝㪈㪐 㪌㪘
㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪪㪜㪘㪫㩷㪪㪮㪠㪫㪚㪟
㪈
㪘
㪧㪦㪮㪜㪩
㪚㪄㪊㪏
㪞㪥㪛
㪚㪄㪊㪏
㪟㪄㪇㪌
㪟㪄㪇㪌
㪞㪥㪛
㪪㪟㪄㪇㪌
㪈
㪊
㪉㪎㪉㩷㩿㪈㪅㪉㪌㪙㪀
㪙
㪚
㪛
㪜
㪝
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷 㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪉
㪉 㪥㪜㪬㪫㪩㪘㪣
㪍
㪠㪥㪫㪜㪩㪣㪦㪚㪢㩷㪣㪘㪤㪧
㪊
㪊
㪪㪟㪄㪈㪋㪘 㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷 㪣㪘㪤㪧
㪉㪊㪉㩷㩿㪰㪀
㪌
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷 㪩㪜㪣㪘㪰 㪚㪄㪊㪐
㪚㪄㪊㪐 㪊
㪩㪰㪐
㪞㪥㪛
㪪㪟㪄㪇㪌
㪉㪎㪊㩷㩿㪙㪀
㪈
㪉㪊㪊㩷㩿㪰㪆㪩㪀
㪉
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪦㪬㪫
㪋
㪉㪇㪐㩷㩿㪇㪅㪏㪌㪩㪀
㪉
㪉㪊㪋㩷㩿㪇㪅㪏㪌㪩㪆㪞㪀
㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪋 㪋
㪌
㪌 㪛㪋 㪈
㪉㪊㪍㩷㩿㪇㪅㪏㪌㪩㪆㪞㪀
㪉
㪉㪊㪋㩷㩿㪇㪅㪏㪌㪩㪆㪞㪀
㪉
㪙㪄㪇㪈
㪣㪠㪝㪫㩷㪣㪦㪚㪢㩷 㪪㪦㪣㪜㪥㪦㪠㪛
㪙㪄㪇㪈
㪞㪥㪛
㪉㪊㪋㩷㩿㪇㪅㪏㪌㪩㪆㪞㪀
㪈
㪍
㪍
㪪㪟㪄㪇㪌
㪉㪎㪋㩷㩿㪇㪅㪏㪌㪙㪀
㪚㪄㪉㪐
㪚㪄㪉㪐 㪉㪊㪎㩷㩿㪇㪅㪏㪌㪙㪀
㪚㪄㪊㪇
㪚㪄㪊㪇 㪉㪊㪐㩷㩿㪇㪅㪏㪌㪙㪀
㪛㪌 㪈
㪉
㪙㪄㪇㪉
㪎
㪞㪥㪛
㪪㪟㪄㪇㪌
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪎
㩷㪭㪜㪟㪠㪚㪣㪜㩷㪚㪦㪥㪫㪩㪦㪣
㪙㪄㪇㪉
㪬㪥㪣㪦㪘㪛㩷 㪪㪦㪣㪜㪥㪦㪠㪛
㪉㪊㪏㩷㩿㪇㪅㪏㪌㪩㪆㪣㪀
㪉㪎㪌㩷㩿㪇㪅㪏㪌㪙㪀
㪉
㪈
㪉㪊㪌㩷㩿㪇㪅㪏㪌㪩㪆㪣㪀
㪏
㪏 㪪㪟
㪈㪊
㪘
㪙
㪚
㪛
㪜
㪝
14-15
㪘
㪙
㪚
㪛
㪜
㪝
㪈
㪈 㪜㪄㪇㪉 㪈 㪙㪩㪘㪢㪜㩷㪝㪣㪬㪠㪛㩷 㪪㪜㪥㪪㪦㪩
㪈㪉
㪉㪈㪇㩷㩿㪈㪅㪉㪌㪩㪆㪞㪀
㪞㪥㪛
㪞㪄㪉㪉
㪞㪥㪛
㪪㪟㪄㪇㪋
㪊㪌㩷㩿㪙㪀
㪞㪄㪉㪊
㪞㪥㪛
㪪㪟㪄㪇㪋
㪉㪎㪍㩷㩿㪈㪅㪉㪌㪙㪀
㪠㪞㪥
㪝㪬㪪㪜㩷㩿㪝㪈㪊㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪜㪄㪇㪉
㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣
㪉
㪉
㪈㪉㩷㩿㪣㪀
㪉
㪪㪟㪄㪈㪌
㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪊㩷㩿㪈㪅㪉㪌㪰㪆㪞㪀
㪋
㪍㩷㩿㪈㪅㪉㪌㪰㪆㪩㪀
㪎
㪎㩷㩿㪈㪅㪉㪌㪰㪆㪙㪀
㪏
㪧㪢㪙
㪫㪜㪤㪧 㪘㪣㪫㩷㪣 㪦㪧㪪
㪊
㪊 㪊 㪍 㪐 㪈㪇
㪝㪬㪜㪣㩿㪣㪧㪞㪀 㪪㪧㪘㪩㪜 㪤㪠㪣 㪞㪣㪦㪮
㪋
㪞㪄㪍㪉
㪟㪦㪬㪩㩷㪤㪜㪫㪜㪩㩷 㪩㪜㪪㪜㪫㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪋
㪉㪋㪇㩷㩿㪞㪀
㪌
㪩㪜㪪㪜㪫
㪌
㪌 㪠㪥㪫
㪍
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣
㪎
㪏
㪏 㪪㪟
㪈㪋
㪘
㪙
㪚
㪛
㪜
㪝
14-16
㪘
㪈
㪉 㪝㪬㪪㪜㩷㩿㪝㪈㪊㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪚㪄㪋㪇
㪞㪄㪍㪏
㪞㪄㪎㪉
㪚㪄㪋㪇
㪞㪄㪉㪇
㪞㪄㪉㪈
㪊
㪉㪈㪍㩷㩿㪩㪆㪰㪀
㪞㪄㪍㪎
㪞㪄㪎㪈
㪞㪄㪉㪐
㪞㪄㪊㪇
㪞㪥㪛
㪪㪟㪄㪇㪋
㪉㪈㪊㩷㩿㪩㪆㪙㪀 㪞㪄㪍㪍
㪞㪄㪎㪇
㪚㪄㪈㪇
㪞㪄㪉㪋
㪚㪄㪇㪉
㪚㪄㪇㪉
㪞㪥㪛
㪪㪟㪄㪇㪋
㪊
㪙㪦㪛㪰 㪞㪥㪛
㪈㪊㪍㩷㩿㪰㪆㪩㪀
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩 㪪㪟㪄㪈㪉
㪚㪄㪇㪐
㪞㪄㪉㪌
㪞㪄㪉㪎
㪚㪄㪈㪇
㪞㪥㪛
㪪㪟㪄㪇㪌
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪮㪘㪩㪥㪠㪥㪞㩷㪣㪘㪤㪧
㪎
㪏
㪏
㪪㪟
㪈㪋㪘
㪘
㪙
㪚
㪛
㪜
㪝
14-17
㪍 㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷 㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩 㪪㪟㪄㪈㪊
㪚㪄㪈㪇
㪞㪄㪍㪌
㪞㪄㪍㪐
㪉㪊㪉㩷㩿㪰㪀
㪌 㪝㪬㪪㪜㩷㩿㪝㪈㪈㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪚㪄㪈㪈
㪞㪄㪉㪍
㪞㪄㪉㪏
㪪㪟㪄㪈㪌 㪜㪥㪞㪠㪥㪜㩷 㪟㪘㪩㪥㪜㪪㪪
㪚㪄㪈㪈
㪌
㪈㪇㪌㩷㩿㪞㪀
㪋 㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷 㪩㪜㪣㪘㪰 㪪㪟㪄㪈㪌
㪋
㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷 㪣㪘㪤㪧
㪊㪉㪸㩷㩿㪇㪅㪏㪌㪩㪆㪮㪀
㪈 㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪣㪘㪤㪧
㪊 㪉㪊㪉㩷㩿㪰㪀 㪉㪎㪎㩷㩿㪙㪆㪰㪀
㪙
㪉
㪜㪥㪞㪠㪥㪜㩷㪚㪟㪜㪚㪢㩷 㪣㪘㪤㪧
㪈㪇㪌㩷㩿㪇㪅㪏㪌㪞㪀 㪈㪊㪻㩷㩿㪇㪅㪏㪌㪙㪀 㪈
㪚
㪛
㪜
㪝
㪈
㪛㪈
㪉
㪈㪊㪻㩷㩿㪙㪀
㪋㩷㩿㪣㪆㪮㪀
㪊㪉㪸㩷㩿㪇㪅㪏㪌㪩㪆㪮㪀 㪈㪈㪇㩷㩿㪇㪅㪏㪌㪞㪀 㪈 㪈㪈㪇㩷㩿㪇㪅㪏㪌㪞㪀
㪏㩷㩿㪰㪆㪞㪀 㪉 㪏㩷㩿㪰㪆㪞㪀 㪈
㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷 㪣㪘㪤㪧 㪉 㪈㪊㪈㩷㩿㪙㪀
㪋㩷㩿㪣㪆㪮㪀 㪣㪧㪞㩷㪧㪩㪜㪪㪪㪬㪩㪜㩷 㪪㪮㪠㪫㪚㪟
㪈㪇㩷㩿㪣㪆㪩㪀
㪫㪆㪚㩷㪫㪟㪜㪩㪤㪦㩷㪬㪥㪠㪫
㪉 㪐㪋㩷㩿㪰㪆㪩㪀
㪣㪧㪞㩷㪜㪤㪧㪫㪰㩷㪣㪘㪤㪧
㪉㪈㪉㩷㩿㪩㪆㪞㪀 㪈 㪊
㪉㪈㪉㩷㩿㪩㪆㪞㪀 㪈㪇㩷㩿㪣㪆㪩㪀 㪊㪍㩷㩿㪙㪀
㪛㪬㪪㪫㩷㪠㪥㪛㪠㪚㪘㪫㪦㪩㩷 㪣㪘㪤㪧 㪛㪬㪪㪫㩷㪠㪥㪛㪠㪚㪘㪫㪦㪩
㪘
㪙
㪈
㪝㪬㪪㪜㩷㩿㪝㪈㪊㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪟
㪘
㪊㪉㩷㩿㪈㪅㪉㪌㪩㪆㪮㪀
㪠㪞㪥㩷㪧㪦㪮㪜㪩
㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧
㪙
㪍㩷㩿㪈㪅㪉㪌㪰㪆㪩㪀
㪚㪟㪘㪩㪞㪜㩷㪣㪘㪤㪧
㪊㩷㩿㪈㪅㪉㪌㪰㪆㪞㪀
㪜
㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣
㪪㪟㪄㪈㪋
㪚 㪮㪘㪫㪜㪩㩷㪫㪜㪤㪧
㪎㩷㩿㪈㪅㪉㪌㪰㪆㪙㪀
㪦㪠㪣㩷㪧㪩㪜㪪㪪㪬㪩㪜
㪈㪈㪇㩷㩿㪇㪅㪏㪌㪞㪀 㪜㪄㪇㪈
㪤 㪘㪚㪚㪜㪣㩷㪂㪌㪭 㪢
㪋
㪈㪉㪋㩷㩿㪈㪅㪉㪌㪣㪆㪮㪀
㪉
㪘㪚㪚㪜㪣㩷㪩㪫㪥
㪈㪉㪊㩷㩿㪈㪅㪉㪌㪣㪆㪙㪀
㪍
㪪 㪘㪚㪚㪜㪣㩷㪂㪌㪭 㪡
㪈㪉㪍㩷㩿㪈㪅㪉㪌㪙㫉㪆㪩㪀
㪌
㪘㪚㪚㪜㪣㩷㪪㪠㪞㪉 㪩
㪈㪉㪈㩷㩿㪈㪅㪉㪌㪙㫉㪀
㪈
㪈㪉㪉㩷㩿㪈㪅㪉㪌㪙㫉㪆㪙㪀
㪊
㪥㪦㪫㪜
㪥
㪌
㪘㪚㪚㪜㪣㩷㪩㪫㪥
㪘㪚㪚㪜㪣㪜㪩㪘㪫㪦㪩㩷㪪㪜㪥㪪㪦㪩
㪘㪚㪚㪜㪣㩷㪪㪠㪞㪈 㪣
㪌
㪈㪉㪌㩷㩿㪈㪅㪉㪌㪣㪆㪩㪀
㪋
㪋
㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪜㪥㪞㪠㪥㪜㩷 㪚㪟㪜㪚㪢㩷㪣㪘㪤㪧 㪪㪟㪄㪈㪋
㪞
㪊
㪪㪟㪄㪈㪇
㪉㪋㪸㩷㩿㪈㪅㪉㪌㪞㪆㪰㪀
㪪㪫㪘㪩㪫㪜㪩㩷㪩㪜㪣㪘㪰
㪊 㪝 㪪㪫㪘㪩㪫㩷㪪㪠㪞㪥㪘㪣
㪜㪥㪞㪠㪥㪜㩷㪚㪟㪜㪚㪢㩷 㪣㪘㪤㪧
㪉
㪈㪊㪋㩷㩿㪈㪅㪉㪌㪰㪆㪣㪀
㪝㪬㪪㪜㩷㩿㪝㪈㪈㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪇㪉
㪞㪥㪛
㪪㪟㪄㪇㪋
㪉
㪋
㪟㪄㪇㪉
㪉
㪈㪊㪎㩷㩿㪩㪆㪞㪀
㪟㪄㪇㪉
㪈㪊㪌㩷㩿㪈㪅㪉㪌㪙㪀
㪊
㪩㪰㪌
㪈
㪚㪄㪇㪌
㪚㪄㪇㪌
㪪㪟㪄㪈㪋㪘 㪫㪆㪚㩷㪫㪟㪜㪩㪤㪦㩷 㪬㪥㪠㪫
㪈㪊㪍㩷㩿㪰㪆㪩㪀
㪚
㪛
㪜
㪝
㪈
㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷 㪩㪜㪣㪘㪰
㪪㪟㪄㪈㪈
㪍
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀 㪊㪅㪌㩷㫋㫆㩷㪌㪅㪌㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊
㪟㪄㪇㪉 㪥
㪎㪇㩷㩿㪈㪅㪉㪌㪣㪀
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩 㪧
㪍㪋㪸㩷㩿㪈㪅㪉㪌㪮㪆㪙㪀
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㩷㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪
㪎
㪫㪆㪤㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩
㪍㪋㩷㩿㪈㪅㪉㪌㪮㪆㪙㪀
㪪㪟㪄㪈㪈
㪍
㩿㪈㪀㩷㪫㪟㪠㪪㩷㪚㪠㪩㪚㪬㪠㪫㩷㪠㪪㩷㪛㪠㪝㪝㪜㪩㪜㪥㪫㩷㪠㪥㩷㪫㪩㪬㪚㪢㩷㪫㪰㪧㪜㪅
㪧 㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩
㪍㪊㩷㩿㪈㪅㪉㪌㪮㪀
㪪㪧㪜㪜㪛㩷㪪㪜㪥㪪㪦㪩
㪪㪜㪜㩷㪥㪦㪫㪜㩷㩿㪈㪀 㪍㪅㪇㩷㫋㫆㩷㪎㪅㪇㩷㫋㫆㫅㩷㪺㫃㪸㫊㫊
㪏
㪏 㪪㪟
㪈㪌
㪘
㪙
㪚
㪛
㪜
㪝
14-18
㪏㪍㩷㩿㪈㪅㪉㪌㪮㪆㪣㪀
㪉
㪏㪎㩷㩿㪈㪅㪉㪌㪞㪆㪮㪀
㩿㪈㪅㪉㪌㪞㪆㪮㪀
㪉
㩿㪈㪅㪉㪌㪞㪀
㪉
㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷 㪩㪜㪣㪘㪰 㪪㪟㪄㪈㪉
㪏㪎
㪊㪇㪈
㪍
㪋
㪈
㩿㪈㪅㪉㪌㪮㪆㪣㪀
㪝㪬㪪㪜㩷㩿㪝㪈㪇㪀 㪈㪉㪭㩷㪠㪞㪥㩷㪧㪦㪮㪜㪩 㪪㪟㪄㪈㪇
㪏㪍
㩿㪈㪅㪉㪌㪙㪆㪩㪀
㪞㪄㪌㪉
㪊㪇㪈㩷㩿㪈㪅㪉㪌㪞㪀
㪘
㪏㪌
㪞㪄㪌㪊
㪈
㪚㪄㪊㪌
㪈
㪞㪄㪌㪇
㪞㪄㪌㪈
㪚㪄㪊㪌
㪪㪟㪄㪈㪇 㪪㪫㪘㪩㪫㩷㪪㪘㪝㪜㪫㪰㩷 㪩㪜㪣㪘㪰
㪈
㪏㪌㩷㩿㪈㪅㪉㪌㪙㪆㪩㪀
㪙
㪚
㪛
㪜
㪝
㪥㪜㪬㪫㪩㪘㪣㩷㪩㪜㪪㪜㪫㩷 㪪㪮㪠㪫㪚㪟
㪚㪄㪊㪍 㪊㪇㪈㩷㩿㪈㪅㪉㪌㪞㪀
㪈
㩿㪈㪅㪉㪌㪙㪀
㪊㪇㪌
㪊㪇㪋
㩿㪈㪅㪉㪌㪩㪀
㩿㪈㪅㪉㪌㪩㪀
㪝㪄㪇㪉
㪋
㪝㪄㪇㪉
㪊㪈㪍
㪚㪄㪊㪈
㪚㪄㪊㪈
㪪㪟㪄㪇㪌
㪙㪦㪛㪰 㪞㪥㪛㩷㪊
㪊㪈㪊㩷㩿㪈㪅㪉㪌㪙㪀
㪝㪦㪦㪫㩷㪛㪠㪩㪜㪚㪫㪠㪦㪥㩷 㪧㪜㪛㪘㪣
㪊
㪊
㪝㪮㪛㩷㪩㪜㪣㪘㪰㩷㪈
㪝㪮㪛 㪉
㪈
㪊㪇㪈㩷㩿㪈㪅㪉㪌㪞㪀
㪩㪜㪭 㪊㪇㪍
㪊
㩿㪈㪅㪉㪌㪙㫉㪀
㪊
㪈
㪊㪈㪇
㩿㪈㪅㪉㪌㪙㪀
㩿㪈㪅㪉㪌㪰㪀
㪋
㪊㪈㪎
㪉
㪊㪇㪋
㩿㪈㪅㪉㪌㪧㪀
㩿㪈㪅㪉㪌㪩㪀 㪚㪄㪊㪉
㪩㪜㪭㩷㪩㪜㪣㪘㪰㩷㪈
㪚㪄㪊㪉
㪚㪄㪊㪍
㪍 㪉
㩿㪈㪅㪉㪌㪙㫉㪀
㪉
㪏㪊 㩿㪈㪅㪉㪌㪙㫉㪀
㪊㪇㪊㩷㩿㪈㪅㪉㪌㪞㪀
㪌
㪪㪟㪄㪈㪉 㪩㪜㪭㪜㪩㪪㪜㩷 㪪㪦㪣㪜㪥㪦㪠㪛
㪌
㪏㪊
㪋
㪋
㪊㪈㪊
㪚㪄㪊㪊
㪚㪄㪊㪊
㪝㪮㪛㩷㪩㪜㪣㪘㪰㩷㪉
㪊
㪩㪜㪭㩷㪩㪜㪣㪘㪰㩷㪈 㪚㪄㪊㪉
㪚㪄㪊㪉
㪍
㪊㪇㪍
㪈
㪍
㪋
㪊㪈㪌
㩿㪈㪅㪉㪌㪙㫉㪀
㩿㪈㪅㪉㪌㪙㪀
㪊
㪊㪈㪋
㪚㪄㪊㪋
㪚㪄㪊㪋
㪩㪜㪭㩷㪩㪜㪣㪘㪰㩷㪉
㪊㪇㪐
㪈
㩿㪈㪅㪉㪌㪙㫉㪀
㩿㪈㪅㪉㪌㪙㪀
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪉
㪊㪇㪎
㪋
㩿㪈㪅㪉㪌㪙㫉㪀
㩿㪈㪅㪉㪌㪮㪀 㪚㪄㪊㪈
㪏㪋
㪍 㪊
㩿㪈㪅㪉㪌㪣㪾㪩㪀
㪝㪮㪛㩷㪩㪜㪣㪘㪰㩷㪈
㪚㪄㪊㪈
㪚㪄㪊㪍
㪪㪟㪄㪈㪉 㪝㪦㪩㪮㪘㪩㪛㩷 㪪㪦㪣㪜㪥㪦㪠㪛
㩷㪝㪦㪦㪫㩷㪛㪠㪩㪜㪚㪫㪠㪦㪥
㪎
㪊㪇㪏
㪏㪋
㪊㪇㪉㩷㩿㪈㪅㪉㪌㪞㪀
㪉
㩿㪈㪅㪉㪌㪣㪾㪆㪩㪀 㪊
㪏
㪏 㪪㪟
㪈㪍
㪘
㪙
㪚
㪛
㪜
㪝
14-19
㪝㪐㩷㪈㪌㪘 㪝㪋㩷㪈㪌㪘
㪊
㪊
㪝㪍㩷㪊㪇㪘
㪝㪎㩷㪊㪇㪘 㪝㪊㩷㪈㪇㪘
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㪪㪙㪝㪊㩷㪈㪇㪇㪘
㪝㪉㩷㪈㪇㪘
㪉
㪪㪙㪝㪉㩷㪈㪇㪇㪘
㪝㪌㩷㪈㪌㪘 㪝㪏㩷㪉㪇㪘
㪘㪄㪇㪍
㪋
㪈
㪝㪈㪈㩷㪈㪇㪘
㪊
㪝㪈㪉㩷㪈㪌㪘
㪉
㪝㪈㪊㩷㪈㪇㪘
㪝㪬㪪㪜 㪧㪬㪣㪣㪜㪩 㪪㪙㪝㪈 㪌㪇㪘
㪋
㪘㪄㪇㪌
㪝㪈㪇㩷㪈㪇㪘
㪈 㪎
㪘㪄㪇㪋
㪉
㪝㪎㩷㪊㪇㪘
㪈
㪘㪄㪇㪌
㪝㪊㩷㪈㪇㪘
㪘
㪙
㪘㪄㪇㪋
㪈㪋
㪉
㪝㪋㩷㪈㪌㪘 㪝㪐㩷㪈㪌㪘
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㪝㪈㪌㩷㪈㪌㪘
㪝㪉㩷㪈㪇㪘 㪝㪌㩷㪈㪌㪘
㪪㪙㪝㪊㩷㪈㪇㪇㪘
㪝㪬㪪㪜㩷㪘㪪㪪㪠㪞㪥㪤㪜㪥㪫
㪝㪈㪋㩷㪈㪇㪘
㪝㪏㩷㪉㪇㪘 㪝㪈㪉㩷㪈㪌㪘
㪝㪈㩷㪈㪌㪘 㪌
㪝㪈㪈㩷㪈㪇㪘
㪚
㪛
㪜
㪝
㪝㪈㪊㩷㪈㪇㪘
㪍
㪝㪈㪎㩷㪊㪇㪘
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀 㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㪈
㪌
㪌
㪍
㪍
㪝㪬㪪㪜㩷㪥㫆㪅 㪪㪙㪝㪈 㪪㪙㪝㪉 㪪㪙㪝㪊 㪝㪈 㪝㪉 㪝㪊 㪝㪋 㪝㪌 㪝㪍 㪝㪎 㪝㪏 㪝㪐 㪝㪈㪇
㪄㪄㪄 㪄㪄㪄 㪄㪄㪄
㪎
㪚㪦㪥㪥㪜㪚㪫㪜㪛㩷㪜㪨㪬㪠㪧㪤㪜㪥㪫
㪏
㪧㪘㪩㪢㩷㪣㪘㪤㪧㪃㩷㪫㪘㪠㪣㩷㪣㪘㪤㪧㪃㩷㪩㪜㪘㪩㩷㪮㪦㪩㪢㪠㪥㪞㩷㪣㪘㪤㪧㪃 㪟㪜㪘㪛㩷㪣㪘㪤㪧
㪝㪈㪉
㪤㪜㪫㪜㪩㩷㪧㪘㪥㪜㪣㪃㩷㪫㪆㪤㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩㪃㩷 㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷㪩㪜㪣㪘㪰㪃㩷㪛㪬㪪㪫㩷㪠㪥㪛㪠㪚㪘㪫㪦㪩㩷㪣㪘㪤㪧㪃 㪫㪆㪚㩷㪦㪠㪣㩷㪫㪜㪤㪧㩷㪣㪘㪤㪧㪃㩷㪠㪥㪫㪜㪩㩷㪣㪦㪚㪢㩷㪣㪘㪤㪧㩷㪩㪜㪣㪘㪰㩷㪉
㪙㪘㪚㪢㩷㪣㪘㪤㪧㪃㩷㪙㪘㪚㪢㩷㪙㪬㪱㪱㪜㪩㪃㩷㪝㪣㪘㪪㪟㪜㪩㩷㪩㪜㪣㪘㪰㪃 㪫㪬㪩㪥㩷㪪㪠㪞㪥㪘㪣㩷㪣㪘㪤㪧㪃㩷㪪㪫㪦㪩㪦㪙㪜㩷㪣㪘㪤㪧㪃 㪫㪆㪤㩷㪚㪟㪘㪥㪞㪜㩷㪪㪦㪣㪜㪥㪦㪠㪛
㪪㪫㪦㪧㩷㪣㪘㪤㪧 㪟㪦㪩㪥㪃㩷㪠㪞㪥㩷㪩㪜㪣㪘㪰㪃㩷㪪㪫㪘㪩㪫㪜㪩㩷㪩㪜㪣㪘㪰 㪄㪄㪄 㪄㪄㪄 㪄㪄㪄 㪄㪄㪄 㪄㪄㪄 㪄㪄㪄 㪥㪜㪬㪫㪩㪘㪣㩷㪣㪦㪚㪢㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩㪃㩷㪝㪮㪛㪆㪩㪜㪭㩷㪪㪦㪣㪜㪥㪦㪠㪛㪃 㪪㪫㪘㪩㪫㩷㪪㪘㪝㪜㪫㪰㩷㪩㪜㪣㪘㪰㪃㩷㪪㪜㪘㪫㩷㪪㪮㪃㩷 㪤㪘㪪㪫㩷㪣㪦㪚㪢㩷㪚㪦㪥㪫㪩㪦㪣㪣㪜㪩㪃㩷㪣㪠㪝㪫㩷㪣㪦㪚㪢㩷㪪㪦㪣㪜㪥㪦㪠㪛㪃㩷 㪬㪥㪣㪦㪘㪛㩷㪪㪦㪣㪜㪥㪦㪠㪛 㪜㪥㪞㪠㪥㪜㩷㪟㪘㪩㪥㪜㪪㪪㪃㩷㪜㪥㪞㪠㪥㪜㩷㪚㪟㪜㪚㪢㩷㪣㪘㪤㪧
㪝㪈㪊
㪪㪧㪘㪩㪜㩷㪈㪇㪘 㪪㪧㪘㪩㪜㩷㪈㪌㪘 㪄㪄㪄 㪄㪄㪄
㪝㪈㪈
㪝㪈㪋 㪝㪈㪌 㪝㪈㪍 㪝㪈㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪈㪎
㪪㪟
㪏
㩷㪝㪬㪪㪜㩷㪙㪦㪯
㪎
㪘
㪙
㪚
㪛
㪜
㪝
14-20
㪪㪙㪝㪉㩷㪈㪇㪇㪘 㪝㪈㪇㩷㪈㪇㪘
㪝㪈㪍㩷㪉㪇㪘
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㪝㪈㩷㪈㪌㪘
㪝㪍㩷㪊㪇㪘
㩿㪥㪦㪫㩷㪠㪥㩷㪬㪪㪜㪀
㪘
㪙
㪈
㪞㪩㪦㪬㪧㩷㪘
㪄 㪍
㪉 㪎
㪊 㪏
㪋
㪘㪄㪇㪈
㪄
㪞㪩㪦㪬㪧㩷㪙
㪉
㪙㪄㪇㪈
㪈 㪉
㪙㪄㪇㪉
㪈
㪉
㪉 㪎
㪄 㪄
㪄 㪄
㪄 㪎
㪄 㪍
㪉 㪌
㪈 㪄
㪈
㪊
㪍
㪘㪄㪇㪊
㪈
㪘㪄㪇㪉
㪌
㪋
㪄 㪄
㪄 㪎
㪄 㪄
㪄
㪘㪄㪇㪋
㪌
㪌
㪄
㪈
㪄
㪉
㪄
㪊
㪄
㪄
㪘㪄㪇㪌
㪄
㪄
㪍
㪈㪋
㪄
㪄
㪍
㪄
㪄
㪎
㪘㪄㪇㪍
㪈
㪉
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪏
㪏
㪎
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪪㪟
㪈㪏
㪘
㪙
㪚
㪛
㪍
㪛
㪌
㪜
㪋
㪜
㪊
㪝
㪚
㪉
㪝
㪈
14-21
㪘
㪙
㪚
㪛
㪜
㪝
㪈
㪉
㪊
㪋
㪌
㪚㪄㪇㪏
㪍
㪚㪄㪇㪋
㪚㪄㪇㪎
㪚㪄㪇㪊
㪈
㪚㪄㪇㪍
㪚㪄㪇㪉
㪊
㪚㪄㪇㪌
㪚㪄㪇㪈
㪉
㪊 㪄
㪈 㪊
㪉
㪎
㪊
㪊
㪄
㪈
㪉
㪚㪄㪈㪌
㪌
㪍
㪈
㪉
㪈㪇
㪋
㪌
㪊
㪈
㪐
㪄
㪋
㪄
㪉
㪄
㪌
㪊
㪄
㪈
㪚㪄㪉㪈
㪎
㪎
㪚㪄㪇㪐
㪈
㪈
㪉
㪉
㪊
㪋
㪉
㪚㪄㪉㪊
㪄
㪚㪄㪉㪉
㪊
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪋
㪚㪄㪈㪋
㪋
㪉
㪚㪄㪈㪊
㪉
㪄
㪋
㪉
㪈
㪊
㪊
㪊
㪉
㪉
㪋
㪄
㪈
㪄
㪊
㪚㪄㪈㪉
㪉
㪈
㪌
㪚㪄㪉㪇
㪉
㪈
㪉
㪚㪄㪈㪐
㪋
㪚㪄㪈㪈
㪚㪄㪈㪎
㪉
㪚㪄㪈㪏
㪈
㪄
㪊
㪈
㪉
㪉
㪉
㪊
㪋
㪉
㪌
㪉
㪈
㪈
㪄 㪋
㪈
㪚㪄㪊㪇
㪉
㪋
㪊
㪊
㪄 㪋
㪚㪄㪉㪏
㪈
㪈
㪈
㪊
㪉 㪌
㪚㪄㪉㪎
㪈
㪋
㪉
㪚㪄㪈㪍
㪊 㪄
㪊
㪌
㪈
㪊 㪄
㪚㪄㪉㪍
㪈 㪋
㪄
㪉
㪉 㪉
㪄
㪈
㪉
㪉 㪌
㪈 㪋
㪊
㪚㪄㪉㪐
㪉
㪈
㪊
㪈
㪍
㪈
㪚㪄㪈㪇
㪉
㪉
㪉
㪊
㪞㪩㪦㪬㪧㩷㪚
㪈
㪄 㪋
㪚㪄㪉㪌
㪊
㪈
㪏
㪏
㪪㪟
㪈㪐
㪘
㪙
㪚
㪛
㪜
㪝
14-22
㪘
㪈
㪞㪩㪦㪬㪧㩷㪚
㪉
㪊
㪋
㪍
㪊 㪊
㪈 㪋
㪉 㪊
㪈 㪋
㪉 㪋
㪈 㪄
㪉 㪍
㪄 㪍
㪄 㪄
㪉 㪋
㪈
㪚㪄㪊㪌
㪉
㪚㪄㪊㪋
㪄
㪚㪄㪊㪊
㪈
㪚㪄㪊㪉
㪋
㪚㪄㪊㪈
㪊
㪉 㪈
㪍
㪋
㪉
㪉
㪈 㪊
㪄
㪊
㪚㪄㪊㪐
㪈
㪚㪄㪊㪏
㪉
㪌
㪉
㪈 㪊
㪚㪄㪊㪍
㪍
㪊
㪈 㪉
㪈 㪊
㪉
㪎
㪚㪄㪊㪎
㪉
㪊
㪈
㪏
㪘
㪙
㪚
㪪㪟
㪉㪇
㪚
㪎
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪛
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪏
㪛
㪍
㪜
㪌
㪜
㪉
㪈
㪚㪄㪋㪇
㪊
㪋
㪋
㪈
㪊
㪝
㪙
㪉
㪝
㪈
14-23
㪘
㪙
㪚
㪈
㪉
㪊
㪋
㪜㪄㪇㪈
㪞㪩㪦㪬㪧㩷㪜
㪈
㪞㪩㪦㪬㪧㩷㪝 㪝㪄㪇㪈
㪈
㪌
㪍
㪊
㪄
㪝㪄㪇㪉
㪉
㪈
㪉
㪈㪈
㪌 㪄
㪋 㪄
㪄 㪏
㪉 㪎
㪈
㪊
㪄
㪜㪄㪇㪉
㪈㪉
㪋
㪈
㪜㪄㪇㪊
㪈
㪜㪄㪇㪋
㪌
㪍
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪏
㪏
㪎
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪪㪟
㪉㪈
㪘
㪙
㪚
㪛
㪍
㪛
㪌
㪜
㪉
㪋
㪜
㪊
㪝
㪉
㪝
㪈
14-24
㪘
㪙
㪚
㪛
㪜
㪝
㪈
㪞㪩㪦㪬㪧㩷㪞
㪊
㪚㪘
㪋
㪞㪄㪇㪎㪃㪇㪏
㪚㪙
㪉
㪞㪄㪇㪌㪃㪇㪍
㪚㪘
㪞㪄㪈㪈㩷㫋㫆㩷㪈㪊
㪚㪙
㪞㪄㪇㪈㩷㫋㫆㩷㪇㪋
㪚㪘
㪣㪘
㪚㪙
㪚㪘
㪞㪄㪋㪎
㪞㪄㪉㪐㪃㪊㪇
㪚㪙
㪞㪄㪋㪋
㪞㪄㪉㪎㪃㪉㪏
㪞㪄㪋㪊
㪚㪙
㪞㪄㪍㪉
㪚㪙
㪣㪘
㪞㪄㪍㪈
㪚㪘
㪞㪄㪉㪌㪃㪉㪍
㪚㪪㪧
㪚㪘
㪞㪄㪌㪐㪃㪍㪇
㪙㪘
㪚㪙
㪞㪄㪉㪋
㪚㪙
㪚㪙
㪞㪄㪌㪏
㪙㪘
㪉
㪋
㪞㪄㪉㪉㪃㪉㪊
㪞㪄㪋㪉
㪊
㪞㪄㪉㪇㪃㪉㪈
㪚㪙
㪞㪄㪋㪇㪃㪋㪈
㪚㪪㪧
㪞㪄㪌㪎
㪙㪛
㪈
㪌
㪞㪄㪈㪋㪃㪈㪌
㪞㪄㪈㪍
㪚㪘
㪚㪘
㪣㪘
㪚㪙
㪚㪙
㪞㪄㪋㪏㪃㪋㪐
㪣㪜
㪞㪄㪊㪈
㪌
㪚㪙
㪍
㪞㪄㪈㪎㪃㪈㪏
㪞㪄㪈㪐
㪣㪜
㪎
㪚㪙
㪚㪘
㪚㪘
㪞㪄㪌㪍
㪞㪄㪊㪍㪃㪊㪎
㪚㪙
㪞㪄㪌㪌
㪙㪘
㪞㪄㪊㪊㩷㫋㫆㩷㪊㪌
㪚㪙
㪞㪄㪌㪋
㪙㪛
㪞㪄㪊㪉
㪞㪄㪌㪇㩷㫋㫆㩷㪌㪊
㪣㪘
㪎
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪣㪘
㪍
㪏
㪚㪘
㪞㪄㪊㪏㪃㪊㪐
㪏
㪪㪟
㪉㪉
㪘
㪙
㪚
㪛
㪜
㪝
14-25
㪘
㪙
㪈
㪞㪄㪍㪊
㪞㪩㪦㪬㪧㩷㪞
㪚㪙
㪊
㪈
㪞㪩㪦㪬㪧㩷㪟 㪟㪄㪇㪈
㪋
㪚㪘
㪉
㪜 㪧
㪝 㪩
㪞 㪪
㪟
㪊
㪞㪄㪍㪐㩷㫋㫆㩷㪎㪉
㪥
㪞㪄㪍㪌㩷㫋㫆㩷㪍㪏
㪄
㪞㪄㪍㪋
㪤
㪚㪘
㪣
㪚
㪚㪙
㪢
㪙
㪣㪘
㪟㪄㪇㪉
㪡
㪘
㪏㪌
㪟㪄㪇㪊
㪏㪎 㪄 㪊㪇
㪏㪍
㪋
㪌
㪈
㪌
㪉
㪄
㪊
㪄
㪊
㪌
㪉
㪋
㪈
㪟㪄㪇㪋
㪋
㪉 㪍
㪍
㪋
㪟㪄㪇㪌
㪄
㪈 㪊
㪎
㪚㪠㪩㪚㪬㪠㪫㩷㪥㪘㪤㪜
㪏
㪏
㪎
㩷㪚㪦㪥㪥㪜㪚㪫㪦㪩
㪪㪟
㪉㪊
㪘
㪙
㪚
㪛
㪍
㪛
㪌
㪌
㪜
㪋
㪜
㪚
㪉
㪊
㪝
㪍
㪉
㪝
㪈
14-26
Cat Lift Trucks
Service Manual
GC35K - GC70K STR Lift Trucks
99739-8D100
Mitsubishi Caterpillar Forklift America Inc. 2121 W. Sam Houston Parkway N. Houston, TX 77043-2305 © 2016 MCFA. All rights reserved. CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow", the "Power Edge" trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission. All registered trademarks are the property of their respective owners. Some products may be shown with optional equipment.
99739-8D100
06/16
60A
ALTERNATOR +
AC
RD 10
RD 8
UNUSED
CAN1+ CAN1-
5V_ext1 5V_rtn1 CRK_POS CRK_NEG CAM_POS CAM_NEG SPD_POS SPD_NEG
SPK_COIL1a SPK_COIL1b SPK_COIL2a SPK_COIL2b SPK_COIL3a SPK_COIL3b SPK_COIL4a SPK_COIL4b IAT ECT EGT AUX_DIG1 AUX_DIG2 AUX_DIG3 Vswitch AUX_ana_PU1 AUX_ana_PU2 AUX_ana_PU3 5V_ext2 5V_rtn2 GOV1 GOV2 OILP AUX_ana_PUD1
TACH Vbat
Ground STARTER RELAY EGOH_1 EGOH_2 EGOH_4 BUZZ AUX_PWM5 AUX_PWM5_Rec Vbat MIL Ground DBW+ DBW_ FPUMP
TMAP
PE/LB 18
BK/LG 18
LB/BE 18
YW/GY 18
LG 18
LG/RD 18
1 S8 2 4G 3 S7 4 4G
LG 18
TN/GN 18 BE/OE 18
CM0612
5V_rtn1 39 IAT
4 3 2
5V_ext1
1
7 MAP
S8 BE/PK 18 BE/WE 18
TWP-1
TWP-1
S9
CAM SENSOR PE/OE 18
A S9 B 4G C S7
GY/BN 18
S7
LG/RD 18
BK/LG 18
CAM_NEG
A
23 CAM_POS
B
BK/WE 18
TWP-6
TWP-7
TWP-7
BK/LG 18
RD/WE 18 RD/BK 18
TWP-5
PK/GN 18 BK/YW 18
S10
BK/LG 18
C
A B 4G 2 EGO_2 C S16 D 4G 73 EGOH_2
A
S10 5V_rtn1
GN/WE 18
S16
B
CF0240
EGO2
5V_ext1
GY/BN 18 PE/OE 18
A
D C
S10 TWP-6
C
A S10 5V_rtn1 B 4G 1 EGO_1 C S16 D 4G 72 EGOH_1
PK/GN
CM0269
PE/WE 18 WE/PE 18
BK/LG 18 GN/OE 18
TWP-7
LG/RD 18
EGO1
S10
BK/LG 18
D
B
CF0240 YW 18
CRANKSHAFT POS SENSOR S7
LG/RD 18
S19
CM1134
PE/WE 18
TR0049 STARTER SOLENOID
Locking Tab
1 S7 5V_ext1 2 S19 CRK_NEG 3 4G 21 CRK_POS
WE/PE 18
TWP-6
1
2
3
WE 14
YW/GY 18
ECT
TN/WE 18 TN/WE 18 BK/LG 18
A 4G 40 ECT B S10 5V_rtn1
A
CM1151
B
RD 18
PK/TN 18
PK/GN 18
S16
BE/YW 18
LG/PE 18 LG/BK 18
S8
S7
OIL PRESSURE BK/LG 18
1 2 S7 3 4G
A
A S18 B S16
B
LB 18
CM1100 S18
5V_ext1
1
53 OILP
RD/TN 16
WE/LB 18 N/C
2
V R2
3
S18
S12
BE/PK 18 TWP-4
PK/TN 18
S11
BK 18
BK 16
RD/TN 18
WE/LB 18 BK/WE 18
WE/BK 18
WE/BK 18 PK/TN 18
S11
BN/WE 16
A 4G B S11
F
85
X 2
4
1 5
86
AB
3
G
N 30
87A 87
R1
STARTER RELAY
D
N/C PK/GN 14
S16
C
75 EGOH_4
B
CM0115
F1-5A VSW
P
A
B
EC0196
EC0379
A
PK 18 1
Vswitch
GN/YW 18 BK 16
CM0113
M
20A
2 PK/TN 18
PK/WE 18
DEPR
TN/OE 18
S3 S6
TN 18
WE 18
S4
BE/PK 18
TWP-3
TWP-3
PK/GN 18 BK 18
BE 18
TWT-2
PK/BK 18
S12
BE/WE 18 RD/TN 18
1 CAN TERM 1 2 S4 CAN1+ 3 FUSEBOX K 4 S14 Ground 5 S6 CAN16 S12 Vbat
CM1823
CAN TERM 1
A
1 4 2 5 3 6
WE 18
A DEPR
S16
IGNITION COIL PK/GN 16 YW/BK 18
1 CAN1 +
TWP-1
A S4
CAN1 +
CF0054
PK/GN 18 YW 18
S14 S14
BK 18
S14
MOD D
IGNITION MODULE
CAN TERM 2 WE 18
A S16 B IGNITION C n/a
YW/BK 18
A S16 B 4G 31 SPK_COIL1a C S14 Ground D IGNITION COIL B
H S18
CM0607 B
C
RD/TN 14
5A
THROTTLE TN/OE 18 BK/LG 18
S8
S7
LG/RD 18 PK/WE 18
BK 8
LB/BE 18 PE/LB 18
GROUND
S7
TR0377
CM1833
R PK/GN 18
A
B
C
TN/GN 18 BE 18 LB/PK 18 GN/YW 18 BE/YW 18 PE/YW 18 BE/OE 18 BK/LG 18 LG/RD 18 RD/WE 18 TWP-5
RD/BK 18 LG/BK 18 LG/PE 18
D
FUSEBOX P - VSW 4G 77 AUX_PWM5 TEMPSENDER 4G 87 AUX_PWM1 4G 88 AUX_PWM2
TN/GN 18
FUSEBOX G - STRT CMD 4G 80 MIL 4G 46 AUX_ana_PU1
S8 5V_rtn1 S7 5V_ext1 4G 25 SPD_POS 4G 26 SPD_NEG 4G 50 5V_rtn2
BE/PK 18
4G 49 5V_ext2
A CONNECTOR1
C
BE/WE 18
CM0610
TF0742 A
B
J
K
L
D
E
M
N
P
G
H
R
S
BE/PK 18 TWP-2
4G 9 FPP1
TEMPSENDER PE/YW 18
S2
S5
4G 8 AUX_ana_PD1
TWP-2
BE/WE 18
10
K PK/GN 18
PK/GN 16
7
8
B PK/GN 16
83 DBW_ 5V_rtn1 5V_ext1
6 5
6 TPS2 5 TPS1
DIAGNOSTIC BK/LG 18
9
F4-20A AJ IGNITION
4
3 2
J
1
RD 14
S8
TWP-1
A B C D E F G H J K L M N P R S
TWT-1
TN 18
F5-5A DEPR
S20
CM0852
82 DBW+
1 S8 5V_rtn1 2 3 4 4G 44 AUX_DIG3 5 6 7 S2 CAN1+ 8 S5 CAN1-
CM1831 4 3 2 1 8 7 6 5
E N
F G
S12
TWP-1
PK 18
C
4 RD/TN 16
A
S12
CONNECTOR 1 BN/WE 16
1 4G 2 S8 3 S7 4 4G 5 4G 6 4G
3
F6-25A STARTER 11
25A
LOADING VIEW
D
GROUND TR0377
RD 16
F2-20A ECM
20A
5A
60A
RD/TN 16
S14
TR0379
E
LB/PK 18
LOCKOFF
BK/YW 18
D
A S3 CAN1 + B S6 CAN1 C S11 Vswitch D S14 Ground E S12 vBAT F n/a
BE/WE 18
RD 14
CF0115
MASTER TRACK
PK/BK 18
RD/TN 18
Z
BK 12
ALTERNATOR -
POWER RELAY
S8 5V_rtn1
LG/RD 18
LB 18
CM1151
ALTERNATOR
TN/GN 18
TWP-1
AUX_PWM1 AUX_PWM2 AUX_PWM4
GN/WE 18
TWP-4
TPS1 TPS2 MAP AUX_ana_PD1 FPP1 FPP2-IVS AUX_ana_PUD2 AUX_ana_PUD3
GN/OE 18
TWP-4
4G90 ECM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
TWP-1
EGO_1 EGO_2 EGO_3
TR0200L
TR0200L
TWP-1
TR0379
BATT +
BATT +
MAXI FUSE
BK/LG 18
AD
RD 8
A
12 RD/TN 14
S T U Y
V W X Z
AA
AB
C
H
M
P
AC
AD
B
AJ
L
Q
AE
AF
A
J
K
R
AG
AH
CB0186 WIRE INSERTION VIEW
®
Lift Trucks
Service Manual Chassis & Mast GC35K
GC40K
GC40K STR
GC45K SWB
GC45K STR GC45K
AT87-00001-up
GC55K
AT88-00001-up
AT87A-00001-10230
AT88A-00001-10230
AT87A-10231-20230
AT88A-10231-20230
AT87A-20231-up
AT88A-20231-up
AT87-00001-up
GC55K STR
AT88-00001-up
AT87A-00001-10230
AT88A-00001-10230
AT87A-10231-20230
AT88A-10231-20230
AT87A-20231-up
AT88A-20231-up
AT87-00001-up
GC60K
AT89-00001-up
AT87A-00001-10230
AT89A-00001-10230
AT87A-10231-20230
AT89A-10231-20230
AT87A-20231-up
AT89A-20231-up
AT87-00001-up
GC70K
AT89-00001-up
AT87A-00001-10230
AT89A-00001-10230
AT87A-10231-20230
AT89A-10231-20230
AT87A-20231-up
AT89A-20231-up
AT87A-20231-up
GC70K STR
AT89-00001-up
AT88-00001-up
AT89A-00001-10230
AT88A-00001-10230
AT89A-10231-20230
AT88A-10231-20230
AT89A-20231-up
For use with GM4.3L, G6 Engine Service Manual and Fuel System Supplements
99739-82100
FOREWORD This service manual is a guide to servicing of Cat Lift Trucks for 3.5 thru 7.0 ton models. The instructions are grouped by systems to serve the convenience of your ready reference. Long productive life of your lift trucks depends to a great extent on correct servicing — the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Cat Lift Trucks reserves the right to change specifications or design without notice and without incurring obligation. The GM4.3 Liter engine’s fuel system was changed to comply with the EPA guidelines in 2004 and again at the beginning of 2007. This manual has minimal information on the fuel systems. Please see the Fuel System Supplement for information regarding the Multi Port Fuel Injection System (MPFI). Also see the engine service manual for general engine repair or rebuild. For the items pertaining to the engine, refer to the following service manuals: • GM4.3L (G6) Engine Service Manual • GM4.3L 2004~2006 Fuel System Supplement • GM4.3L 2007~2009 Fuel System Supplement
SAFETY RELATED SIGNS The following safety related signs are used in this service manual to emphasize important and critical instructions: WARNING
Indicates a specific potential hazard resulting in serious bodily injury or death.
CAUTION
Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of the machine.
NOTE
Indicates a condition that can cause damage to, or shorten service life of the machine.
Pub. No. 99739-82100
WARNING
SAFETY WARNING
WARNING
The proper and safe lubrication and maintenance for this lift truck, recommended by Cat Lift Trucks, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance.
Do not operate this truck unless you have read and understood the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death. 4.
Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.
5.
Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.
6.
To avoid back injury, use a hoist when lifting components which weighs 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.
7.
To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.
8.
Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.
9.
Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquid under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.
The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1.
Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product.
2.
Always wear productive glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.
3.
Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.
10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use lesser quality fastener if replacements are necessary. Do not mix metric fastener with standard nuts and bolts. 12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not Operate” tag in the Operator’s Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operation. Reinstall the wiring so it is not damaged nor it will be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. 17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibrations or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
HOW TO READ THIS MANUAL Disassembly diagram (example)
2
1 4
Each disassembly diagram is followed by Disassembly sequence and Suggestions disassembly.
3
▲
1 Cover, Bolt, Washer (part name) 2 Output shaft (part name)
▲
Disassembly sequence
▲
Suggestion for disassembly (1) Output shaft removal Unit: mm (in.) Clearance between cylinder and piston
A
0.020 to 0.105 (0.00079 to 0.00413)
B
0.15 (0.0059)
A: Assembly standard B: Repair or service limit
Symbols or abbreviations OP..........................Option R1/4 ......................Taper pipe thread (external) 1/4 inch (formerly PT1/4) Rc1/8 ....................Taper pipe thread (internal) 1/8 inch (formerly PT1/8) G1/4A ....................Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 ....................Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
GROUP INDEX Group
Items
GENERAL INFORMATION Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical Data.
1
COOLING SYSTEM
Description, Removal and Installation, Inspection and Adjustment, Fan Belt Inspection, Fan Belt Adjustment.
2
ELECTRICAL SYSTEM
Description, Disassembly and Re-assembly, Major Electrical Components, Battery Maintenance, Typical Open Circuit Voltage, Lamp Bulb Specifications, Electrical System Schematics.
3
POWER TRAIN
Specifications, Structure, Reduction Ratio, Procedures and Key Points for Removal and Installation.
4
POWERSHIFT TRANSMISSION 1-Speed Transmission (GC35K-GC55K STR), Specifications, Structure, Removal and Installation, Torque Converter, Transmission, Control Valve, Adjustment, Automatic 2-speed Transmission (GC60K-GC70K STR), Specifications, Structure, Transmission, Solenoid Valve, Adjustment, Troubleshooting, Service Data.
5
FRONT AXLE
Specifications, Structure, Procedures and Key Points for Removal and Installation, Axle Shaft and Hub, Reduction Differential, Troubleshooting, Service Data.
6
REAR AXLE
Specifications, Structure, Procedures and Key Points for Removal and Installation, Rear Axle Assembly, Steering Cylinder, Adjustment, Troubleshooting, Service Data.
7
BRAKE SYSTEM
Specifications, Structure, Master Cylinder, Wheel Cylinder, Wheel Brake, Parking Brake Lever, Adjustment and Tests, Troubleshooting, Service Data.
8
STEERING SYSTEM
Specifications, Structure, Procedures and Key Points for Removal and Installation, Steering Control Valve, Troubleshooting, Service Data.
9
HYDRAULIC SYSTEM
Specifications, Description, Removal and Installation, Disassembly and Re-assembly, Inspection and Adjustment, Hydraulic Circuit Diagram, Troubleshooting, Service Data.
10
MASTS AND FORKS
Specifications, Description, Disassembly and Re-assembly, Inspection and Adjustment,Troubleshooting, Service Data.
11
SERVICE DATA
Inspection Standards, Periodic Replacement of Parts, Special Tool Table.
12
GENERAL INFORMATION
Vehicle Exterior .......................................................................................................................... 1 - 1 Models ........................................................................................................................................ 1 - 1 Serial Number Locations ............................................................................................................ 1 - 2 Dimensions.................................................................................................................................. 1 - 4 Technical Data ............................................................................................................................ 1 - 5
1
GENERAL INFORMATION
Vehicle Exterior • This Service Manual deals with all components or systems of Cat lift trucks; except for the engine and attachment, which are covered in the respective manuals.
102530A
Models This manual applies to the following vehicle models (names). Truck Models
Transmission
Serial Number
Engine Mounted
GC35K AT87-00001-up AT87A-00001~10230 AT87A-10231-20230 AT87A-20231-up
GC40K GC40K STR GC45K SWB
1-Speed
GC45K STR GM4.3L Gasoline Engine GC45K
AT88-00001-up AT88A-00001~10230 AT88A-10231-20230 AT88A-20231-up
GC55K GC55K STR GC60K GC70K GC70K STR
Automatic 2-Speed
AT89-00001-up AT89A-0000~10230 AT89A-10231-20230 AT89A-20231-up 1
GENERAL INFORMATION
Serial Number Locations
Name Plate
Chassis Serial Number (Former Models)
Mast Number
Transmission Serial Number
1-2
Gasoline Engine Serial Number
Chassis Serial Number (New Models)
GENERAL INFORMATION
Chassis and Mast Model Identification [Chassis] GC 55 K
Generation designator
Maximum capacity 55 :5500kg (12000lb) Engine type GC: gasoline engine type
[Mast] A
55 A
33
Maximum lifting height (“33” stands for 3300mm.) Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 55:5.5 ton class
Kind of mast A: simplex mast B: duplex mast C: triplex mast
1-3
GENERAL INFORMATION
Dimensions
F
K
J
I
D A
G
H B
N C
L E
1-4
M 206999
GENERAL INFORMATION
Technical Data Ref. No. A
B
Unit: mm (in.) Truck Models GC35K
Items Maximum lift Simplex mast Free lift (Floor to forktop)
GC40K
GC40K STR
3050 (120)
2900 (114)
Simplex mast
150 (5.9)
160 (6.3)
Duplex mast
920 (36.2) 3.0 m (118 in.) mast
895 (35.2) 2.8 m (112 in.) mast
Triplex mast
800 (31.5) 4.0 m (157 in.) mast
920 (36.2) 4.3 m (169 in.) mast
C
Fork length
D
Tilt angle (forward – backward)
E
Overall length (OLH)
F
Overall width Standard (outside) Wide tread (option)
G
Overall height (to top of mast lowered)
2155 (85.0)
H
Overall height (to top of overhead guard)
2155 (85.0)
1220 (48) 5/10 Simplex, Duplex mast 6/5 Triplex mast
deg. 2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
1180 (46.5) 1270 (50.0)
4250 (167)
4125 (162)
Overall height (mast extended) Duplex mast
4250 (167) 3.0 m (118 in.) mast
4080 (160.6) 2.8 m (112 in.) mast
Triplex mast
5250 (206.7) 4.0 m (157 in.) mast
5560 (218.9) 4.3 m (169 in.) mast
Simplex mast I
GC45K SWB
Standard
940 (37.0)
Wide tread (option)
1040 (41.0)
J
Tread (front)
K
Tread (rear)
980 (38.5)
L
Wheelbase
1575 (62.0)
M
Rear overhang
N
Underclearance (at frame)
485 (18.8)
525 (20.3)
335 (13.3)
150 (5.9)
1-5
565 (22.1)
GENERAL INFORMATION
Unit: mm (in.) GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
2900 (114)
2350 (93)
160 (6.3)
165 (6.5)
GC70K STR
895 (35.2) 2.8 m (112 in.) mast 895 (35.2) 4.0 m (157 in.) mast
900 (35.4) 3.5 m (138 in.) mast 1220 (48)
5/10 Simplex, Duplex mast 6/5 Triplex mast 2730 (107)
2910 (115)
6/10 Simplex mast 6/5 Triplex mast 2640 (104)
2950 (116)
1320 (52.0)
2730 (107)
1440 (56.5)
1420 (56.0) 2155 (85.0)
2205 (87.0)
2155 (85.0)
2205 (87.0)
4125 (162)
3585 (141)
4080 (160.6) 2.8 m (112 in.) mast 5560 (218.9) 4.0 m (157 in.) mast
4785 (188.3) 3.5 m (138 in.) mast
1015 (40.0)
1130 (44.5)
1120 (44)
470 (18.1)
965 (38.0)
1160 (45.5)
1780 (70.0)
1830 (72.0)
650 (26.1)
380 (15.1)
590 (23.1)
150 (5.9)
200 (7.9)
1-6
340 (13.1)
GENERAL INFORMATION
Technical Data GC35K
GC40K STR
GC40K
Traveling performance
Work performance
Truck Models Capacity/load center
kg/mm (lb/in.)
Maximum lift height Simplex
mm (in.)
3050 (120)
2900 (114)
Lift speed (loaded)
540 (105)
390 (78.0)
Lowering speed (loaded)
mm/sec. (fpm)
550 (108)
440 (86.5)
Mast tilt (forward-backward)
degree
Free lift
mm (in.)
Gradeability at 1 mph (1.6 km/h)
mm (in.)
Loaded No loaded
%
Loaded No loaded
Overall length to fork face Overall width
Overall height
2340 (92.0)
2245 (88.5)
2295 (90.5)
2100 (82.5)
2350 (92.5)
37
33
32
27
23.8
21.1
21.5
17.7
42
37
36
30
23.8
21.1
21.5
17.7
2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
1180 (46.5)
Wide tread (optional)
1270 (50.0)
To top of mast (lowered)
2200 (86.5)
2350 (92.5)
To top of mast (extended)
4250 (167.5)
4130 (162.5)
2155 (85.0)
mm (in.)
1575 (62.0) Standard
940 (37.0)
Wide tread (optional)
1040 (41.0) 980 (38.5)
Rear
485 (18.8)
Single Front wheels
Service weight -no load Single wheels (without load) Axle Front loading Rear
525 (20.3)
335 (13.3)
565 (22.1)
150 (5.9) 22×9×16
mm
Rear Weight
18.5 (11.5)
2090 (82.5)
Underclearance (at frame) Tire size
19 (12.0)
2285 (90)
Rear Overhang
160 (6.5)
2235 (88.0)
Wheelbase Front
150 (6.0)
Standard
To top of overhead guard
Tread
4500/600 (10000/24)
19.5 (12.5)
Minimum turning radius Minimum intersecting isle Standard
4000/500 (8000/24)
5/10
Loaded Travel Powershift km/h transmission speed No load (mph) models
Gradeability at stall
Dimensions
3500/500 (7000/24)
GC45K SWB
18×7×12.12
kg (lb)
5200 (11500)
5600 (12300)
5700 (12700)
6500 (14300)
2050 (4600)
2025 (4400)
2150 (4900)
1925 (4200)
3150 (6900)
3575 (7900)
3550 (7800)
4575 (10100)
1-7
GENERAL INFORMATION
GC45KSTR
GC45K
GC55K
4500/600 (10000/24)
GC55K STR
GC60K
5500/600 (12000/24)
GC70K
6000/600 (13500/24)
7000/600 (15500/24)
2900 (114)
2360 (93)
390 (78.0)
360 (71.0)
440 (86.5)
540 (106.0)
5/10
6/10
160 (6.5)
165 (6.5)
18.5 (11.5)
18 (11.5)
21 (13.0)
19.5 (12.5)
GC70K STR
20.5 (12.5) 23 (14.5)
22.5 (14.0)
2440 (96.0)
2550 (100)
2350 (92.5)
2570 (101.0)
2400 (94.5)
2345 (92.5)
2455 (96.5)
2255 (89)
2395 (94.5)
2220 (87.5)
26
22.6
22.2
24.5
21.7
21.4
23.8
20.2
20.9
22.2
19.7
20.4
30
26
25
30
27
26
23.8
20.2
20.9
22.2
19.7
20.4
2730 (107)
2910 (115)
2460 (104)
2950 (116)
1320 (52.0)
2700 (106)
1440 (56.5)
1420 (56.0) 2350 (92.5)
2530 (99.5)
4130 (162.5)
2370 (93.0)
2155 (85.0)
2205 (87.0)
1780 (70.0)
1830 (72.0)
1015 (40.0)
1135 (44.5)
1115 (44.0) 965 (38.0) 470 (18.1)
18×8×12.12
1160 (45.5)
650 (26.1)
380 (15.1)
590 (23.1)
150 (5.9)
200 (7.9)
22×12×16
28×12×12 18×8×12.12
340 (13.1)
22×8×16
6600 (14500)
7200 (15800) 7400 (16200)
8800 (19300)
9500 (20900)
9700 (21300)
2625 (5700)
2425 (5300)
2625 (5700)
3300 (7300)
3300 (7200)
3500 (7500)
3975 (8800)
4775 (10500) 4775 (10500)
5500 (12000)
6200 (13700)
6200 (13800)
1-8
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. Truck Models GC35K
GC40K STR
GC40K
Items Engine model
GM4.3L
Type
Gasoline
Cooling system
Water cooled
No. of cylinders-arrangement
6-90°V
No. of strokes
4
Type of combustion chamber
Semi-spherical
Valve arrangement
Overhead
Type of cylinder liners
Integral
Cylinder bore × stroke, mm (in.)
101.6×88.39 (4.00×3.48)
Engine
Displacement, cc (cu in.)
4293 (262)
Compression ratio
9.2 : 1
Rated output, PS/rpm
94/2450
Rated torque, kgf·m/rpm
31.0/1200
Min. rpm
750-800, 650-700
Max. rpm
2650-2700, 2600-2650
Dimensions (L×W×H), mm (in.)
710×620×740 (28.0×24.4×29.1)
Weight, kg (lb)
260 (573)
Installation position
Rear
Ignition
Spark
Firing order
Ignition system
1-6-5-4-3-2
Initial ignition timing, BTDC deg
0° Gasoline, 8° L.P.G., ECU Controlled
Fuel tank capacity, liter (U.S.gal)
66 (17.4)
Ignition coil
Fuel system
GC45K SWB
Distributor
Type
Mold
Type
Pointless
Type of spark advance control
Internal solid state circuit, ECU Controlled
Model Spark plug
AC #41-932, R42LTS
Size, mm (in.)
14 (0.55)
Gap, mm (in.)
1.24 (0.0488), .89 (.035)
Carburetor
Type
Single Barrel, MPFI
Governor
Type
Electronic
Fuel pump
Type
Electromagnetic
Air cleaner
Type × Number
Cyclone with paper element × 1
1-9
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
GM4.3L Gasoline Water cooled 6-90°V 4 Semi-spherical Overhead Integral 101.6×88.39 (4.00×3.48) 4293 (262) 9.2 : 1 92.6/2450 31.0/1200 750-800, 650-700 2650-2700, 2600-2650 710×620×740 (28.0×24.4×29.1) 260 (573) Rear Spark 1-6-5-4-3-2 0° Gasoline, 8° L.P.G., ECU Controlled 80 (21.1)
128 (34.0) Mold Pointless Internal solid state circuit AC #41-932, R42LTS 14 (0.55) 1.24 (0.0488), .89 (.035) Single Barrel, MPFI Electronic Electromagnetic Cyclone with paper element × 1
1-10
GC70K STR
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. Truck Models GC35K
GC40K STR
GC40K
Engine lubrication system
Type
Starter
Alternator
Battery
Type
Cooling system
Items
Pressure feed
Oil pump
Gear pump
Oil filter
Paper element
Oil cooler
Oil to water type
Refill capacities, liter (U.S.gal)
GC45K SWB
Oil pan
4.2 (1.1)
Oil filter & cooler
0.8 (0.2)
Total
5.0 (1.3) Forced circulation
Radiator
Plate fins with pressure cap
Refill capacity, liter (U.S.gal) Water pump
18.2 (4.82) Centrifugal type, V-belt driven, Serpentine belt driven
Thermostat/ Opening Temp F°
Wax type/ 180
Type × number
Group 24
Voltage, V
12
Capacity, AH (5Hr)
45
Type
3-Phase AC
Manufacturer
MANDO, AC Delco
Rated output, V-A
12-50, 12-70
Regulator
Built in IC type
Type
Electromagnetic
Manufacturer
Delco Remy
Voltage-output, V-kW
12 - 0.75
1-11
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. GC45K STR
GC45K
GC55K
GC55K STR
GC60K
Pressure feed Gear pump Paper element Oil to water type 4.2 (1.1) 0.8 (0.2) 5.0 (1.3) Forced circulation Plate fins with pressure cap 11 (2.9) Centrifugal type, V-belt driven, Serpentine belt driven Wax type/ 180 Group 24 12 45 3-Phase AC MANDO, AC Delco 12-50, 12-70 Built in IC type Electromagnetic Delco Remy 12 - 0.75
1-12
GC70K GC70K STR
GENERAL INFORMATION
Truck Models GC35K
GC40K STR
GC40K
Items Type Torque converter
3-element, 1-stage, 2-phase
Manufacturer’s model
Okamura M15
Stall torque ratio
3.2
Control and shift
Power train
Transmission Powershift Reduction gear
Ratios
Hydraulic and column shift
Forward
2.898
Reverse
2.907
Type of gear
Spiral bevel
Gear ratio
4.571
Housing
Banjo
Differential Type of gear and pinion number
Gear
Straight bevel-2
Pinion
Straight bevel-4
Transmission/ torque converter oil liter (U.S. gal)
14 (3.7)
Differential gear oil liter (U.S. gal)
9.1 (2.4)
Steering system
Type
Full Hydrostatic power steering
Steering wheel diameter, mm (in.)
330 (13)
Power cylinder ID × rod diam., mm (in.) Power steering
85×60 (3.3×2.4)
Effective stroke, mm (in.)
155 (6.1)
Relief pressure, kPa (kgf/cm2) [psi]
11768 (120) [1706]
Traveling system
Flow rate, liter (U.S.gal)/min
23 (6.07)
Front axle
Full-floating tubular type
Rear axle
Elliott type
Suspension system
Front
Fixed type
Rear
Center-pivot type
Toe-in, mm (in.) Wheel alignment
0
Camber
1.0°
Caster
0°
Kingpin inclination
0°
1-13
GC45K SWB
GENERAL INFORMATION
GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
3-element, 1-stage, 2-phase Okamura M15 3.2 Hydraulic and column shift 2.898
(1st/2nd) 5.104/2.882
2.907
(1st/2nd) 5.104/2.882
Spiral bevel
Hypoid gear
4.571
4.857 Banjo Straight bevel-2 Straight bevel-4 Transmission/ Torque oil 15 (3.9) 9.1 (2.4) Full Hydrostatic power steering 328 (12.9) 85×60 (3.3×2.4)
155 (6.1)
180 (7.1)
11768 (120) [1706]
14710 (150) [2133] 23 (6.07) Full-floating tubular type Elliott type Fixed tpe Center-pivot type 0 1.0° 0° 0°
1-14
GC70K STR
GENERAL INFORMATION
Truck Models GC35K
GC40K STR
GC40K
Items
Brake system
Type Service brakes
Parking brake
Self-adjusting, duo-servo
Drum diameter, mm (in.)
317.5 (12.50)
Lining (length×width thick×number), mm (in.)
330×63×10-2 (13×2.48×0.39-2)
Master cylinder ID, mm (in.)
28.57 (1.125)
Wheel cylinder ID, mm (in.)
31.75 (1.250)
Type
Mechanical, mounted on wheels
Brake fluid cc (cu.in)
130 (7.9)
Brake booster
Mastervac (vacuum suspended)
Body
Assembled-frame type Type
Gear
Manufacturer’s type Gear pump
Control valve Hydraulic system
GC45K SWB
Flow regulator valve
KFP3240 AMBAS
Rated discharge, liter (U.S.gal)/rpm
98 (25.89)/2450
Drive line
Universal joint
Type
6000-C193
Relief pressure, MPa (kgf/cm2) [psi]
19.12
Type
+0.5 0
(195
+5 0
) [2773
+71 0 ]
Variable (Adjustable)
Regulated flow rate, liter (U.S.gal)/min
100 (26.4)
115 (30.38)
Simplex mast ID, mm (in.) Lift cylinders Stroke, mm (in.)
60 (2.36)
70 (2.75)
Duplex mast ID, mm (in.) First lift cylinders Stroke, mm (in.)
90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
55 (2.17)
60 (2.36)
1590 (62.60)
1585 (62.40)
90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
60 (2.36)
70 (2.75)
1480 (58.27)
1530 (60.24)
1650 (65)
Duplex mast ID, mm (in.) Second lift cylinders Stroke, mm (in.) Triplex mast ID, mm (in.) First lift cylinders Stroke, mm (in.) Triplex mast ID, mm (in.) Second lift cylinders Stroke, mm (in.) Tilt cylinders
ID, mm (in.)
100 (3.937)
Stroke, mm (in.)
120 (4.724)
Hydraulic tank capacity, liter (U.S.gal)
46 (12.1)
1-15
GENERAL INFORMATION
GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
GC70K STR
Self-adjusting, duo-servo 317.5 (12.50) 330×63×10-2 (13×2.48×0.39-2) 28.57 (1.125) 31.75 (1.250) Mechanical, mounted on wheels 130 (7.9) Mastervac (vacuum suspended) Assembled-frame type Gear KFP3240 AMBAS
SPG2-48L194
98 (25.89)/2450
117.6 (31.07)/2450 Universal joint 6000-C193 19.12
+0.5 0
(195
+5 0
) [2773
+71 0 ]
Variable (Adjustable) 115 (30.38)
165 (43.56)
70 (2.75)
80 (3.15) 1650 (65)
110 (4.33) 845 (33.27) 60 (2.36) 1585 (62.40) 110 (4.33)
125 (4.92)
845 (33.27)
855 (33.66)
70 (2.75)
80 (3.15)
1530 (60.24)
1495 (58.86)
100 (3.937)
110 (4.33)
120 (4.724)
139 (5.472)
52 (13.6)
69 (18.2)
1-16
GENERAL INFORMATION
Truck Models GC35K
GC40K
Items
Mast and forks
Mast model
GC40K STR
GC45K SWB
CJ type
Flange ID × flange Outer back thickness × flange front thickness × Inner, Middle web thickness Main rollers
Bearing
Side rollers
Bearing
118×28×24×13 (4.6×1.1×0.9×0.5)
130×30×26×15 (5.1×1.2×1.0×0.6)
118×24×24×12 (4.6×0.9×0.9×0.47)
130×26×26×13 (5.1×1.0×1.0×0.5)
Ball bearing
Diam × width, mm (in.)
118×32 (4.65×1.26)
130×34 (5.12×1.34)
Lubricated type needle roller bearing
Diam × width, mm (in.)
52×36 (2.05×1.42)
Lift chains
BL834
Fork (length × width × thick), mm (in.)
1220×150×50 (48×6×2)
Fork spread (outer width), mm (in.)
1060 (41.5)
1-17
BL1034
GENERAL INFORMATION
GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
GC70K STR
CJ type 130×30×26×15 (5.1×1.2×1.0×0.6)
150×34×30×20 (5.9×1.3×1.2×0.8)
130×26×26×13 (5.1×1.0×1.0×0.5)
150×30×30×15 (5.9×1.2×1.2×0.6)
Ball bearing 130×34 (5.12×1.34)
150×36 (5.91×1.42)
Lubricated type needle roller bearing 52×36 (2.05×1.42)
58×40 (2.3×1.6) BL1034
1220×150×60 (48×6×2.4)
1220×150×65 (48×6×2.56)
1060 (41.5)
1230 (48.5)
1-18
COOLING SYSTEM
Description .................................................................................................................................. 2 - 1 Removal and Installation ............................................................................................................ 2 - 2 Inspection and Adjustment.......................................................................................................... 2 - 4 Fan Belt Inspection .............................................................................................................. 2 - 4 Fan Belt Adjustment ............................................................................................................ 2 - 4
2
COOLING SYSTEM
Description
6 •
5 •
8 •
9 •
4 1 •
• 7
•
•
3
2
207009
1 2 3 4
5 6 7 8 9
Engine Universal joint Gear pump Fan belt
2-1
Cooling fan Upper hose Lower hose Radiator Transmission Oil Cooler
COOLING SYSTEM
Removal and Installation Fan Belt Removal 1. Method by removing radiator
3
2 1
207010
Removal sequence 1 Universal joint 2 Tension pulley bolt (loosening only) 3 Belt Start by: Remove the radiator cover.
2-2
COOLING SYSTEM
Suggestions for removal and installation (1) Loosen the tension pulley bolt until the fan tension becomes loose. CAUTION Do not loosen the lock bolt to such an extent that the tension pulley is removed. (2) Move the tension pulley toward the fan, then remove the belt. Installation To install, follow the reverse of removal procedure and do the following steps: (1) Before installing the belt, turn the fan to check for smooth rotation. Replace the bearing if it generates abnormal sound. (2) After putting the belt on the drive and driven pulleys, push it midway between the pulleys to make sure the tension pulley moves freely. Then, tighten the pulley bolt.
2-3
COOLING SYSTEM
Inspection and Adjustment Fan Belt Inspection (1) Check to make sure the belt is free of oil, grease or other foreign matter. Replace the belt if necessary. A slightly dirty belt can be re-used by cleaning with cloth or paper. Do not attempt to clean the belt with gasoline or the like. (2) At the time of overhauling the engine or adjusting the belt tension, closely check the belt and replace it if it is defective. Fan Belt Adjustment (1) Loosen the tension pulley bolt by one to two full turns with ratchet wrench.
Tension pulley bolt 207011
(2) The belt will be properly tightened by the tension spring. Tighten the tension pulley bolt.
2-4
ELECTRICAL SYSTEM
Description .................................................................................................................................. 3 - 1 Console Box ........................................................................................................................ 3 - 1 Sub Panel .............................................................................................................................. 3 - 2 Disassembly and Reassembly .................................................................................................... Console Box ........................................................................................................................ Components in Console Box................................................................................................ Combination Meter ..............................................................................................................
3-3 3-3 3-4 3-5
Major Electrical Components .................................................................................................... Starter Switch (with Anti-restart Lock)................................................................................ Lighting Switch ................................................................................................................... Fuse Box .............................................................................................................................. Spare Terminals ....................................................................................................................
3-6 3-6 3-7 3-8 3-8
Battery Maintenance .................................................................................................................. 3 - 9 Typical Open Circuit Voltage...................................................................................................... 3 - 10 Lamp Bulb Specifications .......................................................................................................... 3 - 12 Electrical System Schematics .................................................................................................... Chassis (2007-01~up) .......................................................................................................... Engine (2007-01~up)............................................................................................................ Chassis w/ Neutral Safety Switch (2005-11~2006-12)........................................................ Chassis w/o Neutral Safety Switch (2004-01~2005-10)...................................................... Engine (2004-01~2006-12) .................................................................................................. Chassis (1998-01~2003-12) ................................................................................................ Engine, Gasoline (1998-01~2003-12) .................................................................................. Engine, LPG (1998-01~2003-12) ........................................................................................
3 - 13 3 - 13 3 - 15 3 - 17 3 - 19 3 - 21 3 - 23 3 - 25 3 - 27
3
ELECTRICAL SYSTEM
Description Console Box
4
1 Engine coolant temperature gauge 2 Speed selector switch (Only for 6 & 7 ton models) (moved to head guard pillar in 2006) 3 Fuel gauge 4 Service hourmeter 5 OK monitor (Indicator Lights) 6 Starter switch 7 Light switch 8 Fuse box
5 3 1 7 6
2 8
102868
OK monitor 1
2
3
4
5
6
7
8
102869
Function No.
Indicator light
OFF
On or flickering
1
Powershift transmission oil temp. indicator light
Normal
Overheating
2
Air cleaner element indicator light
Normal
Clogged
3
Brake fluid level indicator light
Normal
Low
4
Engine oil pressure indicator light
Normal
Low
5
Alternator not charging indicator light
Normal
Abnormal
6
LPG residual pressure alarm lamp
Normal
Small
7
Malfunction indicator lamp (moved to head guard pillar in 2006)
Normal
Service engine
8
Engine coolant level warning light
Normal
Low
Remarks
Option Option
How to check indicator light bulbs The bulbs are normal if the indicator lights come ON when the starter switch key is turned to ❙ (ON) position. (The indicator lights will go OFF when the engine starts.) 3-1
ELECTRICAL SYSTEM
Sub Panel The sub panel is mounted at the right front pillar of the head guard.
104794
1st speed mode/automatic mode selector switch (For 6 and 7 Ton Models as standard and others as optional) Automatic mode (1st speed
2nd speed)
1st speed mode
Select the 1st speed mode for operating in the speed-limit area [14 km/h (8.7 mph) max.], climbing or traction. 104789
104575
Driving interlock indicator lamp Flickers if the operator leaves the seat with the direction lever in the forward or reverse position while the engine is running.
Neutral indicator lamp Glows when the direction lever is placed in Neutral (N) position.
ECM warning light (GASOLINE) (IF EQUIPPED) Glows when ECM (engine control module) is abnormal. Consult your Cat lift truck dealer.
3-2
ELECTRICAL SYSTEM
Disassembly and Reassembly Console Box
2
4
⎧ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎨ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎩
3
1 207751
Disassembly 1. Disconnect the electrical wires at connectors 1. 2. Remove screws 2 (four) securing the cover. 3. Remove screws 3 (six) and separate the front and rear panels. 4. Remove screws 4 (four) securing the instrument panel.
Reassembly To reassemble the console box, follow the reverse of disassembly procedure.
NOTE To replace the instrument panel bulbs, remove screws 3 and 4.
3-3
ELECTRICAL SYSTEM
Components in Console Box
4
3 2 1
5
6
207752
4 Light switch 5 Starter switch 6 Fuses
1 Power relay 2 Power relay 3 Turn signal relay
3-4
ELECTRICAL SYSTEM
Combination Meter Disassembly
1
2 3 4 5
6
7 8 9 206480
Sequence 1 Instrument panel 2 Dial 3 Engine coolant temperature gauge 4 Service hour meter 5 Fuel gauge CAUTION Be careful not to damage the printed circuit when disassembling the combination meter.
6 7 8 9
Meter case Printed circuit Bulb Socket
Bulb replacement For bulb replacement, remove the socket from the printed circuit by turning it counterclockwise. For configuration of the indicator lights, refer to “OK Monitor”.
Reassembly To reassemble the combination meter, follow the reverse of disassembly sequence. 3-5
ELECTRICAL SYSTEM
Major Electrical Components Starter Switch (with Anti-restart Lock) This switch has a built-in anti-restart lock, so the key cannot be turned from ❙ (ON) to (START) position while the engine is running. This prevents starter breakage or flywheel damage caused by an operator re-starting the truck when the engine is running.
(OFF) (ON)
B
(START)
203561A Connection Terminal
B
Component Fuse box, battery, Key alternator position ● (OFF) ❙ (ON) (START)
● ● ●
M Fuse box, fuel-cut solenoid
S Starter, neutral switch (powershift transmission)
● ●
●
3-6
ELECTRICAL SYSTEM
Lighting Switch
8 (0.3)
8 (0.3)
OFF 1st 2nd Knob position Stroke, mm (in.)
206481
Connection chart Terminal Component Knob position ● (OFF) 1st position 2nd position
B Battery (fuse)
T Tail lights, instrument light
H Working Head lights
Head lights
● ●
● ●
●
● ●
3-7
P
ELECTRICAL SYSTEM
Fuse Box
Code A
Amp 10 A
B C
15 A 15 A
D
15 A
E F G H J
15 A 10 A 10 A 15 A 10 A
A B C D E F G H J
Circuit Solenoid (F - R) Instrument panel light, turn signals, backup lights Spare terminal Tail lights, clearance lights, working lights (option) Head lights Spare fuse Horn Fuel pump relay Engine, ECU
101441D
Spare Terminals The spare terminal cord extends from the fuse box in the console box. (Another spare terminal is located on the chassis-side main harness.) Wire color: Lg (light green) Removing the console box rear panel will expose this spare terminal which is fastened to the harness protector with vinyl tape. Spare terminal
3-8
206424
ELECTRICAL SYSTEM
Battery Maintenance 1. State of charge and electrolyte specific gravity (S.G.) adjustment Specific gravity reading at 20°C (68°F)
State of charge
Adjustment
1.280 to 1.265
Fully charged
Check each cell for S.G.
1.260 to 1.225
One-half charged
Recharge battery and adjust electrolyte S.G. Make sure there is neither faulty components, loosely connected cord nor corroded connection.
1.220 or below
Discharged
Recharge battery. If difference in S.G. is large, adjust it during recharging.
When S.G. difference A cell with a low S.G. During recharging, adjust S.G. to 1.280 to 1.265. among cells is more than is in shorted condition. If difference in S.G. is more than 0.040 and a low S.G. 0.040 Recharge until voltage is found in certain cells only, replace battery. and S.G. stabilize and have remained constant for more than 2 hours.
2. Specific gravity reading and state of charge To check the battery for state of charge, take hydrometer readings on its electrolyte. The battery may be fully charged if the S.G. reading is 1.280 to 1.265 at 20°C (68°F). The state of charge can be told from the way the electrolyte level goes down to expose the cell plates. If addition of distilled water is necessary every month or so, the battery is overcharged. If addition is not required for more than 3 months, it is likely that the battery is inadequately charged.
(4) When connecting the cables to the battery, begin with the cable for the positive (+) terminal. When disconnecting them from the battery, begin with the cable for the negative (–) terminal. CAUTION Be sure to turn OFF the starter switch before disconnecting or connecting the battery cables to prevent the IC regulator from suffering damage.
3. Charging precautions (1) In slow charging, the charging current should be about 1/10 the capacity of the battery to be charged. (2) In quick charging, the battery capacity in ampere should not be exceeded. (3) During charging, adjust the charging current to prevent the electrolyte temperature from rising beyond 45°C (113°F).
3-9
ELECTRICAL SYSTEM
Typical Open Circuit Voltage Charge Level
Voltage (12V)
100%
12.7
75%
12.4
50%
12.2
25%
12.0
Discharged
11.9
More than 50% of the time an adjusted battery is found to be discharged only.
The tools required to test a battery are: • Load tester, refer to tool manual. • Volt meter (digital is recommended) • Safety glasses (preferably a full face shield) Battery load test procedure 1. Connect clamps to battery posts. Engine and all electrical accessories must be off when testing battery. 2. Hold load switch “on” for 10 seconds, and note the battery’s capacity. 3. Read meter with load still on and refer to battery analysis table. Cold Temperature Effects — The battery will test lower when cold than warm. For more accurate results, please reduce the battery’s nominal rating by 50 cranking amperes (one step meter scale) for each –6.7°C (20°F) drop. If cranking ampere rating is 300 and battery temperature is –17.8 °C (0°F), test as 200 cranking ampere battery (i.e. 2 step down). Temperature Compensation Battery Temperature Deceased Battery Rating by:
–6.7°C (+20°F)
–17.8°C (0 °F)
–28.9°C (–20°F)
50AMPS
100AMPS
150AMPS
3-10
ELECTRICAL SYSTEM
Battery Analysis Table (Meter reading after 10 seconds with load switch On) Load Test Good (Green)
Battery Condition Battery capacity is okay. Battery may or may not be fully charged. Check specific gravity of battery to determine state of charge. If specific gravity is less than full charge, check for electrical drain or possible charging system trouble. Recharge battery to full level.
Weak or Bad, But Needle Remains Steady (Yellow or Red)
Battery capacity is not satisfactory. Battery may be either defective or not fully charged. Check specific gravity to determine which condition exists. If charging does not bring specific gravity to full charge level, battery should be replaced.
Weak or Bad, But Needle Continues To Fall (Yellow or Red)
Battery may be defective or very run down. Release load switch and note volt meter reaction. Voltage recovery to 12 volt or above within seconds indicates defective battery. Slow voltage recovery indicates run down condition. For best results, check specific gravity.
3-11
ELECTRICAL SYSTEM
Lamp Bulb Specifications Watts
No. of bulbs
Glass
2
Clear
27
Tail/stop lamp
2
Red
23/8
Option
Backup lamp
2
Clear
10
Option
Working lamp (rear)
2
Clear
27
Option
Instrument panel lamp
2
Clear
1.4
Color code of socket: 12V (black)
OK monitor warning lamp
8
Clear
1.4
Color code of socket: 12V (grey)
Lamp description
Head lamp
Combination lamp (rear)
12V
Shape
203563
Remarks
200016A
3-12
POWER TRAIN
Specifications .............................................................................................................................. 4 - 1 Structure ...................................................................................................................................... 4 - 2 Reduction Ratio .......................................................................................................................... 4 - 4 Procedures and Key Points for Removal and Installation .......................................................... Removal of Engine .............................................................................................................. Installation ............................................................................................................................ Removal of Transmission and Reduction Differential ........................................................ Installation ............................................................................................................................ Refill Capacities (Approximate) ..........................................................................................
4-6 4-6 4 - 10 4 - 11 4 - 12 4 - 13
4
POWER TRAIN
Specifications Truck Models
GC35K thru GC55K STR
Running gear
Differential Reduction Transmission
Transmission system
Torque converter
Items Type
GC60K thru GC70K STR
Three-element one-stage two-phase
Manufacturer model
M15
Stall torque ratio
3.2
Operation method
F/R electrical column shift, H/L automatic transmission Forward
1st : 2.898
1st : 5,104 2nd : 2,882
Reverse
1st : 2.907
1st : 5.104 2nd : 2.882
Spiral bevel gear
Hypoid gear
4.571
4.857
Transmission ratio
Gear type Reduction ratio Housing Type and number of gears
Banjo-type Large
Straight bevel gear × 2
Small
Straight bevel gear × 4
Front axle type
Full-floating axle tube type
Front wheel suspension
Fixed frame type
4-1
POWER TRAIN
Structure GC35K thru GC55K STR 11
4
•
6
5
3
2
1
• • •
• •
12 9 10
• •
7
8
207753
1 2 3 4 5 6
Engine (GM4.3) Flywheel Torque converter (M15) Transmission Input shaft (1st axle) Counter shaft (2nd axle)
7 8 9 10 11 12
Counter shaft (3rd axle) Output shaft (4th axle) Reduction differential Front axle Front wheel hub Wheel brake
The transmission system transmits drive power generated by the engine to the drive shaft. It consists of the following equipment. (3) Reduction differential The reduction differential reduces rotational speed and distributes power to the left and right driving wheels.
(1) Torque converter The torque converter plays the role of the clutch. It also increases and transmits engine torque to the transmission. (2) Transmission The transmission changes rotational speed when engine torque is transmitted to the universal joint.
It also prevents slippage by controlling the rotational speed of the two wheels (in turning to the left/right). 4-2
POWER TRAIN
GC60K thru GC70K STR 11 4
5
6
3
2
1
• •
•
•
• •
12
9 10
• •
7
8
207754
1 2 3 4 5 6
7 8 9 10 11 12
Engine (GM4.3) Flywheel Torque converter (M15) Transmission Input shaft (1st axle) Counter shaft (2nd axle)
The transmission handles 1st and 2nd shifts in forward and reverse modes.
4-3
Counter shaft (3rd axle) Output shaft (4th axle) Reduction differential Front axle Front wheel hub Wheel brake
POWER TRAIN
Reduction Ratio GC35K thru GC55K STR Numbers in parentheses indicate the number of gears.
(25)
(29)
(32)
(22)
(37)
(7)
(40)
(32) (51)
207753
Gear mode
Transmission
Forward
2.898 (
40 51 × 32 22
Reverse
2.907 (
29 40 51 × × 37 25 22
Reduction bevel gear
)
4.571
( 327 )
)
4-4
Overall reduction ratio 13.246 13.289
POWER TRAIN
GC60K thru GC70K STR Numbers in parentheses indicate the number of gears.
(52) (34)
(24)
(34)
(24)
(18) (52) (7)
(36)
(45)
(34) (49)
207754
Speed
Transmission
Reduction bevel gear
1st
5.104 ( 45 × 49 )
2nd
2.882 ( 36 × 49 )
1st
45 49 × 5.104 24 18
2nd
2.882 ( 36 × 49 )
24
Forward
Reverse
34
34
24.791
18 18
(
Overall gear ratio
4.857
( 347 )
)
14.000 24.791 14.000
18
4-5
POWER TRAIN
Procedures and Key Points for Removal and Installation Removal of Engine (1)
1
3
5
5
6
10
3
8
5
8 2 7
4 7
4
9
207015
1 2 3 4 5
Lamp harnesses, Overhead guard Engine cover, Seat Radiator cover Floor plate Battery cable, Battery
6 7 8 9 10 4-6
Reserve tank Steering wheel, Forward/reverse lever assembly Transmission oil hoses Transmission oil cooler, Bracket Cowl
POWER TRAIN
Removal of Engine (2)
16 11
14 19 16
15
13
17
12
18
207016
11 12 13 14 15
Upper hose Fan belt Tension pulley Fan assembly Lower hose
16 17 18 19
Exhaust pipe (left and right) Air cleaner hose Air cleaner Engine control cable
NOTE Items 16 and 19 were changed in 2004. Item 19 is not used and item 16 has the same O-ring and clamping flange on both ends. 4-7
POWER TRAIN
Removal of Engine (3)
20
24 Lifting lug
25
25 22
Lifting lug 26 20
25
23
22
21 21
21 207019
20 21 22 23
Engine harnesses Vacuum hoses, Vacuum tank Hoses (Engine oil) Fuel hose
24 Universal joint 25 Engine mounting bolt, Cushions 26 Engine assembly NOTE Item 23 fuel pump and hose was changed in 2004. Lifting lugs moved to opposite sides of engine. 4-8
POWER TRAIN
Removal of Engine Remove the power line in the following sequence. 1. Remove the engine. 2. Remove the transmission and the reduction differential. Preparation (1) Remove the ground button clamp from the battery. (2) Drain cooling water from the radiator. (3) Drain engine oil and oil in the oil cooler piping. Key points for removal 1. When removing the transmission oil cooler, do not spill oil from the cooler. 2. Remove the fan and the tension pulley as subassemblies. 3. Remove the engine control cable from the engine. 4. Remove the harnesses from the engine at the socket and terminal. To prevent damage, tack the removed harnesses along the main harness. 5. Remove the engine oil hose from the engine oil filter inlet/outlet. 6. Before removing the engine, attach a wire to the engine lifting lug and lift the engine by using a crane until the wire is braced. Lifting lug
Engine unit (service weight) kg (lb) 270 (595) Lifting lug
207020
7. Place wood blocks or a jack under the transmission case, because the rear leg of the transmission is removed. 8. Remove the universal joint from the engine.
207017
4-9
POWER TRAIN
Installation Follow the removal sequence in reverse. Key points for installation 1. When installing the engine mounting nut, tighten the nut a quarter rotation from the position where the nut contacts with the mounting bracket. 2. When installing the engine exhaust pipe, replace the gasket with a new one. 3. When installing the battery cables, make sure all wires are connected correctly, then connect the negative (–) terminal of the battery. 4. Refill cooling water. Fill the radiator with antifreeze coolant to the specified level. Unless otherwise specified, use a solution of 40% water to 60% anti-freeze concentration with soft service water. 5. Add engine oil. 6. Check the oil level of the hydraulic tank and the transmission. Refill if necessary. 7. Check after engine start Start the engine after checking related parts, and check vibration. If the engine vibrates excessively, retighten the engine mounting bolts and check if vibration decreases.
4-10
Bracket
Cushion Bracket at frame 207018
POWER TRAIN
Removal of Transmission and Reduction Differential 2 1 1
1
2
1
4 8
7
6
3
5
5 207021
1 2 3 4
Cords (ground), Harnesses Oil cooler hoses Tube (Brake fluid) Inching cable
5 6 7 8
4-11
Brake pipe Pedal assembly Front axle shaft Transmission and reduction differential
POWER TRAIN
Removal Remove the transmission and the reduction differential after removing the engine as mentioned before. Preparation (1) Drain transmission oil. (2) Drain oil from the front axle housing. Key points for removal 1. Remove the oil cooler hoses from the transmission. Place the removed hoses at the right of the frame. 2. Remove the inching cable from the transmission. 3. When removing the transmission and the reduction differential, use two wire ropes. Cow-hitch each wire at the gravity center.
Key points for installation 1. Output shaft shim adjustment (Unit: mm) Replace the output shaft and the reduction gear as an assembly if the gear teeth are defective. When installing the output shaft, adjust shims and check the tooth contact. Torque converter drive automatic 2-speed transmission Determine the thickness of shims according to the figure below before installing the bearing. Dimension “a” is punched on the upper surface of differential carrier. Shim thickness C = 1.7 + a/100 – b a: Machining error of differential carrier b: Machining error of bevel pinion gear 2. When installing the differential assembly to the front axle housing, clean the mounting surfaces and apply liquid gasket to the surfaces, then tighten bolts. 3. After connecting cable the brake pedal and the inching pedal cable, check that the level of each pedal and protrusion of the clutch valve plunger conform to the standard dimensions. 4. Fill the transmission and the front axle housing with oil. Check for oil leaks. 5. Bleed air from the brake fluid lines.
4-12
Centerline of axle
Installation Follow the removal sequence in reverse.
c
±b ± a 100 202825
POWER TRAIN
Refill Capacities (Approximate) Unit: liter (U.S.gal) Truck Models Items Fuel tank Engine coolant
Engine oil
GC35K GC40K GC40K STR GC45K SWB/STR 66 (17.4)
GC60K GC70K GC70K STR
80 (21.1)
128 (34.0)
Engine
7.15 (1.9)
Radiator
3.2 (0.8)
Reserve tank
0.65 (0.2)
Total
11 (2.9)
Oil pan
4.2 (1.1)
Oil filter
0.8 (0.2)
Total
5.0 (1.3)
Transmission/torque converter oil
14 (3.7)
Differential gear oil Hydraulic oil
GC45K GC55K GC55K STR
15 (3.9) 9.1 (2.4)
46 (12.1)
Brake fluid cc (cu.in)
52 (13.6) 130 (7.9)
4-13
69 (18.2)
POWERSHIFT TRANSMISSION
1-speed Transmission (GC35K thru GC55K STR) .................................................................... 5 - 1 Specifications .............................................................................................................................. 5 - 1 Structure ...................................................................................................................................... Torque Converter ................................................................................................................ Transmission 1-Speed .......................................................................................................... Powershift Control................................................................................................................ Control Valve........................................................................................................................ Powershift Transmission Hydraulic System Schematic ......................................................
5-2 5-2 5-3 5-4 5-4 5-5
Removal and Installation ............................................................................................................ 5 - 6 Torque Converter ........................................................................................................................ Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Reassembly ..........................................................................................................................
5-7 5-7 5-8 5 - 10
Transmission .............................................................................................................................. Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Reassembly ..........................................................................................................................
5 - 12 5 - 12 5 - 18 5 - 21
Control Valve .............................................................................................................................. Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Reassembly ..........................................................................................................................
5 - 27 5 - 27 5 - 28 5 - 29
Adjustment .................................................................................................................................. Oil Pressure Measurement.................................................................................................... Inching Valve Test ................................................................................................................ Stall Speed Measurement .................................................................................................... 10-m (33-ft) Starting Acceleration Test .............................................................................. Inching Pedal Adjustment ....................................................................................................
5 - 30 5 - 30 5 - 30 5 - 31 5 - 31 5 - 32
5
Automatic 2-speed Transmission (GC60K thru GC70K STR) .................................................. 5 - 34 Specifications .............................................................................................................................. 5 - 34 Structure ...................................................................................................................................... Transmission 2-Speed .......................................................................................................... Automatic 2-speed Change Mechanism .............................................................................. Solenoid Valve...................................................................................................................... Powershift Transmission Hydraulic System Schematic 1-Speed ........................................ Powershift Transmission Hydraulic System Schematic 2-Speed ........................................
5 - 35 5 - 35 5 - 36 5 - 37 5 - 38 5 - 39
Transmission .............................................................................................................................. Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Reassembly ..........................................................................................................................
5 - 42 5 - 42 5 - 51 5 - 52
Solenoid Valve ............................................................................................................................ Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Reassembly ..........................................................................................................................
5 - 58 5 - 58 5 - 59 5 - 59
Adjustment .................................................................................................................................. 5 - 59 2-Speed Transmission Electrical Systems Troubleshooting ...................................................... 5 - 61 Troubleshooting .......................................................................................................................... 5 - 68 Service Data ................................................................................................................................ 5 - 72
POWERSHIFT TRANSMISSION
1-speed Transmission (GC35K thru GC55K STR) Specifications Truck Models Torque converter Transmission
Power transmission
Items Type Manufacturer model Stool torque ratio Operation type
GC35K thru GC55K STR 3 element 1 stage 2 phases M15 3. 2 F/R electric column shift 2.898 (40 × 51 ) 2.898 32 × 22 2.907 ( 29 × 40 × 51 ) 2.898 37 × 25 × 22
Forward Gear ratio Backward
WARNING Disconnect the battery, console box and ECU before doing any welding on the truck
5-1
POWERSHIFT TRANSMISSION
Structure Torque Converter
12 3
4
1 2 9 16
8
10 15
17
5
13
14
6
1 2 3 4 5 6 7 8 9
7, 11
Turbine assembly Stator assembly Flexible plate Pump impeller Pump boss Roller Spring Stator hub Thrust washer
206589
10 11 12 13 14 15 16 17
5-2
Thrust washer Spring cup Drive cover Pilot boss Ball bearing Ball bearing Thrust bearing Spacer
POWERSHIFT TRANSMISSION
Transmission 1-Speed 4
b 3
•
•
• a
2
• 5
•
•
9
c •
•
6 •
7 •
1
e •
• h
d • f •
8
g 207728
Range
2nd shaft 1st shaft
Path
Forward
c ⎯→ e f g h
Reverse
d b a e f g h
3rd shaft
4th shaft
206591
1 2 3 4 5
Flexible plate Torque converter assembly Oil pump assembly Control valve Countershaft (2nd shaft)
6 7 8 9
NOTE Figure shows GC35K thru GC55K STR. 5-3
Clutch shaft (1st shaft) Countershaft (3rd shaft) Output shaft (4th shaft) Turbine shaft (1st shaft)
POWERSHIFT TRANSMISSION
Powershift Control
R N
F
8
1
2
7
4 9 6
3
5
206592
1 2 3 4 5
Transmission shift lever Inching bracket Control valve Solenoid valve (for F) Solenoid valve (for R)
6 7 8 9
Clutch valve plunger Inching lever Cable Inching pedal
Control Valve Section B-B 1
• B
B
Section C-C
• 2 C
3
C
•
• 4
Section D-D •
D
5
1 Accumulator piston 2 Main regulator valve 3 Clutch valve plunger
4 Inching valve 5 Directional spool 5-4
D
206593
5-5
PI
PM Main pressure PC Clutch pressure PI Torque converter 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1] inlet pressure PL Lube oil pressure 0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7] All tests run At 1600 ± 100 engine rpm
Solenoid valve
Gear pump 47 liter (12.4 U.S.gal)/ min at 2450 rpm
PM
(Valve top surface with M stamp)
Torque converter inlet pressure
Suction strainer
PD
Torque converter outlet pressure
Torque converter
Unit: MPa (kgf/cm2) [psi] 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8] 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Lubricating circuit
PL
Oil cooler
P2
R Directional valve (Valve top surface)
F
↔R F↔
R
(Valve top surface with D stamp)
206594
Solenoid valve
Last chance filter
FR filter
PC
Clutch (inching) valve
Main regulator valve
Accumulator valve
POWERSHIFT TRANSMISSION
Powershift Transmission Hydraulic System Schematic
POWERSHIFT TRANSMISSION
Removal and Installation Removal (1) Drain coolant and oil from the engine, transmission, and oil cooler piping. (2) Drain gear oil from the front axle housing. (3) Remove the front axle shafts. (4) Unscrew the torque converter flexible plate mounting bolts and remove the engine from the truck. (5) Remove the transmission and the differential as an assembled unit from the truck. (6) Separate the transmission from the differential.
Installation (1) Couple the transmission to the differential. Install the torque converter into the transmission case. Install the torque converter so that the distance between the end face of the housing and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.). (2) Install the transmission and differential assembly on the front axle. (3) Install the front axle shafts. (4) Couple the transmission to the engine and mount it on the truck. Make sure the clearance between the flywheel and the flexible plate is approximately 0 to 2 mm (0 to 0.078 in.) when the transmission is coupled to the engine. If the clearance is zero, it is an indication that the torque converter is improperly coupled to the pump gear or splines. Recouple the transmission to the engine correctly. Tighten the flexible plate mounting bolts to the flywheel through the access hole in the case. NOTE Tighten the bolts evenly in a criss-cross pattern. (5) Connect pipes to the radiator. (6) Fill the following parts with oil or water. Front axle ..................Gear oil Transmission ............Torque converter oil Radiator, engine ........Coolant, anti-freeze coolant Replenish engine oil, hydraulic oil, etc. NOTE For removal/installation of the engine, and the transmission and differential assembly, make reference to the topics, REMOVAL AND INSTALLATION, POWER TRAIN.
5-6
POWERSHIFT TRANSMISSION
Torque Converter Disassembly 4 5
6
7
3
6
4 7
1
2
3 206595
Sequence 1 Bolts, Spring washers, Plate 2 Flexible plate, Pilot boss, O-ring 3 Bolts, Drive cover, Ball bearing 4 Spacer, Turbine assembly 5 Thrust washer, Thrust bearing
6 Stator assembly, Rollers, Hub, Spring, Spring cup 7 Ball bearing, O-ring, Pump boss, Pump impeller, Bolts
Suggestion for disassembly The torque converter assembly has no drain plug and cannot be drained completely. Drain oil by turning pump boss 7 downward when the assembly is removed.
5-7
POWERSHIFT TRANSMISSION
Inspection and Repair Pump impeller (1) Check for cracks. (2) Check for oil leaks due to loose pump boss bolts at impeller or defective O-ring. (3) Check the face of pump boss for wear in contact with oil seal.
O-ring
Stator assembly (1) Check the stator assembly blade for cracks and loose fit to the clutch cam. (2) Check the clutch hub and cam for wear or flaws. (3) Check the springs and spring caps for wear, breakage or distortion. (4) Check the rollers for flaws, distortion or wear. (5) Check the clutch hub splines for defects. (6) Check the thrust washers for wear or other defects. A: Standard value B: Repair limit Service limit Unit: mm (in.) -0.03 65 -0.049 A Outside diameter of (2.56 -0.0012 -0.00193) clutch hub 1 B 6.49 (2.555) 8.1 -0-0.015 A -0 Diameter of clutch (0.32 -0.00059) rollers 2 B 7.985 (0.31437) 2.0 -0-0.05 A Thickness of thrust (0.08 -0-0.0020 ) washer 3 B 1.75 (0.0689) 3 -0-0.05 A Thickness of thrust (0.12 -0-0.0020 ) washer 4 B 2.75 (0.1083)
202882
4
•
2 3 1 206596
Turbine runner (1) Check the blades for cracks. (2) Check the fit of turbine boss in the runner. (3) Check the turbine boss splines for wear or other defects. Pilot boss Check the portion in contact with the pilot bearing for wear or other defects. A: Standard value B: Repair limit Service limit
Diameter of portion A in contact with pilot B bearing 1
20
–0.007 –0.020
1
Unit: mm (in.)
(0.78 –0.00028 –0.00079 ) 206990
19.85 (0.781)
5-8
POWERSHIFT TRANSMISSION
Flexible plate (1) After installing flexible plate, measure the face runout of the plate with a dial gauge. Replace the plate if the runout exceeds the service limit. A: Standard value B: Repair limit Service limit
Face runout of flexible plate
Unit: mm (in.)
A
0.2 (0.008)
B
0.5 (0.020)
(2) When the flexible plate is installed on the transmission, make sure the clearance between the end face of the transmission case and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.).
4 to 6 mm (0.157 to 0.236 in.) 206597
NOTE After installing the flexible plate, fasten the plate to the transmission case with wire.
5-9
POWERSHIFT TRANSMISSION
Reassembly
•
1
16
11 •
12
7 3 •
15 •
2 •
•
•
• 13 14
• •
•
• •
••
• 10 9 8 6 4 5
206598
Sequence 1 Pump impeller 2 Pump boss, O-ring, Bolt, Washer 3 Ball bearing 4 Stator assembly 5 Spring, Spring cap 6 Rollers 7 Stator hub 8 Thrust washer
9 10 11 12 13 14 15 16
5-10
Thrust bearing Thrust washer Turbine assembly Drive cover, O-ring, Bolt, Washer Spacer Ball bearing Pilot boss, O-ring Flexible plate, Bolt, Washer
POWERSHIFT TRANSMISSION
Suggestions for reassembly (1) Stator assembly (a) Position stator hub 7 in the stator as shown. Put spring 5 and spring cup 5 in each hole, and press in the roller 6 while pushing the spring cap. (b) Install total of ten rollers, and restore the stator hub to its original position. (c) Upon reassembling, rotate the stator hub by hand, making sure that it rotates in one direction.
5
5
6
7 202885A
(2) Selection of spacer Measure the dimensions “A”, “B” and “C”, and select spacer D so that the trust clearance is 0.2 to 0.8 mm (0.0078 to 0.0315 in.) and insert it in place. Part numbers
Thickness of spacer mm (in.)
91823-01700
2.5 (0.098)
91823-01600
2.7 (0.106)
91823-01400
3.0 (0.118)
A
D
C
B
206599
Standard dimensions mm (in.)
5-11
A
22.1 (0.87)
B
16 (0.63)
C
3.5 ± 0.05 (0.138 ± 0.002)
POWERSHIFT TRANSMISSION
Transmission Disassembly Control valve and strainer 3
4
2 1
6
5 6
35K - 55K New 5 206600
Sequence 1 Drain plug, Washer 2 Torque converter thermo unit 3 Control valve
4 Subplate, Gasket 5 Strainer pipe, Bolts 6 Strainer assembly, Gasket, Bolts
NOTE Suction pipe replaced by hose on 35K - 55K models.
5-12
POWERSHIFT TRANSMISSION
Pump body assembly
6 1 2 5 4
3 4
202887
Disassembly sequence 1 Pump body, Oil seal, Bushing 2 Internal gear, Drive gear, O-ring 3 Stator shaft, Cap, Dowel pin
4 Valve, Spring, Washer, Snap ring 5 Gasket 6 Turbine shaft, Seal ring, Snap ring
NOTE It is not necessary to remove the cap and dowel pin from the stator shaft or the bushing and oil seal from the pump body unless they are defective. Suggestion for disassembly Removing pump body assembly Unscrew all bolts securing the pump body assembly, and remove the assembly by making use of the jacking bolt holes in the stator shaft.
Bolt
Special tool needed Bolt
67284-15400 202888
5-13
POWERSHIFT TRANSMISSION
Countershaft (2nd shaft)
3 5 1 2
6 7 4
206601
Disassembly sequence 1 Snap ring 2 Rear cover, O-ring 3 Countershaft 4 Ball bearing
5 Countergear 6 Ball bearing 7 Countergear, Snap ring
Suggestion for disassembly Removing bearings Remove snap ring 1 from its groove in advance. Screw a sliding hammer into the tapped hole in shaft 3, pull off the shaft, and remove bearings 4 and 6 from the transmission case. Countershaft (3rd shaft)
6 7 3 5 2
1
4
202890
5-14
POWERSHIFT TRANSMISSION
Disassembly sequence 1 Snap ring 2 Rear cover, O-ring 3 Countershaft 4 Ball bearing
5 Countergear 6 Roller bearing (inner) 7 Countergear, Snap ring
Output shaft (4th shaft) 3 4
2
1 5 202891
Disassembly sequence 1 Output cover 2 Output shaft subassembly 3 Ball bearing
4 Output gear 5 Shims
Suggestion for disassembly Removing output shaft Using the special tool A, pull out the output shaft. The output gear will interfere with the input shaft drum; this makes it necessary to remove the output shaft by tapping the output gear with a copper hammer through the countershaft (3rd shaft) mounting hole. Special tool needed Puller A
A
91868-02100
Shims Reuse the shims removed during disassembly.
Shims Reuse
202892
the shims
110 160
130
5-15
10 17 ×1.25 M10× 202893
POWERSHIFT TRANSMISSION
Forward-reverse clutch shaft 8 20 6 4
3
2
5
7
28 30
1
29
27
26
25
29
23
16
21
22
14
24
15
12
19 16
13
10
9
11
17 18
19
207729
Current production Disassembly sequence 1 Servo case, O-ring 2 O-ring 3 Seal ring 4 Ball bearing 5 Thrust washer 6 Forward gear 7 Needle bearing 8 Thrust washer 9 Ball bearing 10 Thrust washer 11 Reverse gear 12 Needle bearing 13 Thrust washer 14 Snap ring 15 Pressure plate
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
NOTE It is not necessary to remove the balls and screws from the clutch piston, the screw from the clutch shaft, or the steel ball from the servo case. 5-16
Friction plate, Mating plates Snap ring Pressure plate Friction plate, Mating plates Snap ring Retainer Spring Clutch piston, Ball, Screw Seal ring Snap ring Retainer Spring Clutch piston, Ball, Screw Seal ring Clutch shaft
POWERSHIFT TRANSMISSION
Forward-reverse clutch shaft 8 20 6
2
4
3
5
7
29
28 30
27
26
25
29
1 23
16
21
22
14
24
15
19 12
10
9
11 13
16 17 18 19
206602
First Production Disassembly sequence 1 Servo case [O-ring] 2 O-ring 3 Seal ring 4 Ball bearing 5 Thrust washer 6 Forward gear 7 Needle bearing 8 Thrust washer 9 Ball bearing 10 Thrust washer 11 Reverse gear 12 Needle bearing 13 Thrust washer 14 Snap ring 15 Pressure plate
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
NOTE It is not necessary to remove the balls and screws from the clutch piston, the screw from the clutch shaft, or the steel ball from the servo case. 5-17
Friction plate, Mating plates Snap ring Pressure plate Friction plate, Mating plates Snap ring Retainer Spring Clutch piston [Ball, Screw] Seal ring Snap ring Retainer Spring Clutch piston [Ball, Screw] Seal ring Clutch shaft
POWERSHIFT TRANSMISSION
Suggestion for disassembly Disassembling clutch drum Using the special tool A or an arbor press, compress return springs 22 and 27, and remove snap rings 20 and 25. Special tool needed Piston tool A
A
92267-00300
Inspection and Repair Oil pump (1) Install the internal gear and the drive gear in the pump body, and measure top clearance 2. (2) Using a dial gauge, measure side clearance 1 between the gears and the pump case. (3) Measure clearance 3 of the drive gear in the pump boss (notch). (4) Check the relief valve for distortion or other defects. A: Standard value B: Repair limit Service limit Unit: mm (in.) Truck Models GC35K thru Items GC55K STR 0.05 to 0.11 A (0.0019 to 0.0043) Side clearance 1 B 0.20 (0.0079) 0.6 to 0.66 A (0.0236 to 0.0259) Top clearance 2 B 0.8 (0.031) 0.2 to 0.4 A Drive gear clearance (0.008 to 0.016) in pump boss notch 3 B 1.0 (0.039)
207504A
1 3 2
202897
Pump boss A: Standard value B: Repair limit Service limit Unit: mm (in.) Truck Models GC35K thru Items GC55K STR 70 -0-0.046 Diameter of portion in A contact with oil seal (2.76 -0-0.00181 ) and bushing 1 B 6.90 (2.7520) 70.06 to 70.10 Inside diameter of A (2.7583 to boss bushing 2 2.7598) B 70.3 (2.768)
Stator shaft (1) Make sure that bearings fit tight to the shaft. (2) Check the splines for wear or damage. (3) Check the oil passages for clogging. 5-18
2
1
202898
POWERSHIFT TRANSMISSION
Clutch pistons (1) Shake each piston, making sure that the balls move freely in the piston. NOTE Do not overhaul the pistons unless they are defective. (2) Check the seal rings and their grooves for wear or damage. Friction plates and mating plates (1) Check for sign of seizure, uneven contact, warpage or excessive wear. (2) Check the splines for wear or damage.
Seal ring
Clutch drums (1) Check the mating plate sliding surfaces for wear or damage. (2) Check the clutch piston sliding surfaces for wear or damage. Clutch gears (forward and reverse) (1) Check the gear and the splines for wear or damage. (2) Check the gear surface in contact with needle roller bearing for wear or damage. A: Standard value B: Repair limit Service limit Unit: mm (in.) Truck Models GC35K thru Items GC55K STR 2.3 ± 0.07 A Thickness of mating (0.091 ± 0.0028) plate 1 B 2.1 (0.083) 2.6 ± 0.1 A Thickness of friction (0.102 ± 0.004) plate 2 B 2.2 (0.087) 0.10 to 0.30 Backlash of friction A plate with gear 3 (0.0039 to 0.0118) 4 -0.01 -0.03 A Width of seal ring 4 (0.16 -0.0004 -0.0012 ) B 3.5 (0.138) +0.2 4 +0.1 A +0.008 Width of seal ring (0.16 +0.004 ) groove in piston 5 B 4.5 (0.177) Free length of clutch 62.9 (2.476) spring 6 spring constant A [k = 31.312 (3.193) [k = N/mm (kgf/mm) [178.648]] [lbf/in.]] B 62 (2.440) 2.5 ± 0.05 A Width of clutch piston (0.098 ± 0.0020) seal ring 7 B 2.0 (0.079) 2.5 +0.2 +0.1 A Width of clutch piston (0.098 +0.008 +0.004 ) seal ring groove 8 B 3.1 (0.122)
5-19
207590
7, 8
6 3
2 1 4
5 206603
POWERSHIFT TRANSMISSION
Turbine shaft and clutch shaft Check the seal ring and the contact surface for wear or damage. A: Standard value B: Repair limit Service limit Unit: mm (in.) Truck Models GC35K thru Items GC55K STR 2.5 ± 0.05 A Width of turbine shaft (0.098 ± 0.0020) seal ring 1 B 2.0 (0.079) 2.5 +0.2 0 +0.1 Width of piston seal A +0.008 ring groove in turbine (0.098 +0.004 ) shaft 2 B 3.0 (0.118) 35 +0.025 +0 0 Inside diameter of A turbine shaft in contact (1.38 +0.00098 ) +0 with seal ring 3 B 35.2 (1.386) 2.5 ± 0.05 A Width of clutch shaft (0.098 ± 0.0020) seal ring 4 B 2.0 (0.079) 2.5 +0.2 0 +0.1 A +0.008 Width of clutch shaft (0.098 +0.004 ) seal ring groove 5 B 3.0 (0.118) 35 +0.025 +0 0 Inside diameter of servo A case in contact with seal (1.38 +0.00098 ) +0 ring 6 B 35.2 (1.386)
4
5
6
2
1
3 207591
Clutch shaft, countershaft, and output shaft (1) Check the splines for wear or damage. (2) Check oil passages for clogging. Gears Check each gear for worn teeth or splines. Strainer assembly Disassemble and clean. Replace the strainer if defective. 5-20
POWERSHIFT TRANSMISSION
Reassembly Forward-reverse clutch shaft subassembly
10 6
7 8
9
••
•
3
8
7
• •
•
18
9
10 6
13
•
14
•
19
•
•
15
20 •
•
•
•
•
• •
••
• • •
•
•
1 12
21
11
• •
17
16
5
4
2
5
•
3
2
4 207530
Sequence 1 Input shaft 2 Seal ring, Piston seal 3 Piston 4 Spring 5 Retainer 6 Snap ring 7 Mating plates 8 Friction plate 9 Pressure plate 10 Snap ring 11 Thrust washer
12 13 14 15 16 17 18 19 20 21
5-21
Needle bearing Gear (R drive) Thrust washer Ball bearing Thrust washer Needle bearing Gear (F drive) Thrust washer Ball bearing Seal ring
POWERSHIFT TRANSMISSION
Forward-reverse clutch shaft (1st shaft) 2
•
•
D
• 1
• C •
B
• E
206607
Reassembly sequence 1 Servo case [O-ring, Bolt, Washer] 2 Forward-reverse clutch shaft assembly Start by: (1) Install the following parts to the transmission case in advance: • Ball bearing B for output shaft • Outer race C of roller bearing for countershaft (3rd shaft) • Ball bearing D for countershaft (2nd shaft) (2) Put outer gear E in the transmission case.
Suggestions for reassembly (1) Install the forward-reverse clutch shaft in an assembled unit. (2) Put ATF oil on the inside surface of servo case and the seal ring.
5-22
POWERSHIFT TRANSMISSION
Suggestions for reassembly (1) When inserting pistons 3 into clutch drum, put ATF oil on its seal ring portion. (2) Installing return spring Using the special tool A or an arbor press, compress springs 4, retainer 5 and install snap ring 6. Special tool needed Piston tool A
A
92267-00300
207504A
(3) Installing clutch plates (a) Make sure that the combination and number of the plates are correct. Install the plates while putting ATF oil on them. When replacing the friction plates 8, replace the mating plates 7, too.
Friction plate Mating plate
207731
(b) Installing thrust washers Make sure that the oil-groove side of thrust washers 11, 14, 16, 19 faces the gear when installed. Put ATF oil on washers before installing thrust washers.
203800
(4) After assembling the clutch, apply pressure air of approximately 98 kPa (1.0 kgf/cm2) [14.2 psi] to the oil hole to make sure that the piston moves smoothly without any sign of air leaks.
5-23
POWERSHIFT TRANSMISSION
Output shaft (4th shaft)
4 6 15 7 12 10 11 8 9 13 14 •
• •
••
• • • 4 206693 • •
1
• 2 5
3 207733
Reassembly sequence 1 Ball bearing 2 Gear 3 Shims
4 Output shaft assembly 5 Bolt, Washer
Suggestions for reassembly Install the output shaft as an assembly. (a) Reassembly sequence 6 Output shaft 7 Taper roller bearing 8 O-ring 9 Oil seal race (b) Put LG2 grease on the oil seal. (c) Tighten nut 13 to the specified torque, and stake it in place to prevent loosening. N·m Tightening torque (kgf·m) [lbf·ft]
353 to 392.2 (36 to 40) [79.3 to 88.1]
Special tool needed Wrench
91868-00300
5-24
(Install 10 to 12 in an assembly unit.) 10 Bearing case 11 Oil seal 12 O-ring 13 Nut 14 Snap ring 15 Output cover
POWERSHIFT TRANSMISSION
Countershaft (3rd shaft)
3
2 7
• 4
6 •
5
•
• • •
• •
1
207734
Reassembly sequence (Install 1 to 4 in an assembly unit.) 1 Countershaft 2 Snap ring 3 Snap ring, gear
4 5 6 7
Roller bearing inner race Gear Ball bearing Cover, O-ring, Bolt, Washer
Suggestion for reassembly Reassemble shaft 1, snap ring 2, gear 3 and roller bearing inner race 4 outside the transmission case, without fitting the snap ring in its groove, then put the shaft in the case, and fit it to gear 5 inside the case. 2
1
3
4 202908
6
Countershaft (2nd shaft)
3
5
4
1
8 • 2
• •
• •
•
• •
• 7
207735
5-25
POWERSHIFT TRANSMISSION
Reassembly sequence 1 Ball bearing (Install 2 to 5 in an assembly unit.) 2 Countershaft 3 Snap ring
4 5 6 7 8
Snap ring, gear Collar Gear Ball bearing Cover, O-ring, Bolt washer
Suggestion for reassembly Install shaft 2 to the transmission case with snap ring 3 temporarily fitted to the shaft.
2
3
5
4 •
•
206611
Pump body assembly
5 1
2
•
3 •
• • • • •
• 6
•
4 207736
Reassembly sequence (Install 1 to 4 in an assembly unit.) 1 Pump body, Oil seal, O-ring 2 Internal gear, Drive gear, O-ring 3 Stator shaft Suggestion for reassembly (1) Install the pump body to the transmission case in assembled state. (2) Put engine oil on the internal gear and drive gear 2 when installing them to pump body 1. (3) Put grease on the oil seal and bushing of pump body 1. 5-26
206692
4 Dowel pin 5 Pump body assembly, Gasket, Bolt, Washer 6 Turbine shaft, Snap ring, Seal ring
POWERSHIFT TRANSMISSION
(4) Upon reassembling, measure each gear backlash with a dial gauge. Unit: mm (in.) 0.14 to 0.27 (0.0055 to 0.0106) 0.14 to 0.26 (0.0055 to 0.0102)
Backlash of countergear with output gear Backlash of other gears
Control valve and strainer To reassemble, follow the reverse of disassembly sequence. Replace the gaskets.
Control Valve Disassembly 9 13
14
B
4
4 B 5
A
12
6 6
15
1
11 8
7
2
3
10
2 A 1
206613
10 Oil seal Sequence 11 Plug, Bearing roller, O-ring 1 Solenoid valve, O-ring 12 Accumulator spring seat, Pin, O-ring 2 O-ring, Spring seat, Spring 13 Drain plug, Gasket 3 Directional spool 14 Orifice screw, O-ring 4 Cover, O-ring, Bolt, Washer 15 Control valve body 5 Accumulator piston, Accumulator spring 6 Regulator valve, Spring seat, O-ring, NOTE Main relief spring, Slug Do not remove oil seal 10 unless it is defective. 7 Stopper pin, O-ring 8 Clutch valve plunger, Clutch valve spring, To remove stopper pin 7 use a M4x0.7 threaded bolt or screw 25 mm (1 in.) long. Clutch valve, Return spring, Slug 9 Filter, O-ring (last chance filter) 5-27
POWERSHIFT TRANSMISSION
Inspection and Repair (1) Check the valve housing for clogged oil passages. (2) Check each plunger for sign of wear, damage or seizure. (3) Check the oil seals for damaged lips. (4) Check the orifice in the main regulator valve for clogging. Also check the valve spring for weakness or damage.
200220 A: Standard value B: Repair or service limit Unit: mm (in.) Truck Models GC35K thru Items GC55K STR Free length of main relief 75 (2.95) valve inner spring 1 A [k = 2.122 spring constant, (0.215) [12.050]] [k = N/mm (kgf/mm) [lbf/in.]] B 72 (2.83) Free length of main relief 50 (1.97) valve outer spring 2 A [k = 0.838 spring constant, (0.0855) [4.783]] [k = N/mm (kgf/mm) [lbf/in.]] B 48 (1.89) Free length of clutch 39 (1.54) valve spring 3 A [k = 2.128 spring constant, (0.217) [12.141]] [k = N/mm (kgf/mm) [lbf/in.]] B 38 (1.50) Free length of clutch 28 (1.10) valve spring 4 A [k = 0.479 spring constant, (0.0488) [2.730]] [k = N/mm (kgf/mm) [lbf/in.]] B 26.5 (1.04) Free length of torque converter 32 (1.26) inlet/outlet pressure A [k =4.560 regulating valve spring 5 (0.465) [26.017]] spring constant, [k = N/mm (kgf/mm) [lbf/in.]] B 31 (1.22) Free length of accumulator 91 (3.58) valve outer spring 6 A [k = 7.303 spring constant, (0.0745) [41.666]] [k = N/mm (kgf/mm) [lbf/in.]] B 89 (3.50) Free length of accumulator 130 (5.12) valve inner spring 7 A [k = 0.597 spring constant, (0.0609) [3.408]] [k = N/mm (kgf/mm) [lbf/in.]] B 128 (5.04) Free length of directional 32.5 (1.279) spool spring 8 A [k = 8.616 spring constant, (0.8786) [49.158]] [k = N/mm (kgf/mm) [lbf/in.]] B 32 (1.26)
5-28
7 6 1 2 3 4 8 8
206614
5
203001
POWERSHIFT TRANSMISSION
Reassembly
1
Section B-B
12 11
4 B 2
12
Section C-C
B
5
10
10 C
C
8 12 7
6
9
D
D
Section D-D
15
8
13
7
14
15
3 206593
Sequence 1 Control valve body 2 Orifice screw 3 Filter 4 Accumulator spring seat, O-ring, Pin 5 Plug, O-ring, Bearing roller 6 Oil seal 7 Filter, O-ring (last chance filter) 8 Clutch valve plunger, Clutch valve, Clutch valve spring, Return spring, Slug
9 Stopper pin, O-ring 10 Regulator valve, Slug, Main relief spring, Spring seat, O-ring 11 Accumulator piston, Accumulator spring 12 Cover, O-ring, Bolt, Washer 13 Directional spool 14 Spring seat, Spring, O-ring 15 Solenoid valve, O-ring
Start by: Thoroughly wash the oil passages in the valve, and make sure that they are not clogged.
5-29
POWERSHIFT TRANSMISSION
Adjustment Oil Pressure Measurement (1) Connect a pressure gauge (20 kgf/cm2) to the main pressure and the clutch pressure taps (Rp1/8) 92067-00300. Special tools needed Connector * Hose * Meter
Torque converter inlet pressure
92067-00300 64309-17722 64309-17713 •
Tools marked with the asterisk (*) are involved in the gauge kit 64309-17700. (2) Start and run the engine at idling speed, and check to make sure that the oil level is correct in the transmission case. (3) Warm up until the torque converter oil temperature gauge indicates the green zone. (4) Run the engine at 1000 to 1500 rpm. NOTE Observe the engine tachometer reading.
• •
Main pressure
206615
Unit: MPa (kgf/cm2) [psi] Main pressure (engine at 1600 ± 100 rpm)
A
Clutch pressure (engine at 1600 ± 100 rpm)
A
Torque converter inlet pressure (engine at 1600 ± 100 rpm)
A
Lubrication pressure (engine at 1600 ± 100 rpm)
A
0.98 to 1.23 (10.0 to 12.5) [142.2 to 177.8] 0.98 to 1.23 (10.0 to 12.5) [142.2 to 177.8] 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1] 0.05 to 0.29 (0.5 to 3.0) [7 to 43]
Inching Valve Test Start by: (1) Raise the front axle housing with a jack and place wood blocks under the outer mast. Tilt the mast forward to raise the front wheels. (2) Block the rear wheels.
Hydraulic pressure test tools (reference) Single speed transmission Special tool * Connector * Hose * Connector * Gauge
Number
Remarks
64309-17733
Torque converter inlet
PT1/8 thread
● ●
64309-17722 64309-17731
For gauge
●
64309-17714
588 kPa (6 kgf/cm2) [85 psi]
●
Tools marked with an asterisk (*) are involved in the gauge kit 64309-17700.
Clutch pressure kPa (kgf/cm2) [psi]
CAUTION Remember, the front wheels will rotate when the clutch pressure is tested. Procedure (1) Set the inching pedal stroke to the specified value. (2) Connect a pressure gauge to the clutch pressure tap (Rp1/8) 92067-00300. Use the same special tools. (3) Move the forward-reverse lever to the forward position. (4) Gradually pull out the clutch (inching) valve plunger from its fully pushed position, and plot the oil pressure curve relative to the plunger stroke. Make sure that the pressure curve is identical with the curve shown. 5-30
Clutch pressure
981 (10) [142]
216 (2.2) [31] 0
5 (0.20)
10 (0.39)
Clutch valve stroke mm (in.) 202914
POWERSHIFT TRANSMISSION
Stall Speed Measurement (1) Run the engine at idling speed, and check that the oil level is correct in the transmission case. (2) Warm up the torque convertor oil. (3) Block the front and rear wheels, and apply the parking brake. (4) Run the engine at idling speed. (5) Move the forward-reverse lever to the forward position and depress the brake pedal with left foot and gradually depress the accelerator pedal all the way. Under this condition, observe the engine tachometer reading to measure the stall speed. Truck Models Item Stall speed, rpm (tolerance: ± 100 rpm)
GC35K thru GC60K thru GC55K STR GC70K STR 2000
2080
CAUTION Do not attempt to depress the inching pedal. Do not continue “Stall speed” run for more than 10 seconds. Failure to follow this precaution would result in destruction of the torque converter. (6) Similarly read the stall speed for reverse drive. NOTE (a) Any stall speed within ± 100 rpm of the specification is satisfactory. (b) If the engine or torque converter is changed, the stall speed will vary since the stall speed is determined by the combination of engine and torque converter. 10-m (33-ft) Starting Acceleration Test (1) Be ready with the engine idling and the forward-reverse lever in the neutral position. (2) At the signal, shift into forward and, at the same time, depress the accelerator pedal all the way. (3) Measure the amount of time that elapses for the truck to travel 10 meters (33 ft) with a stop watch. (4) Measure for reverse travel, too. Travel time (No load)
5 seconds, maximum
5-31
POWERSHIFT TRANSMISSION
Inching Pedal Adjustment (1) Adjusting brake pedal (a) Bleed air out of the brake lines from the reserve tank through master cylinder to the wheel cylinder. (b) Adjust and check the clearance between the drum and brake lining. (c) Install lock nut 2 (right-hand thread), push rod 3 (right-hand thread), lock nut 4 (lefthand thread) and clevis 5 (left-hand thread) on push rod 1 of the brake booster. Make sure that L1 dimension is within the standard values. L2 dimension is used for actual check. Screw-in length should be the same for left-hand and right-hand threads.
5
4
3
L2
2
1
L1
207000
Unit: mm (in.) L1
155 (6.1)
L2
88 (3.46)
(d) Install the push rod assembly on the brake pedal. (e) Adjust the brake pedal height A to 160 mm [6.3 in.] by turning the stopper bolt, and tighten the lock nut. (f) Start the engine (g) Depress the brake pedal by hand to check play B of the brake pedal. Brake pedal play B mm (in.)
5 (0.197)
C B A
Lock nut Stopper bolt
Push Rod assembly
If the play is not within the standard values, loosen lock nuts 2 and 4 and turn push rod 3 to adjust dimension L1. Brake pedal stroke C mm (in.)
37 (1.456)
206932
5-32
POWERSHIFT TRANSMISSION
(2) Adjusting inching pedal (a) Connect a pressure gauge to the clutch pressure tap. NOTE For the special tools to be used with the pressure gauge, refer to page 5-30.
Stopper bolt F
(b) Adjust the above-floor height “A” of the inching pedal to 175 mm (6.89 in.) by means of the stopper bolt. (c) Adjust clearance B between the inching pedal and the brake pedal contact surface to be 16 mm (0.63 in.) with the stopper bolt and fix this clearance with the lock nut. (d) Start the engine, and release the brake pedal. Depress the inching pedal until the brakes start applying (resistance is felt on the pedal). Under this condition, adjust the inching cable length so that spool stroke “D” is 16.5 mm (0.649 in.) (oil pressure: 0 kPa (0 kgf/cm2) [0 psi]). Inching pedal stroke E (brake functioning)
Unit: mm (in.) 82.4 (3.24)
E
Lock nut A Stopper bolt
B
207001
Inching cable
(e) Release the inching pedal, and make sure that clutch valve plunger stroke “C” is 8 to 9.5 mm (0.314 to 0.374 in.) at the pressure of 883 to 1079 kPa (9 to 11 kgf/cm2) [128 to 156 psi]. If plunger stroke “C” is not within the standard values, readjust the brake and the brake pedal as shown below: • The stroke is 9.6 mm (0.378 in.) or more: The shoe to lining clearance is too small. • The stroke is 7.9 mm (0.311 in.) or less: The shoe to lining clearance is too large.
207002
Unit: mm (in.)
C
175 (6.89) 16 (0.63)
8 to 9.5 C Clutch valve plunger stroke (0.314 to 0.374) Clutch valve plunger stroke D at brake functioning 16.5 (0.649) Inching pedal stroke E (brake functioning) 82.4 (3.24) F Inching pedal stroke 152 (5.98)
5-33
981 (10) [142] 216 (2.2) [31] 10 5 0 (0.39) (0.20)
Clutch valve plunger stroke mm (in.)
Clutch oil pressure kPa (kgf/cm2) [psi]
Inching pedal height A (from frame to top of pedal pad) Clearance between inching B pedal stopper bolt and brake pedal
D
207686
POWERSHIFT TRANSMISSION
Automatic 2-speed Transmission (GC60K thru GC70K STR) Specifications Truck Models
GC60K thru GC70K STR
Torque converter Transmission
Power transmission
Items Type Manufacturer model Stool torque ratio Operation type
Gear ratio
3 element 1 stage 2 phases M15 3. 2 F/R electric column shift H/L automatic transmission 49 ) 1-speed 5.104 (45 24 × × 18 Forward 2-speed 2.882 ( 36 × 49 ) 34 × 18 1-speed 5.104 ( 45 × 49 ) 24 × 18 Backward 49 ) 2-speed 2.882 ( 36 34 × × 18
5-34
POWERSHIFT TRANSMISSION
Structure Transmission 2-speed b
4
c
h
•
a • 6
•
•
2
• • g
•
7
•
1
•
•
3
• e 8 •
d
•
•
•
k
•
• •
• f
9
•
4
5
•
i
11
207737
j 10
Power flow
2nd shaft 1st shaft
Range
3rd shaft 4th shaft
12
Forward 1 st (F1)
h f i j k
Forward 2nd (F2)
g d i j k
Reverse 1 st (R1)
e b c f i j k
Reverse 2nd (R2)
e b a d i j k
206617
1 2 3 4 5 6
Flexible plate Torque converter assembly Pump body assembly Control valve Solenoid valve Countershaft ( 2nd shaft)
7 8 9 10 11 12 5-35
Path
Input shaft (1st shaft) Countershaft (3rd shaft) Output shaft (4th shaft) Magnet strainer Speed sensor Plus generator
POWERSHIFT TRANSMISSION
Automatic 2-speed Change Mechanism Speed selector switch
Speed sensor
Control system
E.C.U.
Speed selector switch
Power source
Solenoid valve
Speed sensor
206618
Location control devices The automatic 2-speed transmission consists of an F2-R2 powershift transmission and a control system comprising speed sensor, electronic control unit (E.C.U.) and solenoid valve. Speed can be changed from “Automatic” to “1st speed” mode by means of the speed selector switch. The speed selector switch was moved to the head guard pillar in 2006.
Selector switch position
Travel speed 1-speed
0 to 9 km/h (0 to 5.6 mph)
2-speed
9 to 24.5 km/h (5.6 to 15.2 mph)
Automatic 2 speeds
1st speed
0 to 14 km (0 to 8.7 mph)
NOTE E.C.U. - Electronic control unit 5-36
POWERSHIFT TRANSMISSION
Solenoid Valve
• 4
3
1
2
5
6 206619
1 Solenoid body 2 Solenoid valve 3 Spring
4 Cover 5 Cover 6 Solenoid valve (electric)
NOTE (1) Torque converter (2) Control system (3) Control valve For the three systems, make reference to 1-speed Transmission section. Removal and installation For removal and installation, make reference to 1-speed Transmission section. Disassembly For disassembly of torque converter, control valve and control system, make reference to 1-speed Transmission section.
5-37
5-38 Suction strainer
Lubricating circuit
PL
PD
PI
PM Main pressure PC Clutch pressure PI Torque converter 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1] inlet pressure PL Lube oil pressure 0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7] All tests run At 1600 ± 100 engine rpm
Solenoid valve
Gear pump 47 liter (12.4 U.S.gal)/ min at 2450 rpm
PM
(Valve top surface with M stamp)
Torque converter inlet pressure
Torque converter outlet pressure
Torque converter
Unit: MPa (kgf/cm2) [psi] 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8] 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Lube Oil
Oil cooler
P2
R Directional valve (Valve top surface)
F
↔R F↔
R
206594
Solenoid valve
Last chance filter
FR filter
PC
(Valve top surface with D stamp)
Clutch (inching) valve
Main regulator valve
Accumulator valve
POWERSHIFT TRANSMISSION
Powershift Transmission Hydraulic System Schematic 1-Speed
5-39
At 1600 ± 100 engine rpm
PL Lube oil pressure 0.01 to 0.15 (0.1 to 1.5) [1.42 to 21.3]
PI Torque converter 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1] inlet pressure
0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Unit: MPa (kgf/cm2) [psi]
PC Clutch pressure
All tests run
PM
PI
↔R F↔ directional valve
Solenoid valve
Gear pump 47 liter [12.4 U.S.gal]/ min at 2450rpm
Main Pressure
(Valve top surface with M stamp)
Torque converter inlet pressure
0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Suction strainer with magnet 100 mesh
Lubricating circuit
PL
Torque converter PO outlet pressure
PM Main pressure
Lube oil Pressure
Oil cooler air to oil
Torque converter
P2
Last chance filter
PC
Solenoid valve
FR filter
206620
Clutch pressure
(Valve top surface with D stamp)
Main regulator valve
Accumulator valve
POWERSHIFT TRANSMISSION
Powershift Transmission Hydraulic System Schematic 2-Speed
POWERSHIFT TRANSMISSION
Hydraulic Control (Forward 1st Speed)
203804
5-40
POWERSHIFT TRANSMISSION
Hydraulic Control (Forward 2nd Speed)
203805
5-41
POWERSHIFT TRANSMISSION
Transmission Disassembly Control valve and side cover 4 5 3
6
7 1 2 9 8 206621
Sequence 1 Drain plug, Washer 2 Thermo unit 3 Oil level gauge 4 Solenoid valve 5 Control valve
6 7 8 9
5-42
Subplate, O-ring, Gasket Speed sensor, Speed sensor cover, O-ring Strainer assembly, O-ring Side cover, Gasket
POWERSHIFT TRANSMISSION
Output shaft (4th shaft)
2 4
1 3
203806
Disassembly sequence 1 Output cover 2 Output gear
3 Output shaft subassembly 4 Tapered roller bearing, Race, Nut, Snap ring
Suggestions for disassembly (1) Removing output shaft Use the special tool A to remove output shaft subassembly 3. Output gear 2 will interfere with the gear of the countershaft (3rd shaft). This makes it necessary to remove output shaft subassembly 3 while tapping output gear 2 with a copper hammer through the side cover hole. Special tool needed Special tool A
(the same tool transmission)
91868-02100
is
used
for
1-speed
A
202892
The ball bearing remains in the transmission case. (2) Disassembling output shaft Usually, it is not necessary to disassemble output shaft subassembly 3. When it has to be disassembled, use an arbor press to remove the bearing. Take care not to lose the shims during disassembly. (3) When removing the nut, the caulked area is ground off. Replace the nut with a new one in reassembly. 5-43
200091
POWERSHIFT TRANSMISSION
Pump body
1
1
2
3
202922
Disassembly sequence 1 Pump body, Roller bearing (outer race), Bushing, Oil seal, Gasket, O-ring
2 Stator shaft, Valve, Spring washer, Snap spring, Steel ball 3 Drive gear, Driven gear
Suggestion for disassembly (1) Removing pump body assembly Unscrew all body mounting bolts. Using the jacking bolts, remove the subassembly. Jacking bolt
67284-15400
(2) It is not necessary to remove the steel ball and the plug fitted to the pump body or the bushing, oil seal, steel ball, cap, etc. fitted to the stator shaft unless they are defective.
202923
5-44
POWERSHIFT TRANSMISSION
Countershaft (3rd shaft)
1 8 6
7 2 3 4 5
9
206622
Disassembly sequence 1. Cover, O-ring 2. Roller bearing (inner race) 3. Spacer 4. Output gear (countergear) 5. Gear (forward 1st speed countergear)
6. 7. 8. 9.
Suggestions for disassembly (1) Removing countershaft Attach a sliding hammer to countershaft 9, and remove the shaft complete with ball bearing 8. Roller bearing 2 comes off first. Or install a bearing puller on the backside of output gear 4 to remove bearing inner race 2 and gear out the front of transmission case. Tap end of countershaft 9 to the rear. Then remove gear and countershaft.
5-45
Spacer Gear (forward 2nd speed countergear) Ball bearing Countershaft
POWERSHIFT TRANSMISSION
Input shaft (1st shaft)
6
13
16 14
15
5 2 1
17
4
13
3
15 16
12
8
7
2
9 11 13
10
14 12 12
11
12
207595
Current production Input shaft assembly (consisting of parts 2 thru 17) Disassembly of input shaft assembly Disassembly sequence 1 Servo case, O-ring 2 Seal ring 3 Ball bearing 4 Thrust washer 5 Gear (forward 2nd speed drive), Needle roller bearing 6 Thrust washer 7 Ball bearing 8 Thrust washer NOTE Do not remove the steel ball fitted to the servo case or the screw fitted to the input shaft. 5-46
9 Gear (forward 1st speed drive), Needle roller bearing 10 Thrust washer 11 Snap ring, Pressure plate 12 Friction plates, Mating plates 13 Snap ring, Retainer 14 Clutch ring 15 Clutch piston, Steel ball, Screw, Seal ring 16 Seal ring 17 Input shaft
POWERSHIFT TRANSMISSION
Input shaft (1st shaft) 1st production 6
13
14
2
16
15
5 4
13
17
3 1
15 16
12
7 9
11
2
8
10
14 13 12 12
11
12
Sequence 1 Servo case, O-ring 2 Seal ring 3 Ball bearing 4 Thrust washer 5 Gear (forward 2nd speed drive), Needle roller bearing 6 Thrust washer 7 Ball bearing 8 Thrust washer 9 Gear (forward 1st speed drive), Needle roller bearing
10 11 12 13 14 15 16 17
NOTE Do not remove the steel ball fitted to the servo case or the screw fitted to the input shaft. 5-47
Thrust washer Snap ring, Pressure plate Friction plates, Mating plates Snap ring, Retainer Clutch spring Clutch piston Steel Ball, Screw, Seal ring Seal ring Input shaft
POWERSHIFT TRANSMISSION
Suggestion for disassembly (1) Removing input shaft ball bearing Use the special tools to remove ball bearing 3 from the input shaft. Special tools needed: Puller A Plate B Complete Puller Assembly
A
91268-13810 B 202926
(2) Disassembling input shaft Using the special tool or a press, compress clutch spring 14, and remove snap ring 13. Special tool needed Piston tool C
C
92267-00300
202927
(3) Clutch piston Shake clutch piston 15 and make sure that the balls move freely in the piston. Then, it is not necessary to disassemble the clutch piston.
5-48
1st production style
POWERSHIFT TRANSMISSION
Countershaft (2nd shaft)
Current production
17
5 1
2
3
4
15 16
12
11 13
11
14
3
6
12
8
12
2
7
9 13 16
10
14
15 12
207596
B: Countershaft assembly (consisting of parts 2 thru 17) Sequence 1 Servo case, O-ring 2 Seal ring 3 Ball bearing 4 Thrust washer 5 Gear (reverse 2nd speed drive), Needle roller bearing 6 Thrust washer 7 Snap ring 8 Thrust washer 9 Gear (reverse 1st speed drive), Needle roller bearing
10 11 12 13 14 15
Thrust washer Snap ring, Pressure plate Friction plates, Mating plates Snap ring, Retainer Clutch spring Clutch piston, Seal ring, Steel ball, Screw 16 Seal ring 17 Countershaft
5-49
POWERSHIFT TRANSMISSION
Countershaft (2nd shaft)
1st production 5 3
1
17
4 15
2 16
2 12
3
11 13
14 12
8
6
7
9 11
10 13 15
16
14 12
207596
Countershaft assembly (consisting of parts 2 thru 17) Sequence 1. Servo case, O-ring 2. Seal ring 3. Ball bearing 4. Thrust washer 5. Gear (reverse 2nd speed drive), Needle roller bearing 6. Thrust washer 7. Snap ring 8. Thrust washer 9. Gear (reverse 1st speed drive), Needle roller bearing
10. 11. 12. 13. 14. 15.
Thrust washer Snap ring, Pressure plate Friction plates, Mating plates Snap ring, Retainer Clutch spring Clutch piston, Seal ring, Steel ball, Screw 16. Seal ring 17. Countershaft
Suggestion for disassembly For disassembly of the countershaft and the clutch piston, make reference to disassembly of input shaft.
5-50
POWERSHIFT TRANSMISSION
Inspection and Repair For the following parts, make reference to 1-speed Transmission. (1) (2) (3) (4) (5) (6) (7) (9) (10) (11)
Oil pump Pump boss Stator shaft Clutch pistons Friction plates and Mating plates Clutch drums Clutch gears Input shaft, Countershaft, Output shaft Gears Strainer assembly
Input Shaft, Servo Case and Seal Rings Check the contact surfaces of each part for wear or damage.
A: Standard value B: Repair limit Service limit Unit: mm (in.) Truck Models GC35K thru Items GC55K STR 2.5 ± 0.05 A Width of input shaft (0.098 ± 0.0020) seal ring 1 B 2.0 (0.079) 2.5 +0.2 +0.1 Width of seal ring groove A (0.098 +0.008 +0.004 ) in input shaft 2 B 3.0 (0.118) 35 +0.025 +0 Inside diameter of A stator shaft in contact (1.38 +0.00098 ) +0 with seal ring 3 B 35.2 (1.386) 2.5 ± 0.05 A Width of input shaft (0.098 ± 0.0020) seal ring 4 B 2.0 (0.079) 2.5 +0.2 +0.1 A Width of input shaft (0.098 +0.008 +0.004 ) seal ring groove 5 B 3.0 (0.118) 35 +0.025 +0 Inside diameter of clutch A shaft in contact with (1.38 +0.00098 ) +0 seal ring 6 B 35.2 (1.386)
NOTE The dimensions of the seal rings and their grooves for the countershaft (2nd shaft) are identical with those for the input shaft.
1, 2
4, 5 6
3
5-51
207597
POWERSHIFT TRANSMISSION
Reassembly Ball bearing and oil seals
2
•
1
202930
Sequence 1 Ball bearing
2 Oil seals NOTE
Removal of the output shaft will leave the ball bearing and oil seals in the transmission case. Remove them for replacement only when they are found defective. Suggestion for reassembly Use the special tool to install the oil seals. Pay attention that the two oil seals face opposite to each other as the illustrations. Special tool needed Installer
Transmission case Oil seals Special tool
91868-02200
203479
5-52
POWERSHIFT TRANSMISSION
Countershaft (2nd shaft) and input shaft (1st shaft)
1 • •
2 3 1 • •
207738
Start by: Reassemble the input shaft subassembly. Reassemble the countershaft subassembly. NOTE The clutches are common to the input shaft and countershaft. Reassembly of input shaft subassembly and countershaft subassembly Assembly sequence is the same as that in the forward-reverse clutch shaft subassembly of the 1speed Transmission. Reassembly sequence 1 Servo case, O-ring 2 Countershaft subassembly 3 Input shaft subassembly
A
Suggestions for reassembly Installing clutch spring (1) Using the special tool A or a press, compress clutch spring, and fit snap ring. Special tool needed Piston tool A
92267-00300 207504
5-53
POWERSHIFT TRANSMISSION
(2) When inserting clutch piston into the drum of the countershaft or input shaft, put ATF oil on the seal rings. (3) Installing clutch plate Make sure that the combination and number of the plates are correct. Reassemble the plates while putting ATF oil on each plate. When replacing the friction plates, replace the mating plates as a set. (4) After reassembling, apply pressure air of approximately 98 kPa (1.0 kgf/cm2) [14.2 psi] to the oil hole to make sure that the pistons move freely without any sign of air leaks. Countershaft (3rd shaft)
5
9
6 1
• •
• • •
• •
• •
2
8
3
7
207739
4
Reassembly sequence 1 Countershaft 2 Ball bearing 3 Gear (F2 countergear) 4 Spacer 5 Gear (F1 countergear)
6 7 8 9 5-54
Output gear (counter) Spacer Roller bearing (inner race) Cover, O-ring
POWERSHIFT TRANSMISSION
Suggestions for reassembly (1) Install ball bearing 2 on countershaft 1 and insert it into the transmission case. (2) When placing gear (forward 2nd speed countergear) 3 in the transmission case, slightly pull out the input shaft subassembly and countershaft subassembly (2nd shaft) to prevent interference of these shafts with the gear. (3) Align ball bearing 2 and inner race 8 of roller bearing, which are installed at the ends of countershaft 1, with the end surfaces of the countershaft. Pump body
1 • • •
2
• 3
207740
Reassembly sequence 1 Pump body, Outer race of roller bearing, Oil seal, Bushing 2 Pump drive gear, Pump driven gear Suggestions for reassembly (1) Install the pump body to the transmission case in the assembled state. (2) Put ATF oil in the internal gear and drive gear when installing them to the pump body. 5-55
3 Stator shaft, Valve, Spring washer, Snap ring
POWERSHIFT TRANSMISSION
(3) Put LG2 grease on the oil seal and bushing of the pump body 1. Output shaft
3 • 2
•
• 1 207741
Reassembly sequence 1 Output gear 2 Output shaft subassembly Suggestions for reassembly (1) Install the output shaft as subassembly 2. (2) Shim adjustment of output shaft (Unit: mm) Before installing the bearing, determine the required thickness of shims by referring “a” and “b” to this formula: Thickness of shims (C) = 1.7 + a - b 100 where a: machining error indicated in a unit of 1/100 mm on differential carrier by pushing. b: machining error of bevel pinion. (3) Put light grease on the oil seals fitted to the transmission case.
Centerline of axle
3 Output cover
c
±b ± a 100 202825
5-56
POWERSHIFT TRANSMISSION
(4) Upon reassembling, measure each gear backlash with a dial gauge.
Backlash of forward 1st speed gear with forward 2nd speed Backlash of forward gear with reverse gear Backlash of countergear with output gear
Unit: mm (in.) 0.14 to 0.23 (0.0055 to 0.0091) 0.14 to 0.24 (0.0055 to 0.0094) 0.14 to 0.25 (0.0055 to 0.0098)
Torque converter Stator shaft
Turbine shaft
•
•
•
Torque converter assembly Pump boss 207742
Reassembly Install the torque converter assembly to the transmission. Suggestion for reassembly (1) Align the splines of the transmission-side stator shaft, the turbine shaft and the pump boss completely. The distance between the end face of the housing and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.) if the torque converter is properly placed in the transmission. Apply ATF oil to the sliding surfaces of the oil seal and the bushing. (2) The torque converter is only inserted and not secured. Attach the flexible plate to the housing with a wire.
4 to 6 mm (0.157 to 0.236 in.) 206597
5-57
POWERSHIFT TRANSMISSION
Control valve and side cover To reassemble, follow the reverse sequence of disassembly. Suggestion for reassembly (1) Replace the gaskets and O-rings with new ones.
Solenoid Valve Disassembly
5
4
6
3
1 2
1
202936
Sequence 1 Cover, Gasket 2 Solenoid valve, O-ring 3 Cover, O-ring
4 Spring 5 Solenoid valve 6 Solenoid body, Gasket
5-58
POWERSHIFT TRANSMISSION
Inspection and Repair (1) Check the valve body for clogged oil passages. (2) Check the valve for wear, damage or seizure. (3) Check the spring for damage or fatigue.
A: Standard value B: Repair limit Service limit Unit: mm (in.) Truck model GC35K thru Item GC70K STR Free length of solenoid 65 (2.56) valve spring. Spring rate A [k=0.183 (10.25)] [k=kgf/mm (lbf/in.)] B 63 (2.48)
Reassembly
4
3
1
2
Reassembly sequence 1 Solenoid body 2 Solenoid valve 3 Spring
6
5
206619
4 Cover, O-ring, Bolt, Washer 5 Solenoid valve, O-ring 6 Cover, Gasket, Bolt, Washer
Start by: Wash the valve body thoroughly, making sure that all oil passages are free from clogging.
Lube oil pressure
Torque converter inlet pressure
Adjustment Oil pressure measurement The taps differ from those for the 1-speed transmission. For the test method and oil pressure specifications, refer to 1-Speed.
Alternate lube oil test port
• • • •
•
Main pressure Unit: MPa (kgf/cm2) [psi] PM Main pressure
0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
PC Clutch pressure
0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
PI Torque converter 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1] inlet pressure PL Lube oil pressure 0.01 to 0.15 (0.1 to 1.5) [1.42 to 21.3] All tests run
At 1600 ± 100 engine rpm
5-59
Clutch pressure
206631
POWERSHIFT TRANSMISSION
Hydraulic pressure test tools Hydraulic pressure test tools 2-speed transmission Tool name/ number
Remarks
Main/clutch
Torque converter inlet/lube oil
*Connector 92067-00300
Rp1/8 thread
●
–
*Connector 64309-17733
Rc1/8 thread
–
●
*Connector 91268-02300
Rp1/8 thread
–
–
*Gauge 64309-17714
588 kPa (6 kgf/cm2) [86 psi]
–
●
*Gauge 64309-17713
1961 kPa (20 kgf/cm2) [284 psi]
●
–
●
●
●
●
*Hose 64309-17722 *Connector 64309-17731
For gauge
Tools marked with an asterisk (*) are involved in the 64309-17700 gauge kit.
For the following four items,refer to the section “1-speed Transmission”. • Measurement of oil pressure • Measurement of stall speed • 10-m (33-ft) starting acceleration • Inching pedal adjustment 2nd speed/auto selector switch test Move the selector switch mounted on the side face of console box (moved to the sub panel mounted on the right front overhead guard leg in 2006) to each position, and make sure that the transmission functions properly. In the 1st speed position, the truck runs at a maximum speed of 14 km/hr (8.7 mph) and a greater torque is available at the drive axle. In the auto position, the transmission automatically shifts from 1st to 2nd range when the travel speed reaches 9 km/hr (5.6 mph) to allow the truck to run at a maximum speed of 24.5 km/hr (15.2 mph).
104794
206632
5-60
POWERSHIFT TRANSMISSION
2-Speed Transmission Electrical Systems Troubleshooting
Part Numbers: ECU’s Models
Transmissions
Part Numbers
System Type
GC 60K — 70K STR
2 -Speed
16A20-28001
Carburetion
GC 60K — 70K STR
2 -Speed
16A23-18001
MPFI
Transmissions
Part Numbers
System Type
GC60K — 70K STR
2-Speed
69321-08101
Carburetion
GC60K — 70K STR
2-Speed
97433-01100
MPFI
Pulse Generator / Speed Sensor Models
Solenoids Solenoid Types
Part Numbers
Voltage
Type
System Type
GC60K — 70K STR
Speed
91828-11200
12V
N/O
Carburetion
GC60K — 70K STR
Speed
93728-00901
12V
N/C
MPFI
GC60K — 70K STR
Directional
93728-20701
12V
N/O
Carburetion and MPFI
Models
Solenoid Note: 12 Volt: Working Voltage 8 to 16 Volts NOTE The part numbers listed above should be used as reference only. Parts numbers can change without notice. Check parts system for updated part information.
5-61
POWERSHIFT TRANSMISSION
ECU Self-Diagnostic Test The Electronic Control Unit (ECU) has a selfdiagnostic feature built in a 1-chip microcomputer. The computer processes the signal received from the pulse generator through the ECU speed selector and automatically selects the speed according to the signal received from the pulse generator. It has two LED indicator fault lights that flash a pattern of flashes for testing the ECU, Pulse Generator and Shift Solenoid. The selfdiagnostic feature is intended to help take the guesswork out of troubleshooting the power shift transmission electrical system. The indicator fault lights are located on the rear mounting face of the ECU. Remove the ECU mounting bolts to access the fault lights. The indicator lights will flash in one the following patterns (ECU with no fault, Pulse Generator / Speed Selector Fault and Shift Solenoid Fault) when a problem occurs in the electrical control system of the 2-speed transmission. A fault code will continue to flash until the key switch is turned to the OFF position. If any other pattern of flashes occurs, the ECU is defective and should be replaced.
ECU: Failure Indicator Lights
GREEN RED
NOTE It is possible to have a combination of failed components at the same time. Be sure to check all components (Pulse Generator, Speed and Directional solenoids) before replacing the ECU. ECU Test 1. Turn the key switch to the On position. 2. For the first 10 seconds, the green light comes ON and the red light flashes. 3. For 10 seconds and more, the green light is ON and the red light is OFF. Condition Light Colors Green Red
Key Switch Key Switch on 0-10 Sec. on after 10 Sec. ON
ON
Flash
OFF
5-62
POWERSHIFT TRANSMISSION
Pulse Generator / Speed Sensor Fault: Green Light
Shift Solenoid Fault: Transmission must be accelerated to shifting speed before fault will appear.
ON
Red Light
ON OFF
ON OFF
Green Light OFF
ON
Red Light
NOTE System resets automatically after repair.
ON OFF
Pulse Generator Test 1. Set the parking brake and block the rear wheels. 2. Raise the front wheels off the ground either by lifting with a crane or tilting the mast backwards and placing a wood block which can bear the weight of the truck under the outer the mast, and tilt forward until the front tires are off the ground. 3. Disconnect the pulse generator from the wire harness. Sometimes called speed sensor. 4. Connect a digital voltmeter (VOM) to the wires coming from the pulse generator. NOTE The Pulse Generator is not polarity sensitive. 5. Set the VOM to 0 — 20 AC voltage scale. 6. Start the truck and place the directional lever to forward or reverse. 7. Slowly raise the rpm while watching the VOM. 8. The minimum reading at shifting point should be 0.860 AC volts.
Use a voltmeter set on 0 to 40 DC volts to test the solenoid for proper voltage to the shift speed solenoids. NOTE 12 Volt Solenoid: Working Voltage 8 to 16 Volts.
Solenoid
Neutral
—
— OFF OFF
F1 ON OFF
F2 ON OFF
R1 ON OFF
R2 ON OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Forward Solenoid Reverse Solenoid
Forward
Reverse
1985 - 12/2003 Models
First Speed Solenoid 2004 and up Models
The minimum volt reading will vary depending on the gear ratio of the truck.
5-63
OFF
Solenoid Voltage Test
First Speed Solenoid
NOTE Moving the pulse generator closer or further away from the output gear will change the readings and frequency pattern from the generator.
OFF
NOTE System resets automatically after repair.
NOTE
9. The Maximum output reading is 1.004 AC volts.
ON
POWERSHIFT TRANSMISSION
Oscilloscope Shop Test 1. Set the parking brake and block the rear wheels. Raise the front wheels off the ground either by lifting with a crane or tilting the mast backwards and placing a wood block which can bear the weight of the truck under the outer mast, and tilting the mast forward until the front tires are off the ground. 2. Disconnect the pulse generator from the wire harness. Sometimes called speed sensor. 3. Connect an oscilloscope to the wires coming from the pulse generator and check the following reading and frequency pattern to ensure the pulse generator is working properly. NOTE The Pulse Generator is not polarity sensitive. NOTE Moving the pulse generator closer or further away from the output gear will change the readings and frequency pattern from the generator.
SCOPE READINGS
B A
5-64
POWERSHIFT TRANSMISSION
Meter Readings Good
Bad
Ref A
Ref B
Histogram
Min/Max
Period
4.23 ms
360 us
Frequency
236 Hz
2.78 kHz
Pos. Pulse Width
2.14 ms
302 us
Neg. Pulse Width
2.09 ms
57.7 us
Rise Time
1.93 ms
9.61 ms
Fall Time
878 us
6.4 us
Pos. Duty Cycle
50.67%
83.96%
Neg. Duty Cycle
49.33%
16.04%
Pos. Overshoot
5.10%
0.00%
Neg. Overshoot
4.46%
0.00%
Peak to Peak
3.44 V
800 mV
Amplitude
3.14V
800 mV
High
1.56 V
400 mV
Low
-1.58 V
-400 mV
Maximum
1.72 V
400 mV
Minimum
-1.72 V
-400 mV
Mean
-25.3 mV
6.93 mV
Cycle Mean
-4.03 mV
-22 mV
RMS
1.04 V
86 mV
AC RMS
1.04 V
95.8 mV
Cycle RMS
1.03 V
72.7 mV
Cycle AC RMS
1.03 V
67.8 mV
Burst Width
17 ms
19.9 ms
Measure Mode
5-65
POWERSHIFT TRANSMISSION
Fault Notes:
5-66
POWERSHIFT TRANSMISSION
Speed Selector System: (Example)
Speed selector switch
Electronic control unit (ECU)
Output gear
Electric signal
Pulse generator 0.5 mm (0.02 in.)
Speed (solenoid) valve
Hydraulic pressure signal Transmission case
5-67
1st speed clutch 2nd speed clutch
POWERSHIFT TRANSMISSION
Troubleshooting Torque converter drive transmission Engine
Torque converter
Low engine output Low engine performance
— Adjust the engine — Adjust the engine
Insufficient oil Air intake from intake side
— Replenish — Retighten or replace pipe and gasket — Repair or replace — Replace spring — Disassemble or replace defective part — Replace magnet strainer — Replace after measurement of oil pressure — Replace stator assembly, hub and roller — Repair or replace impeller Replace bearing
Spool failure of main regulator valve Worn spring of main regulator valve Worn oil pump (Low or insufficient discharge) Clogging of magnet strainer Worn seal ring and O-ring
Low output
Seizure of stator free wheel Damage and contact of impeller
Transmission
Air intake from intake side Water inclusion into oil Insufficient oil Adjustment failure of pedal link (Brake shift and forward-reverse) Clutch slippage due to low main pressure Worn seal ring and O-ring Damaged clutch piston Seizure or drag of friction plate
— Adjust pressure after measurement of oil pressure — Replace after measurement of oil pressure — Replace piston — Replace plate
Large driving resistance on underbody parts
— Inspect or adjust brake parts
Torque converter
Damaged flexible plate Insufficient oil Defective oil pump drive system Broken turbine shaft Low oil pressure (Main pressure)
— Replace — Replenish — Replace — Replace — Check for wear of the oil pump gear, or replace
Transmission
Insufficient oil Adjustment failure of inching pedal link Worn servo case seal ring Worn input shaft O-ring Non-removal of input shaft plug Seizure of clutch Broke shaft Damaged clutch drum (Snap ring groove) Broken snap ring for clutch drum Clogging of clutch oil circuit Worn splines of shaft
— Replenish — Adjust — Replace — Replace — Repair — Replace — Replace — Replace — Replace — Clean or replace — Replace
Body
No transmission of power
— Retighten or replace — Replace oil — Replenish — Adjust
Body
Damaged transmission system (Reduction — Refer to each section gear, Differential, Front axle) 5-68
POWERSHIFT TRANSMISSION
Torque converter
Abnormal noise
Transmission
High abnormal noise
Broke flexible plate Damaged bearings Contact of impeller Loose bolt Worn splines Worn oil pump
— Replace — Replace — Replace — Retighten or replace bolt — Replace — Disassemble or replace
Dragging noise due to clutch seizure Wear or seizure of bearing Damaged gear Loose bolt Worn splines
— Replace clutch plate — Replace — Replace — Retighten or replace bolt — Replace
Clogging of oil strainer Failure of main regulator valve spool Large pipe resistance Cold time (High viscosity)
— Clean or replace — Disassemble or replace — Replace — Check applicable lubrication oil before replacement — Replace — Check applicable lubrication oil before replacement
Failure of instruments Use of incorrect oil
Low abnormal noise
Clogging of oil strainer Failure of oil pump Excessive oil leakage (1) Failure of main regulator spring (2) Failure of main regulator valve spool Air intake
— Clean or replace — Replace
Insufficient oil
— Replenish
From oil seal
— Check lip and sliding surface for wear. Replace seal — Retighten or replace packing
From case connection Oil leakage
From various joints and pipes From drain plug From crack Oil leak from transmission case (1) Water inclusion into oil (2) Air intake from intake side joint (3) Oil leak from air breather hole Excessive oil quantity
5-69
— Replace spring — Repair or replace spool — Retighten or replace packing
— Repair or replace pipe, gasket and O-ring — Retighten or replace gasket — Replace — Replace oil — Retighten and replace packing — Repair — Drain oil to the proper level
Abnormally high oil temperature
POWERSHIFT TRANSMISSION
Incorrect oil quantity Clogging of oil strainer Contact of impeller Failure of stator Air intake Inclusion of water into oil Large resistance on pipe (Low circulation flow rate) Wear or seizure of bearings Failure of instruments
— Replenish or drain — Clean or replace — Repair or replace impeller — Replace stator assembly — Retighten or replace O-ring — Replace oil — Repair or replace
Transmission
Drag of clutch Wear or seizure of bearings Failure of control link
— Replace clutch plate — Repair or replace — Repair or replace — Use properly
Body
Improper use of body Failure of body (1) Damaged fan belt (2) Clogging of oil cooler (3) Drag of brake Failure of main regulator valve
— Repair or replace valve assembly — Check applicable lubrication oil before replacement — Check applicable lubrication oil before replacement
Torque converter
Abnormally high main pressure
Cold time Use of incorrect oil
Abnormally low main pressure
Abnormally low clutch oil pressure
— Repair or replace — Replace
— Replace — Clean or replace — Inspect or adjust
Clogging of magnet strainer Failure of oil pump Defective coil spring of main regulator valve Defective spool of main regulator valve Intake of air Insufficient oil quantity Defective control link Defective clutch valve
— Clean or replace — Replace — Replace spring
Clogging of magnet strainer Failure of oil pump (Wear) Defective coil spring of main regulator valve Defective spool of main regulator valve Intake of air Insufficient oil quantity Defective control link Defective clutch valve Broken seal ring of servo case Broken clutch seal ring
— Clean or replace — Replace — Replace spring
5-70
— Repair or replace spool — Retighten or replace packing — Replenish — Repair or replace — Repair or replace
— Repair or replace spool — Retighten or replace packing — Replenish — Repair or replace — Repair or replace — Replace — Replace
POWERSHIFT TRANSMISSION
Stall speed is not within the standard value
No speed change (2-speed T/M)
— Adjust engine Low engine output if both forward and reverse speed are a little low Failure of stator and free wheel if both — Replace stator assembly forward and reverse speed are abnormally low — Repair or replace Defective inching link or clutch slippage if the value exceeds the standard Mode selector switch remains at 1-speed Failure of solenoid valve Clogging of solenoid valve inlet orifice Defective solenoid valve spool Defective solenoid valve spring Defective E.C.U. control box
5-71
— Set the switch to Auto — Replace — Clean or replace — Repair or replace spool — Replace spring — Inspect and replace shim
POWERSHIFT TRANSMISSION
Service Data
A : Standard value B : Repair limit
Torque converter drive transmission
Service limit Unit: mm (in.)
Truck Models Items Stall speed (rpm, tolerance ± 100 rpm)
A
GC35K thru GC55K STR
GC60K thru GC70K STR
2000
2080
Oil pressure standard value Main oil pressure at Eng. 1600 ± 100 rpm MPa (kgf/cm2) [psi] A
0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Clutch oil pressure at Eng. 1600 ± 100 rpm MPa (kgf/cm2) [psi] A
0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
T/C inlet oil pressure at Eng. 1600 ± 100 rpm MPa (kgf/cm2) [psi] A
0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1]
Lubrication oil pressure at Eng. 1600 ± 100 rpm
0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7]
A
MPa (kgf/cm2) [psi] 10 m (33 ft) standing acceleration (without load) (sec.)
A
Within 5
A
Oil seal and bushing contact face 1 (inside diameter)
70
-0 -0.046
(2.76
-0 -0.00181 )
B
69.90 (2.7520)
A
70.06 to 70.10 (2.7583 to 2.7598)
B
70.3 (2.768)
Pump boss
Boss bushing inside diameter 2
0.01 to 0.15 (0.1 to 1.5) [1.42 to 21.3]
1
2
A
Diameter of flywheel insertion area 1
20
Pilot boss
B
-0.007 -0.020
(0.78
-0.00028 -0.00079 )
202896
19.85 (0.781)
1
206990
5-72
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission
Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
Items Side clearance 1
Oil pump
Top clearance 2 Clearance at notch between drive gear and pump boss 3
GC60K thru GC70K STR
A
0.05 to 0.11 (0.002 to 0.0043)
B
0.20 (0.008)
A
0.6 to 0.66 (0.0236 to 0.0259)
B
0.8 (0.031)
A
0.2 to 0.4 (0.008 to 0.016)
B
1.0 (0.04)
1 3 2 202897
A
Outside diameter of clutch hub 1 Outside diameter of clutch roller 2
Stator
Outside diameter of thrust washer 3 Thickness of thrust washer 4
65
-0.03 -0.049
(2.56
-0.0012 -0.00193 )
B
64.9 (2.555)
A
-0 8.1 -0 -0.015 (0.32 -0.00059 )
B
7.985 (0.31437)
A
2.0 -0.05 (0.08 -0.0020 )
B
1.75 (0.0689)
A
3 -0.05 (0.12 -0.0020)
B
2.75 (0.1083)
-0
-0
-0
-0
4 • 2 1
3 206596
Runout of flexible plate 1 (in free condition)
0.2 (0.008)
B
0.5 (0.020)
A
4 to 6 (0.157 to 0.236)
Flexible plate
Distance from case end face to flexible plate mounting face 2
A
1 2
5-73
206597
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission
Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
Items Thickness of mating plate 1 Thickness of friction plate 2 Backlash between friction plate and gear 3
2.3 ± 0.07 (0.09 ± 0.0028)
B
2.1 (0.083)
A
2.6 ± 0.1 (0.102 ± 0.004)
B
2.2 (0.087)
A
0.1 to 0.3 (0.004 to 0.012) 4 –0.01 –0.03 (0.16
B
Free length of clutch spring 6 Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
6
3
–0.0004 –0.0012 )
3.5 (0.138)
A
Seal ring groove width of piston 5
Clutch
A
A
Width of seal ring 4
GC60K thru GC70K STR
4
+0.2 +0.1
(0.16
+0.008 +0.004 )
B
4.5 (0.177)
A
62.9 (2.476) [k = 31.312 (3.193) [178.648]]
B
62 (2.440)
2 1 4
5
N.m (kgf.m) A [lbf.ft]
353 to 392.3 (36 to 40) [79.4 to 88.2]
Output shaft (4th shaft)
Lock nut tightening torque 1
206603
200408
5-74
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission (1-speed transmission)
Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
GC60K thru GC70K STR
2.5 ± 0.05 (0.098 ± 0.002)
—
2.0 (0.08)
—
Items A
Seal ring width of turbine shaft 1
B A
Piston seal ring groove width of turbine shaft 2
B A
Seal ring contact surface inside diameter 3 of stator shaft Clutch piston seal ring width 4
35
— —
A
2.5 ± 0.05 (0.098 ± 0.002)
—
2.0 (0.08)
—
2.5 +0.2 +0.1
(0.098
+0.008 +0.004 )
—
B
3.1 (0.122)
—
A
2.5 ± 0.05 (0.098 ± 0.002)
—
2.0 (0.08)
—
A B A
Seal ring contact surface inside diameter of servo case 8
(1.38
—
+0.008 +0.004 )
35.2 (1.386)
B
Clutch shaft seal ring groove width 7
+0.2 +0.1
B
A
Clutch shaft seal ring width 6
—
3.0 (0.118)
B
Clutch piston seal ring groove width 5
Main shaft and servo case
2.5
+0.2 +0.008 +0.1 (0.098 +0.004 )
B
6, 7
2.5
+0.2 +0.1
(0.098
+0.008 +0.004 )
—
3.0 (0.118) 35 +0.025 +0
(1.38
—
+0.00098 ) +0
35.2 (1.386)
— —
1, 2
8
4, 5
3
Gear Shaft backlash
207743
Countergear and output gear
A 0.14 to 0.27 (0.0055 to 0.0106)
—
Other gears
A 0.14 to 0.26 (0.0055 to 0.0102)
—
Backlash at each shaft spline
A 0.036 to 0.206 (0.0014 to 0.0081)
—
5-75
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission (Automatic 2-speed transmission)
Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
GC60K thru GC70K STR
A
—
2.5 ± 0.05 (0.098 ± 0.002)
B
—
Items Seal ring width of input shaft 1 Seal ring groove width of input shaft 2 Seal ring contact surface inside diameter of stator shaft 3 Input shaft seal ring width 4
Input shaft and servo case
Input shaft seal ring groove width 5 Seal ring contact surface inside diameter of servo case 6 Clutch piston seal ring width 7 Clutch piston seal ring groove width 8
A
—
B
—
2.0 (0.08) 2.5
+0.2 +0.1
(0.098
+0.008 +0.004 )
3.0 (0.118) +0.025 35 +0
+0.00098
A
—
B
—
35.2 (1.386)
A
—
2.5 ± 0.05 (0.098 ± 0.002)
B
—
A
—
B
—
(1.38 +0
)
2.0 (0.08) 2.5
+0.2 +0.008 +0.1 (0.098 +0.004 )
3.0 (0.118) (1.38 +0.00098 ) +0
A
—
B
—
35.2 (1.386)
A
—
2.5 ± 0.05 (0.098 ± 0.002)
B
—
A
—
B
—
35
+0.025 +0
2.0 (0.08) 2.5
+0.2 +0.008 +0.1 (0.098 +0.004 )
3.0 (0.118)
6
4, 5
3 7, 8
5-76
1, 2 207744
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission (Automatic 2-speed transmission)
Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
GC60K thru GC70K STR
A
—
2.5 ± 0.05 (0.098 ± 0.002)
B
—
Items Seal ring width of countershaft 1 Seal ring groove width of countershaft 2 Seal ring contact surface inside diameter of pump body 3 Clutch piston seal ring width 4 Clutch piston seal ring groove width 5
Counter shaft and servo case
Countershaft seal ring width 6 Countershaft seal ring groove width 7 Seal ring contact surface inside diameter of servo case 8
6, 7
8
A
—
B
—
2.0 (0.08) 2.5
+0.2 +0.008 +0.1 (0.098 +0.004 )
3.0 (0.118) 35
+0.025 +0
(1.38 +0.00098 ) +0
A
—
B
—
35.2 (1.386)
A
—
2.5 ± 0.05 (0.098 ± 0.002)
B
—
2.0 (0.08) (0.098 +0.008 +0.004 )
A
—
B
—
3.1 (0.118)
A
—
2.5 ± 0.05 (0.098 ± 0.002)
B
—
A
—
B
—
A
—
B
—
2.5
+0.2 +0.1
2.0 (0.08) 2.5
3.0 (0.118) 35
+0.025 +0
(1.38 +0.00098 ) +0
35.2 (1.386)
3
4, 5
+0.2 +0.008 +0.1 (0.098 +0.004 )
1, 2
Gear Shaft Shaft backlash
207745
Gears for forward 1-speed and 2-speed
A
—
0.14 to 0.23 (0.0055 to 0.0090)
Forward and reverse gears
A
—
0.14 to 0.24 (0.0055 to 0.0094)
Countergear and output gear
A
—
0.14 to 0.25 (0.0055 to 0.0098)
Backlash at shaft splines
A
—
0.036 to 0.206 (0.0014 to 0.0081)
5-77
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission
Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
GC60K thru GC70K STR
Free length 1 of main relief valve inner spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
75 (2.95) [k = 2.122 (0.215) [12.050]]
B
72 (2.83)
Free length 2 of main relief valve outer spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
50 (1.97) [k = 0.838 (0.0855) [4.783]]
B
48 (1.89)
Free length 3 of clutch valve spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
39 (1.54) [k = 2.128 (0.217) [12.141]]
B
38 (1.50)
Free length 4 of clutch valve spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
28 (1.10) [k = 0.479 (0.0488) [2.730]]
B
26.5 (1.04)
Free length 5 of torque converter inlet/outlet oil pressure A regulating valve spring B Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
32 (1.26) [k = 4.560 (0.465) [26.017]]
Free length 6 of accumulator valve outer spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
91 (3.58) [k = 7.303 (0.0745) [41.666]]
B
89 (3.50)
Free length 7 of accumulator valve inner spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
130 (5.12) [k = 0.597 (0.0609) [3.408]]
B
128 (5.04)
Free length 8 of directional spool spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]]
A
32.5 (1.279) [k = 8.616 (0.8786) [49.158]]
B
32 (1.26)
31 (1.22)
▲
6
▲ ▲
▲
7
1 2 3 ▲
▲
Control valve
Items
▲
203001
4
5
▲
206614 8
8
5-78
POWERSHIFT TRANSMISSION
A : Standard value B : Repair limit
Torque converter drive transmission
Service limit Unit: mm (in.)
Truck Models GC35K thru GC55K STR
Items
—
65 (2.56) [k = 1.795 (0.183) [10.239]]
—
63 (2.48)
Solenoid valve
A Free length 1 of solenoid valve spring Spring constant [k = N/mm (kgf/mm) [lbf/in.]] B
GC60K thru GC70K STR
Inching pedal
1
206619
Inching pedal height 1 (from top of frame to top of pedal pad)
A
175 (6.89)
Clearance between stopper bolt and brake pedal 2
A
16 (0.63)
Plunger stroke 3
A
8 to 9.5 (0.314 to 0.374)
Plunger stroke at brake functioning 4
A
16.5 (0.649)
Inching pedal stroke 5 (brake functioning)
A
82.4 (3.24)
Inching pedal stroke 6
A
152 (5.98)
6
5
Inching pedal control
1
2
3 4
206636
5-79
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications .............................................................................................................................. 6 - 1 Structure ...................................................................................................................................... 6 - 2 Procedures and Key Points for Removal and Installation .......................................................... Front Tire .............................................................................................................................. Front Axle Assembly ............................................................................................................ Reduction and Differential ..................................................................................................
6666-
3 3 4 6
Axle Shaft and Hub .................................................................................................................... Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Assembly ..............................................................................................................................
6- 7 6- 7 6- 9 6 - 10
Reduction Differential ................................................................................................................ Disassembly ........................................................................................................................ Inspection and Repair .......................................................................................................... Assembly ............................................................................................................................ Adjustment ..........................................................................................................................
6 - 12 6 - 12 6 - 13 6 - 14 6 - 16
Troubleshooting .......................................................................................................................... 6 - 19 Service Data ................................................................................................................................ 6 - 20
6
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications Truck Models
Running gear
Differential Reduction
Transmission
Items Gear type
GC35K thru GC55K STR
GC60K thru GC70K STR
Spiral bevel gear
Hypoid gear
4.571
4.857
Reduction ratio Housing type
Banjo type
Type and number of gears
Large
Straight bevel gear x 2
Small
Straight bevel gear x 2
Front axle type Suspension
Full-floating axle tube type Front wheel
Frame fixing type
6-1
FRONT AXLE AND REDUCTION DIFFERENTIAL
Structure
1
5
6
7
8
• •
•• • • •
•
2
3
4
206653
1 2 3 4
Front wheel hub drum Front axle support Axle shaft Axle housing
5 6 7 8
6-2
Reduction bevel pinion Reduction bevel gear Differential case Differential carrier
FRONT AXLE AND REDUCTION DIFFERENTIAL
Procedures and Key Points for Removal and Installation Front Tire Removal 1 Wheel nut Special tool needed
2
Front tire 2
Wheel socket
41mm
Preparation (1) Set the parking brake, and block the rear wheels. (2) Loosen the wheel nuts about two rotations, and lift the vehicle with a crane or a hydraulic unit.
1
206654
(a) Lifting the vehicle with a crane Attach a wire rope to the outer and inner mast crossmembers, and lift the vehicle. Use protection cloth for the wire rope. NOTE For both methods, place jack stands under the frame to prevent from falling. 206665
(b) Lifting the vehicle with the mast Tilt the mast fully backward, place wood blocks which can bear the weight under the mast, and tilt the mast forward until the front tires are off the ground. Installation Follow the removal sequence in reverse. Be careful with the following key points. Tighten wheel nuts evenly to the specified torque to prevent the wheels from wobbling After tire replacement, drive the truck for a while and then recheck the torque of the wheel nuts again.
200227
Tightening sequence 1
NOTE
8
5
Insure wheel nut mounting holes are free of paint and grease before installing wheel nuts. 3
4
Wheel nut tightening torque N·m (kgf·m) [lbf·ft]
551±55 (56.2 ± 5.6) [406.5 ± 40.6]
7
6 2
6-3
206655
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Axle Assembly Preparation (1) Pull the hand brake lever, and place wheel stoppers at the front and rear tires. (2) Remove the mast and the lift bracket assembly. (Refer to Mast and Fork section.) (3) Loosen the front tire nuts about two rotations, and jack up the vehicle. (4) Place a stand under the frame on both sides at the front so that the vehicle becomes level. (5) Remove the front tires. (Refer to Front Tire Removal procedure.) (6) Drain differential oil. NOTE If replacing the front axle housing, carry out the above preparation. Removal 3 2
3
4
1
206666
Sequence 1 Axle shaft, Bolt, Spring washer 2 Bolt, Spring washer
3 Nuts, Spring washers, Bolts 4 Front axle assembly 6-4
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for removal (1) Removing axle support bolts (a) Place wood blocks under the front of the transmission to support it.
←Wood block 206667
(b) Attach a wire rope with protection cloth to the mast fitting on the front axle assembly, and lift the assembly until the wire is braced. Wind the wire rope twice firmly. (c) To remove bolts, remove the bolts at the top on both sides, and insert a guide bar. Then remove the other bolts. Installation Follow the removal sequence in reverse. Be careful with the following key points. (1) Clean the mounting surface on the differential carrier completely, and apply liquid gasket before installation. (2) Apply liquid gasket to the mounting surface of the axle shaft, and tighten bolts. Tightening torque of axle shaft bolts N·m (kgf·m) [lbf·ft]
128.3 ± 12.8 (13.1 ± 1.3) [94.7 ± 9.4]
(3) Tighten axle support bolts to the specified torque. Tightening torque of axle support bolts
GC35K thru GC55K STR
GC60K thru GC70K STR
N·m (kgf·m) [lbf·ft]
693.8 (70.8) [512]
877.1 (89.5) [647.3]
6-5
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reduction and Differential When replacing the reduction gear, replace the gear and pinion as a set. Tooth contact of the reduction gear and the reduction pinion must be adjusted by mating the transmission on the pinion side and the differential carrier on the gear side. Therefore remove the transmission and the differential carrier from the frame before adjusting the tooth contact. Remove the engine before removing or installing the transmission. (Refer to Power Line section.) Place the transmission on a stable work bench, and remove the differential carrier.
6-6
FRONT AXLE AND REDUCTION DIFFERENTIAL
Axle Shaft and Hub Disassembly
6
1 5 4 3 2
206656
Sequence 1 Front tire 2 Axle shaft, Bolt, Spring washer 3 Bolt, Lock washer, Lock nut 4 Taper roller bearing (inner)
5 Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal 6 Retainer, O-ring
NOTE Normally, disassemble the front axle while the axle housing is installed to the frame.
Preparation (1) Loosen front wheel nuts about two rotations, and jack up the vehicle. (2) Place stands under the frame on both sides at the front so that the vehicle is at the level position when viewed from the front. (3) Remove the front tires. (4) Drain differential oil. 6-7
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for disassembly (1) Removing lock nut Use the special tool A to remove the lock nut. Special tool needed (GC35K thru GC55K) Socket wrench A
A
100mm
(GC60K thru GC70K STR) Socket wrench A
03703-49000 200232
(2) Removing front wheel hub Use a hub puller or a gear puller to remove the front wheel hub. If the interfit of the taper roller bearing (inner race) is tight, the inner oil seal may fall off and the taper roller bearing may remain in the axle housing. In this case, insert a wedge-shape tool between the taper roller bearing (inner) and the retainer to take out the taper roller bearing.
Special tool
200233
(3) Using a bearing puller, remove the inner race of tapered roller bearing left on the axle housing, along with the seal retainer.
203651
6-8
FRONT AXLE AND REDUCTION DIFFERENTIAL
Inspection and Repair (1) Axle shaft 2 (a) Check the splines for wear. Install the differential bevel gear to the splined end of axle shaft, and turn the gear back and forth. Measure the free movement of the gear (looseness between mating splines) with a dial guage as shown. A: Standard value
B: Repair limit Service limit
Looseness of the axle shaft spline mm (in.)
A
0.07 to 0.17 (0.0028 to 0.0067)
B
0.5 (0.020)
200235
(b) Measuring axle shaft bend (i) Attach a dial gauge to the center of the axle shaft, and rotate the axle shaft. Measure bend of the axle shaft. A: Standard value
B: Repair limit Service limit
Axle shaft bend A (1/2 of gauge reading) mm (in.) B
1.0 or less (0.039) 2.0 (0.079)
(ii) Attach a dial gauge to the edge of the flange, and rotate the axle shaft. Measure deflection of the flange. A: Standard value
B: Repair limit Service limit
Flange deflection mm (in.)
A
0.04 (0.0015)
B
0.5 (0.020)
(2) Retainer 6 Check for wear or damage on the retainer circumference. (3) Front hub drum 5 If uneven wear or damage is found on the inner surface of the brake drum, grind and repair. A: Standard value Inner diameter of brake drum mm (in.)
A B
B: Repair limit Service limit 317.5
+ 0.2 + 0.078 ) 0 (12.5 0
318.5 (12.539)
6-9
200276
FRONT AXLE AND REDUCTION DIFFERENTIAL
Assembly
6
•
• 4
•• •
•
5
•
• •
3
•
•
• • ••
•
5
1
2
206657
Sequence 1 Retainer, O-ring 2 Front hub dram assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal
3 4 5 6
6-10
Taper roller bearing (inner) Lock nut, Lock washer, Bolt Axle shaft, Bolt, Spring washer Front tire, Wheel nut
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for assembly (1) Front hub drum assembly 2 (a) Press in the taper roller bearing (outer). (b) Press in a new oil seal. Make sure that the lip is in correct direction. (c) Press in the taper roller bearing (outer). (d) Insert the spacer. (e) Fill the roller holder of the taper roller bearing (inner) with grease. Use your palm to push grease into the roller holder. Insert the taper roller bearing (inner). (f) Press in a new oil seal. Make sure that the lip is in correct direction. (g) Fill the front hub with grease. (Refer to the figure on the right.) Apply grease thinly to oil seal lips. Make sure that no grease is in the drum.
(a)
Key points for (e) (b) (c) (d) (f)
206658
(2) Hub bearing preload Wind a wire around the hub bolt twice, attach a spring balance to the wire. Pull and measure the tangential force. Hub bolt pitch: ø260 mm (10.23 in.) Tangential force at the hub bolt N (kgf) [lbf]
25.5 to 40 (2.3 to 4.1) [5.06 to 9.02]
If the preload is within the standard range, insert the lock ring, apply LOCTITE No. 271, and tighten bolts. 9.8 ± 1.0 Bolt tightening torque (1.0 ± 0.1) N·m (kgf·m) [lbf·ft] [7.2 ± 0.7]
(3) Axle shaft 5 When installing the axle shaft, apply liquid gasket to the mating surface with the hub, and tighten bolts to the specified torque. Axle shaft tightening torque N·m (kgf·m) [lbf·ft]
128.3 ± 12.8 (13.1 ± 1.3) [94.7 ± 9.4]
(4) Wheel nuts 6 Tighten wheel nuts to the specified torque evenly to prevent tire shimmy. (Refer to Front Tires Installation section.)
6-11
206659
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reduction Differential Disassembly 3 5 6 4
7
7 8 5
9
7
7
2
10
1
3 206660
Sequence 1 Bolt, Lock washer, Lock plate 2 Bolt, Lock washer, Bearing cap 3 Side bearing nuts 4 Differential carrier 5 Taper roller bearing, Bolt, Spring washer, Differential case (right)
6 7 8 9 10
Preparation Remove the differential carrier from the transmission case.
6-12
Differential bevel gear, Thrust washer Differential bevel pinion, Thrust washer Spider Differential bevel gear, Thrust plate Taper roller bearing, Bolt, Differential case (left), Reduction bevel gear
FRONT AXLE AND REDUCTION DIFFERENTIAL
Key points for disassembly NOTE (1) Measure the backlash of the gear before disassembly, and use the measurement for assembly. (2) Put a match mark across one of the bearing cap adjusting screws and the carrier, and use the mark for assembly. A: Standard value Item
Truck Models GC35K thru GC60K thru GC55K STR GC70K STR
200241
Backlash between 0.25 to 0.33 0.30 to 0.41 reduction gear and A (0.0098 to (0.0118 to pinion mm (in.) 0.0129) 0.0161)
Removing bearing Remove the inner bearing with a bearing puller. Inspection and Repair (1) Reduction bevel gear (a) Check the tooth contact pattern of the reduction bevel gear and pinion. Check the gear teeth for wear, pitting, flaking or chipping. Minor flaws on the tooth serfaces can be repaired by grinding with an oil stone or sandpaper. If the gear is badly damaged and requires replacement, replace the gear and pinion as a set. (2) Differential (a) Check for scoring at the mating part of the differential case and the side bearing inner race. (b) Check for crack on the differential case, and for wear or damage on the sliding part between the gear and the thrust washer. (c) Check for wear, loss or scoring on the differential bevel gear and the pinion gear teeth. Check for wear or damage on the thrust washer plate. (d) Check the internal diameter of the differential pinion gear and for wear of the spider shaft. A: Standard value
B: Repair limit Service limit
Clearance between A pinion gear and spider mm (in.) B
0.169 to 0.278 (0.0066 to 0.0109) 0.5 (0.02)
6-13
202821
FRONT AXLE AND REDUCTION DIFFERENTIAL
Assembly
5
7 9
•
• • •
•
•
•
8
8 • •
11 •
• •
• •
•
12
11
•• • • • •
10
6
5
1
3
10
•
4
2 206661
Sequence 1 Differential case (left) 2 Reduction bevel gear, Bolt 3 Differential gear, Thrust washer 4 Spider 5 Differential bevel pinion, Thrust washer 6 Differential bevel gear, Thrust washer Key points for assembly (1) Tightening reduction bevel gear Apply LOCTITE No. 271 to bolts, and tighten to the specified torque. Reduction gear tightening torque N·m (kgf·m) [lbf·ft]
225.5 ± 9.8 (23.0 ± 1.0) [166.3 ± 7.2]
6-14
7 8 9 10 11 12
Differential case (right), Bolt Taper roller bearing Differential carrier Bearing cap, Bolt, Lock washer Side bearing nut Bolt, Lock plate, Lock washer
FRONT AXLE AND REDUCTION DIFFERENTIAL
(2) Installing differential bevel pinions The thrust washers of bevel gear are used for adjusting the backlash of the bevel gears with the pinion. Measure the backlash and, if it exceeds the service limit, replace the thrust washers. A: Standard value B: Repair limit Service limit Backlash of the A differential bevel gear mm (in.) B
0.20 to 0.40 (0.008 to 0.016) 0.6 (0.024)
(3) Installing differential case (a) Assemble the left and right cases by using the match mark, and tighten bolts. (b) Apply LOCTITE No. 271 to the threads of the bolts, and tighten the bolts evenly to ensure free gear movement. Differential case tightening torque N·m (kgf·m) [lbf·ft]
122.5 ± 9.8 (12.5 ± 1.0) [90.4 ± 7.2]
(4) Installing differential case assembly (a) After positioning the case assembly on the carrier, fit the bearing caps tentatively by making the cap bolts snug tight. The caps are to be secured tight after the bearing preload has been adjusted. (b) Discriminate between the right and left caps, and position each cap correctly by referring to the marks. (c) Tighten bolts to the specified torque. Bearing cap tightening torque N·m (kgf·m) [lbf·ft]
202786
161.8 ± 9.8 (16.5 ± 1.0) [119.3 ± 7.2]
202787
200241
6-15
FRONT AXLE AND REDUCTION DIFFERENTIAL
Adjustment Adjusting bearing preload Wind a coil on a reduction gear bolt, attach a spring scale to the coil and pull. Read the tangential force when the gear starts rotation. Adjust the preload by tightening the side bearing nuts on both sides. NOTE Before measuring the preload, tap the back of the bevel gear with a copper hammer while winding the gear by hand.
Tangential force at side bearing N (kgf) [lbf]
12.7 to 25.4 (1.3 to 2.6) [2.8 to 5.7]
Inspecting back runout Attach a dial gauge to the back surface of the reduction gear at the largest radius, and measure the back runout while rotating the gear. If the measurement exceeds the standard value, inspect the reduction gear tightening and the taper roller bearing. If the measurement exceeds the standard value, replace together with the pinion gear. A: Standard value Back runout of reduction bevel gear mm (in.)
206662
B: Repair limit Service limit A
0.15 or less (0.006)
B
0.20 (0.008)
6-16
200249
FRONT AXLE AND REDUCTION DIFFERENTIAL
Adjusting backlash Adjust the backlash after installing the differential carrier assembly to the transmission case. Attach the dial gauge needle vertically to the tooth surface of the bevel gear. Move the bevel gear forward and backward (in rotating direction) and check the deflection of the needle. Adjust the backlash with the side bearing nut. A: Standard value Truck Models Item Reduction gear and pinion gear mm (in.)
A
GC35K thru GC55K STR
GC60K thru GC70K STR
0.25 to 0.33 (0.0098 to 0.0129)
0.33 to 0.41 (0.0129 to 0.0161)
200247
Backlash Large Small
Large Backlash
Small
Large Small
205611
Adjusting tooth contact Apply machinist’s dye on three or four teeth of the reduction gear thinly and evenly. Rotate the reduction gear forward and backward by hand several times. Check tooth contact by the shape of contact area. Adjust faulty tooth contact as follows.
200250
6-17
FRONT AXLE AND REDUCTION DIFFERENTIAL
Tooth Contact of Reduction Gear Condition of tooth contact
1
Contact area is 1/2 or more of the tooth.
2
Only small end of the tooth has strong contact. (Toe contact)
3
4
Adjustment
Not required.
1 2 1
Only large end of the tooth has strong contact. (Heel contact)
1. Pull the reduction pinion gear shim to reduce engagement. 2. Move the reduction gear closer to the pinion gear to adjust backlash.
2 1
Only upper end of the tooth has strong contact. (Face contact)
1. Insert the reduction pinion gear shim to increase engagement slightly. 2. Move the reduction gear away from the pinion gear to adjust backlash.
2
Only lower end of 5
the tooth has strong contact. (Flank contact)
1. Insert the reduction pinion gear shim to increase engagement. 2. Move the reduction gear away from the pinion gear to adjust backlash.
1. Pull the reduction pinion gear shim 1 2
to reduce engagement slightly. 2. Move the reduction gear closer to the pinion gear to adjust backlash. 203670
NOTE For contact at the toe or the heel, judge the condition of tooth contact according to the contact of the reduction gear teeth as shown in figures above. For contact at the face or the flank, repeat the above procedure until good contact is obtained.
6-18
FRONT AXLE AND REDUCTION DIFFERENTIAL
Troubleshooting Front axle and reduction differential Wear of reduction gear teeth Maladjustment or wear of the reduction gear bearing Breakage of hub bearing Faulty engagement of the reduction pinion gear and the reduction gear of the output shaft
— Replace the reduction gear — Repair or replace the bearing — Replace the bearing — Adjust the tooth contact
Breakage of reduction gear bearing or hub bearing Loss of differential gear tooth or wear of thrust washer Mixing of foreign matter in axle housing Loose axle shaft bolt or differential carrier bolt
— Replace bearing
Abnormal noise generated at curves
Wear of contact area between differential gear and differential case Loss or wear of the differential gear or the pinion gear teeth, or seizure, wear or tear with the spider
— Replace
Overheated reduction case after driving
Breakage of bearing due to excessive preload on bearing Insufficient backlash of the output shaft reduction gear
— Replace the bearing and adjust the preload — Adjust the tooth contact and backlash
Abnormal noise generated continually during driving
Abnormal noise generated irregularly during driving
6-19
— Replace the gear or the washer — Clean the housing and replace oil — Tighten bolts
— Replace
FRONT AXLE AND REDUCTION DIFFERENTIAL
Service Data Front Axle A: Standard value
B: Repair limit Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
Item Axle shaft flange deflection
Hub and wheel
Axle shaft bend (1/2 of gauge reading)
GC60K thru GC70K STR
A
0.04 (0.0016)
B
0.5 (0.02)
A
1.0 or less (0.04) or less
B
2.0 (0.08)
Hub bearing preload 1 Tangential force at the hub bolts position A N (kgf) [lbf]
22.5 to 40 (2.3 to 4.1) [5.06 to 9.02]
Tightening torque of axle shaft bolts 2 A N·m (kgf·m) [lbf·ft]
128.3 ± 12.8 (13.1 ± 1.3) [94.7 ± 9.4]
Tightening torque of wheel bolt nuts 3 A N·m (kgf·m) [lbf·ft]
307.9 ± 30.7 (31.4 ± 3.1) [227.1 ± 22.7]
Tightening torque of front axle support bolts 4 A N·m (kgf·m) [lbf·ft]
693.8 (70.8) [512]
877.1 (89.5) [647.3]
Tightening torque of wheel nuts 5 A N·m (kgf·m) [lbf·ft]
551 ± 55 (56.2 ± 5.6) [406.5 ± 40.6]
Tightening torque of lock ring bolts 6 A N·m (kgf·m) [lbf·ft]
9.8 ± 1.0 (1.0 ± 0.1) [7.2 ± 0.7]
Tire service limit 7
B 4 5
6
•
7
3
•
48.3 (1.9)
•
•
• 2
1
206663
6-20
FRONT AXLE AND REDUCTION DIFFERENTIAL
Service Data A: Standard value
Reduction Differential
B: Repair limit Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
Item Differential bevel gear backlash 1 Clearance between differential bevel pinion and spider 2
A
0.20 to 0.40 (0.008 to 0.016)
B
0.6 (0.024)
A
0.169 to 0.278 (0.0066 to 0.0109)
B
0.5 (0.02)
Preload at differential side bearing 3 Tangential force at reduction bevel gear bolt A N (kgf) [lbf]
Reduction differential
Back runout of reduction bevel gear 4
GC60K thru GC70K STR
12.7 to 25.4 (1.3 to 2.6) [2.8 to 5.7]
A
0.15 or less (0.006)
B
0.2 (0.08)
Backlash between reduction bevel gear and T/M pinion gear 5
A
0.25 to 0.33 (0.0098 to 0.0129)
0.30 to 0.41 (0.0118 to 0.0161)
Looseness of the axle shaft spline 6
A
0.07 to 0.17 (0.0028 to 0.0067)
B
0.5 (0.02)
Tightening torque of reduction bevel A gear bolts 7 N·m (kgf·m) [lbf·ft]
225.5 ± 9.8 (23.0 ± 1.0) [166.3 ± 7.2]
Tightening torque of differential A case bolts 8 N·m (kgf·m) [lbf·ft]
122.5 ± 9.8 (12.5 ± 1.0) [90.4 ± 7.2]
Tightening torque of side bearing A cap bolts 9 N·m (kgf·m) [lbf·ft]
161.8 ± 9.8 (16.5 ± 1.0) [119.3 ± 7.2]
5
9
8
1
6-21
4
7
2
6
3 206664
REAR AXLE
Specifications .............................................................................................................................. 7 - 1 Structure ...................................................................................................................................... 7 - 2 Rear Axle .............................................................................................................................. 7 - 2 Steering Cylinder.................................................................................................................. 7 - 3 Procedures and Key Points for Removal and Installation .......................................................... 7 - 4 Rear Tires.............................................................................................................................. 7 - 4 Rear Axle .............................................................................................................................. 7 - 7 Rear Axle Assembly.................................................................................................................... 7 - 9 Disassembly.......................................................................................................................... 7 - 9 Assembly .............................................................................................................................. 7 - 12 Steering Cylinder ........................................................................................................................ Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Assembly ..............................................................................................................................
7 - 14 7 - 14 7 - 15 7 - 16
Adjustment .................................................................................................................................. 7 - 17 Adjustment of Minimum Turning Radius ............................................................................ 7 - 17 Troubleshooting .......................................................................................................................... 7 - 18 Service Data ................................................................................................................................ 7 - 19
7
REAR AXLE
Specifications Truck Models Item
GC35K thru GC55K STR
Axle type
Elliot
Rear axle
Suspension Wheel alignment
GC60K thru GC70K STR Center pivot
Toe-in Camber angle Caster angle Kingpin angle
mm (in.)
Steering cylinder inner diameter × Rod external diameter
mm (in.)
Effective stroke
mm (in.)
7-1
0 1.0° 0° 0° 85 × 60 (3.34 × 2.36) 155 (6.10)
180 (7.07)
REAR AXLE
Structure Rear Axle GC35K thru GC55K STR 8
6
6
4
• • A
•
•
• 4
•
•
A
2
3
•
1
3
8
206637
GC60K thru GC70K STR
•
9
1
• • 4
5
•
206935 3
• •
206639
• Section A-A
1 2 3 4 5
Rear axle Steering cylinder Tie rods (left and right) Knuckles (left and right) Rims (left and right)
7
4 206638
6 7 8 9
Stopper bolts (left and right) Pins (two pins for each side) Rear axle supports (front and rear) Tires (left and right)
The knuckle is operated with a double-action Steering cylinder piping is different between steering cylinder. GC35K thru GC55K STR and GC60K thru The rims to which the tires are inserted serve as GC70K STR. wheel hubs. 7-2
REAR AXLE
Steering Cylinder
4
12
3
11
4
13
6
7, 8
5
9
2
10
1
206640
1 2 3 4 5 6 7
Cylinder tube Piston rod Piston Cylinder head Bushing Dust seal Oil seal
8 9 10 11 12 13
Double-action cylinder is used. The above figure shows a steering cylinder for GC60K thru GC70K STR. For GC35K thru GC55K STR, the stroke becomes shorter.
7-3
Backup ring Wear ring Piston seal Bolt Spherical bushing Stopper ring
REAR AXLE
Procedures and Key Points for Removal and Installation Rear Tires Preparation (1) Set the parking brake, and block the front wheels. (2) Use the counterweight lifting hole and lift the truck, or use a jack. (3) Lift the truck until the right and left rear tires are off the ground and rotate freely. (4) Place wood blocks under the flat bottom of the rear axle on both sides, and lower the vehicle.
206641
Removal
5
6
6 4
3 2 1 206642
Sequence 1 Cap, Gasket 2 Lock nut, Lock plate 3 Taper bearing (inner) Remove 4 to 6 together.
4 Rim tire assembly 5 Oil seal 6 Taper bearing (outer) 7-4
REAR AXLE
Key points for removal 1. Since the rim tire assembly falls easily, prevent fall with a sleeper block before removal. Be careful not to damage the oil seal on the rim. 2. Knock out the outer race of the taper bearing by attaching a batten to the notch inside the rim. Installation Follow the removal sequence in reverse. Be sure to follow the key points below. Key points for installation 1. Replace the oil seal with a new one. 2. Clean grease off the taper bearing and the rim. Fill in new grease. Apply grease to the oil seal lip.
Oil seal
Grease •
206639
7-5
REAR AXLE
3. Adjust the hub bearing preload. (1) Tighten the inner nut temporarily. (2) Insert a ø24 round bar to the cast hole of the rim. Attach a spring scale to the round bar, and measure the tangential force. Truck Models Item Tangential force N (kgf) [lbf]
GC35K thru GC55K STR
GC60K thru GC70K STR
41.2 to 49.0 (4.2 to 5.0) [9.2 to 11.0]
44.1 to 52.9 (4.5 to 5.4) [9.9 to 11.9]
206643
Tighten the inner nut to achieve the specified value. (3) After adjusting the preload, add a new lock washer and tighten the outer nut to the specified torque. Truck Model Item Outer nut tightening torque N·m (kgf·m) [lbf·ft]
GC35K thru GC70K STR
•
Lock washer Outer nut
• Inner nut
157 +200 (16 +20) [115.7 +140]
206639
(4) Bend the lock washer to both sides (inward and outward).
(5) Fill the cap with grease, and install the cap. 205436
7-6
REAR AXLE
Rear Axle Remove the rear tires before removing the rear axle. Refer to Rear Tires Removal procedure as mentioned before. Be sure to carry out the preparation, and follow the key points for removal. Removal 2
3
2
1
Sequence 1 Steering hose 2 Rear axle support, Bolt and Washer Key points for removal (1) Remove the steering hose. Put a plug on the removed hose to prevent oil leakage. Plug: 05530-30300 (G 3/8) (2) Before removing the rear axle support bolt, pry the rear axle assembly with a bar, and measure the front and rear clearances. If the total value is 0.8 mm (0.03 in.) or more, insert thrust washers and adjust the clearances when installing the bolt. (3) After removing the rear axle support bolt, remove the rear axle assembly to the side square to the vehicle. 7-7
207747
3 Rear axle assembly, Thrust washer
REAR AXLE
Preparation (1) After removing the rear tires, remove the wood blocks under the rear axle, and insert a carriage. Insert the carriage so that the rear axle can be removed to the side. (2) Place wood blocks under the balance weight on both sides.
206645
Installation Follow the removal sequence in reverse. Carry out the following procedures.
0.8 mm (0.03 in.) or less
(1) Adjusting bearing support clearances Adjust the front and rear clearances by using thrust washers so that the total clearance becomes 0.8 mm (0.03 in.) or less. NOTE Insert thrust washers evenly.
206651
Unit: mm (in.) Truck Models
Item
GC35K thru GC55K STR
GC60K thru GC70K STR
1.0 (0.039)
3.2 (0.125) 1.6 (0.062) 0.8 (0.031)
Thrust washer type 2.0 (0.078)
(2) Removing support bushing Do not remove the bushing in the support if acceptable. If not, replace the bushing together with the support assembly, or break and remove the bushing. Assemble a new bushing so that the match mark faces downward (toward the grease nipple). NOTE Assemble a new bushing so that the joint faces downward (toward the grease nipple). 7-8
Bushing joint
205431
REAR AXLE
Rear Axle Assembly Disassembly GC35K thru GC55K STR 7
8 14 5 8 5 11
2 3 12
10
4
6 10
13
9 1
9
207748
Sequence 1 Taper roller bearing (inner), Retainer 2 Bolt, Washer, Tie rod pin, Spacer, Dust seal, Ring, Bearing 3 Tie rod 4 Bolt, Washer, Clamp 5 Oil pipes (L.H., R.H.) 6 Bolt, Spring washer 7 Steering cylinder
8 Elbows, O-rings 9 Cover, Plate, O-ring, Taper roller bearing (outer), Oil seal, Bolt, Washer 10 Taper roller bearings (inner), Knuckle 11 Plug 12 Oil seal, Taper roller bearing (outer) 13 Bolt, Lock nut 14 Rear axle housing
7-9
REAR AXLE
GC60K thru GC70K STR 8 7
14
8 5
4 6 13
4 207746
Since different oil pipes 5 are used for GC60K thru GC70K STR, clamps of different shapes are used. Elbows 8 are also different.
7-10
REAR AXLE
Key points for disassembly (1) Removing cover (a) Remove the six bolts from cover 9. (b) Remove the plug at the center of the cover. (c) Screw in a cover puller bolt (nominal diameter: 12 mm, pitch: 1.25 mm, thread length: 50 mm or more), and remove cover 9.
Puller bolt 9 205430A
(2) Inspect the taper roller bearing (outer) and the oil seal that are pressed into cover 9. Do not disassemble if acceptable. Do not disassemble the taper roller bearing (outer) and oil seal 12 that are pressed into rear axle 14 if acceptable. (3) Rings and bearings 2 remain at knuckle 10 and steering cylinder 7 respectively at disassembly. Inspect the rings and bearings, and do not disassemble if acceptable. (4) Remove oil pipes 5 from the elbows. Then remove elbows 8.
2
2 7
10
•
•
•
•
206638
7-11
REAR AXLE
Assembly
12
12 10
13
9
9
A
B
B
•
• A
11
7
11
1
1
5
11 2
206647
•
3
• •
•
•
14
• •
•
•
••
• •
•
8
7
•
•
• •
•
6 3 • 206638
•
• •
• •
Section A-A 4
3
• Section B-B 206648
Sequence 1 Rear axle housing 2 Taper roller bearing (outer), Oil seal 3 Knuckle, Taper roller bearing (inner) 4 Cover, Taper roller bearing (outer), Oil seal, O-ring, Plate, Plug 5 Plug 6 Bearing, Ring 7 Steering cylinder
8 9 10 11
Bearing, Ring Elbows (L.H., R.H.) Bolt, Spring washer Tie rod, Tie rod pin, Dust seal, Collar, Spacer, Bolt, Spring washer 12 Oil pipes (L.H., R.H.) 13 Bolt, Lock nut 14 Taper roller bearing (inner), Retainer 7-12
REAR AXLE
•
Grease •
Key points for assembly 1 Filling grease Fill the taper roller bearing at knuckle 3 with grease. In particular, apply sufficient grease in the roller holder. Apply grease to the oil seal lip, too. The taper roller bearing at knuckle was changed to a greasable type in 2007.
2
Oil seal •
Grease
• 206648
Tighten bolt 10 of steering cylinder 7 to the specified torque. Tightening torque N·m (kgf·m) [lbf·ft]
3
Oil seal
262 ± 40 (26.7 ± 4) [193.1 ± 28.9]
Adjusting knuckle bearing preload Drive in cover 4 without inserting a plate, and measure the clearance between rear axle housing 1 and the cover. Insert a plate thinner than the clearance by 0.1 mm (0.0039 in.), and tighten the cover with a bolt. Attach a spring scale to the edge of the knuckle arm, and check that the tangential force is the specified value. Item
Truck Models GC35K thru GC60K thru GC55K STR GC70K STR
Tangential force N (kgf) [lbf]
30.4 to 79.4 26.5 to 67.6 (3.1 to 8.1) (2.7 to 6.9) [6.82 to 17.82] [5.94 to 15.18]
If the specified value is not obtained, readjust the plate. Clearance 206649
7-13
REAR AXLE
Steering Cylinder Disassembly 5
6
4
A 6
2
2
1
1
A
3
1
206650
Sequence 1 Nut, Spring washer, Bolt 2 Cylinder head, Dust seal, Backup ring, Oil seal, O-ring, Bushing 3 Cylinder tube
4 Piston rod, Piston 5 Wear rings (2 pieces), Piston seal 6 Stopper ring, Bearing
NOTE (1) Do not remove bushing 2 from the cylinder head if acceptable. (2) Do not remove bearing 6 from piston rod 4 if acceptable.
7-14
REAR AXLE
Inspection and Repair (1) Cylinder tube 3 Check for wear, damage or rust inside the cylinder. (2) Piston rod 4 Check for rust, damage, scratches or impact marks on the rod surface. (3) Rings and gaskets Replace the entire seal kit with new one.
205439
A: Standard value
B: Repair limit Service limit Unit: mm (in.)
Internal diameter
A
85 (3.346)
of cylinder tube 1
B
85.15 (3.352)
External diameter of piston rod 2
A
60 (2.36)
2
1
206640
7-15
REAR AXLE
Assembly NOTE: Parts marked with * are included in the seal kit. 1
5
3
6
1
6
4
2
*
*
*
Sequence 1 Piston rod, Piston 2 Bearing, Stopper ring 3 Wear rings (2 pieces), Piston seal 4 Cylinder tube
*
206640
5 Cylinder head, Bushing, O-ring, Oil seal, Backup ring, Dust seal 6 Bolt, Spring washer, Nut
Key points for assembly (1) Replace the seal kit parts shown in the above figure when assembling. (2) Clean the parts completely before assembly, and make sure that no dust is on them. (3) Apply oil to the piston seal, O-ring, gasket, dust seal and inside the cylinder before assembly. (4) Procedure for installing piston seal (a) Grip the piston seal lightly by hand five or six times to soften the seal before installation. (b) Grip the piston rod in a vice so that the vice does not damage the rod. Apply a little oil to the piston seal. Insert one side of the seal into the fitting groove of the piston, and insert the other side. (c) After installing the piston seal, insert the wear ring. (5) Make sure that seal and rings on the cylinder head are installed in correct directions. (6) Tighten nut 6 to the specified torque. Nut tightening torque N·m (kgf·m) [lbf·ft]
*
200352
59.8 (6.1) [44] 205552
7-16
REAR AXLE
Adjustment Adjusting of Minimum Turning Radius (1) Measure the turn angle of the rear wheel by using a turning radius gauge. (2) If the turning angle is out of the specified range, adjust the angle with the stopper bolt on the knuckle. Truck Models Item Turning angle (inward) (outward) degree
GC35K thru GC55K STR
GC60K thru GC70K STR
82° 59°
80° 55°
Stopper bolt (left and right) Lock nut
NOTE Check clearance between stopper bolt, thread end and steer cylinder rod when fully turned in both directions.
206652
(3) While driving the vehicle at low speed, turn the steering wheel fully in both directions, and check the diameter of the tire tracks at the outside of the rear wheel in both turning operations. (4) Minimum turning radius R is obtained from half of the turning diameter plus the length from the center of the rear tire to the outside edge of the counterweight.
R
Unit: mm (in.) Item Truck Models GC35K GC40K GC40K STR GC45K SWB/STR GC45K GC55K GC55K STR GC60K GC70K GC70K STR
Minimum turning radius 2235 (87.99) 2285 (89.96) 2090 (82.28) 2340 (92.12) 2440 (96.06) 2550 (100.39) 2350 (92.52) 2570 (101.18) 2570 (101.18) 2470 (97.24)
202800
7-17
REAR AXLE
Troubleshooting
Heavy steering wheel operation
Insufficient grease in rear axle or steering parts Faulty steering system
Slow return of steering wheel
Over-tightening of steering system or rear axle parts
— Retighten to the specified torque
Steering wheel prone to move to one side
Gap in external diameters between right and left tires
—Replace with genuine tires
Shudder of steering wheel
Wear or breakage of taper roller bearing Faulty steering system
—Replace the bearing —Refer to Steering System section, and inspect or repair
Uneven or early wear of rear tires
Misalignment of wheels —Realign wheels Different tire types for right and left wheels —Replace with genuine tires
7-18
—Supply grease —Refer to Steering System Troubleshooting section
REAR AXLE
Service Data A: Standard value
B: Repair limit Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
Items Turning angle (L.H., R.H.)
GC60K thru GC70K STR
(deg) A
3°
Toe-in
A
Caster
(deg) A
0°
Camber
(deg) A
1°
Steering angle
0
Inward
(deg) A
82°
80°
Outward
(deg) A
59°
55°
Tangential force at knuckle bearing 1 A N (kgf) [lbf]
30.4 to 79.4 (3.1 to 8.1) [6.82 to 17.82]
26.5 to 67.6 (2.7 to 6.9) [5.94 to 15.18]
Tangential force at hub bearing 2 N (kgf) [lbf] A
41.2 to 49.0 (4.2 to 5.0) [9.2 to 11.0]
44.1 to 52.9 (4.5 to 5.4) [9.9 to 11.9]
Front and back clearance for center pin 3
A
0.8 or less (0.031)
(total) B
1.2 (0.047)
Tightening torque of steering cylinder A bolt 4 N·m (kgf·m) [lbf·ft]
262 ± 40 (26.7 ± 4) [193.1 ± 28.9]
Outer nut tightening torque 5 A N·m (kgf·m) [lbf·ft]
157 +200 (16 +20) [115.7 +140]
Hose tightening torque 6 N·m (kgf·m) [lbf·ft] Tire service limit 7
A
49 ± 4.9 (5 ± 0.5) [36.1 ± 3.6]
B
48.3 (1.9) 7
4
←⎯
6
45.7 (1.8)
1
←
2
• • 3
• •
206637
• 5
206639
7-19
REAR AXLE
A: Standard value
B: Repair limit Service limit Unit: mm (in.)
Truck Models
GC35K thru GC55K STR
Item A
85 (3.346)
B
85.15 (3.352)
External diameter of piston rod 2
A
60 (2.36)
Bolt tightening torque 3
A
59.8 (6.1) [44]
Internal diameter of cylinder tube 1
Steering cylinder
GC60K thru GC70K STR
N·m (kgf·m) [lbf·ft]
3
2
1
206640
7-20
BRAKE SYSTEM
Specifications .............................................................................................................................. 8 - 1 Structure ...................................................................................................................................... Brake System........................................................................................................................ Master Cylinder and Reservoir Tank .................................................................................. Wheel Brake ........................................................................................................................ Brake Booster ......................................................................................................................
8-2 8-2 8-3 8-4 8-5
Master Cylinder .......................................................................................................................... Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Assembly ..............................................................................................................................
8-7 8-7 8-8 8-9
Wheel Cylinder .......................................................................................................................... Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Assembly ..............................................................................................................................
8 - 10 8 - 10 8 - 11 8 - 11
Wheel Brake................................................................................................................................ Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Assembly ..............................................................................................................................
8 - 12 8 - 12 8 - 13 8 - 15
Parking Brake Lever .................................................................................................................. 8 - 17 Inspection and Repair .......................................................................................................... 8 - 17 Installation ............................................................................................................................ 8 - 17 Adjustment and Tests .................................................................................................................. Automatic Adjuster Test ...................................................................................................... Procedure for Manual Adjustment ...................................................................................... Brake Fluid Line Bleeding .................................................................................................. Inspecting Reservoir Tank Level Sensor ............................................................................ Procedures for Brake Pedal Adjustment .............................................................................. Brake Booster Test ..............................................................................................................
8 - 18 8 - 18 8 - 18 8 - 19 8 - 19 8 - 20 8 - 21
Troubleshooting .......................................................................................................................... 8 - 23 Service Data ................................................................................................................................ 8 - 25
8
BRAKE SYSTEM
Specifications Truck Models
GC35K thru GC55K STR
GC60K thru GC70K STR
Items Type
Hydraulic front-wheel braking drum internal expansion duo-servo type
Main Brake
Brake system
Drum diameter
mm (in.)
Lining dimension mm (in.) (Length × Width × Thickness Number of unit)
317.5 (12.50) 330 × 63 × 10 - 2 (13 × 2.48 × 0.39 - 2)
324 × 100 × 10 - 2 (12.75 × 3.93 × 0.39 - 2)
Master cylinder internal diameter mm (in.)
28.57 (1.125)
Wheel cylinder internal diameter mm (in.)
31.75 (1.250)
Brake booster Parking brake
Brake booster master back type (Vacuum booster) Type
Hydraulic front-wheel braking drum internal expansion type
8-1
BRAKE SYSTEM
Structure Brake System
3
8
9
2 7
4 5
6 1 206936
1 2 3 4 5
Wheel brake Parking brake lever Brake pedal Brake booster Master cylinder
6 7 8 9
8-2
Wheel cylinder Reservoir tank Vacuum tank to Engine (intake manifold)
BRAKE SYSTEM
Master Cylinder and Reservoir Tank
2 4
12 3 ± 2 mm (0.118 ± 0.078 in.) Indicator ON position (energized in emergency)
15
3
13
5
11
6 16
10
7 9
14 8
1
206672
1 2 3 4 5 6 7 8
Cylinder Snap ring Piston Secondary cup Spacer Primary cup Thimble Spring
9 10 11 12 13 14 15 16
8-3
Snap ring Piston assembly Reservoir tank Cap seal Reservoir cap Indicator assembly Cap assembly Reservoir assembly
BRAKE SYSTEM
Wheel Brake 5 4 6
3 2 1
11 A
A 10
7 9
8
12 13
Section A-A 206671
1 2 3 4 5 6
Parking lever Shoe and lining (primary) Strut Return spring Wheel cylinder Dust shield
7 8 9 10 11 12 13
8-4
Return spring Adjusting screw Adjusting lever Fitting link assembly Shoe and lining (secondary) Parking cable Backing plate
BRAKE SYSTEM
Brake Booster (GC35K thru GC55K STR) 1
18
2 3
19
4
5 6 7 8 9 10 11 1213 14
20 21 22 23 24 25 26 27
15 16 17
28 202805
1 2 3 4 5 6 7 8 9 10
Retainer Silencer Filter Retainer Spring Spring Retainer Valve body seal Bearing Retainer
11 12 13 14 15 16 17 18 19 20
Key Reaction disc Pushrod body Rod Pushrod seal Plate Retainer Operating rod Valve body guard Poppet assembly
8-5
21 22 23 24 25 26 27 28
Poppet washer Valve plunger Cylinder shell (rear) Diaphragm Diaphragm plate Valve body Spring Cylinder shell (front)
BRAKE SYSTEM
Brake Booster (GC60K thru GC70K STR) 1
12
1 2 3 4 5 6 7 8 9 10 11
13
2
14
3
15
16
4
17
5
18
6
19
7
20
Silencer Filter Poppet washer Cylinder shell (rear) Diaphragm (rear) Diaphragm plate (rear) Pushrod Diaphragm (front) Diaphragm plate (front) Pushrod seal Project stud
21
12 13 14 15 16 17 18 19 20 21 22
8-6
8
9
10
22
Operating rod Retainer Valve body guard Spring Poppet assembly Valve plunger Reaction disc Spring Cylinder shell (front) Cylinder plate Pipe
11
206933
BRAKE SYSTEM
Master Cylinder Disassembly
2
1
11
5 8
7
9 10 4 6
12
3
206674
Sequence 1 Clamp 2 Filler union 3 Snap ring 4 Piston Remove piston 4 and parts 6 to 10 as sub-assembly. 5 Spring
6 7 8 9 10 11 12
8-7
S-cup Snap ring Thimble P-cup Spacer Cylinder Repair kit
BRAKE SYSTEM
Inspection and Repair (1) Cylinder body (a) Check the cylinder bore for rusting, erosion or scoring. (b) Check the condition of the inlet and relief ports. Check joint thread for damage. (2) Piston Check the piston for damage and replace the piston if damaged. Insert the piston to the cylinder. If the clearance between the piston and cylinder exceeds the service limit, replace the master cylinder. (3) Return spring Measure the free length of the return spring. If the measurement exceeds the service limit, replace the return spring.
8-8
A: Standard value B: Repair limit Service limit Clearance between A cylinder and piston mm (in.) B
0.020 to 0.105 (0.0008 to 0.00413) (Replace every year)
A: Standard value B: Repair limit Service limit Free length of return spring mm (in.)
A
104 (4.09)
B
(Replace every year)
BRAKE SYSTEM
Assembly
10
8
7
6
5
4
3
1
2
9
206675
Sequence 1 to 6 Piston assembly 1 Piston 2 Secondary cup 3 Spacer 4 Primary cup 5 Thimble
6 7 8 9 10
Key points for assembly (1) Do not reuse the disassembled piston and cups. (2) Clean metal parts with volatile solvent, and blow compressed air for drying. (3) Apply brake fluid thinly to the cylinder bore and the piston cup. (4) Tighten the clamp to the specified torque. Clamp tightening torque N·m (kgf·m) [lbf·ft]
6.9 to 8.8 (0.7 to 0.9) [5.1 to 6.5]
8-9
Snap ring Spring Cylinder Snap ring Filler union, Clamp
BRAKE SYSTEM
Wheel Cylinder Disassembly NOTE: Parts marked with * are included in the seal kit. 1 2 3 8 5
*
6 7
4 3 2 1
200812
Sequence 1 Connector ring 2 Boot 3 Piston 4 Piston cup
5 Return spring 6 Bleeder screw, Cap 7 Cylinder body
NOTE Repair kit parts periodically.
should
be
replaced
8-10
BRAKE SYSTEM
Inspection and Repair (1) Cylinder body (a) Check the bore of the body for rusting, erosion or scoring. (b) Check the threads of the bleeder screw and oil pipe screw connections for damage. (2) Piston (a) Check the outer surfaces for rusting or scoring. (b) Insert the piston to the body. If the clearance between the piston and body exceeds the service limit, replace the wheel cylinder.
Clearance between cylinder and piston mm (in.)
A: Standard value B: Repair limit Service limit 0.020 to 0.105 A (0.0008 to 0.00413) B
0.15 (0.0059)
(3) Piston cups Check each cup for swelling or other defects and replace if any defect is found.
Fit of the piston cups in cylinder body mm (in.)
A: Standard value B: Repair limit Service limit 1.85 A (0.0728) B
0.65 (0.0256)
(4) Boot Replace the boot if it is damaged or deteriorated due to aging. Replace the boot every year. Assembly Follow the disassembly sequence in reverse. Be careful with the following key points. (1) Apply brake fluid evenly to the cylinder bore and the piston cup. (2) Be careful not to damage the lip of the cup. (3) Assemble the cup in correct direction.
8-11
200280
BRAKE SYSTEM
Wheel Brake Disassembly
6
12
13
11
2
8
2
1 2
4 5 10
6
7 9
3
203796
Sequence 1 Return springs 2 Fitting link assembly, Split pin, Plane washer, Spring and link assembly, Lever and Link 3 Adjusting lever, Adjusting spring 4 Return spring 5 Adjusting screw 6 Hold-down spring, Cup and Pin Preparation (1) Remove the front tires. (2) Remove the wheel hub and drum. (3) Separate the parking lever at the lower side of the wheel brake and the parking cable fitting. (4) Remove the brake pipe from the wheel brake assembly. 8-12
7 8 9 10 11 12 13
Strut, Retainer and Web washer Shoe and lining (secondary) Shoe and lining (primary) Parking lever, Retainer and Web washer Wheel cylinder Parking cable Backing plate
BRAKE SYSTEM
Key points for disassembly (1) Removing return springs Use the special tool A to remove the return springs from the shoe guide plate. A
Special tool needed Spring remover A
64309-15400
200271
(2) Removing hold-down springs Use the special tool B to remove the shoe hold-down springs from the backing plate. B
Special tool needed Spring retainer B
91868-00600
Inspection and Repair (1) Backing plate (a) Check the backing plate for cracks. (b) Check the tightening torque of mounting bolts. Tightening torque N·m (kgf·m) [lbf·ft]
200272
238.3 to 284.3 (24.3 to 29.0) [53.5 to 63.9]
(2) Shoe and lining assembly (a) Check the lining and shoe for crack or breakage. (b) Replace the lining if severely stained with oil, burned or otherwise deteriorated. (c) Check the lining thickness. If the thickness exceeds the service unit, replace the lining. A: Standard value B: Repair or Service limit
Lining thickness mm (in.)
A
10 (0.39)
B
4.2 (0.16)
203005
8-13
BRAKE SYSTEM
(3) Brake drums If uneven wear or damage is found inside each brake drum, grind and repair. A: Standard value B: Repair or Service limit
Brake drum internal diameter mm (in.)
A B
317.5 +0.2 +0 0 (12.500 +0.008 ) +0 318.5 (12.539)
(4) Adjusting screw Check for wear on wheel teeth. Also check if the wheel rotates smoothly.
200274
(5) Parking brake link (a) Check the lever support pin and pin hole for wear, and replace the link if severely worn. (b) Check the parking cable, and replace if it is stretched, damaged or rusted. (6) Other inspection parts (a) Check the shoe return spring for cracks or fatigue. (b) Check the adjusting screw for cracks or fatigue.
8-14
BRAKE SYSTEM
Assembly 3
13
1
7 5 4
12
8 6 A
A
10 11
9
Section A-A
2 206680
Sequence 1 Backing plate 2 Parking cable 3 Wheel cylinder 4 Parking lever, Retainer and Web washer 5 Shoe and lining (primary) 6 Shoe and lining (secondary) 7 Strut, Retainer and Web washer 8 Hold-down spring, Cup and Pin
8-15
9 10 11 12
Adjusting screw Return spring Adjusting lever, Adjusting spring Fitting link assembly, Link, Lever, Spring and link assembly, Plane washer, and Split pin 13 Return spring
BRAKE SYSTEM
Key points for assembly (1) Installing wheel cylinder Apply liquid gasket to the mounting surface of cylinder, then tighten the bolt to the specified torque. Tightening torque N·m (kgf·m) [lbf·ft]
17.6 to 26.4 (1.8 to 2.7) [13.0 to 19.5]
(2) Greasing Apply a thin coat of the specified brake grease to the following parts: (a) Shoe ledges (6 places) (Backing plate surface contacting with the shoes) (b) Anchor pin surface in contact with the shoe web (c) Pin surface interfitting to the automatic adjust lever hole (3) Installing shoes and linings Make sure that the push rod of the wheel cylinder is correctly inserted to the shoe web.
206678
(4) Installing return springs Use the special tool A to install the return springs to the backing plate pins. Special tool needed Spring installer A
A
64309-15400
(5) Installing automatic adjuster (a) Clean adjusting screw parts and apply grease to the threads and the fitting of screw socket. Make sure the screw rotates smoothly by hand. If the screw rotation is sluggish, replace the screw with a new one. (b) Adjusting screws in LH wheel brakes are different from those in RH wheel brakes. The LH thread is used on the LH wheel brake and the RH thread is used on the RH wheel brake. (6) Installing parking cable Tighten the parking cable to the specified torque. Parking cable tightening torque N·m (kgf·m) [lbf·ft]
200276
200277
41.1 to 54.9 (4.2 to 5.6) [30.3 to 40.5]
8-16
BRAKE SYSTEM
Parking Brake Lever
Released
Activated 1 2 3 4
5 6
205504
1 Grip 2 Stud
3 Lever assembly 4 Rod assembly
Inspection and Repair (1) Replace the lever support pin if the pin or pin hole is severely worn. (2) Replace the parking brake cable if stretched, damaged or rusted. Installation After connecting the parking brake wire, the operating force of the parking brake lever should be 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]. the operating force of the parking brake lever should be (400 to 445 N (40 to 45 kgf) [90 to 100 lbf] for 7 ton model only)
8-17
5 Bracket 6 Parking brake wire
BRAKE SYSTEM
Adjustment and Tests Automatic Adjuster Test (1) With all wheel brake components installed correctly, the drum-to-shoe clearance should be within the correct range of 0.4 to 0.6mm (0.016 to 0.024in.). Push the cable with thumb to pull the adjusting lever. Observe the lever turns the adjusting screw by one tooth, and remove the push to observe the adjusting screw returns to the original position.
206676
(2) If the lever fails or is sluggish to turn the adjusting screw in the above test, the likely cause is that the lever is not properly positioned relative to the sprocket wheel. Be sure that the lever is so positioned that its actuating tip touches the sprocket wheel at a level about 9 mm (0.35 in.) under the center line of the screw, as shown. (3) Where the automatic adjusting device is suspected of malfunctioning during normal use of the machine, the following possible causes must be considered: (1) Check that springs A and B are correctly installed. (2) Any of these parts is in bad condition and requires replacement: a) fitting cable, b) adjusting lever, and c) adjusting screw.
200282
Procedure for Manual Adjustment Insert a screw driver to the adjustment hole on the back of the backing plate. Force down and rotate the wheel of adjusting screw to adjust the clearance between the drum and lining.
Clearance between drum and lining (one side) mm (in.)
0.4 to 0.6 (0.016 to 0.024)
8-18
200283
BRAKE SYSTEM
Brake Fluid Line Bleeding When part of the brake fluid line is disassembled for repair, or when brake pedal movement is spongy, bleed the brake fluid line. Bleeding requires two people. Start the engine and keep it idling during bleeding operation. (1) Fill the reservoir with fluid. Always keep the reservoir more than half full of fluid during bleeding operation. (2) Insert a vinyl tube to the bleeder screw of the wheel cylinder. Insert the other end of the tube to a container filled with brake fluid. (3) Have one person step (pump) on the brake pedal several times and while holding the pedal depressed, release the bleeder screw. Before the fluid stops flowing in the vinyl tube, tighten the bleeder screw. (4) Repeat the above procedure until there is no air bubbles in the brake fluid. Fill the reservoir tank with brake fluid to the specified level.
206677
NOTE If brake pedal feels soft, a vacuum pump may be needed to bleed all the air out of the master cylinder, lines, and wheel cylinders. NOTE (a) Be careful to maintain sufficient fluid level in the reservoir tank. (b) Use brake fluid of the specified brand. Do not mix different types of fluids. (c) Start bleeding with the brake fluid of the wheel cylinder on the right side (far side from the master cylinder).
Inspecting Reservoir Tank Level Sensor (a) The sensor is normal if OK monitor lamp lights when brake fluid level is under MIN line of the oil tank. (b) If the lamp does not light, check the lamp bulb for breakage. (c) If the bulb is normal, carry out continuity test for the lever sensor of reservoir tank. 8-19
206673
BRAKE SYSTEM
Procedures for Brake Pedal Adjustment (1) Bleed brake fluid of the brake reserve tank from the master cylinder to the wheel cylinder. (2) Adjust and confirm the clearance between the drum and lining. (3) Attach lock nut (right-hand thread) 2, push rod (right-hand thread) 3, lock nut (left-hand thread) 4, and clevis (left-hand thread) 5 to push rod 1 of the brake booster. Make sure that dimension L1 is the specified value. Use dimension L2 for checking. Screw in the right-hand and left-hand threads to the same length.
5
4
3
2
L2
1
L1
Unit: mm (in.) L2
88 (3.46)
207000
(4) Install the push rod assembly to the brake pedal. (5) Rotate the stopper bolt and adjust brake pedal height A to 175 mm (6.9 in.), and fix the stopper bolt with a lock nut. (6) Start the engine. (7) Push the brake pedal by hand and check brake pedal free play B. Truck Models Item
GC35K thru GC55K STR
GC60K thru GC70K STR
Brake pedal free 21 to 35 23 to 27 play B mm (in.) (0.83 to 1.83) (0.9 to 1.45)
B
155 (6.10)
C
L1
Lock nut A
Stopper bolt
Push rod assembly
If the play exceeds specified range, loosen lock nuts 2 and 4, then turn push rod 3 to adjust dimension L1. Truck Models
(8) Item
Brake pedal stroke C mm (in.)
206932
GC35K thru GC70K
37 (1.456)
8-20
BRAKE SYSTEM
2. Test method with a simplified tester Use a vacuum gauge, a pressure gauge and a force gauge. Bleed the pressure gauge, and proceed as follows: (1) Unloaded air-tightness test Start the engine, and stop the engine when the vacuum gauge reads approx. 66.5 kPa (500 mmHg). The brake booster is in good condition if the vacuum drop in 15 seconds after the engine stoppage is 3.32 kPa (25 mmHg) or less. (2) Loaded air-tightness test Start the engine, and depress the brake pedal with a stepping force of 20 kg (44 lbs). Stop the engine when the vacuum gauge reads approx. 66.5 kPa (500 mmHg). The brake booster is in good condition if the vacuum drop in 15 seconds after the engine stoppage is 3.32 kPa (25 mmHg) or less.
8-21
(3) Characteristic test of brake booster Carry out this test after tests (1) and (2). ➀ Non-booster action test Make sure that the vacuum gauge reads 0 kPa (0 mmHg) when the engine is stopped. Depress the brake pedal with stepping forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf]. The brake booster is in good condition if the generated hydraulic pressure meets the specification.
Generated hydraulic pressure
Brake Booster Test 1. Test method without a tester Carry out the following three tests. If no problem is found, the brake booster is in good condition. (1) Run the engine at an idling speed for 1 to 2 minutes, then stop it. Depress the brake pedal with normal stepping force several times. If the pedal stroke decreases every time the pedal is depressed, the brake booster is in good condition. If the stroke does not change, the brake booster is defective. (2) Depress the brake pedal several times while the engine is stopped. Start the engine while the brake pedal is depressed. If the pedal goes down, the booster is in good condition. If not, the booster is defective. (3) Depress the brake pedal while the engine is running. While the pedal is depressed, stop the engine, and keep the pedal depressed for about 30 seconds. If the pedal height does not change, the booster is in good condition.
Stepping force: 98 N (10 kgf) [22 lbf]
686 kPa (7.0 kgf/cm2) [99.5 psi]
Stepping force: 196 N (20 kgf) [44 lbf]
1373 kPa (14 kgf/cm2) [199 psi]
3
1
To engine 4
2
206938
1 Pressure gauge 2 Vacuum gauge
3 Stepping force 4 Vacuum tank
BRAKE SYSTEM
➁ Booster action test
NOTE The operation test outlined above is a simplified test. Be sure to carry out a bench test for the individual booster as specified by the manufacturer if the booster is defective.
Low Noise Brake Shoes Low noise brake shoes are now available for complaints about squealing and grabbing problems. For shoe type see stamp-on shoe lining. L706 Standard Lining L783 Anti Grab & Squealing
8-22
Truck Models Items Generated hydraulic pressure
Start the engine. Depress the brake pedal with stepping forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf] when the vacuum gauge reads 66.5 kPa (500 mmHg). The brake booster is in good condition if the generated hydraulic pressure meets the specification.
GC35K thru GC55K STR
GC60K thru GC70K STR
Stepping force: 2354 kPa 2942 kPa 98 N (24 kgf/cm2 or more) (30 kgf/cm2 or more) (10 kgf) [341 psi] [427 psi] [22 lbf] Stepping force: 3628 kPa 5198 kPa 196 N (37 kgf/cm2 or more) (53 kgf/cm2 or more) (20 kgf) [526 psi] [757 psi] [44 lbf]
BRAKE SYSTEM
Troubleshooting
Insufficient braking force
Oil leakage from master cylinder primary cup Oil leakage from wheel cylinder cup Oil leakage from oil pipe joint Worn lining Oil on lining Air in hydraulic system
Excessive pedal stroke
Defective master cylinder piston cup Low oil level in reservoir tank Excessive clearance of master cylinder push rod Brake fluid leakage
Wheel brake
Automatic adjuster not activate
Oil or grease on lining or drum Imbalance in braking power Brake drum shimmy or loose mounting Lining surface too smooth Worn lining Brake squeaking
Loose mounting bolt of backing plate Loose wheel bearing Dirty drum
Abnormal noise from brake (clicking noise)
Shoe anchor end contacting with anchor Excessive wear of shoe ledge Excessive wear of wheel cylinder piston 8-23
*Check cylinder for wear If acceptable, replace piston cup. If piston cup is deformed, replace cup and brake fluid. Use genuine parts and brake fluid — Retighten or replace pipe and joint — Replace — Clean or replace lining — Bleed master cylinder and wheel cylinder — Replace piston cup — Supply oil — Adjust — Refer to above section marked with * — Check cable guide and adjusting screw for correct installation. If automatic adjuster still does not activate, replace fitting link assembly, lever, and adjusting screw — Clean with brake cleaner 21651 and repair. If oil and grease cannot be removed from lining, replace lining — Replace drum. Adjust and retighten loose mounting — Scrub lining surface with abrasive paper — Replace shoe and lining assembly — Retighten — Adjust pre-load and retighten — Clean drum with brake cleaner 21651 — Repair or replace — Replace backing plate — Replace wheel cylinder
BRAKE SYSTEM
Loose connection of vacuum hose Squashed or torn vacuum hose Foreign matter adhesion or damage on vacuum valve or exhaust valve in brake booster Element clogging in brake booster Damaged diaphragm of brake booster Foreign matter mixing in brake cylinder
— Repair — Replace hose — Repair or replace
Spongy pedal
Insufficient brake cylinder fluid Brake cylinder liquid leakage Improper bleeding
— Supply — Repair or replace — Bleed
Insufficient parking brake stroke
Insufficient clearance between brake and lining
— Adjust to standard clearance
Abnormal noise from parking brake in driving
Insufficient clearance between brake lining and drum Warped brake drum
— Adjust to standard clearance — Repair brake drum according to repair standard, or replace
Parking brake
Heavy pedal
— Clean cylinder and supply cylinder liquid
— Adjust clearance between brake lining and drum. If parking brake still does not produce stopping force, check parking brake cable length Brake lining worn beyond service — Replace shoe and lining assembly limit Excessive clearance between brake — Adjust clearance between brake lining and drum lining and drum — Adjust pulling force to 245 Insufficient pulling force of to 294 N (25 to 30 kgf) [55 parking brake lever to 66 lbf] Parking brake cable exceeding specified length
Parking brake not producing stopping force
— Clean or replace — Replace
8-24
BRAKE SYSTEM
Service Data
A : Standard value Unit: mm (in.) Truck Models
Item
GC60K thru GC70K STR
Pedal height 1 (between top surface of flame and upper pedal edge)<None>
A
Free play of brake pedal 2
A 21 to 35 (0.83 to 1.38) 23 to 37 (0.91 to 1.46)
Brake pedal stroke 3
A 45 to 70 (1.77 to 2.76) 45 to 70 (1.77 to 2.96)
175 (6.9)
Tightening torque of master cylinder A mounting bolt N·m (kgf·m) [lbf·ft]
11.7 (1.2) [8.68]
Tightening torque of brake booster A mounting bolt N·m (kgf·m) [lbf·ft]
39.2 to 49.0 (4 to 5) [28.9 to 36.1]
Tightening torque of vacuum pipe union nut mounting bolt A N·m (kgf·m) [lbf·ft]
12.7 to 17.6 (1.3 to 1.8) [9.4 to 13.0]
Tightening torque of brake pipe union nut mounting bolt A N·m (kgf·m) [lbf·ft]
11.7 (1.2) [8.68]
3
Brake system
GC35K thru GC55K STR
2
1
206932
8-25
BRAKE SYSTEM
A : Standard value B : Repair or Service limit Unit: mm (in.) Truck Models Items
Master cylinder
GC60K thru GC70K STR
Cylinder body internal diameter 1
A
28.57 (1.125)
Piston external diameter 2
A
28.57 (1.125)
Clearance between cylinder and piston
A
0.020 to 0.105 (0.0008 to 0.00413)
B
0.2 (0.008) (Replace every year)
A
28.57 (1.125)
B
(Replace every year)
A
28.57 (1.125)
B
(Replace every year)
A
104 (4.09)
B
(Replace every year)
Primary cup lip-side external diameter 3 Secondary cup lip-side external diameter 4 Return spring free-movement length 5
5
3
1
2
4
206675
31.75 +0.062 +0
A
Piston external diameter 2
A
Clearance between cylinder and piston
A
0.020 to 0.105 (0.0008 to 0.00413)
B
0.15 (0.006)
A
33.6 ± 0.25 (1.32 ± 0.0098)
B
(Replace every year)
Free-movement length
A
33.4 (1.31)
Mount length
A
14 (0.55)
Return spring 4
Mount weight N (kgf) [lbf] A B
(1.25
+0.00244) +0
Cylinder body internal diameter 1
Piston cup lip-side external diameter 3
Wheel cylinder
GC35K thru GC55K STR
31.75 –0.025 (1.2500 –0.064
–0.00098 ) –0.00252
13 ± 2 (1.6 ± 0.1) [3.5 ± 0.2] (Replace every year)
Tightening torque of wheel cylinder A mounting bolt 5 N·m (kgf·m) [lbf·ft]
18 to 26 (1.8 to 2.7) [13.0 to 20]
Tightening torque of bleeder screw 6 A N·m (kgf·m) [lbf·ft]
6 to 9 (0.6 to 0.9) [4.3 to 6.5]
6
1
2
3
4
8-26
5
200426
BRAKE SYSTEM
A : Standard value B : Repair or Service limit Unit: mm (in.) Truck Models
GC35K thru GC55K STR
Item A
+0.008 317.5 +0.2 ) +0 (12.500 +0
B
318.5 (12.539)
A
10 (0.39)
B
4.2 (0.17)
Clearance between drum and lining 3 (one-side)
A
0.4 to 0.60 (0.016 to 0.024)
Return spring 4
Free-movement length
A
93 (3.66)
Mount length
A
101.2 (3.98)
Mount weight N (kgf) [lbf] A
245 (25) [55
Free-movement length
A
132.2 (4.85)
Mount length
A
152 (5.98)
Mount weight N (kgf) [lbf] A
78 (8) [18]
Brake drum internal diameter 1 Lining thickness 2
Adjusting spring 5
Link (upper) Link assembly (lower) length 6
Wheel brake
GC60K thru GC70K STR
Upper: 97 (3.82) Lower: 97.8 (3.85)
A
Tightening torque of backing plate A mounting bolt 7 N·m (kgf·m) [lbf·ft]
238 to 284 (24.3 to 29.0) [176 to 210]
Tightening torque of parking cable 8 A N·m (kgf·m) [lbf·ft]
41.1 to 54.9 (4.2 to 5.6) [30.3 to 40.5] 1 4 2
4
3 6 7
A 5
A 6
Section A-A 8 206679
8-27
BRAKE SYSTEM
A : Standard value Truck Models Item Lever swing angle A Lever operating effort F
GC35K thru GC55K STR
(deg) A
GC60K thru GC70K STR
71° to 76°
N (kgf) [lbf] A
245 to 294 (25 to 30) [55 to 66]
F
Parking brake
A
205505
8-28
STEERING SYSTEM
Specifications .............................................................................................................................. 9 - 1 Structure ...................................................................................................................................... Steering System .................................................................................................................... Steering Control Valve ........................................................................................................ Tilt Steering Assembly ........................................................................................................
9999-
2 2 3 4
Procedures and Key Points for Removal and Installation .......................................................... 9 - 5 Tilt Steering and Steering Control Valve Assembly ............................................................ 9 - 5 Steering Control Valve ................................................................................................................ Disassembly.......................................................................................................................... Inspection and Repair .......................................................................................................... Assembly ..............................................................................................................................
9999-
7 7 9 9
Troubleshooting .......................................................................................................................... 9 - 14 Service Data ................................................................................................................................ 9 - 15
9
STEERING SYSTEM
Specifications Truck Models
GC35K thru GC55K STR
GC60K thru GC70K STR
Inward
82°
80°
Outward
59°
55°
Steering device
Item Steering angle
External diameter of the steering wheel Steering control valve Type Flow rate
mm (in.)
liter (U.S. gal)/min.
9-1
328 (12.9) Full-hydraulic power steering 23 (6.07)
STEERING SYSTEM
Structure Steering System 5
F
G
F B
4 D
E
C C D
3
E
2
A A
6
Oil flow
1 → Turning to the left E →F →G → Turning to the right D
A →B→C⎯
206668A
1 Tank (hydraulic) 2 Oil pump 3 Priority valve
4 Steering control valve 5 Steering wheel 6 Power cylinder
The steering system reduces the driver’s operating effort through hydraulic pressure by using the load sensing mechanism which consists of the steering control valve (orbitrol), the priority valve, and so on. The operating effort of the steering wheel is converted into the hydraulic pressure by the steering control valve, then into the steering
force on the rear axle by the power cylinder. The priority valve supplies hydraulic oil from the oil pump to the steering control valve. Excessive oil is sent to circuits of other devices. When the steering is in the neutral position, almost all hydraulic oil can be used for driving other devices.
9-2
STEERING SYSTEM
Steering Control Valve 14
13 15
16 17 18
Section B-B
T L
R P
B
B
5
6
7
8
1
9 10 2
11 3
12
4 207749
1 2 3 4 5 6 7 8 9 10 11
Valve housing Wear plate Gerotor set End cap Thrust needle bearing Centering spring Pin Drive shaft Control sleeve Control spool O-ring
12 13 P T L R 14 15 16 17 18
9-3
Spacer Ball Pump port Tank port Cylinder port (left) Cylinder port (right) Check ball retainer O-ring Check ball seat O-ring Set screw
STEERING SYSTEM
Tilt Steering Assembly 11
7 8
1 6° 6° 9
5
10
3 4
2
6
206670A
1 2 3 4 5
Column housing Lower shaft Column bracket Lock cylinder Knob
6 7 8 9 10 11
The tilt steering assembly is installed to the bracket under the dashboard. Push down the knob, and move the steering
Universal joint Upper shaft Column bushing Bushing housing Horn cord Carbon horn contact
wheel forward and backward. The tilt steering assembly can tilt ± 6° around the universal joint. 9-4
STEERING SYSTEM
Procedures and Key Points for Removal and Installation Tilt Steering and Steering Control Valve Assembly
1 10 2
5
3 11 A
6
4
12
16
14
13
7
8 16 16 16
A 9 15 16
13 13
13 13
13 206669
Removal sequence 1 Steering wheel cap, Nut, Washer 2 Steering wheel 3 Transmission shift lever 4 Console box cover 5 Console box 6 Upper cover (front) 7 Lower cover (front) 8 Upper cover (rear)
9 10 11 12 13 14
Lower cover (rear) Floor plate Floor plate (front) Tilt steering assembly Hoses, Connectors Bolt, Washer, Cushion, Collar, Spring washer 15 Steering control box assembly 16 Elbows, Connectors, Pipes
9-5
STEERING SYSTEM
Key points for removal Removing steering wheel Use a special tool to remove the steering wheel. Special tool needed Steering wheel puller
Steering wheel puller
91268-10600
CAUTION Do not hit the end of steering shaft when the steering wheel is removed. 205770
Inspection after installation Steering wheel play Check the steering wheel play while idling the engine. Steering (1) Pull the hand brake lever. Run the engine and warm the hydraulic oil to an operation temperature of 40 to 60°C (104 to 140°F). (2) Attach a spring scale to the rim (or a spoke) of the steering wheel, and measure the steering torque required to turn the steering wheel clockwise or counterclockwise. Steering N·m (kgf·m) [lbf·ft]
1.96 (0.2) [1.44]
Tangential force N (kgf) [lbf]
12.7 (1.3) [2.87]
205771A
Air bleeding Air in the hydraulic system such as the steering cylinder, the flow divider valve and the piping may cause shimmy and abnormal noise. (1) Jack up the rear tires. For procedures, refer to REAR AXLE section. (2) Depress and release the accelerator pedal repeatedly to change the engine revolution speed, while turning the steering wheel to lock-to-lock positions.
9-6
STEERING SYSTEM
Steering Control Valve Disassembly 4 6 11 5
12 7 9
8 10
3
2
1
207750
Sequence 1 End cap, Bolt, O-ring and Spacer 2 Gerotor set, O-ring 3 Drive shaft, Wear plate and O-ring 4 Retaining ring 5 Seal gland bushing, O-ring, Oil seal and Dust seal 6 Thrust needle, Race bearing
7 8 9 10 11
Control sleeve Control spool Pin Centering spring Check valve, Retainer, Ball, O-ring, Check ball seat and Set screw 12 Valve housing
9-7
STEERING SYSTEM
Key points for disassembly (1) Removing retaining ring Remove the retaining ring from the valve housing with a screwdriver.
200665
(2) Removing seal gland bushing Turn the control spool together with the control sleeve. After the pin is at the level position, remove the seal gland bushing.
200666
(3) Removing control spool and control sleeve Remove the control spool together with the control sleeve from the housing by pulling them toward the end of the housing opposite to the flange. Remove the pin. NOTE Turn the control spool and the control sleeve in the valve housing slowly in both directions while pulling out so that they do not stick in the valve housing.
200667
(4) Disassembling control spool and control sleeve Push the control spool in the control sleeve to the front, and remove the centering spring. Turn slowly and pull the control spool from the rear end of the control sleeve. NOTE Put a match mark across the control spool and the control sleeve before disassembly.
200668
9-8
STEERING SYSTEM
Inspection and Repair (1) Inspecting sliding surfaces between the spool and the valve housing and between the spool and the sleeve (a) Check for defective sliding movement in sub-assembly condition. (b) If any defective movement is found, check sliding surfaces. If any defect such as abnormal wear, rust or a scratch is found, replace the steering control valve assembly. Assembly 2 10
9 7 Section B-B
B 8 B 12
4
5
3
6
1 11 207751
Sequence 1 Valve housing 2 Check valve, Retainer, Ball, O-ring, Check ball seat and Set screw 3 Control sleeve 4 Control spool 5 Centering spring 6 Pin
7 Thrust needle, Race bearings 8 Seal gland bushing, Oil seal, Dust seal and O-ring 9 Retaining ring 10 Drive shaft, Wear plate and O-ring 11 Gerotor set, O-ring 12 End cap, O-ring, Spacer and Bolts
9-9
STEERING SYSTEM
NOTE Carry out the following preparations before assembly: (1) Replace damaged parts. (2) Clean all metal parts and blow air for drying. (3) Replace O-rings and seals with new ones. (4) Apply grease to O-rings.
Suggestions for assembly
(1) Check valve assembling Put the retainer in position on the housing. Put the seat in position in the housing with the hole at the bottom. Apply Loctite 271 to the threads of the set screw and tighten the screw to the specified torque. Tightening torque 11.3 N·m (1.2 kgf·m) [8.3 lbt·ft] for set screw
(2) Control spool and sleeve assembling Put the spool in the sleeve with the spring groove in alignment with the spring groove in the sleeve. Make sure the marks put during disassembly are in alignment. NOTE Make sure the spool rotates freely in the sleeve.
200669
Spring groove Spring groove
Matching marks 200670
(3) Centering spring installation Hold two sets of three springs back to back. Using Spring Inserting Tool, put these sets of the springs in the groove with the bevel ends at the bottom. Special tool needed Spring inserting tool
97157-00100 200671
9-10
STEERING SYSTEM
(4) Control spool and sleeve assembly installation to housing Put the pin in the holes in the spool and sleeve. Put the control spool and sleeve assembly in the housing from the rear side while rotating it in both directions with the pin kept level with center of the spool. NOTE Make sure the rear end of the spool and sleeve assembly is even with the rear end of the housing.
(5) Seal installation Put the dust seal in position on the seal gland bushing with the flat side down. Also, put the oil seal in position on the bushing.
200672
Dust seal Seal gland bushing
Quad ring seal 207184
(6) Reassembling the seal gland bushing • Install the dust seal in the bushing with the flat side facing towards the bushing. • Install the quad ring seal in the bushing by smoothing it into place with your finger. • Install the bushing assembly over the spool end with a twisting motion. Tap it into place with a soft head mallet. Make sure the bushing is flush against the bearing race.
•
Install the retaining ring in the housing and pry it with a screwdriver around the entire circumference to ensure a good sitting.
200673
Screwdriver Dust seal Retaining ring Seal gland bushing Quad ring seal O-ring
207195
9-11
STEERING SYSTEM
(7) Reassembling the wear plate • Clamp the housing in a vise, equipped with soft jaws or softened with rag. Clamp lightly over the edges of the mounting area. Do not overtighten the vise jaws. NOTE Check that the spool and sleeve are flush with or slightly below the surface of the housing.
•
207196
Install the O-ring in the housing. Place the wear plate on the housing and align the bolt holes with the tapped holes in the housing.
207169
(8) Reassembling the driver • Make a mark across the splined end of the drive to indicate the direction of the slot at the opposite end of the drive. • Rotate the spool and sleeve assembly until the pin is parallel with the port surface. Install the drive and make sure that it engages the pin. The mark should be parallel to the port surface.
Port surface Drive
Pin parallel with port surface Pin 200675
9-12
STEERING SYSTEM
(9) Reassembling the gerotor set • Install O-ring in the gerotor set. • With the O-ring side of the gerotor set towards the wear plate, align the star valleys A with the mark on the drive B. Noting the parallelism of reference lines A, B, C, and D, align the bolt holes without disengaging the gerotor set from the drive.
Gerotor set star valley
Drive (marked)
Port surface Pin
(10)Reassembling the end cap • Install the drive spacer in the gerotor set. Install the O-ring in the end cap. Install the end cap in the gerotor set and align the holes
207199
End cap Cap screw
O-ring Drive spacer 207200
•
Tighten all screws snug, then tighten them progressively to the specified torque in the sequence as shown.
Initial torque for screws
14.7 N·m (1.5 kgf·m) [10.8 lbf·ft]
Finishing torque for screws
23.5 N·m (2.4 kgf·m) [17.3 lbf·ft]
200677
After installing the end cap, install the steering wheel to the spool and make sure the spool rotates smoothly. 9-13
STEERING SYSTEM
Troubleshooting No steering flow (1) Foreign materials clogged in spool pit (2) Fatigued or damaged spring in the spool
Stiff steering wheel operation
Defect in flow divider valve
— Replace spring.
Malfunction of relief valve (1) Decline in relief pressure
— Adjust relief pressure. 7355 +490 0 kPa +5 (75 0 kgf/cm2) [1066 +71 0 psi] (2) Damage on valve seating surface — Replace valve assembly. (3) Fatigued or damaged spring — Replace springs and adjust relief pressure. Oil leak from relief valve (1) Damaged O-rings on the valve body circumference
— Replace O-rings.
Defect in control valve
Clogging in metering section Malfunction of spool Faulty bearing
— Disassemble and clean. — Disassemble and clean. — Disassemble and replace.
Defect in steering cylinder
Bent piston rod Faulty piston seal
— Repair or replace. — Replace.
Misalignment
Faulty installation of steering valve or tilt column
— Repair.
Others
Flattened pipe or mixing of foreign materials
— Clean or replace oil line.
Sticking of spool or sleeve Breakage of centering spring
— Repair or replace. — Disassemble and replace.
Defect in control valve Unstable steering operation
— Disassemble and clean.
Others
Abnormal noise
Flattened pipe or mixing — Clean or replace oil of foreign materials line. Faulty piston seal of steering cylinder — Replace.
Air trapped in hydraulic fluid Loose installation of power cylinder and socket end 9-14
— Bleed air. — Repair or replace.
STEERING SYSTEM
Service Data A: Standard value Unit: mm (in.) Truck Models
GC35K thru GC55K STR
Items Steering torque (at steering wheel rim) N·m (kgf·m) [lbf·ft] While engine is running at low idle, A rotate wheel at a rate of one full turn per second, keeping standstill. Turning angle
GC60K thru GC70K STR
1.96 (0.2) [1.44]
Inside
deg A
82
80
Outside
deg A
59
55
turns A
4.60
4.27
Total turns of steering wheel
Tightening torque of steering wheel nut A N·m (kgf·m) [lbf·ft]
53.9 to 58.8 (5.5 to 6.0) [39.7 to 43.3]
Tightening torque of steering bracket bolts 3 A N·m (kgf·m) [lbf·ft]
29.4 (3) [21.7]
Steering control valve
Displacement
cc (cu.in.)/rev. A
Flow rate
liter (U.S. gal)/min
Maximum operating pressure MPa (kgf/cm2) [psi]
96 (5.8)
120 (7.3) 23 (6.07)
A
11.7 (120) [1706]
14.7 (150) [2133]
Tightening torque of end cap bolt 1 A N·m (kgf·m) [lbf·ft]
28.4 (2.9) [20.9]
Tightening torque of check valve set A screw 2 N·m (kgf·m) [lbf·ft]
11.7 (1.2) [8.6]
3
2
1
3
200786
9-15
HYDRAULIC SYSTEM Specifications ............................................................................................................................ 10 - 1 Description ................................................................................................................................ Hydraulic Line.................................................................................................................... Hydraulic Tank .................................................................................................................. Gear Pump .......................................................................................................................... Priority Valve ...................................................................................................................... Control Valve ...................................................................................................................... Control Valve Hydraulic Circuit Diagram.......................................................................... Lift and Tilt Cylinders ........................................................................................................ Flow Regulator Valve ........................................................................................................ Down Safety Valve ............................................................................................................
10 - 2 10 - 2 10 - 3 10 - 3 10 - 4 10 - 5 10 - 7 10 - 8 10 - 16 10 - 17
Removal and Installation .......................................................................................................... Gear Pump .......................................................................................................................... Control Valve ...................................................................................................................... Lift Cylinders...................................................................................................................... Tilt Cylinders ......................................................................................................................
10 - 18 10 - 18 10 - 19 10 - 20 10 - 26
Disassembly and Reassembly .................................................................................................. Gear Pump .......................................................................................................................... Control Valve ...................................................................................................................... Lift Cylinders (Simplex Mast) .......................................................................................... Lift Cylinders (Duplex Mast, Triplex Mast) ...................................................................... Lift Cylinders (Triplex Mast) ............................................................................................ Tilt Cylinders ...................................................................................................................... Flow Regulator Valve ........................................................................................................
10 - 27 10 - 27 10 - 30 10 - 33 10 - 37 10 - 43 10 - 49 10 - 52
Inspection and Adjustment........................................................................................................ Hydraulic Oil Level............................................................................................................ Test-run of Gear Pump ...................................................................................................... Control Valve ...................................................................................................................... Main Relief Valve Adjustment .......................................................................................... Attachment Relief Valve Adjustment ................................................................................ Priority Relief Valve Function Check ................................................................................ Flow Regulator Valve Adjustment...................................................................................... Lift and Tilt Cylinders ........................................................................................................ Tests ....................................................................................................................................
10 - 54 10 - 54 10 - 55 10 - 55 10 - 56 10 -57 10 -57 10 - 58 10 -59 10 - 60
Hydraulic Circuit Diagram........................................................................................................ 10 - 61 Troubleshooting ........................................................................................................................ 10 - 62 Service Data .............................................................................................................................. 10 - 65
10
HYDRAULIC SYSTEM
Specifications Truck Models Items
GC35K GC40K GC40K STR GC45K SWB/STR
Type Gear pump
Rated discharge liter liter (U.S. gal)/rpm Driving method
Priority valve
Control valve
Gear type
98 (25.89)/2450
117.6 (31.07)/2450
Engine direct drive
Engine direct drive
11768 (120) [1706]
14710 (150) [2133]
19361 +0.482 (197.6 +0
+5 +0
) [2810
+70 +0
]
+50 15503 +0.345 (158 +3.5 +0 +0 ) [2250 +0 ]
Attachment relief pressure Hydraulic system
GC60K GC70K GC70K STR
Gear type
Relief pressure kPa (kgf/cm2) [psi] Main relief pressure kPa (kgf/cm2) [psi]
GC45K GC55K GC55K STR
Type
Adjustable
Adjustable
Adjustable
Control flow capacity liter/min (U.S.gal/min)
100 (26.42)
115 (30.38)
165 (43.59)
Simplex mast
Internal diameter mm (in.)
60 (2.36)
70 (2.75)
80 (3.15)
Lift cylinders
Stroke
mm (in.)
1650 (65)
1650 (65)
1650 (65)
Duplex mast
Internal diameter mm (in.)
90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
55 (2.17)
60 (2.36)
1590 (62.60)
1585 (62.40)
90 (3.54)
110 (4.33)
125 (4.92)
820 (32.28)
845 (33.27)
855 (33.66)
60 (2.36)
70 (2.75)
80 (3.15)
1480 (58.27)
1530 (60.24)
1495 (58.86)
Flow regulator valve
First lift cylinders Stroke Duplex mast
Internal diameter mm (in.)
Second lift cylinders Stroke Triplex mast
mm (in.)
Internal diameter mm (in.)
Second lift cylinders Stroke Tilt cylinders
mm (in.)
Internal diameter mm (in.)
First lift cylinders Stroke Triplex mast
mm (in.)
mm (in.)
Internal diameter mm (in.)
100 (3.937)
110 (4.33)
Stroke
120 (4.724)
139 (5.472)
Hydraulic oil N level
mm (in.) liter (U.S.gal)
46 (12.1)
10-1
52 (13.6)
69 (18.2)
HYDRAULIC SYSTEM
Description Hydraulic Line 6 to 7 ton class 11 10 9
11
19 12
12 18 7
8 16
6
13 14
17
6 to 7 ton class
5
1
•
3
15 2
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19
Hydraulic tank Suction strainer Return filter Gear pump Priority valve Main relief valve Lift spool Tilt spool Flow regulator valve Down safety valve NOTE
The steering control valve is descried in Group 9 STEERING SYSTEM. The steering cylinder is described in Group 7 REAR AXLE. 10-2
Lift cylinders Tilt cylinders Check valve Steering control valve Steering cylinder Attachment spool Port relief valve Attachment relief valve Hydraulic tank
4 206964
HYDRAULIC SYSTEM
Hydraulic Tank 6 1
•
From control and priority valves
•
To gear pump • 2
5
•
4
•
3
•
1 Cap 3 Drain plug 2 Level gauge 4 Suction strainer The hydraulic tank has a steel-welded structure and is integrated into the frame. The tank is positioned at the center of the right side frame. Oil in the hydraulic tank is sucked into the gear pump via the suction strainer (100 mesh).
206958
5 Return filter 6 Hydraulic tank (for 6 to 7 ton class) Return oil from the lift cylinder is combined with return oil from the control valve and the steering control valve which returns to the hydraulic tank through the return filter (25μ).
Gear Pump 1
2
7
6
4 8
3
9 10
5
5 Side plate 1 Front cover 6 Rear cover 2 Body 7 Bushing 3 Drive gear 8 Oil seal 4 Driven gear The gear pump is an external gear pump. It provides hydraulic oil required to operate the hydraulic system. 10-3
11
12 203831
9 10 11 12
Snap ring Gasket Backup strip Gasket
HYDRAULIC SYSTEM
Priority Valve LS T
2
3 1 4 EF
P
CF
5
6 205648
1 2 3 4 5 6
P T CF EF
Pump port Tank port Control flow port Main flow port (Control valve for operation device) LS Load sensing port
Relief valve Plug Housing Control spring Spool Plug
The priority valve provides necessary amount of hydraulic oil for steering operation from the gear pump to the steering control valve, and sends excessive oil to other operation device circuits. When the steering is at the neutral position, almost all hydraulic oil is used for driving other operation devices. 10-4
Priority relief pressure kPa (kgf/cm2) [psi]
GC35K thru GC55K STR
GC60K thru GC70K STR
11713 (120) [1700]
14641 (150) [2125]
HYDRAULIC SYSTEM
Control Valve
2
9
4
3
8
4
T
1
P
8
•
•
•
•
• •
• •
5 6
6 7
A
A
207060
1 2 3 4 5 6
7 8 9 P T
Inlet section assembly Lift section assembly Tilt section assembly Attachment section assembly Outlet section assembly Main relief valve
The control valve consists of four sections; namely, inlet, lift, tilt and attachment, all being of spool type. The inlet section has a built-in flow divider valve. The tilt section has a builtin tilt lock valve. The attachment section has a built-in shutoff valve or an optional overload relief valve. The
Port relief valve Attachment relief valve Pressure gauge port From priority valve To hydraulic tank
main relief valve is in the oil passage from the oil pump and prevents high oil pressure which could damage the pump. The relief valve for flow divider valve controls the oil pressure below the maximum pressure in the steering circuit. The overload relief valve prevents high oil pressure occurring in the attachment circuit. 10-5
HYDRAULIC SYSTEM
Control Valve
2
3
4
4 8 7 6
1
5
18
9 10 11 14
13 10
12
15 16 17
12 207061
1 2 3 4 5 6 7 8 9
Inlet cover Lift spool Tilt spool Attachment spool End cover O-rings Wipers Screws Seal plates
10 11 12 13 14 15 16 17 18
10-6
Spring seats Springs Spool ends Spool caps Cap screws Tilt-lock valve Spring O-ring O-ring
HYDRAULIC SYSTEM
Control Valve Hydraulic Circuit Diagram
Lift valve
Tilt valve
1B 1A
Attachment valve
2B
2A
3B
Attachment valve
3A
4B
4A
P
T
4
2
1
3
207062
1 Main relief valve 2 Port relief valve 3 Attachment relief valve
4 Gauge port (9/16 - 18UNF - 2B) P From priority valve T To hydraulic tank
GC35K GC60K thru thru GC55K STR GC70K STR Main relief 1 valve Relief pressure kPa (kgf/cm2) [psi]
Port relief 2 valve Attach ment 3 relief valve
19361 +0.5 +0 (197.6 +0.5 +0 ) [2810 +70 +0 ] 11713
14641
(120)
(150)
[1700]
[2125]
15.5 +0.35 +0 0 (158 +3.5 +0 ) [2250 +50 +0 ]
10-7
HYDRAULIC SYSTEM
Lift and Tilt Cylinders Second lift cylinder for simplex mast and triplex mast There are two types for the above lift cylinder: one with a return pipe and the other without a return pipe. The lift cylinder without a return pipe is provided with a check valve in the piston instead of a return pipe. This is called an internal drain type cylinder. Regardless of presence or absence of a return pipe, the bottom of the piston is provided with a cushion mechanism for soft landing. (1) Cylinder without a return pipe Mast used: (1) Simplex mast with raised height of 3.4 m (11.2 ft) or less (2) All triplex masts Detail of inside 9
10
3
Space
One side only
1
Groove
2
7
8
5
Inflow and outflow of oil
OD
ID
d
Groove
4 6
Main components 1 Cylinder tube 2 Piston rod assembly 3 Cylinder head 4 Pipe (integrated with cylinder tube)
5 Cushion bearing 6 Check valve 7 U-ring, Backup ring
10-8
Cushion stroke: 23 mm (0.91 in.)
8 Bushing 9 Wiper ring 10 X-ring
209758
HYDRAULIC SYSTEM
Cushion mechanism when piston descends Action during piston descent 1
(B) Passage (a)
2
Entrapped oil (A) Groove
Descent
Outflow
5
The above illustration shows a condition in which piston rod assembly 2 descends with its self weight and pipe 4 and cushion bearing 5 are beginning to fit in. Cushion bearing 5 is pushed upward by entrapped oil (A) and the piston and cushion bearing 5 make surface contact at (B) area. This blocks the passage (a). The only outflow passage for entrapped oil (A) is clearance (b) between the bore of cushion bearing 5 and the outside of pipe 4. This passage (a) becomes narrower as the piston descends further. Therefore, the descending speed of the piston becomes gradually slower and impulsive contact is avoided.
Passage (b)
4
209760
The inside diameter is further smaller.
Outside diameter without step
Clearance of approx. 0.1 mm (0.004 in.)
Cushion bearing
Pipe
209761
Image of pipe and cushion bearing
10-9
HYDRAULIC SYSTEM
Action during piston ascent (initial stage) 2
1
(B)
Passage (a) Groove
Ascent
Inflow
5
The above illustration shows a condition immediately after the piston rod assembly ascends. Oil that flows in acts on the center of the piston, ascending piston rod assembly 2 slightly. At the same time, cushion bearing 5 descends by being pushed by oil that flows in.
Passage (b)
4
209762
This action opens the (B) area, causing the passage (a) to open. Oil from the passage (a) and passage (b) which opens from the beginning flows in the piston bottom, acting on the entire bottom surface of the piston and pushing piston rod assembly 2 upward.
Cylinder of internal drain type Entrapped oil and air (There normally tends to be negative pressure in this area.)
Groove
Check valve
The above illustration shows a condition in which the piston rod assembly ascends to the vicinity of the highest position. When pressure of oil and air entrapped between the rod and cylinder exceeds the set pressure of the check valve, the check valve opens and dis-
10-10
209763
charges oil and air to pressure oil (internal drain). In the cylinder with a return pipe, this area is connected to the hydraulic tank.
HYDRAULIC SYSTEM
Simplex Mast with Return Pipe Lift Cylinders (A40A)
* * * 6
2
5
7
* *
10 9
11
4
8
1
3 • • •
•
•
•
•
• ••
Parts marked with * are included in the seal kit.
1 2 3 4
Cylinder tube Piston rod Cylinder head Bushing
5 6 7 8
206951
U-ring Wiper ring O-ring U-ring
9 Backup ring 10 Bushing 11 Spacer
Simplex Mast Lift Cylinders with Return Pipe * (A45A, A55A, A70A) 5 6 3 4 * 2 7
*
*
8
13 9 10 11 12
• • •
•
• •
Parts marked with * are included in the seal kit.
1 2 3 4 5
Cylinder tube Piston rod Cylinder head Bushing Holder
6 7 8 9 10
1
202976
U-ring Wiper ring O-ring Piston ring U-ring assembly
10-11
11 U-ring holder 12 Stopper 13 Spacer
HYDRAULIC SYSTEM
Duplex Mast First Lift Cylinder (B40A, B45A, B55A)
* 6
* * 8
3
5
Triplex Mast First Lift Cylinders (C40A thru C70A)
*
*
7 13, 14
4
2
• •
•
*
*
9
1
10
•
•
11 12
•
•
• •
Parts marked with * are included in the seal kit.
1 2 3 4 5
Cylinder tube Piston rod Cylinder head Bushing U-ring
6 7 8 9 10
206950
Wiper ring O-ring O-ring Seal ring assembly Slide ring
11 12 13 14
Check valve Snap ring Plug Gasket
Duplex Mast Second Lift Cylinders (B45A, B55A)
* 6
4
* 7
3
•
* 5
•
8
2
1 18 19 15
• •
• •
9
10
11 13
12
14
• •• •
•
•
16
1 2 3 4 5 6 7
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring
17
Parts marked with * are included in the seal kit.
8 9 10 11 12 13 14
Spacer Piston Set screw Slide ring Check valve Cushion spool Spring 10-12
15 16 17 18 19
206948
Snap ring Valve Steel ball Spacer Snap ring
HYDRAULIC SYSTEM Duplex Mast Second Lift Cylinders (B40A)
* * * 8
7
*
6 5
9
4
•
• •
1
3 18 17
•
2
16
14 12 11 10 13 15
•
•
•
•
• • • • •
Parts marked with * are included in the seal kit.
1 2 3 4 5 6
7 8 9 10 11 12
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring
206949
Backup ring Wiper ring O-ring Piston Slide ring Set screw
13 14 15 16 17 18
Check valve Cushion spool Spring Snap ring Steel ball Set screw
Triplex Mast Second Lift Cylinders (C40A)
* 6
* 5
3
* 7
4
2
1
16
11
12 10
* * 9
Parts marked with * are included in the seal kit.
1 2 3 4 5 6
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring
7 8 9 10 11 12
8
15 14
13
207778A
O-ring U-ring Backup ring Bushing Spring guide Spring 10-13
13 14 15 16
Cushion spool Pin Snap ring Spacer
HYDRAULIC SYSTEM Triplex Mast Second Lift Cylinders (C45A, C55A)
7
6
5
4
3
8
2
1
17 13
14
9
10 11 12 16
15
Parts marked with * are included in the seal kit.
1 2 3 4 5
6 7 8 9 10
Cylinder tube Piston rod Cylinder head Bushing Holder
207779A
U-ring Wiper ring O-ring Piston ring U-ring assembly
11 12 13 14 15 16 17
Holder Stopper Spring guide Spring Cushion rod Spring pin Spacer
Triplex Mast Second Lift Cylinders (C70A)
7
6
5 8
4
3
2
19 14 15 16 18 9 17 10 11 12 13
1
Parts marked with * are included in the seal kit.
1 2 3 4 5 6
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring
7 8 9 10 11 12
Wiper ring O-ring Piston Piston ring U-ring assembly Holder 10-14
207780A
13 14 15 16 17 18
Stopper Spring guide Spring Cushion rod O-ring Set screw
HYDRAULIC SYSTEM
Tilt cylinders
*
* *
9
5
8
10
* 7
3
1
2
12
4
* 6
11
• •
•
• •
• •
•
13, 14 Parts marked with * are included in the seal kit.
1 2 3 4 5
Cylinder tube Piston rod Guide bushing Piston Tilt socket
6 7 8 9 10
206947
Piston seal O-ring Packing Dust seal Buffer ring
10-15
11 12 13 14
Self-lock nut Collar Bolt Spring washer
HYDRAULIC SYSTEM
Flow Regulator Valve GC35K thru GC55K STR 3
6
4
•
5
2
1
•
• •
202978
1 Set bolt, Lock nut 2 Sleeve, O-ring 3 Piston, Spring pin, Washer spring, Valve
4 Spring 5 Spring guide, O-ring 6 Valve body
GC60K thru GC70K STR 10 9
12
7
2
11
13
3
8
4
14
5
6
1 206962
1 2 3 4 5 6 7
Valve body Plug Piston Plate Spring Lock nut Stopper
8 9 10 11 12 13 14
The flow regulator valve is located between each lift cylinder and control valve. It limits the flow of oil forced out of the cylinder when the
Valve Spring disc Connector Elbow nut assembly Spring pin O-ring Snap ring
loaded forks are lowered to keep a constant safe lowering speed regardless of load.
10-16
HYDRAULIC SYSTEM
Down Safety Valve
3
1
4
2
Cut-off flow rate Stamped number
Regulated flow
Free flow
204626
1 Connector 2 Valve
3 Spring 4 Spring pin
The down safety valve is located at the bottom side of right-hand lift cylinder.
This valve provides a means of preventing the load from lowering, unsafely, rapidly, when a hose bursts.
Mast model
Cut-off flow rate Simplex
A40A
A45A, A55A
A70A
Duplex
B40A
B45A, B55A
—
WARNING
Triplex
C40A
C45A, C55A
C70A
120 +5 0 –10
200 +20 0 +0
Do not reuse down safety valve after a lift line hose failure.
(31.7 +1.3 –2.6 )
(52.8 +5.3 +0 )
Cut-off flow rate liter (U.S.gal)/min
90 –0 –15 (23.8 –0 –4 )
10-17
HYDRAULIC SYSTEM
Removal and Installation Gear Pump
4
3
2 1
5
203833
Sequence 1 Universal joint 2 Drive pulley, Lock nut, Boss 3 Main hose, Connector, O-ring Start by: (1) Remove the counterweight. (2) Loosen the fan belt.
Tightening torque
Suggestions 1. Remove the drive pulley lock nut 2 with special tools. Special tool needed Wrench Wrench
4 Suction hose, Elbow, O-ring 5 Gear pump
91868-00100 93768-00100
NOTE The drive pulley lock nut has left-hand threads.
N·m (kfg·m) [lbf·ft]
Universal joint 1
21.6 (2.2) [15.9]
Lock nut 2
78.5 (8.0) [57.9]
Counterweight bolts
Connector 3
2. To reassemble, follow the reverse of disassembly sequence. Tighten the counterweight bolts, Main hose 3 pump outlet joint and main hose to the specified torque. 10-18
800 to 888 (81.6 to 90.6) [590 to 654] 167 (17.0) [123] 117 (12.0) [87]
HYDRAULIC SYSTEM
Control Valve
1
2
3
1 4
6
5 7
206966
Removal sequence 1 Clevis pin, Rod, Clevis, Boot 2 Return hose, Connector, O-ring, Clamp 3 Attachment pipe, Connector, O-ring 4 Tilt pipe, Clamp, Connector, O-ring
5 Delivery pipe, Connector, O-ring 6 Lift pipe, Connector, O-ring 7 Control valve
Start by: (1) Remove the floor plate and dashboard cover. (2) Before disconnecting pipes, tilt the mast to vertical position, lower the forks all the way, and relieve the pressure in the pipes.
10-19
HYDRAULIC SYSTEM
Lift Cylinders Dual-stage Panoramic Mast (Simplex Mast)
6 7 8
5
3 8
1
4
2
Sequence 1 Nuts 2 Fork, Lift bracket 3 Return (low-pressure) hose
207784
4 Hose guard 5 High-pressure hose 6 Set bolt, Shims
7 Cylinder clamp, Cushion, Collar, Shims 8 Lift cylinder, Bracket
Suggestions 1. Lift bracket removal (1) Tilt the mast forward, and lower the inner mast to the bottom. Slacken the lift chains, and remove the nuts from the anchor bolts. It is not necessary to remove the forks. (2) Tilt the mast back to vertical position. Raise the inner mast until the lift bracket becomes free. Then, back the truck away from the lift bracket and fork assembly.
204873A
10-20
HYDRAULIC SYSTEM
2. Removing return hose Lift the mast to the maximum lift position, and turn the key switch off. Disconnect the return hose from the right and left lift cylinders at the connectors. (If applicable).
To hydraulic tank
206965
3. Disconnecting high-pressure hoses Slowly push the lift lever forward to lower the lift bracket to the ground. Disconnect the highpressure hoses at the joints indicated by arrows. Use a container to catch oil flowing out of the hoses.
Right cylinder
Left cylinder
206691
4. Removing set bolts (1) Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, hitch a sling around the mast with protective rag. NOTE The rod end of either lift cylinder is shim adjusted to eliminate the difference in stroke between the cylinders. Before removing the set bolts, make a record of the amount of shims and cylinders to which the shims are fitted.
206967
(2) Tie wood blocks under the inner mast and detach the sling. Make sure the right and left wood blocks are the same in height.
202983
10-21
HYDRAULIC SYSTEM
5. Removing lift cylinders Hitch a sling to the lift cylinder from the rear side of the mast, and remove the cylinder. Hitch the sling before removing the cylinder clamp.
206968
Installation To install, follow the reverse of removal sequence, and do the following steps once completed: 1. Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly. 2. Check the oil level in the hydraulic tank with an oil level gauge. (Make reference to Hydraulic Tank section.) 3. Check to make sure that the lift height is correct. 4. After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders. (Make reference to Group 11 MAST AND FORKS.)
10-22
HYDRAULIC SYSTEM
Lift Cylinders The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full free panoramic mast (Triplex Mast) is used as an example. Triple-stage Full Free Panoramic Mast (Duplex and Triplex Masts)
5
4
2
3 1
207785
Sequence 3 First lift cylinder 4 Chain wheel support assembly 5 Second lift cylinders
1 Nuts 2 Lift bracket assembly
Suggestions
1. Removing lift bracket assembly 2 (1) Lower lift bracket assembly 2, and place wood blocks under the assembly. Tilt the mast forward, lower the inner mast to the bottom, then remove nuts 1 from the anchor bolts of the first lift chains. 10-23
1
207786
HYDRAULIC SYSTEM
(2) Position the mast upright. Raise the inner mast until main rollers 6 of lift bracket assembly 2 become free. Then, slowly move the vehicle in reverse to separate from lift bracket 2. 6 2 201735
2. Removing first lift cylinder 3 (1) Hitch a sling to first lift cylinder 3, and suspend the cylinder with a crane. Wind the sling securely to prevent slipping. (2) Remove the lift cylinder connecting and mounting bolts, and gently remove first lift cylinder 3.
3
207787
3. Removing second lift cylinders 5 (1) Disconnect hoses from second lift cylinders 5. (2) Remove stopper bolts at the upper sections of second lift cylinders 5, and lift the inner mast [dual-stage full free panoramic mast] or middle mast [triple-stage full free panoramic mast] approximately 550 mm (21.67 in.) using slings.
5
207788
10-24
HYDRAULIC SYSTEM
(3) Place wood blocks under the inner mast [dualstage full free panoramic mast] or middle mast [triple-stage full free panoramic mast]. Make sure the right and left wood blocks are the same in height.
202983
(4) Hitch a sling to second lift cylinder 5 behind the mast, remove cylinder clamp retaining bolts, and gently remove second lift cylinder 5. Wind the sling securely to the cylinder. The cylinder cannot be lifted straight up since the mast cross-member is located above the cylinder. Tilt the cylinder and move it away from the cross-member to remove. Be careful not have the hands caught between the cylinder and mast.
5
Installation 207789
To reinstall, follow the removal sequence in reverse, and service as follows. (1) Install chain wheel support assembly 4 parallel to a line connecting the centers of chain anchor bolt holes on first lift cylinder 3 to prevent chains from twisting. (2) Adjust the chain tensions. (See the section Inspection and Adjustment.) Good
(3) Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly. (4) After proper operation is confirmed, check the oil level.
10-25
Bad 207638
HYDRAULIC SYSTEM
Tilt Cylinders
2
•
4 1
3
206971
1 Tilt cylinder pin 2 Hoses
3 Tilt cylinder pin 4 Tilt cylinder
Start by: (1) Lower the forks to the bottom, and tilt the mast fully forward. (2) Hitch a sling to the top crossmember of outer mast, and support the weight of the mast with a hoist. Suggestions 1. Retracting piston rod Remove tilt cylinder pin 1. Start the engine and retract the piston rod to the full stroke, then stop the engine. 2. Disconnecting hoses Disconnect hoses 2 from the cylinder at the connectors. Use a container to catch oil from flowing out of the cylinder. Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of the cylinder when the cylinder is removed. 10-26
206970
HYDRAULIC SYSTEM
Disassembly and Reassembly Gear Pump Disassembly
12 9
8
15
7
13
6
15
15
17 16
14
*
3
15
5
1
4 11 10
2
203836
Sequence 1 Bolt 2 Rear cover 3 Gasket 4 Gasket 5 Backup strip
6 7 8 9 10
11 12 13 14 15
Front cover Gasket Gasket Backup strip Body
NOTE
Side plate Side plate Drive gear Driven gear Bushing
16 Snap ring 17 Oil seal * Snap ring
Suggestions for disassembly
(1) The gear pump is to be overhauled by the manufacturer. Where it has to be overhauled in the field, be sure to follow the suggestions for disassembly. Remember, field overhauling will release the manufacturer from any guarantee.
(1) If gears 13, 14 and side plates 11, 12 are separated from body 10, it might be difficult to restore them to the original state, resulting in defective pump performance. For this reason, remove the gears, side plates and body as a set for replacement of the gaskets 3, 7.
(2) Do not remove oil seal 17 and bushing 15 unless they are defective to require replacement.
(2) Front cover 6 and cover 2 are made of aluminum alloy which is apt to be marred; never give blows of a hammer to them.
Start by: Remove * the snap ring after removing the fan drive pulley. 10-27
HYDRAULIC SYSTEM
Inspection after disassembly 1. Drive and driven gears (1) Inspect the gear teeth for wear, chipping or other defects. Inspect the journals and splines as above. (2) Check the end faces of the gear for wear or damage. (3) Check the journals and splines of the shafts for wear or damage. 2. Pump covers, body and bushings Inspect these parts for wear and damage. Reassembly
4
1
6, 7
200344
13
10
8
9
18
14 2
15
3 4
5
16
17
11, 12
9 203831
Sequence Assemble 1 to 7 to make a subassembly. 1 Front cover 2 Oil seal 3 Snap ring 4 Bushing 5 Gasket 6 Gasket 7 Backup strip Assemble 8 to 12 to make a subassembly. 8 Rear cover 9 Bushing 10 Gasket 10-28
11 Gasket 12 Backup strip Install 13 to 17. 13 Body 14 Driven gear 15 Drive gear 16 Side plate 17 Side plate Install front cover subassembly 1 and rear cover subassembly 8 to body 13. 18 Bolt
HYDRAULIC SYSTEM
Suggestions for reassembly (1) Position rear cover 8 correctly. (2) Clean the mating faces of covers 1, 8 and body 13, making sure that they are free from any oil or grease. (3) Put grease on the lip of oil seal. (4) Lubricate bearings, gears and shafts with clean hydraulic oil before reassembling. (5) Take care not to damage the lip of oil seal by the splines of drive gear 15. (6) Tighten all bolts as evenly as possible. Tightening torque for bolts N·m (kgf·m) [lbf·ft]
98 to 108 (10 to 11) [72 to 80]
10-29
HYDRAULIC SYSTEM
Control Valve Disassembly
26 29
30
3 18
23 21
14
27
10
12
28 20
19
1
7 5
25 17
11 16
24
9 22 15
4
1
8 13
3
6
2 3
207790
10-30
HYDRAULIC SYSTEM
Sequence 1 Relief valve assembly 2 Relief valve assembly 3 Tie-rod bolts, Nuts 4 Outlet section 5 Poppet, Spring 6 Spool cap, Cap screw 7 Spool 8 Spool end, Spring seat, Spring 9 Seal plate, Wiper, O-ring 10 Seal plate, Bolt, Wiper, O-ring 11 Attachment valve body 12 Poppet, Spring 13 Spool cap, Cap screw 14 Spool 15 Spool end, Spring seat, Spring
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Spool plate, Wiper, O-ring Spring, Tilt rock valve Seal plate, Bolt, Wiper, O-ring Tilt valve body Plug, O-ring Poppet, Spring Spool cap, Cap screw Spool Spool end, Spring seat, Spring Spool plate, Wiper, O-ring Seal plate, Bolt, Wiper, O-ring Lift valve body Plug, O-ring Plug assembly Inlet section assembly, O-ring
Suggestions 1. Relief valve assembly Do not remove relief valve assembly 1 and 2 unless it is impossible to adjust the setting of the valve. 2. Lift, tilt and attachment sections (1) Remove the spool from the section, together with plate 9 and screw 6. This applies to spools 14 and 23. (2) Hold the spool in a vise with soft jaw caps, and remove the screw 8 with an Allen wrench.
205028
10-31
HYDRAULIC SYSTEM
Inspection after disassembly Sections, spools and return springs (1) Check each sliding surfaces for cracks and defects. Also, check the check-valve seat for wear. (2) Check the spools for burns and distortion. Also, check for operating force. 177 to 216N (18 to 22 kgf) [40 to 49 lbf]
Spool operating force
(3) Check the tilt lock valve for damage and seizure. Tilt lock valve
203517
Reassembly To reassemble, follow the reverse of disassembly sequence, and do the following steps: (1) Clean the disassembled parts with high flash-point solvent. Blow them dry with compressed air; however, this does not apply to rubber parts. (2) Apply hydraulic oil to the spools when inserting them into the valve blocks. (3) Position the poppet (tilt lock valve) correctly. (4) Apply grease to the O-rings when fitting them between the valve housings to prevent them from twisting. (5) Do not use any type of sealant. (6) Tighten the tie bolts (securing the valve housings) as evenly as possible to prevent distortion of the housings. Remember, a failure to follow this precaution will result in sluggish movement of the spools.
Unit: N·m (kgf·m) [lbf·ft] Tightening torque for tie bolts A
65 (6.6) [48]
Tightening torque for tie bolt B
101 (10.3) [74]
10-32
0.331.
HYDRAULIC SYSTEM
Lift Cylinders (Simplex Mast) Disassembly (No.1) For mast model A40A
Parts marked with * are included in the seal kit.
* 1 4
2
* 7
* 6
*
5
3
*
206954
Sequence 1 Cylinder head 2 Wiper ring, U-ring, O-ring 3 Collar 4 Piston rod
5 U-ring, Backup ring, Bushing 6 Bushing 7 Cylinder tube
NOTE Do not remove bushing 6 from cylinder head 1 unless they are defective. Key points for disassembly Removing cylinder head To remove the cylinder head, wrap the cylinder tube in cloth and hold it with a vice. Remove the cylinder head using the wrench. Special tool needed Wrench
05312-20850 200351
10-33
HYDRAULIC SYSTEM
Disassembly (No.2) For mast models A45A, A55A and A70A
Parts marked with * are included in the seal kit.
4
* 1
* 6
7
2
*
5
* 3
202986
Sequence 1 Holder, Wiper ring 2 Cylinder head, U-ring, O-ring 3 Collar 4 Piston rod
5 Piston ring, U-ring, Holder, Stopper 6 Bushing 7 Cylinder tube
NOTE Do not remove bushing 6 from cylinder head 2 unless they are defective. Key points for disassembly Removing holder To remove the holder from the A70A cylinder, wrap the cylinder in cloth and hold it with a vice. Remove the holder using the wrench. Special tool needed Wrench
Remove the holder from the A45A, A55A cylinder using the spanner.
05312-10600
10-34
Spanner width across flats 85 mm (3.35 in.)
HYDRAULIC SYSTEM
Inspection after disassembly 1. Cylinder tube (1) Check the bore wall for wear, grooving, scratch marks and rusting. (2) Check the welds for cracks. 2. Piston rod (1) Check the rod for deflection on V-blocks with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratch marks, rusting and wear. The rod must be replaced if its threads show a sign of stripping or any other damage. 3. Packings and rings Replace all parts contained in the seal kit, once disturbed.
200319
Reassembly
1
6
5
4
3
2 202976
Sequence (A45A, A55A, A70A) 1 Piston rod 2 Piston ring, U-ring, Holder, Stopper 3 Collar
4 Cylinder tube 5 Cylinder head, bushing, U-ring, O-ring 6 Holder, Wiper ring
(A40A) 1 Piston rod 2 Bushing, Backup ring, U-ring 3 Collar
4 Cylinder tube 5 Cylinder head, Wiper ring, U-ring, Bushing, O-ring
10-35
HYDRAULIC SYSTEM
Key points for reassembly (1) Clean parts completely before reassembly, and make sure that parts are free of dust and other particles. (2) For reassembly, use new seal kit parts. (3) Apply oil to the U-ring, piston ring, O-ring, bushing, wiper ring and the cylinder bore before reassembly. (4) When holding the cylinder with a vice, be careful not to deform the cylinder by overtightening. (5) Before tightening the cylinder head and the holder, apply liquid gasket (THREEBOND #1901) to the threaded sections. Mast Models Item Tightening torque of cylinder head or holder N·m (kgf·m) [lbf·ft]
A40A
A45A, A55A
A70A
304 (31) [224]
422 (43) [311]
490 (50) [362]
10-36
HYDRAULIC SYSTEM
Lift Cylinders (Duplex Mast, Triplex Mast) Disassembly (No.3) First Lift Cylinders For mast models B40A thru B55A, C40A thru C70A
1
*
4 2
*3
7
8
*6
5 Parts marked with * are included in the repair kit.
206955
Sequence 1 Plug, Gasket 2 Cylinder head 3 U-ring, Wiper ring, O-ring, O-ring 4 Piston rod
5 6 7 8
Check valve, Snap ring Slide ring, Seal ring Bushing Cylinder tube
NOTE Do not remove bushing 7 from cylinder head 2 unless they are defective. Key points for disassembly Removing cylinder head To remove the cylinder head, hold the lift chain Wrench mounting area with a vice. Remove the cylinder head using the wrench. Special tool needed 10-37
05312-10800 (B40A, C40A) 05312-11000 (B45A, B55A, C45A thru C70A)
HYDRAULIC SYSTEM
Disassembly (No.4) Second Lift Cylinders Parts marked with * are included in the seal kit.
For mast model B40A
1
2 6
9
*4
5
10 7 8
3
206957A
Sequence 1 Valve, Steel ball 2 Holder 3 Cylinder head 4 Wiper ring, U-ring, Backup ring, O-ring 5 Piston rod NOTE Do not remove bushing 8 from cylinder head 3 unless they are defective. Key points for disassembly Removing holder To remove the holder, wrap the cylinder tube in cloth and hold it with a vice. Remove the holder using the spanner. Spanner
width across flats 65 mm (2.56 in.) 10-38
6 Slide ring, Set screw, Piston 7 Snap ring, Check valve, Spring, Cushion spool 8 Bushing 9 Steel ball, Screw 10 Cylinder tube
HYDRAULIC SYSTEM
Disassembly (No.5) Second Lift Cylinders Parts marked with * are included in the seal kit.
For mast model B45A, B55A
1
6
7 5
2
*4
10
9 8 3
206956
Sequence 1 Valve, Steel ball 2 Cylinder head 3 Spacer 4 U-ring, Wiper ring, O-ring 5 Piston rod
6 7 8 9 10
Spacer, Snap ring Slide ring, Set screw, Piston Snap ring, Check valve, Spring, Cushion spool Bushing Cylinder tube
NOTE Do not remove bushing 9 from cylinder head 2 unless they are defective. Key points for disassembly Removing cylinder head To remove the cylinder head, hold the mast fitting area of the cylinder tube with a vice. Remove the cylinder head using the wrench. Special tool needed Wrench
05312-11000
10-39
HYDRAULIC SYSTEM
Inspection after disassembly 1. Cylinder tube (1) Check the bore wall for wear, grooving, scratch marks and rusting. (2) Check the welds for cracks. 2. Piston rod (1) Check the rod for deflection on V-blocks with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratch marks, rusting and wear. The rod must be replaced if its threads show a sign of stripping or any other damage. 3. Packings and rings Replace all parts contained in the seal kit, once disturbed.
200319
Reassembly First Lift Cylinder (B40A thru B55A, C40A thru C70A) Parts marked with * are included in the seal kit. 7
6 *
1
4
3
2
* *
5
206950A
Sequence 1 Piston rod 2 Check valve, Snap ring 3 Slid ring, Seal ring 4 Cylinder tube
5 Cylinder head, Bushing Install parts 6 to part 5 6 U-ring, Wiper ring, O-ring 7 Plug, Gasket
10-40
HYDRAULIC SYSTEM
Second Lift Cylinders (B40A) Parts marked with * are included in the seal kit. 8
7
1
3
4
*
6
5
2
Sequence 1 Piston rod 2 Cushion spool, Spring, Check valve, Snap ring 3 Piston, Set screw, Slid ring 4 Cylinder tube
206949A
5 Cylinder head, Bushing 6 Holder Install parts 7 to part 6 7 Backup ring, U-ring, Wiper ring, O-ring 8 Steel ball, Screw
Second Lift Cylinders (B45A, B55A) Parts marked with * are included in the seal kit. 9
6
1
5
4
3
*
10
7
8
Sequence 1 Piston rod 2 Cushion spool, Spring, Check valve, Snap ring 3 Piston, Set screw, Slid ring 4 Spacer, Snap ring
2
5 Cylinder tube 6 Spacer 7 Cylinder head Install parts 8 and 9 to part 7 8 Bushing 9 U-ring, Wiper ring, O-ring 10 Steel ball, Valve 10-41
206948A
HYDRAULIC SYSTEM
Key points for reassembly (1) Clean parts completely before reassembly, and make sure that parts are free of dust and other particles. (2) Use new seal kit parts and repair kit parts. (3) Apply oil to the seal kit parts such as U-ring, wiper ring, seal ring and the O-ring and to the slide ring and the bushing before reassembly. Also apply oil to the cylinder bore before reassembly. (4) When holding the cylinder with a vice, be careful not to deform the cylinder by overtightening. (5) Tighten parts such as the cylinder head, holder, piston, set screw and the valve to the specified torque. (Refer to Service Data.) (6) Before tightening the cylinder head and the holder, apply liquid gasket (THREEBOND #1901) to the threaded sections. (7) After reassembling the first lift cylinder, fill the rod chamber with hydraulic oil. Supply hydraulic oil from the plug, and tighten the plug to the specified torque.
Plug
Rod chamber
•
B40A, C40A Amount of hydraulic oil cc (cu. in.)
B45A, B55A, C45A, C55A
C70A
160 to 180 190 to 210 260 to 290 (9.76 to 10.98) (11.59 to 12.81) (15.86 to 17.69) 206950
10-42
HYDRAULIC SYSTEM
Lift Cylinders (Triplex Mast) Disassembly (No.6) Second Lift Cylinders For mast model C40A
Parts marked with * are included in the seal kit.
* 7
* 2
*
*
1
5
6
* 3
4 8
207781
Sequence 1 Cylinder head, bushing 2 Wiper ring, U-ring, O-ring 3 Spacer 4 Piston rod
5 6 7 8
NOTE Do not remove bushing 1 from cylinder head 1 unless they are defective. 10-43
Snap ring, Pin Spring guide, Spring, Cushion spool U-ring, Backup ring, Bushing Cylinder tube
HYDRAULIC SYSTEM
Disassembly (No.7) Second Lift Cylinders Parts marked with * are included in the seal kit.
For mast model C45A, C55A
* 1
7
* 5 2
6
* 3
8 4
207782
Sequence 1 Holder, Wiper ring 2 Cylinder head, U-ring, Bushing, O-ring 3 Spacer 4 Piston rod NOTE Do not remove bushing 2 from cylinder head 2 unless they are defective.
10-44
5 6 7 8
Holder, Stopper, Spring pin Spring guide, Spring, Cushion rod U-ring assembly, Piston ring Cylinder tube
HYDRAULIC SYSTEM
Disassembly (No.8) Second Lift Cylinders Parts marked with * are included in the seal kit.
For mast model C70A
* 1 * 5 *
*
2 7
* 3
4
8
6
207783
Sequence 1 Holder, Wiper ring 2 Cylinder head, Bushing, U-ring 3 Spacer 4 Piston rod
5 Holder, Stopper, U-ring assembly, Piston ring 6 Set screw, Piston, O-ring 7 Spring guide, Spring, Cushion rod 8 Cylinder tube
NOTE Do not remove bushing 2 from cylinder head 2 unless they are defective. 10-45
HYDRAULIC SYSTEM
Key points for disassembly 1. Removing cylinder head or holder To remove the cylinder head or holder, wrap the cylinder tube in cloth and hold it with a vice.
200351
2. Remove the cylinder head or holder using the wrench or the spanner. Special tool needed Wrench
(C40A) 05312-10800 (C70A)
Wrench
05312-11000 (C45A, C55A)
Spanner
width across flats 85 mm (3.35 in.)
Inspection after disassembly 1. Cylinder tube (1) Check the bore wall for wear, grooving, scratch marks and rusting. (2) Check the welds for cracks. 2. Piston rod (1) Check the rod for deflection on V-blocks with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratch marks, rusting and wear. The rod must be replaced if its threads show a sign of stripping or any other damage. 3. Packings and rings Replace all parts contained in the seal kit, once disturbed.
10-46
200319
HYDRAULIC SYSTEM
Reassembly Second Lift Cylinders (C40A)
14
13
12 15
1
11
10
5
3
2
6
9
4
8
7
207778A
Sequence 1 Piston rod Install parts 2 through 9 to part 1. 2 Bushing 3 Backup ring 4 U-ring
5 6 7 8 9 10
Spring seat Spring Cushion spool Pin Snap ring Spacer
11 Cylinder tube 12 Cylinder head kit Install parts 13 through 15 to part 12. 13 U-ring 14 Wiper ring 15 O-ring
Second Lift Cylinders (C45A, C55A)
17 14 16 13 12 15
1
11
10
4
5
2
3
9
8
7
6
207779A
Sequence 1 Piston rod Install parts 2 through 9 to part 1. 2 Piston ring 3 U-ring assembly 4 Spring guide 5 Spring
6 7 8 9 10 11 12
Cushion rod Spring pin Stopper Holder Spacer Cylinder tube Cylinder head 10-47
13 14 15 16 17
Install parts 13 through 15 to part 12. Bushing U-ring O-ring Holder Wiper ring
HYDRAULIC SYSTEM
Second Lift Cylinders (C70A)
19 16 18 17 15 14
13
1
12 2
3
4
7
6
5
8 9 11
10
207780A
Sequence 1 Piston rod Install parts 2 through 11 to part 1. 2 Spring seat 3 Spring 4 Cushion rod 5 O-ring 6 Piston
7 8 9 10 11 12 13
Set screw Piston ring U-ring assembly Stopper Holder Spacer Cylinder tube
Key points for reassembly (1) Clean parts completely before reassembly, and make sure that parts are free of dust and other particles. (2) Use new seal kit parts and repair kit parts. (3) Apply oil to the seal kit parts such as U-ring, wiper ring, seal ring and the O-ring and to the piston ring and the bushing before reassembly. Also apply oil to the cylinder bore before reassembly. (4) When holding the cylinder with a vice, be careful not to deform the cylinder by overtightening. (5) Tighten parts such as the cylinder head, holder, piston, set screw and the valve to the specified torque. (6) Before tightening the cylinder head and the holder, apply liquid gasket (THREEBOND #1901) to the threaded sections.
10-48
14 Holder Install parts 15 through 17 to part 14. 15 Bushing 16 U-ring 17 O-ring 18 Holder 19 Wiper ring
HYDRAULIC SYSTEM
Tilt Cylinders Disassembly GC35K thru GC55K STR Parts marked with * are included in the seal kit.
12
8
7
4 2
5
**
6
3
*
*
1
13
9 11
GC60K thru GC70K STR
10
206953
Sequence 1 Bolt, Spring washer 2 Socket Remove 3 to 7 as a subassembly. 3 Guide bushing 4 Dust seal 5 Packing 6 Buffer ring 7 O-ring
8 9 10 11 12 13
Piston rod Self-lock nut Piston Piston seal Collar Cylinder tube
NOTE
NOTE
(1) The figure above applies to models GC35K thru GC55K STR. The frame fitting of models GC60K thru GC70K STR have a different form. (2) Do not disassemble piston 10 unless they are defective. (3) Collar 12 is for forward tilt angle of 3 degree.
Tilt cylinders with Weber Hydraulik stamped into the cylinder are assembled using thread locking compound. The gland nut must be heated to 300 degrees centigrade before the cylinders can be disassembled. Use Loctite 270 when re-assembling.
10-49
HYDRAULIC SYSTEM
Key points for disassembly Removing guide bushing To remove the guide bushing, wrap the tilt cylinder in cloth and hold it with a vice. Remove the guide bushing using the wrench. Special tool needed
Wrench
GC35K thru GC55K STR
GC60K thru GC70K STR
05312-10800
05312-11000
Weber-Hydraulic Type Cylinders Inactivate the Loctite material by heating up the thread zone (rod guide cylinder barrel) to min. 300°C, 572°F and unscrew the rod guide with a fitting spanner.
200351
Inspection after disassembly 1. Cylinder tube (1) Check the bore wall for wear, grooving, scratch marks and rusting. (2) Check the welds for cracks. 2. Piston rod (1) Check for deflection in as shown. (2) Check for surface flaws such as grooving, scratch marks, rusting and wear. The rod must be replaced if its threads show a sign of stripping or any other damage. 3. Packings and rings Replace all parts contained in the seal kit, once disturbed. Truck Models Items
200319
A: Standard value Unit: mm (in.)
GC35K thru GC55K STR
GC60K thru GC70K STR
Inside diameter of cylinder tube 1
A
100 (3.937)
110 (4.33)
[Guide bushing] Diameter of piston rod 2
A
40 (1.574)
50 (1.968)
Inside diameter of tilt socket bushing (fitted) 3 A
+0.004 40 +0.10 +0.05 (1.574 +0.002 )
+0.004 45 +0.10 +0.05 (1.77 +0.002 )
Inside diameter of cylinder tube head bushing A (fitted) 4
50 +0.039 (1.968 +0.0015 ) +0 +0
50 +0.11 (1.968 +0.043 ) +0 +0
M105×2.0
M115×2.0
[Guide bushing] Thread diameter 5 [Guide bushing] Tightening torque 5
A N·m (kgf·m) [lbf·ft]
[Tilt socket] Thread diameter 6
A 696 ± 69 (71 ± 7) [513 ± 50] M38×1.5
A
Tightening torque
Tilt socket bolt 7
A 262 ± 13 (27 ± 1.4) [195 ± 10.1]
N·m (kgf·m) [lbf·ft]
Self-locking nut 8 A 588 ± 29 (60 ± 3) [434 ± 21.7]
10-50
785 +98 +0 (80
+10 +0
) [578
+72.3 +0
]
M38×1.5 262 ± 13 (27 ± 1.4) [195 ± 10.1] +10 +72.3 981 +98 +0 (100 +0 ) [723.3 +0 ]
HYDRAULIC SYSTEM
5 3
8
6
4
2
1
7 206947
Reassembly Follow the disassembly sequence in reverse. Key points for reassembly (1) Carefully clean all parts to remove any gritty particle. (2) Reassemble the cylinder in the reverse sequence of the disassembling, apply hydraulic oil to the bore wall of the cylinder tube, and also to sealing parts — O-rings, Urings, wiper rings, nylon heels, piston seals, dust seals and packings — so that they will smoothly slide into the bore. (3) When clamping the cylinder tube in the vise in order to run the head into the cylinder tube, be careful not to distort the tube. (4) Before fitting the piston seal to the tiltcylinder piston, squeeze the seal by hand 5 or 6 times to soften it. Hold the piston steady by clamping the rod in the vise; apply a small amount of hydraulic oil to the seal; fit a portion of the seal to the groove; and push the other portions just a little at a time into the groove. For WEBER-HYDRAULIC cylinders use Loctite type 270 when installing the rod guide bushing. Tightening torque for rod guide bushing is 400±40 N•m, (41±5Kgf•m) [295±29lbf•ft).
10-51
200352
200353
HYDRAULIC SYSTEM
Flow Regulator Valve Disassembly (No.1) GC35K thru GC55K STR
2
5
1
3 6 4
3
203722
Sequence 1 Lock nut, Set bolt 2 Sleeve, O-ring 3 Piston, Valve, Spring, Pin and Washer Inspection after disassembly (1) Check the springs for fatigue. (2) Check seat and sliding faces of valve and piston. (3) Check the sliding surfaces of the piston and valve body for damage.
4 Spring, Shims 5 Guide, O-ring 6 Body
NOTE Replace the flow regulator valve as an assembly if any part is defective.
▲
▲
L
Cautions for assembly (1) Clean parts completely before assembly, and make sure that parts are free of dust and other particles. (2) Be careful to mounting direction of piston 3 when installing to the flow regulator valve. (3) Use set bolt dimension L for assembly as follows. Measure and check the lowering speed under rated load. 115 liter/min 1.5 mm (30.38 U.S.gal) (0.059 in.) Control flow rate Dimension L 100 liter/min 3 mm (26.42 U.S.gal) (0.118 in.)
10-52
203708
GC45K thru GC55K STR GC35K thru GC40K STR
HYDRAULIC SYSTEM
Disassembly (No.2) GC60K thru GC70K STR
7 8 9 10
11
4 1 2 3 5 6
Sequence 1 Nut 2 Plug, O-ring 3 Spring 4 Pin
206963
5 6 7 8
Stopper Disc spring Snap spring Plate
Inspection after disassembly (1) Check the springs for fatigue. (2) Check seat and sliding faces of valve and piston. (3) Check the sliding surfaces of the piston and valve body for damage. NOTE Replace the flow regulator valve as an assembly if any part is defective. Reassembly Follow the disassembly sequence in reverse. Control flow rate
165 liter/min (43.6 U.S.gal)
10-53
9 Valve 10 Piston 11 Body
HYDRAULIC SYSTEM
Inspection and Adjustment
H N
L
120 50 33 (4.72) (1.97) (1.3)
295 mm (11.6 in.)
Hydraulic Oil Level
206996
Truck Models Items Hydraulic oil level liter (U.S.gal) Level gauge scale Oil level (from the bottom of tank) mm (in.)
GC35K GC40K GC40K STR GC45K SWB/STR
GC45K GC55K GC55K STR
GC60K GC70K GC70K STR
46 (12.1)
52 (13.7)
69 (18.2)
H
N
N
450 (17.72)
415 (16.34)
415 (16.34)
NOTE Use level gauge scale N or H to check the oil level. Hydraulic Tank 1. Hydraulic oil Check the hydraulic oil in the tank for cleanliness. Oil showing discoloring (Slightly whitish color is allowed as it always appears after the operation.) must be changed. 2. Refill capacities and the amount of oil required. 10-54
3. Suction strainer and return filter. Check for clogging or damage, and clean or replace the strainer and filter.
HYDRAULIC SYSTEM
Test-run of Gear Pump The purpose of a test-run is to break-in the overhauled pump and verify its performance. The use of pump testing equipment, specifically designed as such and commonly used in the service shop, is recommended but is not mandatory. The following procedure, however, assumes that the pump is installed on the truck. (1) Install a hydraulic pressure gauge with a range of 0 to 35200 kPa (0 to 352 kgf/cm2) [0 to 5000 psi]. Installing hydraulic pressure gauge: Remove the plug from the delivery at the hose connector, and install the following tools. Special tools needed Threaded section Connector (9/16 to 18 UNF - 2B) Hose 64309-17722 64309-17731 Connector (for gauge mounting) 64309-17712 Gauge 0 to 35200 kPa (0 to 352 kgf/cm2) [0 to 5000 psi]
Control Valve External oil leakage (1) Check the O-ring between housings for oil leakage. (2) Check the scraper and O-ring for oil leakage. (3) Check the thread connection for oil leakage.
1
4 3
2
NOTE Parts 2 to 4 are included in gauge kit 64309-17701. (2) Set the control lever at the neutral position, and run the engine at 500 to 1000 rpm. The hydraulic gauge reading under neutral condition should become 981 kPa (10 kgf/cm2) [142 psi] or less. Run the pump for 10 minutes and check the pump for abnormal noise. (3) Gradually increase the engine speed to 1500 to 2000 rpm, and run the pump for another 10 minutes under no load. (4) Under the condition of step (3), loosen the adjusting screw of relief valve, and switch the control lever to operating condition. Adjust the adjusting screw and run the pump for 5 minutes with the pressure of 2942 kPa (30 kgf/cm2) [427 psi]. Increase the pressure by 1961 kPa (20 kgf/cm2) [284 psi] and run the pump for 5 minutes. Repeat the 5-minutes running while increasing the pressure by the same amount for each run until the pressure reaches the set pressure of relief valve. (5) While increasing the pressure, check the pump surface temperature of the pump and for abnormal noise. If oil and pump are abnormally heated, continue the test-run under no load after lowering the temperature, or disassemble and inspect the pump. (6) After steps (2) to (5), readjust the relief valve to the specified set pressure, and make sure that the operation speed is normal.
10-55
206987
Spanner
Allen wrench
206988
HYDRAULIC SYSTEM
Oil leakage It is difficult to carry out an oil leakage for the individual control valve. Therefore follow the procedures for inspection of cylinders before and after connecting as is described in (1) to (3) below. Measurement indicates the total leakage from the lift spool, tilt spool, tilt lock valve and the check valves. (Oil temperature: approx. 50°C (122°F) (1) Raise the forks under the rated load to approx. 1 m (40 in.). Tilt the mast forward from the vertical position by approx. 3 to 4 degrees, then stop the engine. (2) Immediately remove the oil return hose and collect oil from the hose. Standard oil discharge in 15 min. cc (cu. in.)
3° to 4°
Approx. 1 m (40 in.)
202991
500 (30.5)
(3) If the lift cylinders or tilt cylinders drift (the mast tilts forward or the fork lowers) excessively in spite of that the amount of oil collected for 15 minutes is less than 560cc (30.5 cu.in.), measure the internal leakage of each cylinder. (The measurement is the assembly standard and not the secure limit). Main Relief Valve Adjustment (1) Install a hydraulic gauge of 35200 kPa (352 kgf/cm2) [5000 psi] to the delivery hose connector. Use the same gauge, connector and the hose used for the test-run of the gear pump. (2) Start the engine, and operate the tilt lever to the backward tilt position at the maximum engine speed. When the tilt cylinder reaches the maximum backward-tilt position, check the pressure gauge. The main relief valve is in good condition if the oil pressure is relieved +5 and the gauge reading is 19361+0.5 +0 kPa (197.6+0 +70 2 kfg/cm ) [2810 +0 psi]. (3) If the relief pressure is incorrect, loosen the relief valve lock nut, and while observing the hydraulic gauge, adjust the pressure using the adjusting screw. (4) While pressing the adjusting screw, tighten the lock nut to secure. (5) After tightening, check the relief valve set pressure again. Main relief valve set pressure MPa (kgf/cm2) [psi]
19361+482 +0 0 (197.6 +5 +0) [2810+70 +0 ]
10-56
206989
Spanner
Allen wrench
206988
HYDRAULIC SYSTEM
Attachment Relief Valve Adjustment (1) Install a hydraulic gauge of 35200 kPa (352 kgf/cm2) [5000 psi] to the left side of control valve. NOTE Use the same equipment and tools as used for adjusting the main relief valve. (2) Start the engine, and operate the attachment lever forward or backward at the maximum engine speed. When the hydraulic pressure of actuator reaches the limit, check the pressure gauge. The secondary relief valve is in good condition if the oil pressure is relieved and the gauge reading becomes the specified value. (3) If the relief pressure is defective, loosen the relief valve lock nut, and while observing the hydraulic gauge, adjust the pressure using the adjusting screw. (4) While pressing the adjusting screw, tighten the lock nut to secure. (5) After tightening, check the relief valve set pressure again. Priority Relief Valve Function Check (1) Install a hydraulic pressure gauge to the position indicated in the figure to the right. Connector 1
91268-01700
Hose 2
64309-17722
Gauge 3
64309-17712 35200 kPa (352 kgf/cm2) [5000 psi]
206995
3
2
NOTE (a) Tools 1 to 3 are included in gauge kit. (b) It is desirable to use a hydraulic gauge with a double capacity of the pressure to be measured.
10-57
1
206983
HYDRAULIC SYSTEM
(2) Start the engine, and turn the steering wheel fully to the left at the maximum engine speed. When the steering wheel stroke reaches the limit, check the pressure gauge. The priority relief valve is in good condition if the oil pressure is relieved and the gauge reading becomes as the following standard value. Truck Models Item Priority relief pressure kPa (kgf/cm2) [psi]
Adjusting plug
GC35K GC60K thru thru GC55K STR GC70K STR 11713 (120) [1700]
14641 (150) [2125]
205668
(3) If the relief pressure is incorrect, remove the T-port piping of the priority valve, and adjust the pressure using the adjusting plug of relief valve. Flow Regulator Valve Adjustment Measure the lowering speed under rated load. If the speed is not the standard value, loosen the lock nut of set bolt and turn the set bolt in either direction. Lowering speed
No load Loaded
GC35K GC40K GC40K STR
GC35K thru GC55K STR Set bolt Lock nut Faster
Unit: mm/sec (fpm) GC45K SWB/STR GC60K GC45K GC70K GC55K GC70K STR GC55K STR
550 (108)
440 (86.6)
540 (106)
500 (98.4)
410 (81)
390 (77)
Slower
203845 GC60K thru GC70K STR
205546
10-58
HYDRAULIC SYSTEM
Lift and Tilt Cylinders Adjusting mast tilt angle (Simplex, Duplex) (1) Place the vehicle on level ground. (2) Tilt the masts backward to the maximum tilt position for a mast without tilt cylinder spacers, then stop the engine. (3) Measure the backward-tilt angle of the mast at both sides. (4) Loosen the tightening bolt of tilt cylinder socket, rotate the tilt cylinder rod and adjust the cylinder stroke until the right and left masts are tilted at the same angle. NOTE It is not necessary to adjust the forward tilt angle, provided that the backward tilt angle is properly adjusted on a mast without spacers. Item
Truck Models GC35K thru GC55K STR
GC60K thru GC70K STR
Simplex Forward tilt Backward tilt deg
5°-10°
6°-9°
Adjusting Mast tilt angle (Triplex) (1) Place the vehicle on level ground. (2) Raise the forks up so when mast is tilted forward to the maximum tilt position the forks will not hit the floor. (3) Measure the forward tilt angle of the mast at both sides. (4) Loosen the tightening bolt of tilt cylinder socket, rotate the tilt cylinder rod and adjust the tilt angle. (5) Tilt mast backward and then slowly tilt mast forward, and observe the stopping of piston rod, right and left, at the moment the tilt cylinder reaches its maximum backward tilt. (6) If right to left piston rods stops before and mast cocks, adjust cylinder rod so that right and left stops at the same time. (7) Slowly tilt mast backward observing the stopping point at tilt cylinder spacers. (8) Add Shims between tilt cylinder socket and spacer, tighten to specified torque. Item
Truck Models GC35K thru GC55K STR
207653
Lift cylinder stroke adjustment (1) Slowly raise the inner mast, and observe the stopping of piston rod, right and left, at the moment the inner mast reaches its maximum lift height. (2) If the top of mast rolls at that moment, it should be adjusted with shims. Abnormal condition can be detected by a little time lag in stopping between right-hand and lefthand piston rods and rolling of the rod with a longer cylinder stroke.
200363
Adjusting method (1) Raise the inner mast, tie blocks under the right and left sides of the mast, and lower the mast until it rests on the blocks. (2) Remove the stopper bolt at the top of lift cylinder which stopped first, retract the piston rod, and insert shims at the top of piston rod end.
GC60K thru GC70K STR
Triplex Forward tilt Backward tilt deg
6°-5°
6°-5° 202983
10-59
HYDRAULIC SYSTEM
NOTE To retract the piston rod, move the lift control lever to the lowering position to let the oil escape from the lift cylinder. (3) Extend the piston rod, and tighten the cylinder stopper bolt. Remove the blocks from under the inner mast. (4) Slowly lower the inner mast to the bottom to ensure the piston rods move smoothly.
(2) Forward tilt by internal leakages (Leakdown) (a) Position the mast upright with rated load, raise the forks approx. 50 cm (20 in.), then stop the engine. (b) Measure the amount of tilt cylinder extension after 15 minutes. mm(in.) Truck Models Item Forward tilt test (rated load)
GC35K GC60K thru thru GC55K STR GC70K STR 30 (1.18)
40 (1.57)
Shims
206985 206974
Tests (1) Descent by internal leakages (Leakdown) (a) Position the mast upright with rated load, raise the forks approx. 1 m [40 in.], then stop the engine. (b) Draw a reference line on a mast, and measure the distance of fork lowering after 15 minutes. mm(in.) Truck Models Item Load descent test (rated load)
GC35K GC60K thru thru GC55K STR GC70K STR 50 (1.97)
70 (2.76)
206984
10-60
HYDRAULIC SYSTEM
Hydraulic Circuit Diagram Control valve ATT relief valve
T Tilt cylinder
4A 4B
3A
Lift cylinder
3B
Port relief valve
2A 2B
1A 1B
Flow regulator valve
Main relief valve P
Steering control valve L R LS T
P
Steering cylinder
LS CF
EF
Priority valve
T P
Relief valve
Engine Gear pump 207063
10-61
HYDRAULIC SYSTEM
Troubleshooting Complaints
Will not lift nor tilt
Will not lift rated load
Lift and tilt cylinders
Lift speed is too slow
Possible causes a) Oil low level b) Relief valve out of order, because of: • Main valve seized • Valve spring broken c) Oil pump defective
Replace. Replace. Replace.
a) Relief valve out of order, because of: • Relief pressure setting too low • Plunger or poppet seat defective • Spring fatigued • O-ring in valve case damaged b) Oil pump defective c) Piston seals worn or damaged
Readjust. Replace. Replace. Replace O-ring. Replace. Replace.
a) Engine idle speed too low b) Control lever installed loosely, resulting in short spool stroke c) Tank strainer clogged d) Pump not delivering enough oil
Lowering speed is too slow
a) Sleeve seized in flow regulator valve b) Dirt in flow regulator valve
Cylinder vibrates when actuated
a) Piston rod distorted b) Air in oil circuit
Mast tilts forward (drift)
Refill.
Tune up engine. Repair or replace. Clean or replace. Repair or replace
Repair. Clean, repair system and replace defective hose. c) Abnormal resistance to flow due to deformation Replace hose. or partial clogging of hose
c) Not enough oil in hydraulic tank Load descends too fast (drift)
Remedies
Repair or replace. Bleed air by operating cylinders through full strokes. Refill.
a) Control valve spool internally leaking b) Sliding (inside) surface of cylinder tube slightly grooved c) Sliding (inside) surface of cylinder tube badly grooved d) Piston seals broken or distorted e) Oil leakage from piping
Replace. Repair or replace cylinder assy. Replace cylinder assy.
a) Control valve spool internally leaking b) Foreign particles lodged between packing
Replace. Replace packing.
10-62
Replace seal kit. Repair or replace.
HYDRAULIC SYSTEM
Lift and tilt cylinders — Continued
Complaints Bushing leaks
Hydraulic tank heats excessively
Possible causes a) Foreign particles lodged between sealing members such as oil seals and dust seals b) Oil seals and dust seals defective c) O-rings damaged d) Cylinder distorted a) Oil viscosity improper b) Overload
Hydraulic tank
c) Local overheating of oil line due to a large restriction to flow d) Relief valve adjustment improper
Replace. Replace. Replace. Repair or replace. Change oil. Check working conditions and, if overloaded, advise the operator to stay within the load limit. Repair or replace.
e) Pressure drop due to fatigued or broken springs f) Gear pump worn g) Outlet pipe or tube deformed, or restricted
Readjust pressure setting. 19.12 +0.5 +0 MPa +70 2 (195 +5 +0 kgf/cm ) [2773+0 psi] Repair or replace and readjust. Replace. Repair or replace.
Cylinders move too slow
a) Shortage of oil due to a natural loss b) Oil leakage due to damaged oil line seals c) Oil viscosity too higher
Refill. Repair or replace. Change oil.
Cylinders move too slow
a) Gear pump defective
Check pump and piping; repair or replace. Check oil for level and condition; add or change oil. Check control valve spools for misalignment; repair or replace. Replace pump.
b) Oil leakage from oil line c) Abnormal oil temperature rise Gear pump
Remedies
d) Gear pump internally leaking
Noise
a) Poor pumping b) Cavitation
Refill. 1) Check suction pipe for any flat portion or loose connection; retighten or replace. 2) Check shaft oil seal for airtightness; replace pump. 3) Check pump case for any outside interference; repair.
10-63
HYDRAULIC SYSTEM
Gear pump - Continued
Complaints
Pump case, drive gear and pump port flange damaged
Possible causes a) Pressure too high b) Distortion or damage due to external strain or stress
Oil leakage from pump
a) Oil leakage past oil seal b) Oil leakage past sliding surfaces of drive shaft c) Pump securing bolts loose d) Excessive internal leakage
Slow or no motion a) Relief pressure setting too low of lift and tilt cylinders
Control valve
b) Relief valve piston seizure
c) O-ring on relief valve body damaged d) Control lever installed loosely, resulting in short spool stroke Load descends or mast tilts forward (drifts) with control lever in neutral Oil leakage
Remedies Replace pump. (Check to see if relief valve setting is correct.) Replace pump. 1) Check to see if return line is restricted. 2) Check to see if pipe connections have been externally stressed. Replace oil seal. Replace whole pump assembly. Retighten. Replace O-ring. Readjust. 19.12 +0.5 +0 MPa 2 (195 +5 kgf/cm ) +0 [2773 +70 +0 psi] Clean piston and check to see if it moves smoothly; or replace whole relief valve assembly. Replace O-ring. Readjust.
Control valve internally leaking
Replace a leaky block assembly.
a) Oil leakage from spool ring cap
Replace O-ring; check spool for flaws and if any, repair or replace a leaky block assembly. Retighten.
b) Loose plugs
10-64
HYDRAULIC SYSTEM
Service Data A: Assembly standard Unit: mm (in.) Truck Models
GC35K GC40K GC40K STR
GC45K SWB/STR GC45K GC55K GC55K STR
GC60K GC70K GC70K STR
Simplex mast
Items Lift speed (rated load/no load)
mm/sec (fpm) [Simplex mast]
A
540/570 (106.0/112.0)
390/420 (78.0/82.5)
360/390 (71.0/76.0)
Lowering speed (rated load)
mm/sec (fpm) [Simplex mast]
A
550 (108)
440 (86.5)
540 (106.0)
Forward tilt angle
A
5°
6°
Backward tilt angle
A
10°
9°
Lift cylinder rod drift (rated load) mm (in.)/15 min. [Oil temperature: 45°C (113°F)]
A
50 (1.97)
50 (1.97)
70 (2.76)
Tilt cylinder rod drift (forward) (rated load) mm (in.)/15 min. [Oil temperature: 45°C (113°F)]
A
30 (1.18)
30 (1.18)
40 (1.57)
19361 +0.5 +0 (197.6) [2810]
kPa (kgf/cm2) [psi]
A
Priority relief valve setting
kPa (kgf/cm2) [psi]
A
11713 (120) [1700]
14641 (150) [2125]
Capacity
liter (U.S.gal)/min
A
98 (25.89)/2450
117.6 (31.07)/2450
Flow rate (no load)
liter (U.S.gal)/min
A
Tightening torque
N·m (kgf·m) [lbf·ft]
A
49 (5) [36]
Tie bolts 7/16˝
A
65 (6.6) [48]
Tie bolts 1/2˝
A
101 (10.3) [74]
Control Return Flow regulator Gear pump valve filter valve
Main relief valve setting
Tightening torque N·m (kgf·m) [lbf·ft]
10-65
100 (26.42)
115 (30.38)
165 (43.59)
HYDRAULIC SYSTEM
A: Assembly standard Unit: mm (in.) Truck Models Items
Lift speed (rated load/no load)
GC35K GC40K GC40K STR
GC45K SWB/STR GC45K GC55K GC55K STR
510/540
350/370
A
Duplex mast
mm/sec (fpm) [duplex mast] Lowering speed (rated load) mm/sec (fpm) [duplex mast]
A
— 100/106
69/73
560 (110)
440 (87)
—
Forward tilt angle
A
5°
6°
Backward tilt angle
A
10°
10°
No. 1 Lift cylinder rod drift (rated load) mm (in.)/15 min.
A
—
—
—
A
30 (1.18)
30 (1.18)
40 (1.57)
510/550
360/390
330/360
(100/106)
(70/77)
(65/71)
560 (110)
460 (91)
510 (100)
[Oil temperature 45°C (113°F)] No. 2 Tilt cylinder rod drift (forward) (rated load) mm (in.)/15 min. [Oil temperature 45°C (113°F)]
Lift speed (rated load/no load) A mm/sec (fpm) [triplex mast] Triplex mast
GC60K GC70K GC70K STR
Lowering speed (rated load) mm/sec (fpm) [triplex mast]
A
Forward tilt angle
A
6°
Backward tilt angle
A
5°
No. 1 Lift cylinder rod drift (rated load) mm (in.)/15 min.
A
[Oil temperature 45°C (113°F)] No. 2
10-66
—
—
—
HYDRAULIC SYSTEM
A: Assembly standard Unit: mm (in.) Mast Models Items
A40A
A45A A55A
A70A
[piston] Inside diameter of cylinder tube 1
A
60 (2.36)
70 (2.75)
80 (3.15)
Diameter of piston rod 2
A
45 (1.77)
50 (1.97)
* 60 (2.36)
Holder thread diameter 3
A
M64×1.5
M79×2.0
M90×2.0
Width across flat 4
A
—
85 (3.35)
—
Tightening torque for cylinder head or holder 4 N·m (kgf·m) [lbf·ft]
A 304 (31) [224]
422 (43) [311]
490 (50) [362]
Lift cylinder (Simplex mast)
Value marked with * becomes 65 (2.56) for the mast size of 6.5 to 7.0 m (256 to 276 in.).
4
2
3
1
202976
10-67
HYDRAULIC SYSTEM
A: Assembly standard Unit: mm (in.) Mast Models Items
B45A B55A
[piston] Inside diameter of cylinder tube 1
A
55 (2.165)
60 (2.362)
Diameter of piston rod 2
A
42 (1.653)
50 (1.968)
Holder thread diameter 3
A
M63×2
M70×2
Tightening torque for holder or cylinder head 4 N·m (kgf·m) [lbf·ft]
A
304 ± 70.6 (31 ± 7.2) [224 ± 52]
343 ± 78.5 (35 ± 8.0) [253 ± 57.8]
Tightening torque of piston 5
A
245 ± 44.1 (25 ± 4.5) [180 ± 32.5]
294 ± 52.9 (30 ± 5.4) [217 ± 39]
A
3.92 ± 0.98 (0.4 ± 0.1) [2.9 ± 0.7]
3.92 ± 0.98 (0.4 ± 0.1) [2.9 ± 0.7]
A
19.6 ± 4.9 (2 ± 0.5) [14.4 ± 3.6]
19.6 ± 4.9 (2 ± 0.5) [14.4 ± 3.6]
A
3.92 ± 0.98 (0.4 ± 0.1) [2.9 ± 0.7]
—
N·m (kgf·m) [lbf·ft] Tightening torque of set screw 6 N·m (kgf·m) [lbf·ft] Second lift cylinders (Duplex mast second cylinders)
B40A
Tightening torque of valve 7 N·m (kgf·m) [lbf·ft] Tightening torque of set screw 8 N·m (kgf·m) [lbf·ft]
B45A, B55A
4
3
6
2
1
206948
7 B40A
5
8
206949
10-68
HYDRAULIC SYSTEM
A: Assembly standard Unit: mm (in.) Mast Models
First lift cylinders (Duplex mast, triplex mast first cylinder)
Items
B40A C40A
B45A, B55A C45A, C55A
C70A
[piston] Inside diameter of cylinder tube 1
A
90 (3.54)
110 (4.33)
125 (4.92)
Diameter of piston rod 2
A
65 (2.56)
75 (2.95)
80 (3.15)
Cylinder head thread diameter 3
A
M95×2
M115×2
M130×2
Tightening torque for holder or cylinder head 4 N·m (kgf·m) [lbf·ft]
A
530 ± 122 (54 ± 12.4) [390 ± 89.7]
834 ± 191 (85 ± 19.5) [614.8 ± 141]
1120 ± 275 (123 ± 28) [890 ± 203]
A
3.92 ± 0.78 (0.4 ± 0.08) [28.9 ± 0.57]
3.92 ± 0.78 (0.4 ± 0.08) [28.9 ± 0.57]
3.92 ± 0.78 (0.4 ± 0.08) [28.9 ± 0.57]
Tightening torque of screw 5 N·m (kgf·m) [lbf·ft]
3
5
4
2
1
206950
10-69
HYDRAULIC SYSTEM
A: Assembly standard Unit: mm (in.) Mast Models
C40A
C45A C55A
C70A
A
60 (2.36)
70 (2.76)
80 (3.15)
Diameter of piston rod 2
A
45 (1.77)
50 (1.97)
60 (2.36)
Cylinder head or holder thread diameter 3
A
M64×1.5
M70×2.0
M90×2.0
Width across flat 4
A
—
85 (3.35)
—
Tightening torque for holder or cylinder head 5 N·m (kgf·m) [lbf·ft]
A
304 ± 70.6 (31 ± 7.2) [224 ± 52.0]
422 (43) [311]
490 (50) [362]
Tightening torque of piston 6 N·m (kgf·m) [lbf·ft]
A
—
—
294 (30) [217]
Tightening torque of set screw 7 N·m (kgf·m) [lbf·ft]
A
—
—
6.86 (0.7) [5.06]
Items Inside diameter of cylinder tube 1
Second lift cylinders (Triplex mast)
3
5
C40A
1
2
207778 C45A, C55A
5
3
4
2
1
207779 C70A
5
3
7
2
6
1
207780
10-70
HYDRAULIC SYSTEM
A: Assembly standard Unit: mm (in.) Truck Models Items
GC60K thru GC70K STR
Inside diameter of cylinder tube 1
A
100 (3.937)
110 (4.33)
[Guide bushing] Diameter of piston rod 2
A
40 (1.574)
50 (1.968)
Inside diameter of tilt socket bushing (fitted) 3
A 40
+0.10 +0.05
(1.574
+0.004 +0.002
Inside diameter of cylinder tube head bushing (fitted) 4
A 50
+0.039 +0
(1.968
+0.0015 +0
[Guide bushing] Thread diameter 5
A
M105×2.0
M115×2.0
A
696 ± 69 (71 ± 7) [513 ± 50]
785 +98 +00 (80 +10 +0 ) [578 +72.3 +0 ]
A
M38×1.5
M38×1.5
Tightening torque for tilt socket bolt 7 A N·m (kgf·m) [lbf·ft]
262 ± 13 (27 ± 1.4) [195 ± 10.1]
262 ± 13 (27 ± 1.4) [195 ± 10.1]
Tightening torque of self-locking nut 8 A N·m (kgf·m) [lbf·ft]
588 ± 29 (60 ± 3) [434 ± 21.7]
981 +98 +00 (100 +10 +0 ) [723.3 +72.3 +0 ]
[Guide bushing] Tightening torque 5
N·m (kgf·m) [lbf·ft]
[Tilt socket] Thread diameter 6
Tilt cylinders
GC35K thru GC55K STR
3
6
8
5
2
+0.004 ) 45 +0.10 +0.05 (1.77 +0.002 )
) 50
+0.11 +0
(1.968 +0.043 ) +0
4
1
8
206947
10-71
MAST AND FORKS
Specifications ............................................................................................................................ 11 - 1 Description ................................................................................................................................ 11 - 6 Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... 11 - 6 Triple-stage Full Free Panoramic Mast (Triplex Mast) ...................................................... 11 - 9 Disassembly and Reassembly .................................................................................................... Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... Dual-stage Full Free Panoramic Mast (Duplex Mast) ........................................................ Triple-stage Full Free Panoramic Mast (Triplex Mast) ......................................................
11 - 12 11 - 12 11 - 16 11 - 21
Inspection and Adjustment ........................................................................................................ Forks .................................................................................................................................... Chain, Chain Wheel Support and Chain Wheel.................................................................. Chain Tension Adjustment .................................................................................................. Clearance Adjustment on Lift Bracket ................................................................................ Mast Clearance Adjustment ................................................................................................ Main Roller Shim Replacement (Simplex Mast) ................................................................ Mast Strip Adjustment ........................................................................................................ Tilt Angle Adjustment ........................................................................................................ Lift Cylinder Stroke Adjustment ........................................................................................
11 - 25 11 - 25 11 - 26 11 - 27 11 - 30 11 - 32 11 - 34 11 - 33 11 - 38 11 - 39
Troubleshooting.......................................................................................................................... 11 - 40 Service Data .............................................................................................................................. 11 - 41
11
MAST AND FORKS
Specifications Truck Models Items
GC35K thru GC40K STR
Mast type Outer
118×28×24×13 (4.6×1.1×0.9×0.5)
130×30×26×15 (5.1×1.2×1.0×0.6)
150×34×30×20 (5.9×1.3×1.2×0.8)
Inner
118×24×24×12 (4.6×0.9×0.9×0.47)
130×26×26×13 (5.1×1.0×1.0×0.6)
150×30×30×15 (5.9×1.2×1.2×0.6)
Type
Mast
Ball bearing
Diameter × width mm (in.)
118×32 (4.65×1.26)
Type Side roller
GC60K thru GC70K STR
CJ type
Mast dimension mm (in.) (flange internal width × flange back-side thickness × flange front-side thickness × web thickness) Main roller
GC45K SWB thru GC55K STR
150×36 (5.91×1.42)
Grease needle
Diameter × width mm (in.)
Lift chain type Fork (length × width × thickness) mm (in.) Fork adjustment interval (external width)
130×34 (5.12×1.34)
mm (in.)
52×36 (2.05×1.42)
52×36 (2.05×1.42)
58×40 (2.3×1.6)
BL834
BL1034
BL1034
1220×150×50 (48×6×2)
1220×150×60 (48×6×2.4)
1220×150×65 (48×6×2.56)
1052 (41.4)
1052 (41.4)
1224 (48.2)
11-1
MAST AND FORKS
Description Simplex Mast (A40A, A45A, A55A, A70A) 9 5 •
4
• 14 1 2 6
10 13
•
3
7
12 12
11
207795
11 10
9
8 D D
Section A-A
Section B-B
Section C-C
Section D-D 206696
1 2 3 4 5
Outer mast Inner mast Lift bracket Lift cylinder Lift chain
6 7 8 9 10
Backrest Fork Mast strip Main roller (mast upper) Main roller (lift bracket upper) 11-2
11 12 13 14
Main roller (inner mast lower) Main roller (lift bracket lower) Side roller Chain wheel
MAST AND FORKS
Duplex Mast (B40A, B45A, B55A)
C
C 5
2
1 6
4 7
B
A
3
B
8
A
207794
15
16
Section A-A
13 11
14
Section B-B
12
10
Section C-C 9 3
1 2 3 4 5 6
Outer mast Inner mast Lift bracket First lift cylinder Second lift cylinder Lift chain
7 8 9 10 11 12
Backrest Fork Side roller bracket Side roller Mast strip Main roller (lift bracket upper) 11-3
Side roller detail 206973
13 14 15 16
Main roller (outer mast upper) Main roller (lift bracket middle) Main roller (lift bracket lower) Main roller (outer mast lower)
MAST AND FORKS
Triplex Mast (C40A, C45A, C55A, C70A)
C
C
6 3 2 1
7
8 5 B
4
B
9 A
A
207791
13
12
16
11 17
18
19
Section A-A
1 2 3 4 5 6
Outer mast Middle mast Inner mast Lift bracket First lift cylinder Second lift cylinder
14 Section B-B
7 8 9 10 11 12
15
10 4
Section C-C
Lift chain Backrest Fork Side roller bracket Side roller Mast strip 11-4
207792
13 14 15 16 17 18 19
Main roller (lift bracket upper) Main roller (outer mast upper) Main roller (middle mast upper) Main roller (lift bracket middle) Main roller (lift bracket lower) Main roller (middle mast lower) Main roller (outer mast lower)
MAST AND FORKS
Operation of Dual-stage Full Free Panoramic Mast (Duplex Mast)
Inner mast First lift cylinder Second lift cylinder
Free-lift height
Forks on the ground
Outer mast
Maximum free lift
Maximum lift
203598
Operation of Triple-stage Full Free Panoramic Mast (Triplex Mast)
First lift chain Inner mast First lift cylinder Middle mast Second lift chain
Second lift cylinder Outer mast
Free-lift height Forks on the ground
Maximum free lift
11-5
Maximum lift
203600
MAST AND FORKS
Removal and Installation Mast and Lift Bracket Assembly Dual-stage Panoramic Mast (Simplex Mast)
2 3
4
5 7
6
1
206697A
Sequence 1 Nuts 2 Forks, Lift bracket 3 Tilt socket pins
4 5 6 7
Low-pressure hose High-pressure hose for lift cylinders Mast-support bearing cap Mast-support bushing
Suggestions 1. Lift bracket removal (1) Tilt the mast forward, and lower the inner mast to the bottom. Slacken the lift chains, and remove the nuts from the anchor bolts. (2) Tilt the mast back to vertical position. Raise the inner mast until the lift bracket becomes free. Then, back the truck away, from the lift bracket and fork assembly.
207084
11-6
MAST AND FORKS
2. Removing lift cylinder high pressure hoses Place the mast in the bottom position, disconnect the hoses at the flow regulator valve. 3. Removing tilt cylinders (1) Hitch a sling to the upper cross-member of the outer and inner masts, then lift with a crane. CAUTION Be sure to use a hoist having a capacity enough to support the mast assembly.
206939
(2) Remove the tilt socket pins, and separate the masts from the tilt cylinders. (3) Start the engine, and pull back the tilt lever to retract the tilt cylinder rods. (4) Disconnect the high-pressure hose for lift cylinders.
206940
4. Removing mast support bearing caps (1) Mark the bearing caps to ensure the correct reassembling before removing them. (2) Remove the cap bolts and lift off the mast assembly. Lay it down flat on a level floor. NOTE Lay the mast assembly on a floor large enough to disassemble the parts. 206941
11-7
MAST AND FORKS
Installation To install, follow the removal sequence in reverse, and service as follows.
6 7
1. Procedure for mounting mast support bushings 7 and caps 6. (1) Apply grease to the inner surfaces of caps and mast support bushings. (2) Install mast support bushings 7 and caps 6, making sure that the sides with larger chamfered area face toward the center of the vehicle. (3) Be sure to tighten the support tightening bolts securely. Model
Apply grease Chamfered faces 203712
A40A thru A70A
Item Bolt tightening torque N·m (kgf·m) [lbf·ft]
290 (29.6) [214]
2. Adjust the chain tensions. (Refer to the Inspection and Adjustment section.) Tighten the nuts to the specified torque.
Anchor bolt
➁ Upper nut
Tightening torque Unit: N·m (kgf·m) [lbf·ft] Model Item
A40A
➂ Double nut (upper)
A45A, A55A, A70A
➀ Double nut (lower)
Upper nut ➁ Double nut (lower) ➀
102709
210 (21.4) [155] 290 (29.6) [214]
3. Air bleeding of lift cylinders Start the engine. Raise and lower the lift bracket with full stroke several times to bleed the cylinder. 4. After proper operation is confirmed, check the oil level.
11-8
MAST AND FORKS
Removal and Installation Mast and lift bracket assembly The following describes the procedures for removing and reinstalling the mast assembly. Note that the triple-stage full free panoramic mast (Triplex Mast) is used as an example. Dual-stage Full Free Panoramic Mast and Triple-stage Full Free Panoramic Mast (Duplex and Triplex Mast)
3
4 1 7
5
6
2
207800
Sequence 1 Nut 2 Fork, Lift bracket assembly 3 Tilt socket pin, Collar, Washer, Bolt
4 5 6 7
Low-pressure hose High-pressure hose for lift cylinders Mast support cap Mast support bushing
Suggestions 1. Removing lift bracket assembly 2 (1) Lower lift bracket assembly 2, and place wood blocks under the assembly. Tilt the mast forward, lower the inner mast to the bottom, then remove nuts 1 from the anchor bolts of the first lift chains.
1
207786
11-9
MAST AND FORKS
(2) Position the mast upright. Raise the inner mast until main rollers 8 of the lift bracket become free. Then, slowly move the vehicle in reverse to separate from lift bracket 2. 8 2
201735
2. Separating mast and tilt cylinders (1) Lower the inner mast. Hitch a sling to the upper cross-member of the outer, middle and inner masts, then lift with a crane. CAUTION Be sure to use a hoist having a capacity enough to support the mast assembly. 207796
(2) Place wood blocks under the tilt cylinder mounting sections, and remove pins 3. Start the engine, and pull back the tilt lever to retract the tilt cylinder rods. (3) Disconnect high-pressure hose 5 for lift cylinders.
Tilt socket pin 207798
3. Removing mast support caps 6 (1) Mark caps 6 to ensure the caps are reinstalled in original positions during reassembly. (2) Remove cap mounting bolts. Dismount the mast assembly from vehicle in the suspended condition. With the lift bracket side facing up, place the mast assembly horizontally on wooden blocks on the level ground. 6
207799
11-10
MAST AND FORKS
Installation
6 7
To install, follow the removal sequence in reverse, and service as follows. 1. Procedure for installing mast support bushings 7 and caps 6 (1) Apply grease to the inner surfaces of caps and mast support bushings. (2) Install mast support bushings 7 and caps 6, making sure that the sides with larger chamfered area face toward the center of the vehicle. (3) Be sure to tighten the support tightening bolts securely.
Item
Model B40A thru B55A C40A thru C55A
Apply grease Chamfered faces 203712
C70A
Bolt tightening torque N·m 290 (29.6) [214] 490 (49.7) [359] (kgf·m) [lbf·ft]
2. Adjust the chain tensions. (Refer to the Inspection and Adjustment section.) Tighten the nuts to the specified torque.
Anchor bolt
➁ Upper nut
Tightening torque Unit: N·m (kgf·m) [lbf·ft] Model Items
B40A C40A
B45A thru B55A C45A thru C70A
Upper nut ➁ Double nut (lower) ➀
210 (21.4) [155] 290 (29.6) [214]
3. Bleeding lift cylinders In the dual-stage full free panoramic mast, only the second lift cylinders are provided with air bleeding valves. The first lift cylinder does not require air bleeding since it is an internal drain type cylinder. In the triple-stage full free panoramic mast, start the engine, raise and lower the lift bracket with several strokes to bleed the cylinder. 4. After proper operation is confirmed, check the oil level 11-11
➂ Double nut (upper) ➀ Double nut (lower) 102709
MAST AND FORKS
Disassembly and Reassembly Dual-stage Panoramic Mast (Simplex Mast) Disassembly 12
15
3
10
11
16 9
10
13
2 8
17
5 2
16
7
6 14
1 4
206942A
Sequence 1 2 3 4 5 6 7
Nuts Forks, Lift bracket Backrest Main roller, Shims Main roller, Snap ring Side roller, Brackets, Shims Lift hose (high pressure), Rubber hose, T-joint, Down safety valve 8 Hose (low pressure) 9 Snap ring, Chain wheel Suggestions 1. Removing mast strips and main rollers Remove bolts 10, 11 to free lift cylinder 16. Displace the tops of the two lift cylinders from inner mast 15. Slide inner mast 15 toward the bottom of outer mast 17, and remove main rollers 13, 14 and mast strips 12. 11-12
10 Cylinder clamps, Seats, Shims, Cushion, Collar, Bolts 11 Bolt, Shims 12 Mast strip, Shims 13 Main roller, Shims 14 Main roller, Shims 15 Inner mast 16 Lift cylinders 17 Outer mast
MAST AND FORKS
2. Inner mast removal After removing the main rollers, hitch a sling to the inner mast crossmember and slide the inner mast to the upper side of the outer mast to clear the outer mast roller shafts. Hitch a sling to the inner mast again and remove it from the outer mast.
207801
Inspection after disassembly 1. Mast (1) Check each roller for wear, binding or other defects. (2) Check each roller on rolling surface for pitting or other defects. (3) Check the mast member and the welded joints of cross members, shafts and supports for cracks. (4) Check the mast support bushings for wear or other defects.
207802
2. Lift bracket (1) Check the main rollers and side rollers for smooth rotation. Inspect each roller for wear and cracks. (2) Check the welded portions of the bracket for cracks. (3) Check the finger bar for bend or distortion. A: Assembly standard Distortion of finger bar
A
5 mm (0.2 in.) maximum
11-13
207091
MAST AND FORKS
3. Lift chains, chain wheels and chain wheel supports (1) Measure the length of each chain to make sure that two chains are equal in length. Also check the chains for wear, indication of breakage, link binding and twist. (2) Check each chain anchor bolt for cracks or defects on thread. (3) Check each chain wheel support and chain wheel for crack or wear. Check that the wheels rotate smoothly. Length of lift chain (per 20 links) A: Assembly standard B: Repair or service limit
Unit: mm (in.)
A40A
A45A A55A
A70A
A
508 (20)
635 (25)
635 (25)
B
523 (20.6)
654 (25.7)
654 (25.7)
4. Mast strips Check the mast strips for damage, wear or distortion. Reassembly To reassemble, follow the reverse of disassembly procedure, and service as follows: 1. Longitudinal clearance adjustment between mast and lift bracket Rollers for mast and lift bracket are available in four sizes (diameters) for selective use. Select the size that will provide a longitudinal clearance of 1 mm (0.04 in.) or less.
Clearance
Clearance
Roller sizes Unit: mm (in.) Diam of main roller
A40A
A45A A55A
A70A
S
117 (4.6)
129 (5.08)
149 (5.86)
M
118 (4.65)
130 (5.12)
150 (5.91)
L
119 (4.68)
131 (5.16)
151 (5.94)
LL
120 (4.72)
132 (5.19)
152 (5.98)
Lower roller
11-14
Upper/middle roller 207806
MAST AND FORKS
2. Cylinder clamps Install each lift cylinder in place (in vertical position) by fitting to the support, and see if there is any clearance between the outer mast and cylinder. Reduce the clearance, if any, to zero by shimming. Shims
207003
3. Mast supports (1) Apply grease to the inside surfaces and grooves of the caps. (2) Install mast support bushings and caps placing the chamfered faces inward.
Mast cap Bushing
Apply grease Chamfered faces 203712
4. Precautions for installing chain anchor kit Be careful not to install the center plate in the position for link plate. (For C40A only)
2
3
1 Stamped mark 4
1 2 3 4
11-15
Link plate (mark is stamped) Center plate (no mark) Link Split pin
207808
MAST AND FORKS
Dual-stage Full Free Panoramic Mast (Duplex Mast) Disassembly
14 15
13
11
12
18 2 2
16
5
9
6 7
11 19
11
10
22
3 3 7
18 22
4
16
1 17
9 21 20
14
8
18
13
207807
Sequence 1 Hose clamp, Bolt, Washer 2 High-pressure hose (First lift cylinder) 3 Bolt, Washer, Shims 4 First lift cylinder 5 Chain guard, Bolt 6 Chain wheel, Snap ring 7 Chain wheel support, Bolt, Washer 8 Down safety valve, O-ring 9 High-pressure hose (Second lift cylinder), Connector 10 Cushion, Collar, Shim, Bolt, Washer, Clamp 11 Bolt, Washer, Shims NOTE The lift bracket disassembly procedure is the same as the dual-stage panoramic mast. 11-16
12 13 14 15 16 17 18 19 20 21 22
Mast strip, Shims Stopper, Shim, Bolt, Washer Main roller, Shims Inner mast Second lift cylinder Down safety valve, O-ring Elbows, O-rings Cylinder bracket Mast cap, Bolt, Washer Bushing Outer mast, Grease nipple
MAST AND FORKS
Preparation With the lift bracket facing up, place the mast horizontally on wood blocks. Place a wood block as a wedge to prevent the inner and middle masts from sliding.
4
Suggestions 1. Removing first lift cylinder 4 (1) Remove retaining bolts 3 from the first lift cylinder. (2) Hitch slings on first lift cylinder 4, and gently remove the cylinder. Use two slings. Wind or tie slings securely to prevent slipping.
2. Removing main rollers 14 and mast strips 12 (1) Remove clamp bolts from the second lift cylinders. (2) Remove bolts from the upper rod sections of the second lift cylinders, and place the cylinders on the outer mast. (3) Check the number of shims and the shim thickness at the rod end sections. (4) Move the inner mast down, then remove main rollers 14, mast strips and shims 12.
3 207006
12
14
14
3. Removing inner mast 15 Using ropes, lift and remove inner mast 15, steering it clear of the roller shaft sections of outer mast 22.
207007
Inspection after disassembly Follow the same inspection procedure as for the dual-stage panoramic mast.
22
15 207008
11-17
MAST AND FORKS
Reassembly Follow the disassembly sequence in reverse. Be careful with the following key point. 1. Front-to-back clearance between the mast and lift bracket Select and install roller so that the clearance is 1 mm (0.04 in.) or less. Roller size Unit: mm (in.) B40A
B45A B55A
S
117 (4.60)
129 (5.08)
M
118 (4.64)
130 (5.12)
L
119 (4.68)
131 (5.16)
LL
120 (4.72)
132 (5.19)
Mast Models
Items
Inner mast
Outer mast •
Lift Bracket •
207080
2. Left-to-right clearance of the inner mast (1) Raise the inner mast to the maximum lift position. Press one side of the inner mast against the outer mast and measure the clearance between the main roller and the outer mast on the other side. The clearance is adequate if the measurement is in the specified range.
Inner mast •
Shims b
•
A: Assembly standard Left-to-right clearance between A outer mast and inner mast mm (in.)
•
Outer mast
Shims a 206688
0.1 to 0.5 (0.004 to 0.020)
(2) If the clearance is out of the specified range, adjust the clearance by increasing and decreasing shim thicknesses a and b. For example, to shift the clearance of 0.5 mm (0.020 in.) outward, insert inner shims a by 0.5 mm (0.020 in.), and remove outer shims b by 0.5 mm (0.020 in.) and tighten bolts.
Shims a Shims b
206686
11-18
MAST AND FORKS
3. Mast strip At the highest raising position, adjust the clearance between the outer mast roller and the rolling surface of inner mast to the specified range with increasing and decreasing shims.
Shims
A: Assembly standard A
mm (in.)
0.1 to 0.5 (0.004 to 0.020)
207004
4. Clearance of lift bracket (1) Measure the front-to-back clearance of the lift bracket main roller. The clearance is adequate if the measurement is in the specified range. A: Assembly standard Front-to-back clearance when in A the entire lifting range mm (in.)
0.1 to 1.0 (0.004 to 0.04)
If the clearance is not adequate, replace the main roller with an oversize main roller. (2) Left-to-right clearance of lift bracket Raise the lift bracket to the maximum lift position. Tilt the lift bracket in the inner mast and measure the clearance between the main roller and side roller. The clearance is adequate if the measurement is in the standard range.
Inner mast
Lift bracket • •
A: Assembly standard Left-to-right clearance at the A highest raising height mm (in.)
0.1 to 0.5 (0.004 to 0.020)
206687A
(3) If the left-to-right clearance is not adequate, adjust the clearance by increasing shim thickness at the side roller.
Shims Roller
Bracket 206689
11-19
MAST AND FORKS
(4) If the left-to-right clearance of the main roller is not adequate, adjust the clearance by increasing and decreasing shims a and b, following the adjustment procedure for main roller clearance between outer mast and inner mast. NOTE Use the main roller at the upper end of the lift bracket to ensure the front-to-back clearance. Use side rollers to ensure the left-to-right clearance. 5. Installing lift cylinder To prevent bend force on the lift cylinder, install lift cylinder vertically to the mast when the mast is at the lowest position If any defect is found, adjust with shims.
Shims
207003
6. Cautions for assembling chain anchor kit Never assemble the center plate to the assembling position of link plate. (1) Link plate (with stamp on surface) (2) Center plate (no stamp on surface) (3) Link (4) Split pin
(2)
(3)
(1)
(4)
Stamp
7. Installing first lift cylinder Install the first lift cylinder of duplex mast so that the lift cylinder is vertical to the mast when the lift cylinder rod is at the lowest position. Make sure that the cylinder does not tilt forward but tilts backward at fitting B against A by 0 to 0.5 mm (0 to 0.02 in.). Use shims for adjustment.
20 mm (0.79 in.)
200383
Shims
B
A
11-20
201752
MAST AND FORKS
Triple-stage Full Free Panoramic Mast (Triplex Mast) Disassembly
18 17 11 24
1
9
1
27 29
27 25
23
12
1
12 26 21
7 14
8 6
28 8 2
20 19
22
28
7
31
16
21
19
13
5 4
19
10
3
13
15
30
207810
Sequence 1 Hose for first lift cylinder, Clamp, Bolt, Washer 2 Bolt, Washer 3 Shims 4 First lift cylinder 5 Stopper bolt, Washer 6 Chain wheel support 7 Chain guard, Plug 8 Snap ring, Chain wheel 9 Pulley bracket, Pulley, Bar, Bolt 10 Nut (chain for second lift cylinder) 11 Mast strip, Shims 12 Main roller, Shims 13 Main roller, Shims 14 Inner mast 15 Nuts 11-21
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Lift chain (for second lift cylinder) Chain guard, Bolt Snap ring, Chain wheel Hose, Band Joint, Connector, Bolt, Washer Hose, Clamp Bolt, Seat, Cushion, Collar Cushion, Shims, Bracket Bolt, Washer, Shims Second lift cylinder Mast strip, Shims Main roller, Shims Main roller, Shims Middle mast Cap, Bolt, Washer Outer mast, Grease nipple
MAST AND FORKS
NOTE The lift bracket disassembly procedure is the same as for the dual-stage full free panoramic mast. Preparation With the lift bracket facing up, place the mast horizontally on wood blocks. Place a wood block as a wedge to prevent the inner and middle masts from sliding. Suggestions 1. Removing first lift cylinder 4 (1) Remove retaining bolts from the first lift cylinder. (2) Hitch slings on lift cylinder 4, and gently remove the cylinder. Use two slings. Wind or tie slings securely to prevent slipping.
4
207811
2. Removing inner mast and main rollers Lower inner mast 14 until the main rollers can be removed. Remove main rollers 12, 13 and mast strips 11.
14 13 11
12
207812
3. Removing inner mast Using slings, lift and remove the inner mast, steering it clear of the roller shaft sections of the middle mast.
14
11-22
207813
MAST AND FORKS
4. Removing main rollers 26, 27 from middle mast 28 and outer mast 30 Remove the bolts that are holding second lift cylinders 24. Place the cylinder rod ends on the outer mast. Lower middle mast 28 until main rollers 26, 27 can be removed. Then, remove the main rollers.
28 27 24
30 207814
26
Inspection after disassembly Follow the same inspection procedure as for the dual-stage full free panoramic mast. Reassembly To reinstall, follow the removal sequence in reverse, and service as follows. 1. Front-to-back clearance between the mast and lift bracket Select and install roller so that the clearance is 1 mm (0.04 in.) or less. Roller size Unit: mm (in.) C40A
C45A C55A
C70A
S
117 (4.60)
129 (5.08)
149 (5.87)
M
118 (4.64)
130 (5.12)
150 (5.90)
L
119 (4.68)
131 (5.16)
151 (5.94)
LL
120 (4.72)
132 (5.19)
152 (5.98)
Mast Models
Items
11-23
Inner mast
Middle mast
Lift bracket
Outer mast
207815
MAST AND FORKS
2. Left-to-right clearance of the inner mast (1) Raise the inner mast to the maximum lift position. Press one side of the inner mast against the outer mast and measure the clearance between the main roller and the outer mast on the other side. The clearance is adequate if the measurement is in the specified range.
Inner mast Shims b
Shims a
A: Assembly standard Left-to-right clearance between A outer mast and inner mast mm (in.)
Middle mast
0.1 to 0.5 (0.004 to 0.020)
Outer mast 207816
(2) If the clearance is out of the specified range, adjust the clearance by increasing and decreasing shim thicknesses a and b. For example, to shift the clearance of 0.5 mm (0.020 in.) outward, insert inner shims a by 0.5 mm (0.020 in.), and remove outer shims b by 0.5 mm (0.020 in.) and tighten bolts. For the items below follow the same reassembly procedures as for the dual-stage full free panoramic mast. 3. Mast strip 4. Clearance of lift bracket 5. Installing lift cylinder 6. Cautions for assembling chain anchor kit 7. Installing first lift cylinder
11-24
Shims a Shims b
207817
MAST AND FORKS
Inspection and Adjustment Forks 1. Carefully inspect the forks for cracks. Special attention should be given to the heel section A, all weld areas and mounting brackets B. Forks with cracks should be removed from service. Magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results.
B A
101628
2. Check the difference in height of one fork tip to the other when mounted on the fork carrier. A difference in fork tip height can result in uneven support of the load and cause problems when loaded. The maximum allowable difference in fork tip elevation C is 5 mm (0.20 in.) for pallet forks. Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference. 3. Check the fork blade D. The fork should be withdrawn from service if the thickness is reduced to less than the allowable thickness. Fork blade length may also be reduced by wear, especially on tapered forks and platens. Withdraw the forks from service when the blade length is no longer adequate for the load size.
C
101629
D
A: Assembly standard B: Repair or Service limit Truck Models Item Fork thickness mm (in)
GC35K GC45K GC60K thru thru thru GC45K SWB GC55K STR GC70K STR
A
50 (2)
60 (2.4)
65 (2.56)
B
45 (1.77)
51 (2.00)
58 (2.28)
11-25
101630
MAST AND FORKS
Chain, Chain Wheel Support and Chain Wheel (1) Check the right and left chains for uneven length, wear, adhesion or torsion. Lift the forks high enough to put their full weight on the carriage and chains. Check to be sure the lift chains have equal tension. (2) Check the chain anchor bolt for cracks or damaged thread. (3) Check the chain wheel support and the chain wheel for cracks, wear or adhesion. NOTE To lubricate lift chains, molybdenum disulfide oil (spray type) is recommended since it is easy to use and provides long lubrication.
A: Assembly standard B: Repair or service limit Mast model
A40A B40A
A55A B55A A70A
A
508 (20)
635 (25)
B
523 (20.6)
654 (25.7)
Item Chain extension mm (in.) /20 links
11-26
20 links
201768
MAST AND FORKS
Tightening Torque
Chain Tension Adjustment
Unit: N·m (kgf·m) [lbf·ft]
Dual-stage panoramic mast (Simplex Mast) Items
! WARNING
Turn the engine/main key to the O (OFF) position before making the inspection or adjustment of lift chains, anchor bolts and nuts. Place blocks below the forks when they are lifted. 1. Inspection of chain tension (1) Place the mast vertical on a level ground, then lower the forks to the ground. Check that the lift cylinders are fully retracted. (2) Raise the forks approx. 100 mm (4.0 in.) from the ground. (3) Turn the key to the O (OFF) position. (4) Place blocks approx. 90 mm (3.5 in.) high below the forks. (5) Push the chains at the middle point between the chain wheel and chains fixed end on the lift bracket. Check the right and left chains for even tightness. 2. Adjustment of right and left chain balance (1) Remove the blocks below the forks. Turn the key to I (ON) position. (2) Lower the forks to the ground and tilt forward until the tips come in contact with the ground. The chains are now slack to facilitate the adjustment. (3) Turn the key to the O (OFF) position. (4) Loosen double nut (lower) ➀, then upper nut ➁. (5) Turn double nut (upper) ➂ to adjust the chain tension. (6) Turn the key to the I (ON) position, and place the mast vertical again. (7) Repeat (2) through (5) of procedure 1. to check the chain tension. 3. Tightening of nuts after adjustment (1) Hold the anchor bolt at two flats with a wrench so as not to twist the chain, then tighten the upper nut ➁ to the specified torque. (2) Hold the double nut (upper) ➂ with a wrench and tighten double nut (lower) ➀ to the specified torque.
11-27
Models
A40A
A45A thru A70A
Upper nut ➁ 210 (21.4) [155] 290 (29.6) [21.4] Double nut (lower) ➀
Anchor bolt
➁ Upper nut
➂ Double nut (upper) ➀ Double nut (lower) 102709
102708
MAST AND FORKS
Dual-stage Full Free Panoramic mast (Duplex Mast) ! WARNING
Turn the engine/main key to the O (OFF) position before making the inspection or adjustment of lift chains, anchor bolts and nuts. Place blocks below the forks when they are lifted. 1. Inspection of chain tension (1) Place the mast vertical on a level ground, then lower the forks to the ground. Check that the lift cylinders are fully retracted. (2) Raise the forks approx. 100 mm (4.0 in.) from the ground. (3) Turn the key to the O (OFF) position. (4) Place blocks approx. 90 mm (3.5 in.) high below the forks. (5) Push the chains at the middle point between the chain wheel and chains fixed end on the lift bracket. Check the right and left chains for even tightness. 2. Adjustment of right and left chain balance (1) Remove the blocks below the forks. Turn the key to I (ON) position. (2) Lower the forks to the ground and tilt forward until the tips come in contact with the ground. The chains are now slack to facilitate the adjustment. (3) Turn the key to the O (OFF) position. (4) Fix anchor bolts on the lift bracket. (5) Turn double nut (upper) ➂ on the lift cylinder to adjust the chain tension. (6) Turn the key to the I (ON) position, and place the mast vertical again. (7) Repeat (2) through (5) of procedure 1. to check the chain tension. 3. Tightening of nuts after adjustment (1) Hold the anchor bolt at two flats with a wrench so as not to twist the chain, then tighten upper nut ➁ to the specified torque. (2) Hold double nut (upper) ➂ with a wrench and tighten double nut (lower) ➀ to the specified torque. 4. When the lift cylinders are fully extended or retracted, check the protrusion of each lift bracket main roller to be 40 % of the roller diameter or less. 11-28
207633
102708
40 % or less 207818
MAST AND FORKS
Triple-stage Full Free Panoramic mast (Triplex Mast) ! WARNING
Turn the engine/main key to the O (OFF) position before making the inspection or adjustment of lift chains, anchor bolts and nuts. Place blocks below the forks when they are lifted. 1. Inspection of chain tension (1) Place the mast vertical on a level ground, then lower the forks to the ground. Check that the lift cylinders are fully retracted. (2) Raise the forks approx. 100 mm (4.0 in.) from the ground. (3) Turn the key to the O (OFF) position. (4) Place blocks approx. 90 mm (3.5 in.) high below the forks. (5) Push the chains at the middle point between the chain wheel and chain fixed end on the lift bracket. Check the right and left chains for even tightness. Adjust the primary and secondary chains (four chains). 2. Adjustment of right and left chain balance (1) Remove the blocks below the forks. Turn the key to I (ON) position. (2) Lower the forks to the ground and tilt forward until the tips come in contact with the ground. The chains are now slack to facilitate the adjustment. (3) Turn the key to the O (OFF) position. (4) Fix anchor bolts on the lift bracket (primary chains) and under the inner masts (secondary chains). (5) Turn double nut (upper) ➂ on the lift cylinder to adjust the chain tension. When the secondary chains are replaced, adjust their tension relatively tight to reduce the risk of interference with the piping pulleys. (6) Turn the key to the I (ON) position, and place the mast vertical again. (7) Repeat (2) through (5) the procedure 1. to check the chain tension. 3. Tightening of nuts after the adjustment (1) Hold the anchor bolt at two flats with a wrench so as not to twist the chain, then tighten upper nut ➁ to the specified torque. (2) Hold double nut (upper) ➂ with a wrench and tighten double nut (lower) ➀ to the specified torque. 4. When the lift cylinders are fully extended or retracted, check the protrusion of each lift bracket main roller to be 40 % of the roller diameter or less.
11-29
207635
102708
40% or less 207634
MAST AND FORKS
Clearance Adjustment on Lift Bracket NOTE The adjustment procedure for the lift bracket is the same for the Simplex Mast, Duplex Mast and Triplex Mast. 1. Front-to-back clearance adjustment on lift bracket main rollers (1) Raise the forks a little from the floor. (2) Insert a bar between the upper part of lift bracket and the inner mast, and push the inner mast to one side. Using feeler gauges, measure the clearance F between the main roller and inner mast on the opposite side.
F
0.1 to 1.0 mm (0.004 to 0.039 in.)
Clearance F
F
(3) If the clearance F is out of specification, use oversize rollers. Roller sizes
207095
F
Unit: mm (in.) Diam. of main roller S M L LL
40A 117 (4.60) 118 (4.64) 119 (4.68) 120 (4.72)
45A 55A 129 (5.08) 130 (5.12) 131 (5.16) 132 (5.19)
70A 149 (5.87) 150 (5.90) 151 (5.94) 152 (5.98)
(4) Lift bracket main rollers (upper and center rollers) The upper rollers should be the same in size or 1-rank larger than the center rollers. 2. Side-to-side clearance adjustment on lift bracket main rollers and side rollers (1) Raise the mast to the top. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go over to the opposite side of the mast, and push the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a bar between the inner mast and lift bracket on the indicator side, and push the lift bracket to the opposite side. (5) Read the indicator. Clearance G1
0.1 to 0.5 mm (0.004 to 0.020 in.)
(6) Adjust clearance G1 between the center main roller and weld plate ➁ at the maximum lift position by increasing or decreasing the thickness of the shim. Do not install a shim at upper main roller ➀. 11-30
F
Middle/lower roller
Upper roller 207806
203818
➀
➀
G1
➁
➁
207821
MAST AND FORKS
For the lift bracket center main roller, to extend 0.5 mm (0.02 in.) , insert a 0.5 mm (0.02 in.) shim (a) on the inside and remove the 0.5 mm (0.02 in.) shim (b) from the lower stopper, then tighten the bolts.
Inner mast
Shims (b)
> > Shims (a) 207156
(7) Lower the lift bracket slightly from the top, then adjust clearance G2 between the side roller and mast by increasing or decreasing the thickness of the shims.
Side roller G2
•
•
206687A
Adjust the side roller clearance by adding shims between the roller bracket and lift bracket. Shims Roller
Bracket 206689
(8) With the lift bracket at the top, adjust clearance G3 with shims. NOTE The lower main rollers are the same to the center main rollers in construction.
G3 207822
11-31
MAST AND FORKS
Mast Clearance Adjustment NOTE Adjust mast clearances at the locations indicated below. 1. Simplex Mast and Duplex Mast: Main rollers between the outer mast and inner mast 2. Triplex Mast: Main rollers between the outer mast and middle mast, and main rollers between the middle mast and inner mast. 1. Front-to-back clearance adjustment on mast main rollers (1) Tilt the mast fully backward. (2) Using feeler gauges, measure the clearance H between the inner mast lower roller and outer mast.
Inner mast
Lift bracket
0.1 to 1.0 mm (0.004 to 0.039 in.)
Clearance H
Outer mast
H
(3) If the clearance H is out of the specification, use oversize rollers.
207099
Roller sizes Unit: mm (in.) Diam. of main roller S M L LL
40A 117 (4.60) 118 (4.64) 119 (4.68) 120 (4.72)
45A 55A 129 (5.08) 130 (5.12) 131 (5.16) 132 (5.19)
70A 149 (5.87) 150 (5.90) 151 (5.94) 152 (5.98)
2. Side-to-side clearance adjustment on inner mast main rollers (1) Raise the mast to the top. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast. (3) Go over to the opposite side of the mast, and push the inner mast against the outer mast. Set the indicator to zero. J
11-32
204886
MAST AND FORKS
(4) Insert a bar between the outer and inner masts on the indicator side, and push the inner mast to the opposite side. (5) Read the indicator. Clearance J
J Inner mast Shims b
0.1 to 0.5 mm (0.004 to 0.020 in.)
Outer mast
Shims A J 206688
(6) If the clearance J is out of specification, adjust by shims.
Shims a Shims b
NOTE Refer to Main Roller Shim Replacement.
206686
3. Side-to-sidel clearance adjustment on outer mast main rollers (1) Raise the mast to the top. (2) Set a dial indicator on the outer mast with its contact point rested on the inner mast. (3) Go over to the opposite side of the mast, and push the outer mast against the inner mast with a bar. Set the indicator to zero. (4) Insert a bar between the outer and inner mast, and push the inner mast to the opposite side. (5) Read the indicator. Clearance K
0.1 to 0.5 mm (0.004 to 0.020 in.)
K
204889
K
207103
11-33
MAST AND FORKS
(6) If the clearance K is out of specification, adjust it by shims.
Shims a Shims b
NOTE Refer to Main Roller Shim Replacement.
207823
Main Roller Shim Replacement (Simplex Mast) 1. Remove the lift bracket from the mast. NOTE Refer to REMOVAL AND INSTALLATION, 1. Lift bracket removal. 2. Lower the inner mast below the outer mast as follows: (1) Raise the front end of the truck, and support that end with block or the like. (2) Remove the upper set bolts from the lift cylinders, and lift the inner mast with a hoist. Remove the hose guard. (3) Remove the clamps from the lift cylinders. Pull the bottom ends of the cylinders from the outer mast, tilt the cylinders to the center of the mast, and tie them to the crossmember of outer mast with rope. (4) Slowly lower the inner mast until it comes in contact with the lift cylinders. (5) Now the main rollers can be removed from the inner and outer masts. Remove the mast strips and shims in advance because they are apt to come off under this condition.
11-34
202961
MAST AND FORKS
Procedure for replacing main roller shims [Dual-stage full free panoramic mast (Duplex Mast)] 1. Separate the lift bracket from the mast. NOTE Refer to "Separating lift bracket" in the Hydraulic System section. 2. Removing first lift cylinder (1) Hitch a sling on the first lift cylinder, and suspend it with a crane. Wind the rope securely to prevent slipping. (2) Remove lift cylinder connecting bolts and mounting bolts, and gently remove the first lift cylinder. NOTE Subsequent removal procedure is the same as the removal procedure for the Simplex Mast (see "Procedure for replacing main roller shims"). 207824
3. Position the inner mast lower than the outer mast by following operations. (1) Lift the front side of the vehicle with a rigid rack or other equipment. (2) Remove set bolts from the upper sections of the lift cylinders, then lift the inner mast. (3) Remove two lift cylinder clamps, dismount the cylinders from the mounting sections at the lower outer mast section. Tilt the cylinders by moving the top sections towards the center of the vehicle, then secure the cylinders to the cross-member of the outer mast with a rope. (4) Lower the inner mast until it contacts the lift cylinders. (5) In this condition, main rollers can be removed from the inner mast and outer mast. Since the mast strips and shims can fall off, remove these parts first.
11-35
202961
MAST AND FORKS
Procedure for replacing main roller shims [Triple-stage full free panoramic mast (Triplex Mast)] 1. Separate the lift bracket from the mast. NOTE Refer to "Separating lift bracket" section in the Hydraulic System section. 2. Removing first lift cylinder (1) Hitch a sling on the first lift cylinder, and suspend it with a crane. Wind the rope securely to prevent slipping. (2) Remove lift cylinder connecting bolts and mounting bolts, and gently remove the first lift cylinder.
First lift cylinder
3. Position the inner mast lower than the middle mast by following operations. (1) Lift the front side of the vehicle with a rigid rack or other equipment. (2) Hitch slings to the upper cross-member of the inner mast, and suspend with a crane. (3) Remove the chain guards for the second lift chain wheels. (4) Dismount the second lift chains on the outer mast side, and place them in front of the inner mast. (5) Lower the inner mast until main rollers can be removed. (6) Place wood blocks under the inner mast for support. (7) In this condition, main rollers can be removed from the inner mast and outer mast. Since the mast strips and shims can fall off, remove these parts first. NOTE In this condition, second lift cylinders cannot be rermoved. 11-36
207787
207826
MAST AND FORKS
4. Position the middle mast lower than the outer mast by following operations. (1) Lift the inner mast to the height of the middle mast, then place wood blocks for support. (2) Hitch slings to both middle mast and inner mast, and suspend with a crane. (3) Remove set bolts from the upper sections of the middle mast lift cylinders, then lift the middle mast and inner mast. (4) Remove two lift cylinder clamps, dismount the cylinders from the mounting sections at the lower outer mast section. Tilt the cylinders by moving the top sections towards the center of the vehicle, then secure the cylinders to the cross-member of the outer mast with a rope. (5) Lower the middle mast and inner mast until main rollers can be removed. (6) Place wood blocks under the middle mast and inner mast for support. (7) In this condition, main rollers can be removed from the inner mast and outer mast. Since the mast strips and shims can fall off, remove these parts first.
207827
11-37
MAST AND FORKS
Mast Strip Adjustment 1. Check the clearance L with the clearance between the outer mast rollers and inner mast set to zero (0) in maximum lift position. Clearance L
L
0.l to 0.5 mm (0.004 to 0.020 in.)
200391
2. If the clearance L is out of specification, adjust it by shims.
Shims
NOTE Refer to Main Roller Shim Replacement. 3. After adjusting the all clearance, move the mast and lift bracket slowly to make sure that they move smoothly through their full stroke. 207004
Tilt Angle Adjustment 1. Park the truck on a level floor. 2. Tilt the mast fully backward and stop the engine. 3. Measure the backward tilt angle of the mast at both sides. 4. To adjust the tilt angle, loosen the bolt of tilt cylinder socket, and adjust the rod length by turning the rod. Adjust cylinder so that there is no difference in stroke tilt angle between the cylinders, left and right.
Bolt
207828
NOTE It is not necessary to adjust the forward tilt angle if the backward tilt angle is properly adjusted. Truck Models Item Forward - backward tilt angle deg
GC35K thru GC55K STR
GC60K thru GC70K STR
5° - 10°
6° - 10°
11-38
MAST AND FORKS
5. After adjusting the tilt angle, tighten the socket bolts to the specified torque. Unit: N·m (kgf·m) [lbf·ft] Tightening torque for tilt cylinder socket bolt
262 ± 13 (27 ± 1.4) [195 ± 10]
Lift Cylinder Stroke Adjustment 1. Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. 2. If the top of the inner mast rolls at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and rolling of the rod with a longer cylinder stroke.
3. Adjusting method (1) Raise the inner mast, place blocks under the right and left sides of the inner mast, and lower the mast until its rests on the blocks. (2) Remove the set bolt at the top of lift cylinder which stopped first, retract the piston rod, and insert shims at the top of piston rod end. (3) Extend the piston rod, and tighten the cylinder set bolt. Remove the blocks from under the inner mast. (4) Slowly lower the inner mast to the bottom to ensure the piston rods move smoothly and that the left and right lift cylinders come to the end of stroke simultaneously.
204698
202983
Shims
206974
11-39
MAST AND FORKS
Troubleshooting Complaints
Possible causes
Remedies
Lift bracket and inner mast a) Clearance between lift rollers and side rollers will not move smoothly incorrect b) Rollers binding on their shafts c) Lift chains strained in movement d) Mast strip clearance incorrect
Readjust clearance, see page 11-32 Relubricate of replace. Relubricate of replace. Shim adjust. 0.1 to 0.5mm (0.004 to 0.020 in.)
Lift bracket or inner mast binds
Readjust by means of shims. 0.1 to 0.5mm (0.004 to 0.020 in.) Readjust, see page 11-27 Readjust, see page 11-39
a) Too much clearance on side rollers
b) Lift chains unequally tensioned c) Shim adjustments unequally made on between left and right lift cylinders (at maximum height) Mast makes noise
Rollers not rotating smoothly on their shafts
Relubricate of replace.
Load descends (drift)
a) Lift cylinder packing damaged b) Sliding (inside) surface of lift cylinder tube damaged
Replace. Replace.
Whole mast shakes
Mast-support bushing or metal worn
Retighten or replace, see page 11-42
Mast is distorted
Off-center loading or overload
Replace mast assembly.
Fork tips differ in height
a) Finger bar bent b) Forks bent c) Un-even loading
Repair or replace. Repair or replace. Repair or replace.
Low oil temperature Second lift cylinders operate while first lift cylinder is moving. [Triple-stage full free panoramic mast]
Lift bracket is spongy when it stops in lifting operation.
Increase oil temperature to 40-50 °C.
Insufficient clearances between lift bracket rollers and sliding surfaces
Readjust rollers.
Clogged pipe
Inspect and clean hydraulic lines.
Insufficient air bleeding
Bleed air completely.
Insufficient air bleeding
Bleed air completely.
11-40
MAST AND FORKS
Service Data A: Assembly standard B: Repair or service limit
Simplex Mast Duplex Mast
Unit: mm (in.)
Forks and chains
Truck Models Items Difference in height between fork tips A
Rollers
Diameter of main roller
S M L LL
Diameter of side roller Distance between outer mast main rollers (inside to inside) A Distance between inner mast main rollers (outside to outside) B Distance between lift bracket main rollers (outside to outside) C1 Distance between lift bracket main rollers (outside to outside) C2 Distance between lift bracket main rollers (outside to outside) D Distance between lift bracket side rollers (outside to outside) E Longitudinal clearance of lift bracket middle rollers (with forks slightly lifted) F Lateral clearance of lift bracket middle main rollers (fully raised) G1 Lateral clearance of lift bracket side rollers (fully raised) G2 Lateral clearance of lift bracket lower main rollers (fully raised) G3 Longitudinal clearance of mast main rollers (in the whole lift range) H Lateral clearance of outer mast, inner mast main rollers (fully raised) J Lateral clearance of outer mast, inner mast main rollers (fully raised) K Mast strip clearance (fully raised) L
GC45K SWB thru GC60K thru GC55K STR GC70K STR 5 (0.2) or less GC45K SWB: 150×50 ± 0.8 (5.9×2 ± 0.03) 150×65 ± 0.8 GC45K, 55K: (5.9×2.56 ± 0.03) 150×60 ± 1.5 (5.9×2.4 ± 0.06) GC45K SWB: 150×45 (5.9×1.77) 150×58 GC45K, 55K: (6.9×2.28) 150×51 (5.9×2.00) 635 (25) 635 (25) 654 (25.7) 654 (25.7) 129 (5.08) 149 (5.86) 130 (5.12) 150 (5.90) 131 (5.16) 151 (5.94) 132 (5.19) 152 (5.98) 52 (2.05) 58 (2.3)
A
150×50 ± 0.8 (5.9×2 ± 0.03)
B
150×45 (5.9×1.77)
A B A A A A A
508 (20) 523 (20.6) 117 (4.6) 118 (4.65) 119 (4.68) 120 (4.72) 52 (2.05)
A
576 (22.68)
566 (22.28)
672 (26.46)
A
644 (25.35)
640 (25.20)
750 (29.53)
A
525 (20.67)
513 (20.20)
613 (24.13)
A
525 (20.67)
513 (20.20)
613 (24.13)
A
532 (20.94)
521 (20.51)
622 (24.49)
A
524 (21.34)
530 (20.87)
632 (24.88)
Thickness of forks (width × thickness)
Length of tilt chains (per 20 links)
Mast and lift bracket
GC35K thru GC40K STR
A
0.1 to 1.0 (0.004 to 0.039)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 1.0 (0.004 to 0.039)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
11-41
MAST AND FORKS
Simplex Mast Duplex Mast
A: Assembly standard Unit: mm (in.) Truck Models
Items
GC35K thru GC40K STR
GC45K SWB thru GC55K STR
GC60K thru GC70K STR
F G1 L
G3 G2 B F
Lift bracket
Inner mast
C1 A
K
E
H C2 J D Outer mast
207829
Mast support bolts Tightening torque N·m(kgf·m)[Ibf·ft] Distortion of finger bar
Upper nut ➁ Double nut (lower) ➀
A A
290 (29.6) [214] 210 (21.4) [155]
290 (29.6) [214]
210 (21.4) [155]
290 (29.6) [214]
A
5 (0.2)
Anchor bolt
➁ Upper nut
➂ Double nut (upper) ➀ Double nut (lower)
11-42
102709
MAST AND FORKS
Triplex Mast
A: Assembly standard B: Repair or service limit Unit: mm (in.)
Forks and chains
Truck Models Items Difference in height between fork tips A
Rollers
Diameter of main roller
S M L LL
Diameter of side roller Distance between outer mast main rollers (inside to inside) A Distance between middle mast main rollers (outside to outside) B Distance between lift bracket main rollers (outside to outside) C1 Distance between lift bracket main rollers (outside to outside) C2 Distance between lift bracket main rollers (outside to outside) D Distance between lift bracket side rollers (outside to outside) E Longitudinal clearance of lift bracket middle rollers (with forks slightly lifted) F Lateral clearance of lift bracket middle main rollers (fully raised) G1 Lateral clearance of lift bracket side rollers (fully raised) G2 Lateral clearance of lift bracket lower main rollers (fully raised) G3 Longitudinal clearance of mast main rollers (in the whole lift range) H Lateral clearance of middle and inner mast main rollers (fully raised) J Lateral clearance of outer and middle mast main rollers (fully raised) K Mast strip clearance (fully raised) L Distance between middle mast main rollers M Distance between inner mast main rollers N
GC45K SWB thru GC60K thru GC55K STR GC70K STR 5 (0.2) or less GC45K SWB: 150×50 ± 0.8 (5.9×2 ± 0.03) 150×65 ± 0.8 GC45K, 55K: (5.9×2.56 ± 0.03) 150×60 ± 1.5 (5.9×2.4 ± 0.06) GC45K SWB: 150×45 (5.9×1.77) 150×58 GC45K, 55K: (6.9×2.28) 150×51 (5.9×2.00) 635 (25) 635 (25) 654 (25.7) 654 (25.7) 129 (5.08) 149 (5.86) 130 (5.12) 150 (5.90) 131 (5.16) 151 (5.94) 132 (5.19) 152 (5.98) 52 (2.05) 58 (2.3)
A
150×50 ± 0.8 (5.9×2 ± 0.03)
B
150×45 (5.9×1.77)
A B A A A A A
508 (20) 523 (20.6) 117 (4.6) 118 (4.65) 119 (4.68) 120 (4.72) 52 (2.05)
A
676 (26.61)
666 (26.22)
672 (26.46)
A
745 (29.33)
740 (29.13)
750 (29.53)
A
513 (20.20)
493 (19.41)
484 (19.06)
A
530 (20.87)
510 (20.08)
504 (19.84)
A
513 (20.20)
493 (19.41)
484 (19.06)
A
520 (20.47)
501 (19.72)
494 (19.45)
Thickness of forks (width × thickness)
Length of tilt chains (per 20 links)
Mast and lift bracket
GC35K thru GC40K STR
A
0.1 to 1.0 (0.004 to 0.039)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 1.0 (0.004 to 0.039)
A
0.1 to 0.5 (0.004 to 0.020)
A
0.1 to 0.5 (0.004 to 0.020)
A A A
0.1 to 0.5 (0.004 to 0.020) 564 (22.20) 546 (22.20) 544 (21.42) 633 (24.92) 621 (24.45) 622 (24.49)
11-43
MAST AND FORKS
Triplex Mast
A: Assembly standard Unit: mm (in.) Truck Models
Items
GC35K thru GC40K STR
GC45K SWB thru GC55K STR
G1
GC60K thru GC70K STR
L
F
G3 Middle mast G2 Lift bracket B N Inner mast
F
C1
K
E H
Outer mast A
J
C2
K
M
D
Middle mast J
207830
Mast support bolts Tightening torque N·m (kgf·m) [Ibf·ft] Distortion of finger bar
Upper nut ➁ Double nut (lower) ➀
A A
290 (29.6) [214]
490 (49.7) [359]
210 (21.4) [155]
290 (29.6) [214]
210 (21.4) [155]
290 (29.6) [214]
A
5 (0.2)
Anchor bolt
➁ Upper nut
➂ Double nut (upper) ➀ Double nut (lower)
11-44
102709
SERVICE DATA
Inspection Standards .................................................................................................................. 12 - 1 Tightening Torques for Standard Bolts................................................................................ 12 - 8 Periodic Replacement of Parts .................................................................................................. Lubrication Chart ................................................................................................................ Fuel and Lubricant Specifications ...................................................................................... Recommended Brands of Lubricants .................................................................................. Weight of Major Components..............................................................................................
12 - 11 12 - 12 12 - 13 12 - 14 12 - 15
Special Tool Table ...................................................................................................................... 12 - 17
12
SERVICE DATA
Inspection Standards : Check or clean : Change or adjust
Inspection/maintenance location and item
Water leaks Radiator filler cap – function Coolant level
Fan belt – tension Cooling system and condition
Engine operation
Cooling fan – condition Rubber hoses – condition Starting and noise Idling and acceleration Exhaust smoke Distributor cap Spark plugs – gap and cleanliness
Air cleaner
Lubrication system
Governor
Fuel system
Preoperation inspection
Every month
Every 12 months
Service data
Visual Visual/feel Visual
Replacement: Every 6 months or 1200 hours 18.2 liter (4.82 U.S.gal) Visual/measure 6 to 9 mm/10 kgf (0.24 to 0.35 in./22 lbf) Tension pulley readjustment
Visual/measure Visual/feel Visual/feel Test/listen Tachometer/test Visual Visual
750 to 800 rpm
Gap gauge
1.14 mm (0.045), .89 (0.035) MPFI
Ignition timing
Timing lamp and special tool
Ignition coil
Circuit tester
0°/700 BTDC/rpm (gasoline), 8°/700 BTDC/rpm (LPG) Primary coil : 1.0 Ω Secondary coil : 10 ± 2 kΩ
Ignition system
Valves
Method
Periodic inspection interval
Clearance for all Thickness gauge valves Element – clogging or Visual damage Oil leaks
Visual
Oil – level and contamination
Visual/feel
Oil filter element – clogging No-load maximum speed Fuel leaks Carburetor – cleanliness Carburetor link – condition Carburetor throttle valve and choke valve
0.4 mm (0.016 in.) in cold state Replacement: Every 6 months or 1200 hours Replacement: Every month or 200 hours 5 liter (1.32 U.S. gal) Replacement: Every month or 200 hours 2600 to 2650 rpm 2700 to 2750 rpm - LP
Check Tachometer Visual Visual Test Test
12-1
SERVICE DATA
Inspection/maintenance location and item
Method
Preoperation inspection
Fuel system Compression pressure
Fuel filter – clogging Check Compression All cylinders gauge Pinion – meshing Starter Test action Alternator Charging Test/visual Level of electrolyte Visual Battery Specific gravity of Hydrometer electrolyte Insulators, connectors Electrical battery terminals – Visual/feel wires looseness, damage or corrosion Looseness, rattle feel/measure corrosion Steering wheel Response Test Tie rods and Looseness, rattle, Visual/wrench pins distortion, damage Knuckles Rattle of kingpins Feel Rear axle Distortion, damage Visual/feel Oil leaks Visual Steering cylinder Looseness at the joint Wrench Free play and higher above floor with Measure pedal depressed Brake pedal Braking distance
Periodic inspection interval Every month
Every 12 months
Service data
Replacement: Every 6 months or 1200 hours
The pressure must not become 686 kpa (7 kgf/cm2) [100 psi] or less.
1.26 or more
When engine is idling: 15 to 30 mm (0.6 to 1.2 in.)
Free play : 5 mm (0.197 in.) Pedal height (at the upper edge of brake pad) : 160 mm (6.3 in.) Loaded standard condition in driving: 5 m (16.4 feet) or less Brake pedal stroke: 37 mm (1.456 in.)
Test/measure
12-2
SERVICE DATA
Inspection/maintenance location and item
Method
Preoperation inspection
Periodic inspection interval Every month
Every 12 months
Service data
Lever swing angle: 71° to 76° Parking brake
Brake application
Test/spring scale
Operating force: 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]
Brake hoses and Fluid leaks, damage pipes or installation
Visual
Brake fluid
Level in reservoir
Visual
Brake booster
Operation
Test
Wheel brakes
Master cylinder and wheel cylinders – operation, wear and damage
Overhaul/visual
Drum to lining clearance
Thickness gauge
0.4 to 0.6 mm (0.016 to 0.024 in.)
Sliding surfaces of shoes and wear of lining
Disassemble/ measure with calipers
4.2 mm (0.17 in.) or more
Drum – wear or damage
Visual/measure
318.5 mm (12.539 in.)
Free length of return springs
Measure
Operation of shoes
Test
Brake drums and shoes
130 cc (7.9 cu. in.)
Anchor pins – seizure Visual
Backing plates
Backing plates – distortion, cracks or damage
Dye check
Fitting cables – damage and length
Visual/measure
Ratchet – wear or damage
Visual
Upper: 97 mm (3.82 in.) Lower: 97.8 mm (3.85 in.)
12-3
SERVICE DATA
Inspection/maintenance location and item
Preoperation inspection
Method
Periodic inspection interval Every month
Every 12 months
GC35K GC40K GC40K STR
Service data GC45K SWB/STR GC45K GC55K GC55K STR
GC60K GC70K GC70K STR
Replacement: Every 6 months or 1200 hours, change oil Oil level and oil leaks Visual
Strainer – clogging
Inching pedal – adjustment
14 liter (3.7 U.S. gal)
Visual
Replacement: Every 6 months or 1200 hours, clean or change
Measure/test
Inching pedal height (above floor) : 175 mm (6.89 in.) Clearance between inching pedal stopper bolt and brake pedal: 16 mm (0.63 in.) Valve spool stroke : 8 to 9.5 mm (0.314 to 0.374 in.) Valve spool stroke at which brake starts to be applied : 16.5 mm (0.649 in.) Inching pedal stroke: 82.4 mm (3.24 in.)
Torque converter drive transmission Item
Pressure Test MPA(Kgf/cm2) [psi]
Main
Eng at 1600 ± 100 rpm
Clutch
Eng at 1600 ± 100 rpm
Service data 0.98 to 1.23 (10.0 to 12.5) [142.2 to 177.8] 0.98 to 1.23 (10.0 to 12.5) [142.2 to 177.8] 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1] 0.05 to 0.29 (0.5 to 3.0) 0.01 to 0.15 (0.1 to 1.5) [7.11 to 42.7] [1.42 to 21.3]
Torque converter inlet Eng at 1600 ± 100 rpm Lubrication Eng at 1600 ± 100 rpm Stall speed
rpm ± 100
2000
10 m (33 ft) starting acceleration Front axle and differential
Front axle
15 liter (4.0 U.S. gal)
5 seconds, maximum 6.2 liter (1.64 U.S.gal) Replacement: Every 6 months or 1200 hours, change oil
Oil level and oil leaks Visual Mounting bolts – tightness
Torque wrench
Cracks, distortion or damage
Dye check/ visual
Looseness of front wheel bearing
Spring scale
Looseness in front/back direction
Operation
Cracks, distortion or damage
Visual
2080
Tangential force on hub bearing: 22.5 to 40 N (2.3 to 4.1 kgf) [5.06 to 9.02 lbf]
Tangential force on hub bearing Rear axle
Looseness of rear wheel bearings
40 to 49 N 41 to 49 N 44 to 49 N (4.1 to 5.0 kgf) (4.2 to 5.0 kgf) (4.5 to 5.0 kgf) [9 to 11 lbf] [9.2 to 11 lbf] [9.9 to 11 lbf]
Spring scale and torque wrench
Lock nut (outer only) N·m (kgf·m) [lbf·ft]
12-4
157 (16.0) [115.7]
SERVICE DATA
Inspection/maintenance location and item
Method
Preoperation inspection
Periodic inspection interval Every month
Every 12 months
GC35K GC40K GC40K STR
Service data GC45K SWB/STR GC45K GC55K GC55K STR
GC60K GC70K GC70K STR
Tires – cuts or damage Visual Tires tread depth and Depth gauge abnormal wear
Wheels
Tires – pebbles, metal chips, etc. between Visual treads Looseness of front wheel nut
551 ± 55 N·m (56.2 ± 5.6 kgf·m) [406.5 ± 40.6 lbf·ft]
Torque wrench
Rims, side rings and Visual wheel discs – damage Oil level and contamination
Replacement: Every 12 months or 2400 hours, change oil liter (U.S. gal)
Visual
46 (12.1) Hydraulic tank
Gear pump
Priority valve
Control valve
52 (13.6)
69 (18.2)
Strainer – clogging
Visual
Replacement: Every 12 months or 2400 hours, clean or change
Return filter – clogging
Visual
Replacement: Every 12 months or 2400 hours, clean or change
Oil leaks or abnormal noise
Visual/listen
Oil leaks
Visual
Relief oil pressure Pressure gauge (for steering cylinder) Oil leaks
Visual
Main relief valve setting
Pressure gauge
*Aux. relief valve setting
Pressure gauge
Control levers and links – rattle
Test/feel
Cracks, distortion or damage
Visual
9316 kpa (95 kfg/cm2) [1351 psi]
19.12 MPa (195 kgf/cm2) [2773 psi]
Fork lifting speed (with rated load) mm/sec (fpm)
Lift cylinders
Function, wear and internal leakage
540 (106)
Visual/watch/ measure
390 (78)
Self-weight drop of lift cylinder (with rated load) mm (in.)/15 min or less 50 (1.97)
Attachment Looseness of mounting bolt
360 (71)
Wrench
* mark: Optional
12-5
70 (2.76)
SERVICE DATA
Inspection/maintenance location and item
Flow regulator valve
Method
Oil leaks
Visual
Lowering speed
Watch/measure
Preoperation inspection
Periodic inspection interval Every month
Every 12 months
GC35K GC40K GC40K STR
Service data GC45K SWB GC45K SWB/STR GC45K GC55K GC55K STR
GC60K GC70K GC70K STR
Lowering speed (with rated load) mm/sec (fpm) 550 (108) 440 (86.5) 540 (106)
Tilt cylinders
Cracks, distortion or damage
Visual
Oil leaks
Visual
Function and wear
Watch/measure
Drift forward tilt (with rated load) mm (in.)/15 min or less 30 (1.18)
Piping
Mounts – rattle or damage
Visual/feel
Socket bolt torque
Wrench
Oil leaks
Visual
Rubber hoses – damage
Visual
40 (1.57)
262 •N•m (27 kgf/cm2) [195 lbf·ft]
Hose reels and swivel joint – distortion or Visual damage Cracks, distortion or damage Mast and lift bracket
Visual/dye check
Mast supports – rattle or damage
Lubricate every 50 hours or weekly
Main rollers – rattle or damage
Visual/thickness gauge/dial gauge
Clearance between rollers and mast (at maximum height) 0.1 to 0.5 mm (0.004 to 0.020 in.)
Chain extension
Measure
Length of lift chains (20 links) 523 mm (20.6 in.)
Chains and chain wheels
Forks and backrest
Chain tension
Feel
Chains – damage, distortion or rusting
Visual
654 mm (25.7 in.)
Chain tension must be equal at the left and right sides.
Chain wheels – wear, Visual distortion or damage Chain wheels bearings – rattle
Feel
Chain anchor bolts – distortion or damage
Visual Fork thickness
Forks – wear and distortion
Visual/measure
Fork stopper pins – damage or distortion
Visual
Backrest mounting bolts – tightness
Wrench
Backrest – distortion or damage
Visual
45 mm (1.77 in.)
12-6
51 mm (2.00 in.)
58 mm (2.28 in.)
SERVICE DATA
Inspection/maintenance location and item
Method
Lightening system
Operation
Test/visual
Horn
Operation
Test/listen
Turn signals*
Operation
Test/visual
Rear view mirror*
Rear vision
Visual
Overhead guard
Damage and looseness
Visual/wrench
Loosen or damaged parts
Visual/wrench
Chassis
Preoperation inspection
Periodic inspection interval Every month
Every 12 months
Service data
Operator seat – Visual damage and looseness Chassis lubrication points
Lubricate
Oil change
Inspect
Lubricate mast supports every week.
* Mark: Optional
12-7
SERVICE DATA
Tightening Torques for Standard Bolts With spring washer
Metric fine thread
Nominal size
101656
Pitch
mm
in.
mm
in.
N·m
kgf·m lbf·ft
N·m
kgf·m lbf·ft
N·m
kgf·m lbf·ft
6
0.24
1
0.04
7.4
0.75
5.4
9.6
0.98
7.1
12.7
1.3
9.4
8
0.32
1.25
0.05
16.7
1.7
12.3
22.6
2.3
16.6
30.4
3.1
22.4
10
0.39
1.25
0.05
34.3
3.5
25.3
45.1
4.6
33.3
69.6
7.1
51.4
12
0.47
1.25
0.05
63.7
6.5
47.0
82.4
8.4
60.8
122.6
12.5
90.4
14
0.55
1.5
0.06
102.0
10.4
75.2
132.4
13.5
97.6
192.2
19.5
141.8
16
0.63
1.5
0.06
154.9
15.8
114.3 202.0
20.6
149.0 287.3
29.3
211.9
18
0.71
1.5
0.06
224.6
22.9
165.6 292.2
29.8
215.5 413.8
42.2
305.2
20
0.79
1.5
0.06
310.9
31.7
229.3 404.0
41.2
298.0 573.7
58.5
423.1
22
0.87
1.5
0.06
413.8
42.2
605.2 537.4
54.8
396.4 763.0
77.8
562.7
24
0.95
1.5
0.06
547.2
55.8
403.6 711.0
72.5
524.4 1006.2 102.6 742.1
27
1.06
1.5
0.06
794.3
81.0
585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30
1.18
1.5
0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33
1.30
1.5
0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36
1.42
1.5
0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39
1.54
1.5
0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8 101656
With spring washer Nominal size
Pitch
6
0.24
1
0.04
8.6
0.88
6.4
10.8
1.1
8.0
14.7
1.5
10.8
8
0.32
1.25
0.05
19.6
2.0
14.5
26.5
2.7
19.5
36.6
3.7
26.8
10
0.39
1.25
0.05
41.2
4.2
30.4
53.0
5.4
29.1
81.4
8.3
60.0
12
0.47
1.25
0.05
74.5
7.6
55.0
97.1
9.9
71.6
144.2
14.7
106.3
14
0.55
1.5
0.06
119.6
12.2
88.2
155.9
15.9
115.0 226.5
23.1
167.1
16
0.63
1.5
0.06
182.4
18.6
134.5 237.3
24.2
175.0 338.3
34.5
249.5
18
0.71
1.5
0.06
263.8
26.9
194.6 343.2
35.0
253.2 487.4
49.7
359.5
20
0.79
1.5
0.06
365.8
37.3
269.8 475.6
48.5
350.8 674.7
68.8
497.6
22
0.87
1.5
0.06
486.4
49.6
358.8 632.5
64.5
466.5 897.3
91.5
661.8
24
0.95
1.5
0.06
643.3
65.6
474.5 836.5
85.3
617.0 1183.7 120.7 873.0
27
1.06
1.5
0.06
934.6
95.3
689.3 1216.0 123.9 894.2 1707.3 174.1 1259.3
30
1.18
1.5
0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33
1.30
1.5
0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36
1.42
1.5
0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39
1.54
1.5
0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3
12-8
SERVICE DATA
Identification Marks on Bolts, Nuts and Studs Strength classification 7T
10.9
kgf·m (lbf·ft) [N·m]
kgf·m (lbf·ft) [N·m]
Metric automotive thread
Metric coarse thread
NOTE 1. Threads and seat surfaces must be in dry state. 2. When there is a difference between the nut and bolt (stud) identification marks, tighten to the torque corresponding to the bolt (stud) identification mark.
Identification mark of nut
6T
4T
No mark
Numerical mark
Dented mark
Notched mark
Embossed mark A0066A
Identification mark of stud 4T
7T
8T
A0067B
12-9
SERVICE DATA
With spring washer
Metric coarse thread
Nominal size
101656
Pitch
mm
in.
mm
in.
N·m
kgf·m lbf·ft
N·m
kgf·m lbf·ft
N·m
kgf·m lbf·ft
10
0.39
1.5
0.06
33.3
3.4
24.6
43.1
4.4
31.8
67.7
6.9
49.9
12
0.47
1.75
0.07
58.8
6.0
43.4
76.5
7.8
56.4
115.7
11.8
85.3
14
0.55
2
0.08
96.4
9.8
70.9
124.5
12.7
91.9
182.4
18.6
134.5
16
0.63
2
0.08 147.14 15.0
108.5 191.2
19.5
141.0 274.6
28.0
202.5
18
0.71
2.5
0.10
203.0
20.7
149.7 264.8
27.0
195.3 383.4
39.1
282.8
20
0.79
2.5
0.10
286.4
29.2
211.2 371.7
37.9
274.1 536.4
54.7
395.6
22
0.87
2.5
0.10
383.4
39.1
282.8 499.2
50.9
368.2 715.9
73.0
528.0
24
0.95
3
0.12
492.3
50.2
363.1 640.4
65.3
472.3 924.8
94.3
682.1
27
1.06
3
0.12
724.7
73.9
534.5 942.2
96.1
695.1 1350.4 137.7 996.0
30
1.18
3.5
0.14
969.9
98.9
715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33
1.30
3.5
0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36
1.42
4
0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39
1.54
4
0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42
1.65
4.5
0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4 With spring washer
Nominal size
101656
Pitch
10
0.39
1.5
0.06
39.2
4.0
28.9
51.0
5.2
37.6
79.4
8.1
58.6
12
0.47
1.75
0.07
69.6
7.1
51.4
90.2
9.2
66.5
135.3
13.8
99.8
14
0.55
2
0.08
112.8
11.5
83.2
146.1
14.9
107.8 215.7
22.0
159.1
16
0.63
2
0.08
172.6
17.6
127.3 224.6
22.9
165.6 323.6
33.0
238.7
18
0.71
2.5
0.10
239.3
24.4
176.5 311.9
31.8
230.0 451.1
46.0
332.7
20
0.79
2.5
0.10
336.4
34.3
248.1 437.4
44.6
322.6 630.6
64.3
465.1
22
0.87
2.5
0.10
392.3
40.0
289.3 587.4
59.9
433.3 842.4
85.9
621.3
24
0.95
3
0.12
578.6
59.0
426.7 753.2
76.8
555.5 1088.5 111.0 802.9
27
1.06
3
0.12
852.2
86.9
628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30
1.18
3.5
0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33
1.30
3.5
0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36
1.42
4
0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39
1.54
4
0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42
1.65
4.5
0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4
Remarks : 1. The tolerance on these torque is ± 10%. 2. These torques are for “dry” condition. 12-10
SERVICE DATA
Periodic Replacement of Parts The parts listed below are important for the safe working of the truck, and are specially designated as the parts to be replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here on all trucks brought into its care. Period Periodic replacement parts
Service 1 month after delivery
*Brake hoses and tubes
Replace
*Brake fluid reservoir tube
Replace
*Lift chains
Replace
*Hydraulic hoses
Replace
*Parts involved in repair kits for master cylinder and wheel cylinders (piston cups, dust seals, etc)
Replace
*Parts involved in repair kits for brake and clutch boosters (seal, retainer assemblies, diaphragms, retainers, silencers, filters, disc assemblies and valve rod assemblies)
Replace
*Stop lamp switch (hydraulic)
Replace
*Rubber parts for steering cylinder
Replace
*Hoses for steering cylinder
Replace
*Fuel hoses
Replace
Engine oil filter element
Replace
Fuel filter element
Replace
Hydraulic tank return filter
Replace
Air cleaner element
Clean Replace
12-11
1 month 6 months
1 year
2 years
MPG
Rear axle center pin (Rear)
12-12 Every 2400 hours or 1 year
Every 1200 hours or 6 months
*
Every 200 hours or monthly
Every 50 hours or weekly
*
ATF - Torque converter oil MPG - Multi-purpose grease GO - Gear oil EO - Engine oil BF - Brake fluid HO - Hydraulic oil
MPG
Rear axle center pin (front)
MPG
MPG
EO
*
Engine oil
BF
*
Pedal bracket
Brake fluid
MPG
*
Mast supports
* MPG
MPG
*
Mast strips (sliding surface)
Lift bracket side rollers (2 locations)
MPG
MPG
MPG
ATF
MPG
GO
MPG
EO
ATF
GO
HO
*
207012
Check and refill Change Lubrication point on both sides
Tie rod pin
Tie rod pin
Water pump
Hydraulic oil
Torque converter oil
Tilt cylinders
Differential oil
Tilt sockets
Lift chains
SERVICE DATA
Lubrication Chart
*
SERVICE DATA
Fuel and Lubricant Specifications Fuel or lubricant
Recommendation
Recommendation for ambient temperature °C (°F) -30 -20 -10 0 10 20 30 (-22) (-4) (14) (32) (50) (68) (86)
Fuel
Consult your lift truck dealer.
Engine oil
API service classification SJ, MIN.
Front axle oil
API service classification multipurpose type GL-4 (gear oil)
Powershift transmission oil
Dexron
SAE 10W or SAE 10W–30 SAE 80W
SAE 90
See Recommended Brands of Lubricants.
Hydraulic oil
SAE 5W F.M.V.S.S. No.116 DOT 3 or DOT 4 (SAE J1703)
Brake fluid
Chassis
Antifreeze solution
See Recommended Brands of Lubricants.
NLGI No.1 grade multipurpose type (lithium base) Consistency: 310–340
Ambient temperature °C (°F) (Long Life Coolant) Concentration, %
SAE 10W
See Recommended Brands of Lubricants.
NLGI No.2 grade multipurpose type Wheel (lithium base) bearings Consistency: 265–295 Grease
SAE 30
SAE 20
-45 (-49)
-39 (-38)
-30 (-22)
-25 (-13)
-20 (-4)
-15 (5)
-10 (14)
60
55
50
45
40
35
30
Remarks: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with one and the same brand at successive service intervals.
12-13
SERVICE DATA
Recommended Brands of Lubricants Engine oils Specifications Viscosity Manufacturer Mobil
API service classification SJ, MIN. SAE 10W
SAE 20W
SAE 30
Mobile Heavy Duty 5W-20, 10W
Mobile Heavy Duty 20W-20, 20W-30
Mobile Heavy Duty 30, 40
Shell
Shell Super Motor Oil
Exxon
XD-3 15W-40
Castrol
Castrol Deusol CRX10W
Castrol Deusol CRX20W
Castrol Deusol CRX30
Greases
Front axle oils (Gear oils) Specifications API service classification GL-4 Viscosity SAE 90 Manufacturer
NLGI No.1
NLGI No.2
Consistency 310 to 340
Consistency 265 to 295
Mobil
90 Pegasus Gear Oil
Mobil Grease JL 77 No.1
Mobil Grease JL 77 No.2
Shell
Shell Spirax EP90
Retinax A No.1
Retinax A No.2
Exxon
Gear Oil GX80W-90
Castrol
Castrol Hypoy
Ronex MP Castrol LM Grease
Powershift transmission oils Specifications Viscosity Manufacturer
Castrol Spheerol API
Brake fluids
Dexron SAE Jl703f
—
Mobil
Mobil ATF220, 200
Mobil Super Heavy Duty Brake Fluid
Shell
Shell Dexron II
Shell Brake Fluid 250
Exxon
Superfld ATF
Brake Fluid DOT – 3
Castrol
Castrol TQ Dexron ® II
Castrol Brake Fluid Crimson
Hydraulic oils Specifications Viscosity Manufacturer
SAE 5W
SAE l0W
Mobil
—
Hydraulic oil 28LP
Shell
Tellus oil 22
Tellus oil T-32
Exxon Castrol
Nuto H32 Castrol Hyspin AWS32
Castrol Hyspin AWS68
Remarks: Brands of oils are subject to change without notice. When you buy oils, select recommended brands and check specification (for example API service classification SC, SAE 10W). 12-14
SERVICE DATA
Weight of Major Components
Unit: kg (lb)
Truck Models GC35K Items Counterweight
1850 (4070)
GC40K GC40K STR 2168 (4770) 2175 (4785)
GC45K STR GC45K SWB GC45K 2990 (6595) 3010 (6620) 2792 (6140)
Engine unit (service weight) 283 (620)
Overhead guard
Dual stage panoramic mast 3m (118 in.)
Outer mast Inner mast Lift bracket (with bracket) Forks (2 pcs) Lift cylinders, etc.
GC60K
4000 (8800)
GC70K GC70K STR 4500 (9900) 5350 (11770)
270 (595)
Power line (engine, transmission and reduction gear & differential) Rear axle
GC55K GC55K STR 3425 (7535) 3610 (7940)
350 (770) 95 (210)
334 (735)
341 (750)
500 (1100)
318 (700) 206 (450) 228 (500)
359 ( 790) 234 (515) 299 (660)
520 (1145) 319 (700) 424 (930)
186 (410) 100 (220)
258 (570) 129 (285)
278 (610) 161 (355)
12-15
SERVICE DATA
Special Tool Table Ref No.
Part number
1 2
93768-00100 91868-00100
Wrench Wrench
3
F1035-10050 67284-15400
Bolt Bolt set
4 5 6
91868-02100 91868-00300 91868-02200
Bevel pinion puller Wrench Installer
7
8
91268-13810 91268-13820 F1035-10020 T24 91268-04100
Puller Plate Bolt Puller Installer
9
—
Piston tool
10
92267-00300 91268-00500
Piston tool Ring puller
11
64309-17700
Gauge kit
12
92067-00300
Connector
13 14 15 16 17 18 19
03703-49000 — 64309-15400 91868-00600 64309-15400 91268-10600 91268-03200
Socket wrench 105mm Socket wrench 100mm Spring remover Spring retainer Spring hook Puller Puller
20
91268-01700
Connector
21
05312-20850 05312-20850
Hook wrench Hook wrench
05312-10600
Hook wrench
05312-10800
Hook wrench
05312-11000
Hook wrench
—
Hook wrench
—
Hook wrench
—
Wheel socket 41mm
22
Description
Applicable model To be used for: Removal/installation of pulley Removal/installation of pulley (used with wrench 93768-00100) Pulling out the torque converter-drive transmission pump body and the direct-drive transmission shifter case Pulling out the bevel pinion assembly Tightening the bevel pinion assembly Driving in the oil seal of the transmission output shaft Removing bearing from the torque-drive transmission (to be used in combination with 91268-13820 plate, F1035-10020 bolt and T24 puller) (Commercial) Driving in the ball bearing of the torque-drive transmission Removal/installation of torque-drive transmission clutch return spring
GC35K thru GC55K STR
GC60K thru GC70K STR
—
— —
Removal/installation of torque converter-drive transmission snap ring Measuring oil pressure of transmission and hydraulic systems Measuring oil pressure of torque converter-drive transmission (used with gauge kit ) Removal/installation of front wheel hub nut Removal/installation of front wheel hub nut Removal of return spring Removal/installation of brake shoe Installation of return spring Removal of steering wheel Removal of steering column needle roller bearing Measuring main oil pressure of the steering system (used with gauge kit 64309-00300) Removal/installation of tilt cylinder bushing Removal/installation of lift cylinder head (for A40A and B55A) Removal/installation of lift cylinder holder (for A75A) Removal/installation of lift cylinder head (for B40A) Removal/installation of lift cylinder head (for B55A) Removal/installation of tilt cylinder guide bushing Removal/installation of tilt cylinder guide bushing Removal/installation or drive wheels
12-16
—
— —
SERVICE DATA
Special Tool Table Ref No.
Part number
Description
23
64309-17722
Hose
24
64309-17712
gauge, 0-5000 psi
25
64309-17713
gauge, 0-3000 psi
26
64309-17714
gauge, 0-100 psi
27
64309-17714
Connector
28
64309-17733
Banjo connector
Applicable model To be used for: Measuring oil pressures, hydraulic, transmission and steering (used with gauge kit) Measuring oil pressures, hydraulic, transmission and steering (used with gauge kit) Measuring oil pressures, hydraulic, transmission and steering (used with gauge kit) Measuring oil pressures, hydraulic, transmission and steering (used with gauge kit) Measuring oil pressures, hydraulic, transmission and steering (used with gauge kit) Measuring oil pressures, hydraulic, transmission and steering (used with gauge kit)
12-17
GC35K thru GC55K STR
—
GC60K thru GC70K STR
SERVICE DATA
360
36 250 68
90 9
1
5
200434
203846
–0.1
35
250
φ125 –8.2
0 φ90 –0.1
Spline details φ26
φ115
φ19 . φ2 134 2.2 25
99 71 35
2
6
200435
203540 φ11
×1.25 M10×
12 6
143
C1.5
55 2
263
75
90
(25)
62
6
21 3
×1.25 M10× 203541
7
200465
×1.5 M10× ×1.5 M14× φ45 φ33
234
17 10
238 250
(12)
22
130
φ39
17
192 4
8
200436
12-18
203542
SERVICE DATA
φ130
13 = 105mm 14 = 100mm
9
203847
13 and 14
203546
10
200438
15
203548
11
203544
16
203549
17
203550
12
12-19
SERVICE DATA
1 in. Drive ×1.25 M12× ×1.25 M8×
18
203551
22
203552
23
45 55
19
24 = 0 to 5000 psi 25 = 0 to 300 psi 26 = 0 to 100 psi
PF3/8-A PF3/8-B
20
203849
24, 25, 26
Flame hardened Hv>500, depth: 2 mm [0.08 in.]
21
27
203556
12-20
41 mm Hex
SERVICE DATA
28
12-21
Electrical System Schematic Chassis (2007-01~up)
Schematic No.
Used for
Truck Model
Serial No.
GC35K, 40K GC40K STR GC45K SWB
AT87A-10231-up
93704-21000 99739-82100 GC45K, 55K GC55K STR GC60K, 70K GC70K STR Pub No. 99739-82100 3-13
AT88A-10231-up AT89A-10231-up
Electrical System Schematic Engine (2007-01~up) HEGO 1 DK GREEN/ORANGE 18
BLACK/LT GREEN 18 BLACK/LT GREEN 18 DK GREEN/WHITE 18 PINK/DK GREEN 18 BLACK/YELLOW 18
GCP 90 WAY CONNECTOR EG01 EG02 EG03 EG04 TPS1 TPS2 MAP AUX ANA PD1 FPP1 FPP2 IVS AUX ANA PUD2 AUX ANA PUD3 CAN TERM + CAN1 + CAN1 CAN2CAN2 + CAN2 TERM + 5V EXT 1 5V RTN CRANK + CRANK CAM + CAM SPEED + SPEED KNOCK1 + KNOCK1 KNOCK2 + KNOCK2 SPARK COIL 1A SPARK COIL 1B SPARK COIL 2A SPARK COIL 2B SPARK COIL 3A SPARK COIL 3B SPARK COIL 4A SPARK COIL 4B IAT ECT EGT AUX DIG 1 AUX DIG 2 AUX DIG 3 VSW AUX ANA PU1 AUX ANA PU2 (FRT) AUX ANA PU3 (FPP2 ONLY) 5V EXT 2 5V RTN GOV1 GOV2 OIL PRESS (FRP) AUX ANA PUD1 PC TX PC RX ALT EXCITE TACH VBAT PROT VBAT INJ1 LS INJ2 LS INJ3 LS INJ4 LS INJ5 LS INJ6 LS INJ7 LS INJ8 LS GROUND STARTER RELAY EGOH 1 EGOH 2 EGOH 3 (LOCKOFF) EGOH 4 BUZZER PWM5 PWM5 RECIRC VBAT MIL GROUND DBW + DBW FPUMP AUX PWM3 RECIRC AUX PWM3 AUX PWM1 AUX PWM2 (STARTER) AUX PWM4 AUX_PWM4_RECIRC
C001
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
DK GREEN/ORANGE 18 DK GREEN/WHITE 18
WHITE/RED 18
A
BLACK/LT GREEN 18
B
BLACK/WHITE 18
HEGO 2
WHITE/BLACK 18 PINK/TAN 18
C
A
D
B
PINK/DK GREEN 18
C004 C005
TWR
C002
LPG TEMPERATURE
PURPLE/LT BLUE 18 LT BLUE/DK BLUE 18 LT GREEN 18 TAN/DK GREEN 18 DK BLUE/ORANGE 18 PURPLE/YELLOW 18
SHD A B C D
LOCKOFF
A B
C003
WHITE/ORANGE 18 BLUE/PINK 18 BLUE/WHITE 18
LT GREEN/RED 18 BLK/LT GREEN 18 PURPLE/WHITE 18 WHITE/PURPLE 18 GRAY/BROWN 18 PURPLE/ORANGE 18 RED/WHITE 18 RED/BLACK 18
LT GREEN 18 LT GREEN/RED 18 YELLOW/GRAY 18 BLACK/LT GREEN 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
YELLOW 18
4 3 2 1
TAN/WHITE 18
A
BLACK/LT GREEN 18
B
ECT
C007
BOSCH_TMAP
C006
TWIST WIRES 10 TURNS(360 DEG)/FULL LENGTH
OIL PRESURE SWITCH LT BLUE 18
5MM RING
RING YELLOW/GRAY 18 TAN/WHITE 18 WHITE/RED 18
BLACK 16
C008
BLACK 10
PINK/TAN 18 DK BLUE/YELLOW 18
LT GREEN /PURPLE 18 LT GREEN/BLACK 18
LT GREEN/PURPLE 18 LT GREEN/BLACK 18 RED/BLACK 18 RED/WHITE 18 LT GREEN/RED 18 BLACK/GREEN 18 DK BLUE/ORANGE 18 PURPLE/YELLOW 18 DK BLUE/YELLOW 18 GREEN/YELLOW 18 LT BULE/PINK 18 DK BLUE 18 TAN/DK GREEN 18 BROWN/WHITE 16 TAN 18 PINK 18
LT BLUE 18 DK GREEN 18 ORANGE 18
RED/TAN 16
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH PINK/DK GREEN 16 A YELLOW/BLACK 18 B PLUG C
S R P N M L K J H G F E D C B A
5V EXT 2 (FPP2 ONLY) 5V RTN 2 VS VS + 5V EXT 1 5V RTN 1 FPP1 FPP2/IVS AUX ANA PU1 MIL START COMMAND CHARGE INDICATION AUX ANA PD1 AUX PWM 5 AUX PWM 1 VSW
IGNITION COIL
C012
C009 10MM RING
BLACK 16 YELLOW/BLACK 18 WHITE/LT BLUE 18 BLACK/WHITE 18 BLACK/YELLOW 18
BLACK 16 YELLOW 18
WHITE/BLACK 18 PINK/DK GREEN 16 BROWN/WHITE 16
BLACK 10
D C B A
IGNITION MODULE
PINK/DK GREEN 18
GROUND
C010 BLACK/LT GREEN 18 1 LT GREEN/RED 18 2 DK GREEN 18 3 ORANGE 18 4 5 6 BLUE/PINK 18 7 BLUE/WHITE 18 8
C011
PINK/DK GREEN 16
RED/TAN 16 GREEN/YELLOW 18 BLACK 16 PINK/WHITE 18 TAN/ORANGE 18
WHITE 16
5MM RING
STARTER SOLENOID LT GREEN/RED 18 WHITE/PURPLE 18 PURPLE/WHITE 18
TAN 18 DK BLUE 18 PINK/BLACK 18
TWR A B C
C013
ANA RTN 5V REF PC TX PC RX UNUSED UNUSED CAN1 + CAN1 -
F2 RED/TAN 14 4
3
RED 14
C014
20A
CRANK SENSOR
C015
ECM 87A WHITE 16
BLK/LT GREEN 18
F6
30 87
LT BLUE/PINK 18
86
PINK/BLACK 18
85
RED/TAN 16
11
12
STARTER RELAY
RED 16
20A
R1
STARTER F4
PINK/DK GREEN 16 8
7
F1 PINK/TAN 18
15A TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
PURPLE/ORANGE 18 GRAY/BROWN 18 LT GREEN/RED 18
TWR A B C
IGNITION
CAM SENSOR
2
1
PINK 18
5A VSW
C016
M3 PINK/DK GREEN 16
60A
R2 WHITE/LT BLUE 18 PINK/DK GREEN 14 RED 14 RED/TAN 18
2 3 5 1 4
2
F5 PINK/DK GREEN 18 9
10A POWER RELAY
PURPLE/LT BLUE 18 LT BLUE/DK BLUE 18 PINK/WHITE 18 LT GREEN/RED 18 BLK/LT GREEN 18 TAN/ORANGE 18
6 5 4 3 2 1
8MM RING
C017
ALTERNATOR+
BATT+
C020
C019 BLUE/WHITE 18 WHITE 18 BLUE/PINK 18
BLACK 18 RED/LT BLUE 16
1 2 3 4 5 6 7 8
CAN CAN + TERM CAN + UNUSED UNUSED GROUND POWER UNUSED
RED 10
8MM RING
RED 10 RED 10
EPR FUSE RED 14
BOSCH THROTTLE
1
MAXI-FUSE
10 RED/LT BLUE 16
EPR CONNECTOR RED 16
C018
A B
PINK/DK GREEN 16
ALTERNATOR
C021 BLACK 10
10MM RING
6MM RING
ALTERNATOR-
C023
GROUND
C022
Schematic No.
Used for
REV C 11-10-06
Truck Model
Serial No.
GC35K, 40K GC40K STR GC45K SWB ESO19-74121 99739-82100
GC45K, 55K GC55K STR GC60K, 70K GC70K STR
Pub No. 99739-82100 3-15
AT87A-10231-up
AT88A-10231-up AT89A-10231-up
Electrical System Schematic Chassis w/ Neutral Safety Switch (2005-11~2006-12)
Schematic No.
Used for
Truck Model
Serial No.
GC35K, 40K GC40K STR GC45K SWB
AT87A-00001-10230
93704-11000 99739-82100 GC45K, 55K GC55K STR GC60K, 70K GC70K STR Pub No. 99739-82100 3-17
AT88A-00001-10230 AT89A-00001-10230
Electrical System Schematic Chassis w/o Neutral Safety Switch (2004-01~2005-10)
Schematic No.
Used for
Truck Model
Serial No.
GC35K, 40K GC40K STR GC45K SWB
AT87A-00001-10230
93704-01000 99739-82100 GC45K, 55K GC55K STR GC60K, 70K GC70K STR Pub No. 99739-82100 3-19
AT88A-00001-10230 AT89A-00001-10230
Electrical System Schematic Engine (2004-01~2006-12)
PED-12124107 CONNECTOR PED-12045773 TERMINAL PED-12052850 LOCK BROWN/BLUE 16 BROWN/GREEN 16 BROWN/WHITE 16 BROWN/YELLOW 16 BROWN/ORANGE 16 TAN LT/BLUE 16
PSIECM FCI 211 PC 56 2S D 009 CONNECTOR 211 A 56 7007 LOCKING CAN 211 A 56 0008 COVER 211 CC 2S 1120 TEAH
DNJ + DNJ 3 DNJ 2 AUX OUT2 AUX ANA PD MAP FPP IAT ECT IVS AUX AKA PU POWER GROUND POWER GROUND ANA RTN 5 VOLT REF VSW EGD 1 KNK + KNK CRANK + CRANK CAM + CAM VBA+ VBASTARTER LOCKOFT FUEL LOCKOFT FUEL PUMP RELAY CONTROL TPS1 TPS2 DBW + DBW DEL PRESSURE TACH MDL AUX ANA PD1 AUX OUT 14 FUEL SELECT AUX ANA PU2 GOV SELECT FTV CAM + CAM RS 232 T1 RS 232 R2 COOL 1 INJ 3 INJ 4 INJ 5 INJ 6 PTV CHARGE LAMP AUX DUT 3
ORANGE/BLUE 16 RED/WHITE 18 WHITE/BLACK 18 WHITE/RED 18 PINK/TAN 18
15 ORANGE/BLUE 16 16 BROWN/BLUE 16 17 BROWN/GREEN 16 5 LT BLUE/WHITE 18 35 TAN/DK GREEN 18 33 LT GRN 18 38 DK BLUE18 32 TAN 18 31 YELLOW/GRAY 18 39 PURPLE/YELLOW 18 36 DK BLUE/YELLOW 18 19 BLACK 16 20 BLACK 16 49 BLACK/LT GREEN 18 50 LT GREEN/RED 18 21 PINK/TAN 18 55 DK GREEN/ORANGE 18 41 42 11 PURPLE/WHITE 18 12 WHITE/PURPLE 18 13 GRAY/BROWN 18 14 PURPLE/ORANGE 18 22 RED/TAN 16 23 RED/TAN 16 9 GRAY/ORANGE 18 8 WHITS/BLACK 18 3 TAN/BLACK 18 10 WHITE/LT BLUE 18 54 PURPLE/LT BLUE 18 54 LT BLUE/DK BLUE 18 24 PINK/WHITE 18 25 TAN/DRANGE 18 37 LT GREEN/BLACK 18 56 YELLOW/LT GREEN 18 26 LT BLUE/BLACK 18 47 BLACK/WHITE 18 4 PURPLE/DK BLUE 18 40 TAN/BROWN 18 48 YELLOW/DK BLUE 18 34 GRAY/DK BLUE 18 18 WHITE/RED 18 43 BLUE/PINK 18 44 BLUE/WHITE 18 51 DK GREEN 18 52 ORANGE 18 27 YELLOW 18 29 BROWN/WHITE 16 30 BROWN/YELLOW 16 28 BROWN/ORANGE 16 1 TAN/LT BLUE 16 2 RED/WHITE 18 7 ORANGE/YELLOW 18 6
SKD A B C D E F TWR A B C D E F
MTRSHD6
FUEL SYSTEM INTERFACE
MTRTWR6
PED-12032848 CONNECTOR PED-12048074 TERMINAL PED-12052850 LOCK
PED-12162193 CONNECTOR OR EQUIV PED-12124875 TERMINAL OR EQUIV YELLOW/ GRAY 18
A
BLACK/LT GREEN 18
B
ECT BOSCH KOMPAKT 1 928 403 736 CONN
12162193
1 928 498 060 TERMINAL 1 928 300 599 SEAL TWIST WIRES 10 TURNS 360 DEGS/FOOT FULL LENGTH
LT GREEN 18 LT GREEN/RED 18 TEN 18 BLACK/LT GREEN 18
4 3 2 1
BOSCH_TMAP
BLACK 12
ALTERNATOR GROUND
BLACK 16 BLACK 12
BLACK 16
RED/TAN 16 RED/TAN 16
GROUND
F1
PINK/TAN 18
TWIST WIRES 10 TURNS 360 DEGS/FOOT FULL LENGTH
TWIST WIRES 10 TURNS 360 DEGS/FOOT FULL LENGTH THIS JUNCTION TO BE WITHIN 3-6 INCHES OF CONN
PED-12110293 CONNECTOR PED-12048074 TERMINAL PED-12052845 LOCK
PURPLE/ORANGE 18 GRAY/BROWN 18 LT GREEN/RED 18
TWR
A B C
PINK 18
VEHICLE INTERFACE
5A PED-12033769 HOLDER PED-12033731 COVER PED-12033997 TERM
PED-12065425 CONNECTOR PED-12048074 TERMINAL PED-12124264 LOCK TWR
DIST/CAM
PINK 18 DK BLUE 18
BLK/LT GREEN 18
BLK/LT GREEN 18 D LT GREEN/RED 18 C DK GREEN 18 B ORANGE 18 A
TWR
RTN SV
LT BLUE/PINK 16 PINK/BLACK 16
TWR
BLK/LT GREEN 18 DK GREEN/ORANGE 18 PINK/DKGREEN 16 BLACK 18
PED-12015798 CONNECTOR PED-12089040 TERMINAL KALE
A B C D
MTRTWR4-EGO
TWR LT BLUE/WHITE 18 TAN/DK GREEN 18 YELLOW/LT GREEN 18 TAN/BROWN 18 GRAY/DK BLUE 18 BLUE/PINK 18 BLUE/WHITE 18 PURPLE/DK BLUE 18
RX
COMM LT GREEN/BLACK 18 FEMALE
START IN (INTERUPT TYPE) START IN (AUTOCRAKING)
MTRTWR10
PED-12176897 CONNECTOR PED-12048074 TERMINAL PED-12160480 LOCK
TX
VSW FPP1 IVS ANA RTN CHANGE LAMP MPL VREF
A B C D E F G H J X
PURPLE/YELLOW 18 BLACK/LT GREEN 18 ORANGE/YELLOW 18 LT BLUE/BLK 18 LT GREEN/RED 18
LT GREEN/RED 18
DIL PRES
A B C D E F G H
AUX OUT 2 SPEED INPUT TACH FUEL SELECT COV SELECT CAN + CAN AUX OUT 1
PED-12047937 CONNECTOR PED-12048074 TERMINAL PED-12066304 LOCK
PUSH-ON-FEMALE
MTRTWR8 PED-12052834 LOCK PED-12020156 TERM (14-20 AWG) PED-12033997 TERM (12-14AWG)
PED-12059595 CONNECTOR PED-12048074 TERMINAL PED-12052845 LOCK
STARTER-RELAY 87A
LT GREEN/RED 18 WHITE/PURPLE 18 PURPLE/WHITE 18
TWR
A B C
F2
RED/TAN 14
LT BLUE/PINK 16
WHITE 16 38
CRANK
87
STARTER SOLENOID
THIS JUNCTION TO BE WITHIN 3-6 INCHES OF CONN
RED 14
RED 12
20A
PINK/BLACK 16
BLACK/WHITE 18 YELLOW/DK BLUE 18 DK BLUE/YELLOW 18 PINK/YELLOW 16 BLACK 16 PINK/DK GREEN 16
PED-12033769 HOLDER PED-12033731 COVER PED-12033997 TERM
PINK/TAN 18 86
GRAY/ORANGE 18 85
RED 12
A
BLACK 16
AUX IN PD2 AUX IN PU2 AUX IN PU1 FUEL PUMP GROUND RELAY FUSED POWER
MTRTWR6
50A
RED 12
MAXI-FUSE
BATT + 1
C YELLOW 18 PINK/DK GREEN 16
A B C D E F
PED-12052848 CONNECTOR PED-12048074 TERMINAL PED-12032834 LOCK
PED-12162189 CONNECTOR PED-121344075 TERMINAL YELLOW/BLACK 18
TWR
MODULE
B A PED-12052834 LOCK PED-12020156 TERM (14-20 AWG) PED-12033997 TERM (12-14AWG)
FUEL-PUMP-RELAY RED 14
PINK/DK GREEN 16 YELLOW / BLACK 18 PLUG
A B C
30 87PINK/YELLOW 16
PED-12146121 CONNECTOR PED-12048074 TERMINAL PED-12052845 LOCK
PINK/TAN 18
TAN/BLACK 18
86
85
F4
PINK/YELLOW 16
15A PED-12033769 HOLDER PED=12033731 COVER PED=12033997 TERM
COIL
RED 12 RED 16
ALTERNATOR
PED-12052834 LOCK PED-12020156 TERM (14-20 AWG) PED-12033997 TERM (12-14AWG)
PED-12162193 CONNECTOR OR EQUIV PED-12124875 TERMINAL OR EQUIV
POWER-RELAY
RED 16 A RED/14 30 BLK/LT GREEN 18 LT GREEN/RED 18 PURPLE/LT BLUE 18 LT BLUE/DR BLUE 18 PINK/WHITE 18 TAN/ORANGE 18
87
2 3 6 5 4 1
AMP-1-967616-1 CONNECTOR AMP-965906-5 TERMINAL AMP-967067-1 SEAL
RED/TAN 14
86
BOSCH THROTTLE WHITE/BLUE 18
85
PINK/DK GREEN 16
F3
PINK/DK GREEN 16
15A PED-12033769 HOLDER PED-12033731 COVER PED-12033997 TERM
PINK/DK GREEN 16 B
ALTERNATOR
12162193 NOTES. ALL WIRE IS SAE J1128 TXL TYPE ALL CONVOLUTE MUST BE FLAME RETARDANT POLYPROPYLEI HARNESS TO BE LABELED WITH PART NUMBER E1351040A
Schematic No.
Used for
Truck Model
Serial No.
GC35K,40K GC40K STR GC45K SWB ESO39-80130
99739-82100
AT87A-00001-10230
GC45K,55K GC55K STR
AT88A-00001-10230
GC60K,70K GC70K STR
AT89A-00001-10230
Pub No.99739-82100 3-21
Electrical System Schematic Chassis (1998-01~2003-12)
Schematic No.
Used for
Truck Model
Serial No.
GC35K, 40K GC40K STR GC45K SWB
AT87-00001-up
ES019-80110 99739-82100 GC45K, 55K GC55K STR GC60K, 70K GC70K STR Pub No. 99739-82100 3-23
AT88-00001-up AT89-00001-up
Electrical System Schematic Engine, Gasoline(1998-01~2003-12) Accerlerator Sensor (Chassis part)
CN102 B8 A6 B7
E.C.U
91920-26100
G GW GR
G GW GR GY G BW
IDLE SW. B6
GY
G GW GR W W W
B8 A6 B7 B6 C4 C5 A3 C6 C7 A8 B3 A7
B GW GA GY GR BR G A Y
C8 C3 B5 C2 A5 A1 B1 A2 C2
308
CN110 VIEW LOOKING INTO CONNECTOR
FRAME
ALTERNATOR Y
S W
CN101
P.U. COIL
B1 B2
A3 C6 C7 D4 G1
CHECK LAMP DIAGNOSIS SW TEST PROGRAM SW
A3 C6 C7 D4 G1
B5
C5
B6
C6
A8
B7
C7
B8
C8
B
CARBURETOR
CN106 Y W R G Br
B2 G0 A2 B1 A1
SHUT SW. OPEN SW.
Y W R G
G GW GR B W
CHOKE HEATER
CIRCUIT CONNECTED
FUEL CUT
INTERNAL ELECTRICAL CONNECTION TO SURFACE OF COMPONENT
CN107 GB GY GR GY
YB
N. C.
OR
CN108
FUEL PUMP
2) ---LINES ARE PROVIDE AS CHASSIS HARNESS. 1) UNLESS OTHERWISE SPECIFIED WIRES ARE 1.25 sqmm.
R
D1 D2
B 91920-02700
STARTER INHIBIT RELAY CN110
D1
FUEL PUMP RELAY DIODE
91920-02720
IDENTIFICATION OF ELECTRICAL WIRES TERMINAL FITING
2RY
2RY
STARTER
DIODE
CN 112
CN 113
F2
CN111
STRIPE COLOR
F4 F3 C6 F7
F9 F5 B GW
0.5 G
BR B GW
D9 D8 D7 D6 D5 YG YB YW BR YW
IDENTIFICATION CODE (EXAMPLE)
CIRCUIT
R STRIPE COLOR
2R
COLOUR
SYMBOL
Starter System
Black
B
Generating System
White
W
Instrument System
Yellow
Y
Green
G
Lighting System
Red
R
Others
Blue
L
Brown
Br
BASE COLOR B
CORD SIZE
B
YB YW
BASE COLOR
S B
D9 D8
YG
CONNECTOR
A5 C2 B5 D0
7 YG YW
CIRCUIT NOT CONNECTED ELECTRICAL CONNECTION TO VEHICLE STRUCTURE
Br
OIL PRESSURE SW.
PURPLE
SYMBOL DESCRIPTION BLADE, SPADE, RING OR SCREW TERMINAL
SW
GBRE
BW GW G GW
CN105
BLANK
C4
A7
MOTOR STEP
C5 D3 C4 D3
+C 6.5O±0.5O
B3
C3
A6
YB
G
PN
G2
C2
A5
W
BLANK
BLANK
W
COIL
A3
L
FLWO.85R
A1 A2
F7-BLACK WIRE STARTER RELAY
F3-BLACK WIRE GROUND
DISTRIBUTOR
CN103
F4-BLACK/RED E.C.U GROUND
C3-GREEN/WHITE E.C.U
ENGINE
408
F9
Signal System
UNIT SENDER
7
F8
A7
CN 109 OK MONITOR (ENG. OIL PRESSURE) STARTER SW. S STARTER SW. M 15A STARTER SW. M 10A CHASSIS EARTH OK MONITOR (ENG. W/TEMP) LINE 74 OK MONITOR (BAT. CHARGING) LINE 1
YB BR YW W B YG YB W SW
+ YG
D6
D5 A8
C8
8
W
BATTERY 308
8
YW W
YB
BR
BR Truck Model
Serial No.
GC35K,40K GC40K STR GC45K SWB
AT87-00001-up
GC45K,55K GC55K STR
AT88-00001-up
GC60K,70K GC70K STR
AT89-00001-up
Lighting Green
Lg
Violet
V
Pink
P
7 24
ENGINE, GASOLINE 4.3L
D5 A8 75 3 73 6 43
Pub No.99739-82100 3-25
Electrical System Schematic Engine, LPG(1998-01~2003-12)
OIL PRESSURE SW. YB
DISTRIBUTOR
ALTERNATOR
N. C
7 ENGINE
COIL
Y
308
P.U. COIL
S W
L
FLWO. 85R
G
W
B FRAME
PN +C
101
GBRE
6.5O±0.5O
CN105
SYMBOL DESCRIPTION
5W
91920-02720
W
91920-02700
YB
BLADE, SPADE, RING OR SCREW TERMINAL CIRCUIT CONNECTED
PURPLE
CIRCUIT NOT CONNECTED ELECTRICAL CONNECTION TO VEHICLE STRUCTURE
2RY
2RY
STARTER
INTERNAL ELECTRICAL CONNECTION TO SURFACE OF COMPONENT
S B
OR
CONNECTOR
2 R
40B
SENDER UNIT 2) ------LINES ARE PROVIDE AS CHASSIS HARNESS. 1) UNLESS OTHERWISE SPECIFIED WIRES ARE 1.25 sqmm. IDENTIFICATION OF ELECTRICAL WIRES
BR
TERMINAL FITING
101 22
7
75
30B
BATTERY STRIPE COLOR
-
+
BASE COLOR
YG
B
YB
2BY
91920-12600
IDENTIFICATION CODE (EXAMPLE) 0.5 G
BR 2BY chassis B YG YB W 5W
COLOUR
SYMBOL
Black
B
Generating System
White
W
Instrument System
Yellow
Y
Signal System
Green
G
Lighting System
Red
R
R STRIPE COLOR
STARTER SW. S STARTER SW. M OK MONITOR (ENG. OIL PRESSURE) CHASSIS EARTH OK MONITOR (ENG. W/TEMP) LINE 74 OK MONITOR (BAT. CHARGING) LINE 1
CIRCUIT Starter System
BASE COLOR
24
CORD SIZE
22 7 75 3 73 6 43
Truck Model
Serial No.
GC35K,40K GC40K STR GC45K SWB
AT87-00001-up
GC45K,55K GC55K STR
AT88-00001-up
GC60K,70K GC70K STR
AT89-00001-up
Others
Blue
L
Brown
Br
Lighting Green
Lg
Violet
V
Pink
P
ENGINE, GM 4.3L LP Pub No. 99739-82100 3-27
Service Manual Chassis & Mast GC35K GC40K GC40K GC45K GC45K GC55K GC55K GC60K GC70K GC70K
AT87B-00001-up
STR SWB STR STR
AT87B-00001-up AT87B-00001-up AT87B-00001-up AT87B-00001-up AT88B-00001-up AT88B-00001-up AT89B-00001-up
STR
AT89B-00001-up AT89B-00001-up
For use with GM4.3L, G6 Engine Service Manual and Fuel System Supplements
99739-82110
FOREWORD This service manual is a guide for servicing Cat® lift trucks. The long productive life of your lift truck(s) depends on regular and proper servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair, or rebuild the lift truck. The descriptions, illustrations, and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference. The GM4.3 liter engine’s fuel system was changed to comply with the EPA guidelines in 2004 and again at the beginning of 2007. This manual has minimal information on the fuel systems. Please see the Fuel System Supplement for information regarding the Multi Port Fuel Injection System (MPFI). Also see the engine service manual for general engine repair or rebuild. For the items pertaining to the engine, refer to the following service: • GM4.3L (G6) Engine Service Manual • GM4.3L 2004~2006 Fuel System Supplement • GM4.3L 2007~2009 Fuel System Supplement Safety related signs
Meanings
R WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
R CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
NOTE indicates a condition that can cause damage to or shorten the service life of the machine.
Unauthorized copying and lending is prohibited.
i
1. Safety R WARNING -
-
The proper safe lubrication and maintenance for these lift trucks, recommended by Cat Lift Trucks, are outlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication or maintenance on these lift trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. The serviceman or mechanic may be unfamiliar with many of the systems on this lift truck. This makes it important to use caution when performing service work. DO NOT operate these lift trucks unless you have read and understood the instructions in the SERVICE MANUAL. Improper lift truck operation is dangerous and could result in injury or death.
A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the lift truck components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. The following is a list of basic precautions that should always be observed: (1) Read and understand all warning plates and decals on the lift truck before operating, lubricating or repairing the product. (2) Always wear protective glasses and protective shoes when working around lift trucks. In particular, wear protective glasses when using a hammer or sledge on any part of the lift truck or its attachments. (3) Use welders gloves, hood/goggles, apron, and other protective clothing appropriate to the welding job being performed. DO NOT wear loose fitting or torn clothing. Remove all rings from fingers when working on machinery. (4) DO NOT work on any lift truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the lift truck before performing any disassembly. (5) Lower the forks or other implements to the ground before performing any work on the lift truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from falling unexpectedly. (6) Use steps and assist grips (if applicable) when mounting or dismounting a lift truck. Clean any mud or debris from steps, walkways, or work platforms before using. Always face lift truck when using steps, ladders, and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. (7) To avoid back injury, use a hoist when lifting components which weigh 23 kg (51 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (8) To avoid burns, be alert of the hot sections and hot fluids in lines, tubes, and compartments, even when lift truck is idle or off.
ii
(9) Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any springs or other pressures, before removing the last two bolts or nuts completely. (10) Be careful when removing filler caps, breathers, and plugs on the lift truck. Wrap a cloth around the cap or plug to prevent being sprayed or splashed by liquids under pressure. Be aware that the danger of being sprayed or splashed is ever greater if it is immediately after stopping the lift truck, as fluids is very hot. (11) Use well maintained tools in a proper way. (12) Install all fasteners with same part number. DO NOT use a lesser quality fastener if replacements are necessary. (13) If possible, make all repairs with the lift truck parked on level, hard surface. Block lift truck so it does not roll while working on or under lift truck. (14) Before starting to work on lift truck, hang "DO NOT Operate" tag in the Operator Compartment. (15) Repairs, which require welding, should be performed only with the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods, or wire to provide a weld metal strength equivalent at least to that of parent metal. (16) DO NOT damage wiring during the removal process. DO NOT reuse the damaged wiring. Install the wiring making sure not to contact sharp corners or hot parts. Place wiring away from oil pipe. (17) Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. (18) Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position. (19) Loose or damaged fuel, lubricant, hydraulic lines, tubes, and hoses could cause fires. DO NOT bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes, and hoses carefully. DO NOT check for leaks with your hands. Pin hole (very small) leaks could result in a high velocity oil stream that will be invisible close to the hose. This oil could penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.
(20) Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube, or seal failure, must be installed correctly. (21) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Place blocks to prevent a device from falling if it is in the raised position. Release the residual pressure when removing a pressurized device. (22) DO NOT operate a lift truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
iii
2. Symbols and Abbreviations Symbol or abbreviation
Meanings
OP.
Option
R1/4
Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8
Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A
Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8
Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
3. Units -
SI Units are used in this manual. The following table shows the conversion of SI unit and customary unit.
Item
SI unit
Metric unit
Yard-pound unit
1N
0.102 kgf
0.225 lbf
Pressure
1 MPa
10.1972 kgf/cm2
145.038 psi
Torque
1 N·m
0.102 kgf·m
0.7376 lbf·ft
1 mm
-
0.039 in.
1m
-
3.281 feet
Weight
1 kg
-
2.205 lb
Temperature
1 °C
-
°F=1.8 x °C+32
Volume
1L
-
0.264 US.gal.
Force
Length
iv
TABLE OF CONTENTS
Chapter 1 GENERAL INFORMATION 1. 2. 3. 4. 5. 6. 7.
Model View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Applicable Truck Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Chassis and Mast Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Chapter 2 COOLING SYSTEM 1. 2. 2.1 2.2 2.3
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Removing Fan Belt (Method by Removing Radiator) . . . . . . . . . . . . . . . . . . .2-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Chapter 3 ELECTRICAL SYSTEM 1. 1.1
2. 2.1 2.2 2.3
3. 3.1 3.2 3.3
4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13
6. 6.1
Electrical Components and Wiring Outline . . . . . . . . . . . . . . . . . . . . . .3-1 Locations of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Console Box Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Disassembling Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Assembling Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Disassembling Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Assembling Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Warning Icons and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Main Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Key Switch (With Anti-restart Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Light Switch and Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Direction (FNR) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Stop Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Speed Sensor (Pulse Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Head Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19 Rear Combination Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 List of Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Mast Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 Mast interlock system functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
TOC-1
TABLE OF CONTENTS
7. 7.1
8. 8.1
9. 9.1 9.2 9.3
10.
Driving Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Driving Interlock System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Neutral System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Neutral System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Battery and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment . . . . . 3-24 Specific Gravity Reading and State of Charge . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Precautions for Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Wire Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
10.1 List of Wire Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
11. 11.1 11.2 11.3 11.4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-26 3-26 3-27 3-27
Chapter 4 POWER TRAIN 1. 2. 3. 3.1 3.2
4. 4.1 4.2 4.3 4.4
5. 5.1
6. 6.1 6.2 6.3
7. 7.1
8.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Structure (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Structure (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Reduction Ratio (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Reduction Ratio (6.0 ton 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Sequence (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Sequence (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Sequence (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6 4-7 4-8 4-9
Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removing Transmission and Reduction Differential . . . . . . . . . . . . . 4-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installing Transmission and Reduction Differential . . . . . . . . . . . . . . 4-14 Suggestions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Chapter 5 POWERSHIFT TRANSMISSION 1. 1.1
2. 2.1 2.2 2.3 2.4
TOC-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1-Speed Transmission (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Transmission 1-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Powershift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
TABLE OF CONTENTS
2.5
3. 3.1 3.2
4. 4.1 4.2
5. 5.1 5.2 5.3 5.4 5.5
6. 6.1 6.2
7. 7.1 7.2 7.3 7.4 7.5 7.6 7.7
8. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11
9. 9.1
10.
Powershift Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Disassembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
After Disassembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Pump Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Turbine Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Pilot Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Flexible Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Assembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 Control Valve and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 Pump Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 Countershaft (2nd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 Forward-Reverse Clutch Shaft (Current Production) . . . . . . . . . . . . . . . . . . .5-17 Forward-Reverse Clutch Shaft (First Production) . . . . . . . . . . . . . . . . . . . . . . .5-18
Inspection and Repair After Disassembling Transmission . . . . . . . .5-19 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 Pump Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Stator Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Clutch Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Friction Plates and Mating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 Clutch Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 Clutch Gears (Forward and Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 Turbine Shaft and Clutch Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22 Clutch Shaft, Countershaft, and Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . .5-22 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22 Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
Assembling Forward-Reverse Clutch Shaft Subassembly . . . . . . . . .5-23 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Assembling Forward-Reverse Clutch Shaft (1st Shaft) . . . . . . . . . . . .5-24
10.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 10.2 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 10.3 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
11.
Assembling Output Shaft (4th Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
11.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26 11.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
12.
Assembling Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
12.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 12.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
TOC-3
TABLE OF CONTENTS
13.
Assembling Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
13.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 13.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
14.
Assembling Pump Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
14.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 14.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
15. 16.
Assembling Control Valve and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Disassembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
16.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
17. 18.
After Disassembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Assembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
18.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 18.2 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
19. 19.1 19.2 19.3 19.4 19.5 19.6
20.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Inching Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Stall Speed Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 10 Meters (33-ft) Starting Acceleration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Adjusting Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Adjusting Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
20.1 Automatic 2-speed Transmission (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . 5-40
21. 21.1 21.2 21.3 21.4 21.5 21.6 21.7 21.8
22. 22.1 22.2 22.3 22.4 22.5 22.6 22.7 22.8
23.
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Transmission 2-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Automatic 2-speed Change Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Powershift Transmission Hydraulic System Schematic 1-Speed . . . . . . . . 5-45 Powershift Transmission Hydraulic System Schematic 2-Speed . . . . . . . . 5-46 Hydraulic Control (Forward 1st Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 Hydraulic Control (Forward 2nd Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Control Valve and Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Output Shaft (4th Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Input Shaft (1st Shaft / Current Production) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 Input Shaft (1st Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Countershaft (2nd Shaft / Current Production) . . . . . . . . . . . . . . . . . . . . . . . . 5-57 Countershaft (2nd Shaft / First Production) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
After Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
23.1 Input Shaft, Servo Case, and Seal rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
24. 24.1 24.2 24.3 24.4
TOC-4
Assembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 Ball Bearing and Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Countershaft (2nd Shaft) and Input Shaft (1st Shaft) . . . . . . . . . . . . . . . . . . Countershaft (3rd Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-60 5-61 5-63 5-64
TABLE OF CONTENTS
24.5 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65 24.6 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66
25.
Assembling Control Valve and Side Cover . . . . . . . . . . . . . . . . . . . . . . .5-67
25.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-67
26.
Disassembling Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68
26.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68
27. 28.
After Disassembling Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68 Assembling Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69
28.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 28.2 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69
29. 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.8 29.9
30.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69 Hydraulic Pressure Test Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-70 2nd Speed/Auto Selector Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-71 2-Speed Transmission Electrical Systems Part Numbers . . . . . . . . . . . . . . . .5-71 ECU Self-Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-72 ECU Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-72 Pulse Generator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 Solenoid Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73 Oscilloscope Shop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-74
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-76
30.1 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-76
31. 31.1 31.2 31.3 31.4 31.5 31.6 31.7 31.8
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-81 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-81 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-82 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-84 Torque Converter Drive Transmission (1-Speed Transmission) . . . . . . . . .5-85 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) 5-86 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) 5-87 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-89 Torque Converter Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-90
Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 1. 2. 3. 3.1
4. 5. 5.1 5.2 5.3
6. 7. 8. 8.1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Removing Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Installing Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Removing Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Installing Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 Removing and Installing Reduction and Differential . . . . . . . . . . . . .6-6 Disassembling Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
TOC-5
TABLE OF CONTENTS
8.2 8.3
9. 9.1 9.2 9.3
10.
Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Inspection and Repair After Disassembling Axle Shaft and Hub . . 6-9 Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Front Hub Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Assembling Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
10.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 10.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
11. 11.1 11.2 11.3 11.4
12.
Disassembling Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Removing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Inspection and Repair After Disassembling Reduction Differential 6-14
12.1 Reduction Bevel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 12.2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
13.
Assembling Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
13.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 13.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
14. 14.1 14.2 14.3 14.4 14.5
15. 16.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Adjusting Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Inspecting Back Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Adjusting Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Adjusting Tooth Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Tooth Contact of Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
16.1 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Chapter 7 REAR AXLE 1. 2. 2.1 2.2 2.3
3. 3.1 3.2 3.3
4. 4.1
5. 5.1 5.2
6. TOC-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Rear Axle (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Rear Axle (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Removing Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installing Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Removing Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Installing Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
TABLE OF CONTENTS
7. 7.1 7.2
8. 8.1 8.2
9. 9.1
10. 11.
Disassembling Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 Rear Axle (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 Rear Axle (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Assembling Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Suggestion for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Disassembling Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Inspection and Repair After Disassembling Steering Cylinder . . . .7-16 Assembling Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
11.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17 11.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
12.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
12.1 Adjusting Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
13. 14.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Chapter 8 BRAKE SYSTEM 1. 2. 2.1 2.2 2.3 2.4 2.5
3. 3.1
4. 4.1 4.2 4.3
5. 5.1 5.2
6. 6.1
7. 7.1 7.2 7.3 7.4
8. 9. 9.1 9.2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Master Cylinder and Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Brake Booster (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 Brake Booster (6.0 to 7.0 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Disassembling Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
Inspection and Repair After Disassembling Master Cylinder . . . . . .8-8 Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
Assembling Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Disassembling Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 Disassembling Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Inspection and Repair After Disassembling Wheel Cylinder . . . . . .8-11 Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Piston Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Assembling Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 Disassembling Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
TOC-7
TABLE OF CONTENTS
9.3
10. 10.1 10.2 10.3 10.4 10.5 10.6
11.
Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Inspection and Repair After Disassembling Wheel Brake . . . . . . . . 8-14 Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Shoe and Lining Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Brake Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Adjusting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Parking Brake Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Other Inspection Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Assembling Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
11.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 11.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
12.
Inspecting and Repairing Parking Brake Lever . . . . . . . . . . . . . . . . . . 8-18
12.1 Parking Brake Lever Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 12.2 Suggestions for Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 12.3 Installing Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
13. 13.1 13.2 13.3 13.4 13.5 13.6
14. 15.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Automatic Adjuster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Procedure for Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Brake Fluid Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Inspecting Reserve Tank Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Procedures for Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Brake Booster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Chapter 9 STEERING SYSTEM 1. 2. 2.1 2.2 2.3
3. 3.1 3.2
4. 4.1 4.2 4.3
5. 5.1 5.2
6. 7. 7.1 7.2
TOC-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Tilt Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Removing Tilt Steering and Steering Control Valve Assembly . . . . 9-5 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Inspection After Installing Tilt Steering and Steering Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Steering Wheel Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Disassembling Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Inspection and Repair After Disassembling Steering Control Valve 9-10 Assembling Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
TABLE OF CONTENTS
8. 9. 9.1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
Chapter 10 HYDRAULIC SYSTEM 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13
3. 3.1 3.2 3.3
4. 4.1 4.2
5. 5.1 5.2
6. 6.1
7. 7.1 7.2
8. 9. 9.1 9.2 9.3
10.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 Hydraulic Line (6 to 7 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 Inlet Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 Solenoid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Lift Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Tilt Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9 Attachment Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10 Control Valve Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20 Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21
Removing Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23
Removing Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24 Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
Removing Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . .10-25 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25
Installing Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . .10-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-27
Removing Lift Cylinders (Duplex and Triplex Mast) . . . . . . . . . . . . . .10-28 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-28 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-29
Installing Lift Cylinders (Duplex and Triplex Mast) . . . . . . . . . . . . . . .10-31 Removing Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32
Disassembling Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33
10.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33 10.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33
11.
Inspection After Disassembling Gear Pump . . . . . . . . . . . . . . . . . . . . .10-34
11.1 Drive and Driven Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34 11.2 Pump Covers, Body, and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34
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TABLE OF CONTENTS
12.
Assembling Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
12.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 12.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
13.
Inspection After Disassembling Control Valve . . . . . . . . . . . . . . . . . . . 10-36
13.1 Sections, Spools, and Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
14. 15. 15.1 15.2 15.3 15.4
16.
Assembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 Disassembling Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . 10-38 Disassembly Sequence (A40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Sequence (A45A, A55A, and A70A) . . . . . . . . . . . . . . . . . . . . . . Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-38 10-38 10-39 10-39
Inspection After Disassembling Lift Cylinders (Simplex Mast) . . . . 10-40
16.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 16.2 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 16.3 Packings and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
17.
Assembling Lift Cylinders (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . 10-40
17.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 17.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
18.
Disassembling Lift Cylinders (Duplex and Triplex Masts) . . . . . . . . . 10-42
18.1 Disassembly Sequence for First Lift Cylinders (B55A and C40A Through C70A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 18.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 18.3 Disassembly Sequence for Second Lift Cylinders (B40A) . . . . . . . . . . . . . . . 10-43 18.4 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 18.5 Disassembly Sequence for Second Lift Cylinders (B45A and B55A) . . . . . 10-44 18.6 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
19.
Inspection After Disassembling Lift Cylinders (Duplex and Triplex Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
19.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 19.2 Piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 19.3 Packings and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
20.
Assembling Lift Cylinders (Duplex and Triplex Masts) . . . . . . . . . . . 10-45
20.1 First Lift Cylinder (B40A Through B55A, and C40A Through C70A) . . . . . 10-45 20.2 Second Lift Cylinders (B40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 20.3 Second Lift Cylinders (B45A and B55A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
21.
Disassembling Lift Cylinders (Triplex Masts) . . . . . . . . . . . . . . . . . . . . . 10-48
21.1 Second Lift Cylinders (C40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 21.2 Second Lift Cylinders (C45A and C55A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 21.3 Second Lift Cylinders (C70A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
22.
Inspection After Disassembling Lift Cylinders (Triplex Masts) . . . . 10-51
22.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 22.2 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 22.3 Packings and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
23.
Assembling Lift Cylinders (Triplex Masts) . . . . . . . . . . . . . . . . . . . . . . . 10-52
23.1 Second Lift Cylinder (C40A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 23.2 Second Lift Cylinders (C45A and C55A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 23.3 Second Lift Cylinders (C70A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
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TABLE OF CONTENTS
24.
Disassembling Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-54
24.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-54 24.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55
25.
Inspection After Disassembling Tilt Cylinders . . . . . . . . . . . . . . . . . . . .10-55
25.1 Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55 25.2 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55 25.3 Packings and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-56
26.
Assembling Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-57
26.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-57
27.
Disassembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-58
27.1 Flow Regulator Valve (3.5 to 5.5 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-58
28. 29.
Inspection After Disassembling Flow Regulator Valve . . . . . . . . . . .10-58 Assembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
29.1 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
30. 31. 32. 32.1 32.2 32.3 32.4 32.5 32.6 32.7 32.8 32.9
33. 34. 35. 35.1 35.2 35.3 35.4 35.5
Inspection After Disassembling Flow Regulator Valve . . . . . . . . . . .10-59 Assembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60 Test-run of Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-62 Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-63 Attachment Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-63 Priority Relief Valve Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-64 Flow Regulator Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-65 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-66 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-68
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-69 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-73 Lift Cylinder (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74 Second Lift Cylinders (Duplex Mast Second Cylinders) . . . . . . . . . . . . . . . .10-75 First Lift Cylinders (Duplex Mast, Triplex Mast First Cylinder) . . . . . . . . . . .10-76 Second Lift Cylinders (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-77 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-78
Chapter 11 MAST AND FORKS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 Removal Sequence of Mast and Lift Bracket Assembly . . . . . . . . . . . . . . . . .11-4 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . .11-4 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . .11-7 Removal Sequence of Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 Suggestions for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . .11-8 Inspecting Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9 Assembly Sequence of Lift Bracket Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10
TOC-11
TABLE OF CONTENTS
1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29
TOC-12
Adjusting Lift Bracket Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Installing Outer/Inner Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Installing Mast Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Installing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19 Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23 Inspecting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23 Inspecting and Adjusting Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24 Checking Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25 Adjusting Clearance Between Lift Bracket Roller and Inner Mast . . . . . . . 11-26 Adjusting Mast Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28 Inspecting and Adjusting Mast Strip Clearance . . . . . . . . . . . . . . . . . . . . . . . 11-30 Adjusting Mast Tilt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 Inspecting and Adjusting Right and Left Lift Cylinder Stroke . . . . . . . . . . 11-31 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33
Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36 Removal Sequence of Mast and Lift Bracket Assembly . . . . . . . . . . . . . . . . 11-38 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . 11-38 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . 11-40 Removal Sequence of Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41 Preparation for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . . . 11-41 Suggestions for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . . 11-42 Inspecting Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43 Assembly Sequence of Lift Bracket Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44 Adjusting Lift Bracket Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 Installing Outer/Inner Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-49 Installing Mast Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50 Installing Second Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51 Installing First Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55 Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-58 Inspecting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-58 Inspecting and Adjusting Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-59 Checking Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-60 Adjusting Clearance Between Lift Bracket Roller and Inner Mast . . . . . . . 11-61 Adjusting Mast Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63 Inspecting and Adjusting Mast Strip Clearance . . . . . . . . . . . . . . . . . . . . . . . 11-65 Adjusting Mast Tilt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke . . 11-66 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-67 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-68
TABLE OF CONTENTS
3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29
Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-70 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-70 Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-71 Removal Sequence of Mast and Lift Bracket Assembly . . . . . . . . . . . . . . . . .11-73 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . .11-73 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . .11-75 Removal Sequence of Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .11-76 Preparation for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . . .11-76 Suggestions for Disassembling Mast and Lift Bracket . . . . . . . . . . . . . . . . .11-77 Inspecting Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-78 Assembly Sequence of Lift Bracket Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-79 Adjusting Lift Bracket Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-80 Installing Outer/Inner Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-84 Installing Mast Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-85 Installing Second Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-86 Installing First Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-87 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-88 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-89 Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-91 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-93 Inspecting Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-93 Inspecting and Adjusting Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-94 Checking Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-95 Adjusting Clearance Between Lift Bracket Roller and Inner Mast . . . . . . .11-96 Adjusting Mast Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-98 Inspecting and Adjusting Mast Strip Clearance . . . . . . . . . . . . . . . . . . . . . . . .11-102 Adjusting Mast Tilt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-102 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke . . .11-103 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-104 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-105
Chapter 12 SERVICE DATA 1. 2. 2.1 2.2
3. 3.1
4. 4.1 4.2 4.3
5. 5.1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . .12-6 Metric Fine Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6 Metric Coarse Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8
Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10 Safety Critical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11 Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12 Adjustment Value and Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14 Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14
TOC-13
TABLE OF CONTENTS
Chapter 13 HOW TO READ CIRCUIT DIAGRAMS 1. 1.1 1.2
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
3. 4.
Description of Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Connector Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
How to Read Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 Sheet Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Connecting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 Relay Contactor and Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 Indication of Connecting Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 Indication of GND (Earth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 Indication of Another Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
How to Read Connector Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Abbreviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Chapter 14 CIRCUIT DIAGRAM
TOC-14
CHAPTER 1 GENERAL INFORMATION
Chapter 1 GENERAL INFORMATION 1.
Model View
This service manual deals with all components or systems of Cat Lift Trucks; except for the engine and attachment, which are covered in the respective manuals.
505703
1-1
CHAPTER 1 GENERAL INFORMATION
2.
Applicable Truck Models
This manual applies to the following lift truck models. Truck model
Transmission
3.5 ton class
GC40K STR 1-Speed
AT87B-00001-up
GC45K SWB GC45K STR GC55K GC55K STR
6.0 ton class
1-2
Engine mounted
GC40K
5.5 ton class
7.0 ton class
Serial number
GC35K
4.0 ton class
4.5 ton class
Truck model
GM4.3L Gasoline Engine AT88B-00001-up
GC60K Automatic 2-Speed
GC70K GC70K STR
AT89B-00001-up
CHAPTER 1 GENERAL INFORMATION
3.
Serial Number Locations
1
4
2
3
5
6 505704
1. 2. 3.
Name Plate Chassis Serial Number (Former models) Gasoline Engine Serial Number
4. 5. 6.
Mast Number Transmission Serial Number Chassis Serial Number (New models)
1-3
CHAPTER 1 GENERAL INFORMATION
4.
Chassis and Mast Model Identification
Chassis
GC 55 K
1 2
3 1. 2.
Generation designator Maximum capacity 55 : 5500 kg (12000 lb)
3.
505819
Engine type GC: Gasoline engine type
Mast
A
55
A
33
1
2
3
4 1. 2.
1-4
Maximum lifting height (“33” stands for 3300 mm.) Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on)
3. 4.
505706
Applicable truck model designation 55: 5.5 ton class Kind of mast A: Simplex mast B: Duplex mast C: Triplex mast
CHAPTER 1 GENERAL INFORMATION
5.
Dimensions
6
10
11
4
9 1 7
8 2
14 3
12
13
5
505707
1-5
CHAPTER 1 GENERAL INFORMATION
6.
Specifications Unit: mm (in.)
1
2
Class
3.5 ton class
Truck model
GC35K
Maximum lift
Free lift (Floor to fork top)
GC45K STR
Simplex mast
150 (5.9)
160 (6.3)
Duplex mast
920 (36.2) 3.0 m (118 in.) mast
895 (35.2) 2.8 m (112 in.) mast
Triplex mast
800 (31.5) 4.0 m (157 in.) mast
895 (35.2) 4.0 m (157 in.) mast
Tilt angle (forward – backward) degree
5
Overall length (OLH)
6
Overall width (outside)
1220 (48) 5/10 Simplex, Duplex mast 6/5 Triplex mast 2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
2730 (107)
Standard
1180 (46.5)
1320 (52.0)
Wide tread (option)
1270 (50.0)
1420 (56.0)
Overall height (to top of mast lowered)
2155 (85.0)
Overall height (to top of overhead guard)
2155 (85.0)
Simplex mast Overall height (mast extended)
GC45K SWB
2900 (114)
4
9
GC40K STR
3050 (120)
Fork length
8
GC40K
4.5 ton class
Simplex mast
3
7
4 ton class
4250 (167)
4125 (162)
Duplex mast
4250 (167) 3.0 m (118 in.) mast
4080 (160.6) 2.8 m (112 in.) mast
Triplex mast
5250 (206.7) 4.0 m (157 in.) mast
5560 (218.9) 4.0 m (157 in.) mast
Standard
940 (37.0)
1015 (40.0)
Wide tread (option)
1040 (41.0)
1120 (44.0)
11 Tread (rear)
980 (38.5)
965 (38.0)
12 Wheelbase
1575 (62.0)
1780 (70.0)
10 Tread (front)
13 Rear overhang 14 Under clearance (at frame)
1-6
485 (18.8)
525 (20.3)
335 (13.3) 150 (5.9)
565 (22.1)
470 (18.1)
CHAPTER 1 GENERAL INFORMATION Class
5.5 ton class
Truck model 1
2
Maximum lift
Free lift (Floor to fork top)
GC55K
GC55K STR
2350 (93)
Simplex mast
160 (6.3)
165 (6.5)
Duplex mast
895 (35.2) 2.8 m (112 in.) mast
-
Triplex mast
895 (35.2) 4.0 m (157 in.) mast
900 (35.4) 3.5 m (138 in.) mast
4
Tilt angle (forward – backward) deg.
5/10 Simplex, Duplex mast 6/5 Triplex mast
5
Overall length (OLH)
2910 (115)
6
Overall width (outside)
9
GC70K
2900 (114)
Fork length
8
GC60K
7.0 ton class
Simplex mast
3
7
6.0 ton class
1220 (48)
2640 (104)
6/10 Simplex mast 6/5 Triplex mast 2950 (116)
2730 (107)
Standard
1320 (52.0)
1440 (56.5)
Wide tread (option)
1420 (56.0)
-
Overall height (to top of mast lowered)
2155 (85.0)
2205 (87.0)
Overall height (to top of overhead guard)
2155 (85.0)
2205 (87.0)
Simplex mast
4125 (162)
3585 (141)
Duplex mast
4080 (160.6) 2.8 m (112 in.) mast
-
Triplex mast
5560 (218.9) 4.0 m (157 in.) mast
4785 (188.3) 3.5 m (138 in.) mast
Standard
1015 (40.0)
1130 (44.5)
Wide tread (option)
1120 (44.0)
-
Overall height (mast extended)
GC70K STR
10
Tread (front)
11
Tread (rear)
965 (38.0)
1160 (45.5)
12
Wheelbase
1780 (70.0)
1830 (72.0)
13
Rear overhang
14
Under clearance (at frame)
650 (26.1)
380 (15.1)
150 (5.9)
590 (23.1)
340 (13.1)
200 (7.9)
1-7
CHAPTER 1 GENERAL INFORMATION
7.
Performance Class
3.5 ton class
Truck model
GC35K kg/mm
Work performance
Capacity/load center
(lb/in.)
Lift speed (loaded) Lowering speed (loaded)
mm (fpm)/ sec.
Mast tilt (forward-backward)
degree
Traveling performance
Powershift Travel transmission speed models Minimum turning radius Minimum intersecting isle Gradability at 1 mph (1.6 km/h) Gradability at stall
1-8
Standard
Loaded No loaded
km/h (mph)
mm (in.)
Loaded No loaded Loaded No loaded
%
4.5 ton class
GC40K STR
4000/500 (8000/24)
GC45K SWB
GC45K STR
4500/600 (10000/24)
3050 (120)
2900 (114)
540 (105)
390 (78.0)
550 (108)
440 (86.5) 5/10
mm (in.)
Free lift
GC40K
3500/500 (7000/24)
mm (in.)
Maximum lift height Simplex
4 ton class
150 (6.0)
160 (6.5)
19 (12.0)
18.5 (11.5) 19.5 (12.5)
2235 (88.0)
2285 (90)
2090 (82.5)
2340 (92.0)
2440 (96.0)
2245 (88.5)
2295 (90.5)
2100 (82.5)
2350 (92.5)
2345 (94.5)
37
33
32
27
26
23.8
21.1
21.5
17.7
23.8
42
37
36
23.8
21.1
21.5
30 17.7
23.8
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Truck model
GC35K
GC40K
GC40K STR
GC45K SWB
GC45K STR
2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
2730 (107)
Overall length to fork face
Overall width
Dimensions
Overall height
1180 (46.5)
1320 (52.0)
Wide tread (optional)
1270 (50.0)
1420 (56.0)
To top of mast (lowered)
2200 (86.5)
2350 (92.5)
To top of mast (extended)
4250 (167.5)
4130 (162.5)
mm (in.)
2155 (85.0)
Wheelbase Front
1575(62.0)
1780 (70.0)
Standard
940 (37.0)
1015 (40.0)
Wide tread (optional)
1040 (41.0)
1115 (44.0)
980 (38.5)
965 (38.0)
Rear Overhang
485 (18.8)
Rear
525 (20.3)
Under clearance (at frame) Front Tire size
Single wheels
Weight
565 (22.1)
470 (18.1)
Front Rear
22x9x16
22x12x16
18x7x12-1/8
18x8x12.1 2
mm
Service weight-no load Axle loading
335 (13.3) 150 (5.9)
Rear
Single wheels (without load)
4.5 ton class
Standard
To top of overhead guard
Tread
4 ton class
kg (lb)
5200 (11500)
5600 (12300)
5700 (12700)
6500 (14300)
6600 (14500)
2050 (4600)
2025 (4400)
2150 (4900)
1925 (4200)
2625 (5700)
3150 (6900)
3575 (7900)
3550 (7800)
4575 (10100)
3975 (8800)
1-9
CHAPTER 1 GENERAL INFORMATION Class
5.5 ton class
Truck model kg/mm
Work performance Traveling performance
GC60K
GC70K
(lb/in.) mm (in.)
2900 (114)
2360 (93)
390 (78.0)
360 (71.0)
Lowering speed (loaded)
mm (fpm)/ sec.
440 (86.5)
540 (106.0)
Mast tilt (forward-backward)
degree
5/10
6/10
Free lift
mm (in.)
160 (6.5)
165 (6.5)
Maximum lift height Simplex Lift speed (loaded)
Travel speed
Powershift transmission models
Loaded No loaded
km/h (mph)
Minimum intersecting isle Gradability at 1 mph (1.6 km/h)
Overall height
22.5 (14.0)
2455 (96.5)
2255 (89)
2395 (94.5)
2220 (87.5)
Loaded
22.6
22.2
24.5
21.7
21.4
20.2
20.9
22.2
19.7
20.4
26
25
30
27
26
20.2
20.9
22.2
19.7
20.4
2910 (115)
2460 (104)
No loaded
%
Loaded No loaded
2950 (116)
2700 (106)
Standard
1320 (52.0)
1440 (56.5)
Wide tread (optional)
1420 (56.0)
-
To top of mast (lowered)
2350 (92.5)
2530 (99.5)
To top of mast (extended)
4130 (162.5)
2370 (93.0)
2155 (85.0)
2205 (87.0)
1780 (70.0)
1830 (72.0)
Standard
1015 (40.0)
1135 (44.5)
Wide tread (optional)
1115 (44.0)
-
965 (38.0)
1160 (45.5)
mm (in.)
650 (26.1)
Rear
Under clearance (at frame) Tire size
23 (14.5)
Standard
mm (in.)
Rear Overhang
19.5 (12.5)
20.5 (12.5)
2400 (94.5)
Wheelbase
Tread
21 (13.0)
2570 (101.0)
To top of overhead guard
Front
18 (11.5)
7000/600 (15500/24)
2350 (92.5)
Overall length to fork face Overall width
6000/600 (13500/24)
GC70K STR
2550 (100)
Minimum turning radius
Gradability at stall
Dimensions
7.0 ton class
5500/600 (12000/24)
Capacity/load center
Front Rear
1-10
GC55K STR
GC55K
6.0 ton class
Single wheels
mm
380 (15.1)
590 (23.1)
150 (5.9)
200 (7.9)
22x12x16
28x12x12
18x8x12.12
22x8x16
340 (13.1)
CHAPTER 1 GENERAL INFORMATION Class
5.5 ton class
Truck model
Weight
Service weight-no load Single wheels (without load)
Axle loading
Front Rear
kg (lb)
6.0 ton class
7.0 ton class
GC55K
GC55K STR
GC60K
GC70K
GC70K STR
7200 (15800)
7400 (16200)
8800 (19300)
9500 (20900)
9700 (21300)
2425 (5300)
2625 (5700)
3300 (7300)
3300 (7200)
3500 (7500)
5500 (12000)
6200 (13700)
6200 (13800)
4775 (10500)
1-11
CHAPTER 1 GENERAL INFORMATION MPFI specs in Bold. If not indicated in bold, specs are for Carburated and MPFI systems. Class
3.5 ton class
Truck model
GC35K
4 ton class GC40K
GC40K STR
Engine model
GM4.3L
Type
Gasoline
Cooling system
4
Type of combustion chamber Valve arrangement
Semi-spherical Overhead
Type of cylinder liners Cylinder bore × stroke, mm (in.)
Engine
Displacement, cc (cu in.)
Integral 101.6×88.39 (4.00×3.48) 4293 (262)
Compression ratio Rated output, PS/min-1 Rated torque, kgf·m/min-1 Min. min-1
9.2 : 1 94/2450
Max. min
31.0/1200
2650-2700, 2600-2650
Dimensions (L×W×H), mm (in.)
710×620×740 (28.0×24.4×29.1)
Weight, kg (lb)
260 (573)
Installation position
Rear
Ignition
Spark
Firing order
1-6-5-4-3-2
Initial ignition timing, BTDC deg Fuel tank capacity, liter (U.S.gal)
Ignition system
92.6/2450
750-800, 650-700
-1
Distributor
0° Gasoline, 8° LPG, ECU Controlled 66 (17.4)
80 (21.1)
Type
Mold
Type
Pointless
Type of spark advance control Model
Spark plug
GC45K STR
6-90°V
No. of strokes
Ignition coil
GC45K SWB
Water cooled
No. of cylinders-arrangement
1-12
4.5 ton class
Internal solid state circuit, ECU Controlled
AC #41-932, R42LTS
Size, mm (in.)
14 (0.55)
Gap, mm (in.)
1.24 (0.0488), .89 (.035)
Internal solid state circuit
Fuel system
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Truck model
GC35K
4 ton class GC40K
GC40K STR
Carburetor
Type
Single Barrel, MPFI
Governor
Type
Electronic
Fuel pump
Type
Electromagnetic
Air cleaner
Type × Number
4.5 ton class GC45K SWB
GC45K STR
Cyclone with paper element × 1
1-13
CHAPTER 1 GENERAL INFORMATION MPFI specs in Bold. If not indicated in bold, specs are for Carburated and MPFI systems. Class
5.5 ton class
Truck model
GC55K
GC55K STR
GM4.3L
Type
Gasoline
4
Type of combustion chamber
Semi-spherical
Valve arrangement
Overhead
Type of cylinder liners
Integral
Cylinder bore × stroke, mm (in.)
101.6×88.39 (4.00×3.48)
Engine
Displacement, cc (cu in.)
4293 (262)
Compression ratio
9.2 : 1 -1
92.6/2450
Rated output, PS/min
-1
31.0/1200
Rated torque, kgf·m/min Min. min-1
750-800, 650-700
-1
Max. min
2650-2700, 2600-2650
Dimensions (L×W×H), mm (in.)
710×620×740 (28.0×24.4×29.1)
Weight, kg (lb)
260 (573)
Installation position
Rear
Ignition
Spark
Firing order
1-6-5-4-3-2 0° Gasoline, 8° LPG, ECU Controlled
Initial ignition timing, BTDC deg Fuel tank capacity, liter (U.S.gal)
Ignition system
Distributor
80 (21.1)
128 (34.0)
Type
Mold
Type
Pointless
Type of spark advance control Model
Spark plug
Internal solid state circuit AC #41-932, R42LTS
Size, mm (in.)
14 (0.55)
Gap, mm (in.)
1.24 (0.0488), .89 (.035)
Carburetor
Type
Single Barrel, MPFI
Governor
Type
Electronic
Fuel pump
Type
Electromagnetic
Air cleaner
GC70K
6-90°V
No. of strokes
Ignition coil
7.0 ton class
Water cooled
No. of cylinders-arrangement
Fuel system
GC60K
Engine model
Cooling system
1-14
6.0 ton class
Type × Number
Cyclone with paper element × 1
GC70K STR
CHAPTER 1 GENERAL INFORMATION MPFI specs in Bold. If not indicated in bold, specs are for Carburated and MPFI systems. Class
3.5ton class
Truck model
GC35K
Engine lubrication system
Type
Gear pump
Oil filter
Paper element
Oil cooler
Refill capacities, liter (U.S.gal)
Cooling system
GC45K SWB
GC45K STR
Oil to water type Oil pan
4.2 (1.1)
Oil filter & cooler
0.8 (0.2)
Total
5.0 (1.3) Forced circulation
Radiator
Plate fins with pressure cap
Refill capacity, liter (U.S.gal)
18.2 (4.82)
Water pump
Type × number Battery
GC40K STR
Oil pump
Thermostat/ Opening Temp C° ( F°)
11 (2.9)
Centrifugal type, V-belt driven, Serpentine belt driven Wax type/ 180 (180) Group 24
Voltage, V
12
Capacity, AH (5Hr)
45
Type Alternator
GC40K
4.5 ton class
Pressure feed
Type
Manufacturer Rated output, V-A Regulator Type
Starter
4 ton class
Manufacturer Voltage-output, V-kW
3-Phase AC MANDO, AC Delco 12-50, 12-70 Built in IC type Electromagnetic Delco Remy 12 - 0.75
1-15
CHAPTER 1 GENERAL INFORMATION Class
5.5 ton class
Truck model Engine lubrication system
Type
Gear pump
Oil filter
Paper element
Oil cooler
Refill capacities, liter (U.S.gal)
Cooling system Battery
GC70K
Oil to water type Oil pan
4.2 (1.1)
Oil filter & cooler
0.8 (0.2)
Total
5.0 (1.3)
Radiator Refill capacity, liter (U.S.gal) Water pump
Type × number
Forced circulation Plate fins with pressure cap 11 (2.9) Centrifugal type, V-belt driven, Serpentine belt driven Wax type/ 180 (180) Group 24
Voltage, V
12
Capacity, AH (5Hr)
45
Type Alternator
GC60K
Oil pump
Thermostat/ Opening Temp C° ( F°)
Manufacturer Rated output, V-A Regulator Type
Starter
GC55K STR
7.0 ton class
Pressure feed
Type
1-16
GC55K
6.0 ton class
Manufacturer Voltage-output, V-kW
3-Phase AC MANDO, AC Delco 12-50, 12-70 Built in IC type Electromagnetic Delco Remy 12 - 0.75
GC70K STR
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Truck model
GC35K
Type Torque converter
4 ton class GC40K STR
GC40K
Manufacturer’s model
Power train
Reduction gear
Differential
3.2
Ratios
2.898
Reverse
2.907
Type of gear
Spiral bevel
Gear ratio
4.571
Housing
Banjo
Type of gear and pinion number
Gear
Straight bevel-2
Pinion
Straight bevel-4
Differential gear oil liter (U.S. gal) Type Steering system
Transmissi on/ Torque oil 15 (3.9)
14 (3.7)
9.1 (2.4) Full hydrostatic power steering
Steering wheel diameter, mm (in.) Power cylinder ID × rod diam., mm (in.) Effective stroke, mm (in.) Relief pressure, kPa (kgf/cm2) [psi] Flow rate, liter (U.S.gal)/min
Traveling system
Hydraulic and column shift
Forward
Transmission/ torque converter oil liter (U.S. gal)
Power steering
330 (13)
328 (12.9)
85×60 (3.3×2.4) 155 (6.1) 11768 (120) [1706] 23 (6.07)
Front axle
Full-floating tubular type
Rear axle
Elliott type
Suspension system
Front
Fixed type
Rear
Center-pivot type
Toe-in, mm (in.) Wheel alignment
GC45K STR
Okamura M15
Control and shift Powershift
GC45K SWB
3-element, 1-stage, 2-phase
Stall torque ratio
Transmission
4.5 ton class
Camber
0 1.0°
Caster
0°
Kingpin inclination
0°
1-17
CHAPTER 1 GENERAL INFORMATION Class Truck model
GC55K STR
GC55K
Type Torque converter
6.0 ton class
5.5 ton class
Manufacturer’s model
Power train
Reduction gear
Ratios
Hydraulic and column shift
Forward
2.898
(1st/2nd) 5.104/2.882
Reverse
2.907
(1st/2nd) 5.104/2.882
Spiral bevel
Hypoid gear
4.571
4.857
Type of gear Gear ratio
Banjo
Type of gear and pinion number
Gear
Straight bevel-2
Pinion
Straight bevel-4 Transmission/ Torque oil 15 (3.9)
Transmission/ torque converter oil liter (U.S. gal) Differential gear oil liter (U.S. gal)
9.1 (2.4)
Type
Full hydrostatic power steering
Steering system
Steering wheel diameter, mm (in.)
328 (12.9)
Power cylinder ID × rod diam., mm (in.) Power steering
Effective stroke, mm (in.) Relief pressure, kPa (kgf/cm2) [psi]
Traveling system
Flow rate, liter (U.S.gal)/min
1-18
85×60 (3.3×2.4) 155 (6.1)
180 (7.1)
11768 (120) [1706]
14710 (150) [2133] 23 (6.07)
Front axle
Full-floating tubular type
Rear axle
Elliott type
Suspension system
Front
Fixed type
Rear
Center-pivot type
Toe-in, mm (in.) Wheel alignment
GC70K STR
3.2
Housing Differential
GC70K
Okamura M15
Control and shift Powershift
GC60K
3-element, 1-stage, 2-phase
Stall torque ratio
Transmission
7.0 ton class
Camber
0 1.0°
Caster
0°
Kingpin inclination
0°
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Truck model
GC35K
Brake system
Type
Service brakes
Parking brake
4 ton class GC40K STR
GC40K
317.5 (12.50)
Lining (length×width thick×number), mm (in.)
330×63×10-2 (13×2.48×0.39-2)
Master cylinder ID, mm (in.)
28.57 (1.125)
Wheel cylinder ID, mm (in.)
31.75 (1.250)
130 (7.9) Mastervac (vacuum suspended)
Body
Assembled-frame type Type
Gear pump
Gear
Manufacturer’s type
KFP3240 AMBAS
Rated discharge, liter (U.S.gal)/min-1
98 (25.89)/2450
Drive line
Universal joint
Type Control valve
Hydraulic system
Flow regulator valve
GC45K STR
Mechanical, mounted on wheels
Brake fluid cc (cu.in) Brake booster
GC45K SWB
Self-adjusting, duo-servo
Drum diameter, mm (in.)
Type
4.5 ton class
Relief pressure, MPa (kgf/ cm2) [psi] Type
6000-C193 19.12
+0.5 +5 +71 0 (195 0 ) [2773 0 ]
Variable (Adjustable)
Regulated flow rate, valve liter (U.S.gal)/min
100 (26.4)
115 (30.38)
Simplex mast Lift cylinders
ID, mm (in.)
60 (2.36)
70 (2.75)
Duplex mast First lift cylinders
ID, mm (in.)
Duplex mast Second lift cylinders
ID, mm (in.)
Triplex mast First lift cylinders
ID, mm (in.)
Triplex mast Second lift cylinders
ID, mm (in.)
Tilt cylinders
Stroke, mm (in.)
Stroke, mm (in.)
Stroke, mm (in.)
Stroke, mm (in.)
Stroke, mm (in.)
1650 (65) 90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
55 (2.17)
60 (2.36)
1590 (62.60)
1585 (62.40)
90 (3.54)
110 (4.33)
820 (32.28)
845 (33.27)
60 (2.36)
70 (2.75)
1480 (58.27)
1530 (60.24)
ID, mm (in.)
100 (3.937)
Stroke, mm (in.)
120 (4.724)
Hydraulic tank capacity, liter (U.S.gal)
46 (12.1)
52 (13.6)
1-19
CHAPTER 1 GENERAL INFORMATION Class Truck model
GC55K
GC55K STR
Brake system
Type
Service brakes
Parking brake
6.0 ton class
5.5 ton class
317.5 (12.50)
Lining (length×width thick×number), mm (in.)
330×63×10-2 (13×2.48×0.39-2)
Master cylinder ID, mm (in.)
28.57 (1.125)
Wheel cylinder ID, mm (in.)
31.75 (1.250)
Type
Mechanical, mounted on wheels 130 (7.9) Mastervac (vacuum suspended)
Body
Assembled-frame type Type
Gear
Manufacturer’s type
KFP3240 AMBAS
SPG2-48L194
Rated discharge, liter (U.S.gal)/ min-1
98 (25.89)/2450
117.6 (31.07)/2450
Drive line
Universal joint
Type
Hydraulic system
Flow regulator valve
6000-C193
Relief pressure, MPa (kgf/cm2) [psi]
19.12
Type Regulated flow rate, valve liter (U.S.gal)/min
+0.5 +5 +71 0 (195 0 ) [2773 0 ]
Variable (Adjustable) 115 (30.38)
165 (43.56)
Simplex mast Lift cylinders
ID, mm (in.)
Duplex mast First lift cylinders
ID, mm (in.)
110 (4.33)
-
Stroke, mm (in.)
845 (33.27)
-
Duplex mast Second lift cylinders
ID, mm (in.)
60 (2.36)
-
1585 (62.40)
-
Triplex mast First lift cylinders
ID, mm (in.)
110 (4.33)
125 (4.92)
Stroke, mm (in.)
845 (33.27)
855 (33.66)
Triplex mast Second lift cylinders
ID, mm (in.)
70 (2.75)
80 (3.15)
Stroke, mm (in.)
1530 (60.24)
1495 (58.86)
ID, mm (in.)
100 (3.937)
110 (4.33)
Stroke, mm (in.)
120 (4.724)
139 (5.472)
52 (13.6)
69 (18.2)
Tilt cylinders
70 (2.75)
Stroke, mm (in.)
Stroke, mm (in.)
Hydraulic tank capacity, liter (U.S.gal)
1-20
GC70K
Drum diameter, mm (in.)
Brake booster
Control valve
GC60K
Self-adjusting, duo-servo
Brake fluid cc (cu.in)
Gear pump
7.0 ton class
80 (3.15) 1650 (65)
GC70K STR
CHAPTER 1 GENERAL INFORMATION Class
3.5 ton class
Truck model
GC35K
4 ton class GC40K STR
GC40K
Mast model
Mast and forks
Side rollers
Outer Inner, Middle
130×30×26×15 (5.1×1.2×1.0×0.6)
118×24×24×12 (4.6×0.9×0.9×0.47)
130×26×26×13 (5.1×1.0×1.0×0.5)
Bearing
Ball bearing
Diam × width, mm (in.)
118×32 (4.65×1.26)
Bearing Diam × width, mm (in.)
52×36 (2.05×1.42) BL834
BL1034
1220×150×50 (48×6×2)
Fork spread (outer width), mm (in.)
1060 (41.5)
Class
5.5 ton class
Truck model
GC55K
GC55K STR
Mast model
6.0 ton class
7.0 ton class
GC60K
GC70K
GC70K STR
CJ type
Flange ID × flange back Thickness × flange front Thickness × web thickness Mast and forks
130×34 (5.12×1.34)
Lubricated type needle roller bearing
Fork (length × width × thick), mm (in.)
Side rollers
GC45K STR
118×28×24×13 (4.6×1.1×0.9×0.5)
Lift chains
Main rollers
GC45K SWB
CJ type
Flange ID × flange back Thickness × flange front Thickness × web thickness
Main rollers
4.5 ton class
Outer
130×30×26×15 (5.1×1.2×1.0×0.6)
150×34×30×20 (5.9×1.3×1.2×0.8)
Inner, Middle
130×26×26×13 (5.1×1.0×1.0×0.5)
150×30×30×15 (5.9×1.2×1.2×0.6)
Bearing Diam × width, mm (in.) Bearing Diam × width, mm (in.)
Ball bearing 130×34 (5.12×1.34)
Lubricated type needle roller bearing 52×36 (2.05×1.42)
Lift chains Fork (length × width × thick), mm (in.) Fork spread (outer width), mm (in.)
150×36 (5.91×1.42)
58×40 (2.3×1.6) BL1034
1220×150×60 (48×6×2.4)
1220×150×65 (48×6×2.56)
1060 (41.5)
1230 (48.5)
1-21
CHAPTER 2 COOLING SYSTEM
Chapter 2 COOLING SYSTEM 1.
Structure
6 5 8
9
4 1
7
3
2 1. 2. 3. 4. 5.
Engine Universal joint Gear pump Fan belt Cooling fan
505708
6. 7. 8. 9.
Upper hose Lower hose Radiator Transmission oil cooler
2-1
CHAPTER 2 COOLING SYSTEM
2. 2.1
Removal and Installation Removing Fan Belt (Method by Removing Radiator)
Preparation Remove the radiator cover. Removal sequence
3
2 1
505709
1. 2.
Universal joint Tension pulley bolt (loosening only)
3.
Belt
Suggestions for removal and installation (1) Loosen the tension pulley bolt 2 until the fan tension becomes loose.
R CAUTION DO NOT loosen the lock bolt to such an extent that the tension pulley is removed. (2) Move the tension pulley toward the fan, then remove the belt.
2-2
CHAPTER 2 COOLING SYSTEM 2.2
Installation
To install, follow the reverse of removal procedure and do the following steps: (1) Before installing the belt, rotate the fan to check for smooth movement. If it generates an abnormal sound, replace the bearing. (2) After putting the belt on the drive and driven pulleys, push it midway between the pulleys to make sure the tension pulley moves freely. Then tighten the pulley bolt.
2.3
Inspection and Adjustment
Fan belt inspection (1) Check to make sure the belt is free of oil, grease, or other foreign matter. Replace the belt if necessary. A slightly dirty belt can be re-used by cleaning with cloth or paper. Do not attempt to clean the belt with gasoline or the like. (2) During engine overhaul or belt tension adjustment, closely examine the belt and replace if defective. Fan belt adjustment (1) Loosen the tension pulley bolt 1 by one to two full turns with ratchet wrench.
1 505710 1. Tension pulley bolt
(2) The belt will be properly secured by the tension spring. Tighten the tension pulley bolt 1.
2-3
CHAPTER 3 ELECTRICAL SYSTEM
Chapter 3 ELECTRICAL SYSTEM 1. 1.1
Electrical Components and Wiring Outline Locations of Electrical Components
1
2 3 4
609254
1. 2.
Switch box Horn
3. 4.
IGN relay Power relay
3-1
CHAPTER 3 ELECTRICAL SYSTEM
2
1
3
609244
1. 2.
Direction lever Meter panel
3.
Light switch and turn signal lever
Console box
1
2 3
Front side
609289
1. 2.
3-2
Direction (FNR) lever Light switch and turn signal lever
3.
Key switch
CHAPTER 3 ELECTRICAL SYSTEM IGN relay
609255
Power relay
609257
Thermoswitch
609245
3-3
CHAPTER 3 ELECTRICAL SYSTEM Speed sensor
609246
Fuse box
609251
3-4
CHAPTER 3 ELECTRICAL SYSTEM
2.
Console Box
2.1
Console Box Outline
1
2 3
Front side
4
609241
1. 2.
Direction (FNR) lever Light switch and turn signal lever Item
Key switch Screw
3. 4.
Key switch Screw (4 pieces)
Tightening torque 4 to 6 N·m (0.41 to 0.61 kgf·m) [2.95 to 4.43 lbf·ft] 1.6 to 2.4 N·m (0.16 to 0.24 kgf·m) [1.18 to 2.77 lbf·ft]
Note: -
Make sure there is no LOCTITE leakage on column cover. Apply LOCTITE 242 or equivalent to the threads of the key switch nut and tighten key switch nut to the specified tightening torque.
3-5
CHAPTER 3 ELECTRICAL SYSTEM 2.2
Disassembling Console Box
4
3 2 1 1 1
1 1
1
506000
1. 2.
Screw (6 pieces) Front cover
3. 4.
Rear cover Steering wheel
Preparation Place the key switch to the OFF position, and remove the cable from the ground side of the battery. (1) Remove screws 1 (2 pieces) that hold front cover 2. (2) Remove screws 1 (4 pieces) that hold rear cover 3. (3) Remove the steering wheel 4.
2.3
Assembling Console Box
To assemble console box follow the reverse of disassembly procedure.
3-6
CHAPTER 3 ELECTRICAL SYSTEM
3.
Meter Panel
3.1
Disassembling Meter Panel
2
3 1
1 5
4
505578
1. 2. 3.
Screw Meter cover Screw
4. 5.
Item Tightening torque of screw 1
Screw Connector
Value 0.2 to 0.4 N·m (0.02 to 0.04 kgf·m) [0.15 to 0.30 lbf·ft]
R CAUTION Be careful not to damage meter cover 2 when disassembling the meter panel.
3.2
Assembling Meter Panel
To assemble the meter panel, follow the reverse of disassembly procedure.
3-7
CHAPTER 3 ELECTRICAL SYSTEM 3.3
Warning Icons and Indicators
1
2
3
4
*
*
*
609243
1. 2.
Brake fluid warning icon Battery charge warning icon
3. 4.
Engine oil pressure warning icon Water temperature warning icon
1. Brake fluid warning icon
3. Engine oil pressure warning icon
-
This warning icon glows when the fluid level is lower than the specified level. 2. Battery charge warning icon
If this icon glows during operation, turn the engine OFF and check the oil level. Add oil as required.
-
If this icon glows during operation, stop the lift truck and check engine coolant level.
-
This warning icon glows when the charging system is not functioning properly. First, check the battery voltage. If the battery is fine, check the alternator drive belt for slippage or breakage.
4.Water temperature warning icon
Note: Warning icons marked with * are not available.
R CAUTION If the lift truck is operated with low engine oil level or with this warning icon glowing, overheating may result.
3-8
CHAPTER 3 ELECTRICAL SYSTEM
4.
Switch Box
1
4
1)
5 2
6
3
2) 2)
7
E00937
1. 2. 3. 4.
First speed mode/automatic mode selector switch (Only for 6 to 7 ton model) Driving interlock indicator icon, Neutral indicator icon ECM warning icon LPG empty indicator icon
1. First speed mode/automatic mode selector switch (Only for 6 to 7 ton model) -
First speed mode is for jobs requiring low travel speed and greater drawbar pull. Travel speed is 0 to 13.3 km/ h (0 to8.3 mph) Automatic mode shifts transmission up and down automatically. First speed is 0 to 9.5 km/h (0 to 5.9 mph). Second speed is 9.5 to 22.8 km/h (5.9 to 14.2 mph) First speed mode for operating at the speed-limit area (14 km/h [8.7 mph] at maximum), climbing or towing a lift truck.
2. Driving interlock indicator Icon/Neutral indicator icon Blinks if the operator leaves the seat with the direction lever in the FORWARD or REVERSE position while the engine is idling. Glows when the direction lever is placed in NEUTRAL (N) position.
5. 6. 7. 1) 2)
Mast interlock indicator icon Clogged air cleaner element indicator icon Torque converter oil temperature warning icon Automatic mode (First speed, Second speed) First speed mode
3. ECM warning icon Glows when engine control module (ECM) is abnormal. Consult your authorized lift truck dealer. 4. LPG empty indicator icon This warning icon glows when LPG is empty. 5. Mast interlock indicator icon This warning icon blinks when the operator is not In the normal operating position in the operator seat for 2 seconds. The mast will not move even if the lift, tilt and/or attachment levers are operated. This warning icon goes OUT if the lift, tilt and/or attachment levers are placed in the NEUTRAL position and the operator sits in the operator seat properly. 6. Clogged air cleaner element indicator icon Glows when air cleaner element is clogged. 7. Torque converter oil temperature warning icon This warning icon glows when the oil temperature is high and the danger of overheating is present.
3-9
CHAPTER 3 ELECTRICAL SYSTEM
5. 5.1
Main Electrical Components Key Switch (With Anti-restart Lock)
The key switch has a built-in anti-restart lock to prevent the key from being turned from ON position to START position while the engine is running. The anti-restart key switch will protect the starter and flywheel from damage by preventing the operator from restarting a running engine.
(OFF) (ON) B
(START)
M
S
505717
Connection table Terminal
B
M
Component
Fuse box, battery, and alternator
Fuse box and fuel-cut solenoid
(OFF)
z
Yes
(ON)
z-------------- ---------- --z
No
(START)
3-10
z-------------- -------------z--------------
S
Key insert/removal
Starter and neutral switch (powershift transmission)
------------z
No
CHAPTER 3 ELECTRICAL SYSTEM 5.2
Light Switch and Turn Signal Lever
1 L 10q 10q
1((
N R
2
3 4
25q25 q
501212
1. 2.
Light switch and turn signal lever Light switch OFF
3. 4.
Light switch 1 (Clearance light) Light switch 2 (Head light)
Note: Arrow indicates the front of lift truck.
1 T-1
T-3 L-2
T-2 L-1 L-3
2 505541
1.
Light switch and turn signal switch
2.
Horn contact
Light switch connection table Terminal
L-1
L-2
L-3
Destination
Power
Tail clearance light
Head light
Switch position OFF 1
z------------- -------------z
2
z------------- -------------z--------------
--------------z
3-11
CHAPTER 3 ELECTRICAL SYSTEM Turn signal switch connection table Terminal
T-1
T-2
T-3
Destination
Flash unit
Turn signal light (R side)
Turn signal light (L side)
Lever position
z------------- -------------z
R (RIGHT turn) N (NEUTRAL)
z------------- -------------z--------------
L (LEFT turn)
5.3
--------------z
Direction (FNR) Switch
FORWARD (F) NEUTRAL (N)
10q 10q
1
1((
REVERSE (R)
2 Terminal 4 Terminal 2
Terminal 3 Terminal 5 Terminal 1 505542
1.
Direction (FNR) lever
2.
Direction (FNR) switch
Note: Arrow indicates the front of lift truck. Connection table Lever position
Terminal
1
2
3
4
5
Destination
Lift truck controller
Grounding
Lift truck controller
Grounding
Lift truck controller
F (FORWARD) N (NEUTRAL) R (REVERSE)
3-12
z-------- ---------z z-------- ---------------------
---------------------
z-------- ---------------------
---------z ---------------------
---------z
CHAPTER 3 ELECTRICAL SYSTEM 5.4
Horn
Check that the horn sounds when applying the specified voltage to both terminals of the horn. Replace the horn with a new one if it does not sound or its sound is abnormal. Operating voltage: 9V to 16 V
609249
5.5
609250
Reserve Tank
This reserve tank is equipped with LPG empty indicator switch. Volume: Maximum 150 cc (9.2 cu. in) / Minimum 50 cc (3.1 cu. in) Note: LPG empty indicator light glows when the brake fluid level reaches the minimum level.
609247
5.6
Stop Light Switch
Connect a tester across the terminals and check that the lights turn ON and OFF when the amount of the push rod extended projection is within the specified value.
1
Measure the insulation resistance value across the terminals when the push rod is pushed in. Replace the switch if the measured insulation resistance value is less than the value listed below:
4mm (0.157 in.)
M10×1.25
2mm (0.079)
OFF ON 501216
1. Push rod
Item Insulation resistance
Limit value 1 M ohm or more with 500V insulation resistance tester
Rated voltage: DC12V
3-13
CHAPTER 3 ELECTRICAL SYSTEM 5.7
Thermoswitch
(1) Apply an ohmmeter between the terminal and body of the sender unit and check for continuity (resistance value). (2) Replace the sender unit if there is no continuity or the measured resistance value is outside the standard resistance value.
2
1
501217 1. Terminal
Item Working temperature range Internal resistance (Switch is in ON position) Insulation resistance (Switch is in OFF position)
Specified value -40°C (-40°F) to 130°C (266°F) 0.5 ohm or less 1M ohm or more
Note: When installing the thermoswitch, tighten to the specified torque. Tightening torque 31.4 to 47.1 N·m (3.2 to 4.8 kgf·m) [23.2 to 34.7 lbf·ft]
3-14
2. Body
CHAPTER 3 ELECTRICAL SYSTEM 5.8
Speed Sensor (Pulse Generator)
M16 x 1.5 mm (0.059 in.)
2
3 1 504590
1. 2.
O-ring Signal/yellow
3.
Ground/Black
Technical data DC resistance Insulation resistance
2.1 K ohm to 2.5 K ohm at +25°C (77°F) Over 1 M ohm at DC 500 V (Between connector terminal and body)
Operating temperature range
-30°C to +120°C (-22°F to +248°F)
Storage temperature range
-40°C to +120°C (-40°F to +248°F)
3-15
CHAPTER 3 ELECTRICAL SYSTEM 5.9
Relay
‣″•‧‟•‣ ••
‼″⁂″⁀
‵ ‴ ‣ ⁓› ‟ ⁄‟ ‣ ․ ⁈ ″‵‥․․‣‒‿•․ ․‧․‥• ‸‽‣‣•
IGN relay
‥• ‥•
‧
‧
1)
501222 1. Connecting diagram
Item Rated operating voltage
Specified value DC12 V
Working voltage
DC 3.0 to 7.0 V [initial, at 20 °C (68°F)]
Open-circuit voltage
DC 1.2 to 3.9 V [initial, at 20 °C (68°F)]
Coil resistance
80 ohm ± 10% [20 °C (68°F)]
Rated exciting current
168 mA ± 10% [20 °C (68°F)]
3-16
CHAPTER 3 ELECTRICAL SYSTEM Power relay
‿ ″ ‶ ⁁ ‒ ※⁀ ‒ ‼″ ⁂ ″ ⁀
‵″‣⁓‟‣․⁈‟⁀‟‧ ″ ‵″ ‣ ․ ‣ ‥ ‧ ‒ ‿ ⁁‧
609249
Item
Coil
Contact
Specified value
Nominal voltage
DC 12V
Pick-up voltage (Initial at 20°C)
DC 8V or less
Drop-out voltage (Initial at 20°C)
DC 0.6V to 6.0V
Coil resistance (at 20°C)
80 ohm ±10%
Rated excitation current
150mA ±10%
Rated consumption voltage
1.8W
Contact resistance (Initial)
Less than 50m ohm (at DC6V 1A)
Rated control capacity
20A 12V DC resistive load [at 85°C (185°F)]
3-17
CHAPTER 3 ELECTRICAL SYSTEM 5.10 Fuse Box
1
9
2
3
4
5
6
7
8 609257
Ref. No.
3-18
Circuit
Amp
1
Driving interlock indicator icon, FWD/REV solenoid, start safety relay, seat switch, mast interlock indicator icon, lift lock solenoid, and unload solenoid
10 A
2
Meter panel, T/M controller, T/C oil temp relay, dust indicator lamp, T/C oil temp lamp, and inter lock lamp relay 2
10 A
3
Engine harness, and engine check lamp
10 A
4
Back light, backup buzzer, flasher relay, turn signal light, strobe light, T/M change solenoid
15 A
5
Parking light, tail light, rear working light, head light
15 A
6
Stop light
10 A
7
Horn, IGN relay, and starter relay
10 A
8
Spare
15 A
9
Spare
10 A
CHAPTER 3 ELECTRICAL SYSTEM 5.11 Head Light
1
1)
2
609252
1. 2.
LED light Wire harness
1)
Light position should not be above the horizontal line
3-19
CHAPTER 3 ELECTRICAL SYSTEM 5.12 Rear Combination Light
1
2
3
1)
8
4
5
7
6
2)
609253
1. 2. 3. 4. 5.
Turn signal light (Yellow) Stop/Tail light (Red) Backup (White) Ground Tail
6. 7. 8. 1) 2)
Stop Back up Turn signal Rear combination light Connector
5.13 List of Lights Light Type
Capacity
Head light
12V-24W
Working light (Option)
12V-12W
Front (option)
Turn signal light Clearance light
12V-6W
Tail / stop light Rear
Backup light Turn signal light
3-20
12V/4.8W
CHAPTER 3 ELECTRICAL SYSTEM
6.
Mast Interlock System
The lift truck senses when the operator is not properly seated in the operator seat and will prevent the mast from operating until the operator is properly seated. In the following cases, the mast interlock system disconnects power to the hydraulic control valve and the mast will not lift, lower, or tilt even if the operating control levers are operated: -
6.1
1) 1)
The operator leaves the operator seat for approximately 2 seconds with the key switch in the U (ON) position regardless of whether the engine is running or not.
1) E00397
Mast interlock system functions
Key Switch
Engine
z (OFF)
Stop
U (ON)
Stop
Z (START)
Running
Operating Control Lever
Mast Interlock indicator light
Lift Lever
Tilt Lever
Seated
OFF
Not Active
Not Active
Not Seated
OFF
Not Active
Not Active
Seated
OFF
Lowering only
Not Active
Not Seated
Blink
Not Active
Not Active
Seated
OFF
Active
Active
Not Seated
Blink
Not Active
Not Active
Operator Seat
R WARNING -
Check the function of the mast interlock system at the daily (prestart) inspection. Even when the engine is not running, while the operator is sitting correctly in the operator seat and with the key switch in the ON position, it is possible for the mast to descend. Please be very careful. The parking brake is not automatically applied when the interlock is activated. When replacing the operator seat, BE SURE to select a genuine Cat lift truck seat with an operator presence switch and an operator restraint system.
Note: The mast interlock will work only for the lift and tilt levers. Attachments can be moved regardless of whether the mast interlock function is operating or not. Therefore, when the attachment lever is operated, some of the attachments will move, even though the engine is not running or the key switch is in the z (OFF) position, as a result of the handling load or of its own weight. When the key switch is in the U (ON) position, the lift lever will lower.
3-21
CHAPTER 3 ELECTRICAL SYSTEM
7.
Driving Interlock System R WARNING
-
Check the function of the driving interlock system at the daily (prestart) inspection. The parking brake is not automatically applied when the driving interlock is activated. When replacing the operator seat, BE SURE to order a genuine Cat lift truck seat with an operator presence switch and an operator restraint system.
-
1) No Power Travel
No Power Travel
1)
E00398 1) No Power Travel
In normal operation, your lift truck will drive in a creep mode when the direction lever is placed in the FORWARD or REVERSE position at engine idling (not depressing the accelerator pedal). If the operator then leaves the operator’s seat, the operator presence switch of the seat is activated to shift the FORWARD or REVERSE position into the NEUTRAL position electrically (the lever itself remains in the FORWARD or REVERSE position), and cut off the engine output to stop the lift truck. In this case, the parking brake does not synchronize with the driving interlock and is not automatically applied the moment the interlock is activated. Depending on the condition of the road (grade, for example), the lift truck may be accelerated, instead of being stopped.
R CAUTION (1) Prior to operating the lift truck, BE SURE to check the driving interlock for function. (2) While driving the lift truck, if you lift your hips above the seat for over 2 seconds, the driving interlock system will be activated, the same as in case of engine idling. (3) Always drive the lift truck correctly with safety in mind. (4) To restore the lift truck to its normal driving condition, sit properly in the operator's seat and depress the brake pedal to hold the lift truck. Then, return the direction lever to the NEUTRAL position and then shift it back into the FORWARD or REVERSE position.
7.1
Driving Interlock System Functions
Conditions Key Engine Switch
ON
3-22
ON
Function
Safety Warning
Operator Seat
Direction Lever
Not Seated
F/R
Driving inoperative
Driving interlock indicator light [BLINK]
Seated
F/R
Driving operative
Driving interlock indicator light [OFF]
Seated to Not Seated
F/R
For approximately 2 seconds driving operative
After approximately 2 seconds driving interlock indicator light [BLINK]
Seated to Not Seated to Seated
F/R
Within approximately 2 seconds driving operative
Within approximately 2 seconds driving interlock indicator light [OFF]
Not Seated to Seated
F/R
Driving inoperative
Driving interlock indicator light [BLINK]
Not Seated to Seated
F / R to N to F/R
Driving inoperative, then Driving interlock indicator light [BLINK] operative after NEUTRAL then [OFF] after NEUTRAL
CHAPTER 3 ELECTRICAL SYSTEM
8.
Neutral System
The lift truck is equipped with a device that prevents the engine from being started if the direction lever is not in the NEUTRAL position.
1 2 3 E00928 1. FORWARD (F) 2. NEUTRAL (N)
3. REVERSE (R)
R CAUTION Check the following when starting the engine: -
No one is around the lift truck. The parking brake is applied. The direction lever is in the NEUTRAL position. Operator is seated in the normal operating position.
8.1
Neutral System Functions
Conditions Safety Function Key Switch
Operator Seat
Direction Lever
OFF or ON
Seated or Not Seated
NEUTRAL
Engine starts only when the direction lever is in the NEUTRAL position
3-23
CHAPTER 3 ELECTRICAL SYSTEM
9. 9.1
Battery and Maintenance State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
Specific gravity reading at 20 °C (68°F)
Condition
Adjustment
1.280 to 1.265
Good
If the difference in S.G. between any two cells is 0.020 or less, continue to use as is. If the difference is more than 0.020, discharge the battery in an efficient manner. If the battery recovers, charge the battery to adjust the electrolyte S.G.
1.260 to 1.225
Half charged
Recharge battery to adjust electrolyte S.G. Check for any shortcircuited cables or corroded cable connections in the electrical system.
1.220 or less
Low battery (caution required)
Recharge battery. If the difference in S.G. is too much, charge the battery to adjust the electrolyte S.G.
If the difference in S.G. is more than 0.040.
A cell with a low S.G. may cause a short circuit. It is caused when electrolyte leaks or electrolyte rate is too high or too low.
Recharge the battery until its voltage and S.G. stabilize and remain constant for more than 2 hours. Charge the battery to adjust the electrolyte S.G. It should read between 1.280 and 1.265. If the difference in S.G. is more than 0.040 and a low S.G. is found in any of the cells, replace the battery with a new one. Conduct a high current discharge test after leaving the battery for 12 to 96 hours.
9.2
Specific Gravity Reading and State of Charge
Fully charged condition can be verified by the electrolyte S.G. (1.280 to 1.265), and also the reduction speed of electrolyte implies the battery condition. If the electrolyte in battery cell decreases to the level where the pole plates are exposed within one month, it may be overcharged. If the electrolyte amount remains sufficient for more than three months, the battery may be charged less.
9.3
Precautions for Battery Charging R CAUTION
(1) In slow charging, the charging current should be about 1/10 the capacity of the battery being charged. (2) In quick charging, the battery capacity in ampere should not be exceeded. (3) During charging, adjust the charging current so that the electrolyte temperature does not exceed 45°C (113°F). (4) When connecting cables to battery terminals, always connect the (+) terminal first, and when disconnecting, remove the (-) terminal first. (5) During charging, hydrogen gas is generated, which requires proper ventilation.
-
1
+
501226
1. Identification
R CAUTION -
3-24
BE SURE to turn OFF the key switch and lighting switch before disconnecting or connecting the battery cables (to prevent IC regulator from damage). When connecting battery cables, BE SURE to obtain the correct connecting angle in order to prevent cables’ interference with other equipment.
CHAPTER 3 ELECTRICAL SYSTEM
10. Wire Color Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first color shows a base color and the second color a marking color. Example: The wire color of B/W shows that its base color is B with a marking W. Note: For wiring identification, the same wiring color must be used for the circuit between the power supply and the load.
R CAUTION Be careful that allowable current of solid wires and that of strand wires are different even if they are of the same diameter.
10.1 List of Wire Color Codes Wire color code
Color name
B
Black
W
White
R
Red
G
Green
Y
Yellow
BR
Brown
L
Blue
LG
Light green
OR
Orange
P
Pink
GY
Gray
SB
Light blue
PU
Purple
3-25
CHAPTER 3 ELECTRICAL SYSTEM
11. Troubleshooting 11.1 Starter System Condition
Key switch
Starter will not crank engine
Possible cause
Action
Weak or dead battery
Recharge or replace
Short or open circuit
Repair or replace
Poor continuity in key switch
Replace
Starter or starter relay defective
Replace
Direction (FNR) lever not in NEUTRAL position
Move the direction lever to NEUTRAL position
Turning OFF key switch Open or short circuit will not stop engine
Repair or replace
11.2 Lighting System Condition
Will not light
Lights (in general)
Will light dimly
Head light
Will not light
Will not blink
Will not go out Turn signal light Will blink too slow
Will blink too fast
Other lights
3-26
Backup light will not light
Possible cause
Action
Weak or dead battery
Recharge or replace
Open or short circuit
Repair or replace
Poor grounding
Clean ground spot and re-make connection
Switch defective
Replace
Weak battery
Check and recharge
Contact points in switches defective
Repair or replace
Loose terminals
Repair
Dirty lenses
Clean
Water drops inside lenses
Dry and replace packings
Bulbs expired in service life
Replace
Lighting switch defective
Replace
Bulbs burnt out
Replace
Turn signal switch defective
Replace
Turn signal relay defective
Replace
Turn signal relay defective
Replace
Bulbs burnt out
Replace
Low wattage of bulbs
Replace to a correct one
Bulbs burnt out
Replace
Turn signal relay defective
Replace
High wattage of bulbs
Replace to a correct one
Turn signal relay defective
Replace
Backup light switch defective
Repair or replace
Bulbs burnt out
Replace
CHAPTER 3 ELECTRICAL SYSTEM 11.3 Alarm Unit Condition
Possible cause
Will not give blast of sound Horn
Will give abnormal sound
Action
Fuses blown out
Check and replace
Short or open circuit
Repair or replace
Horn switch defective
Replace
Horn defective
Replace
Horn button defective
Repair or replace
Horn switch defective
Replace
Horn defective
Replace
11.4 Battery
Condition
Possible cause
Alternator
Tends to run down rapidly
Regulator
Battery
Wiring
Wiring Tends to get overcharged Regulator
Action
Drive belt slipping
Adjust
Stator coil grounded or open-circuited
Repair or replace
Rotor coil open
Replace
Brushes poorly seating on slip rings
Replace brushes if worn Clean holder and polish slip rings
Diode ruptured
Replace
Regulated voltage setting too low
Replace
Not enough electrolyte or wrong concentration of acid to water
Refill and check specific gravity
Battery cell plates deteriorated (forming, possibly internal short-circuit)
Replace
Terminal connections loose
Clean and retighten
Open or loose connection between F terminals of regulator and alternator
Repair
Regulator IC and F terminals shorted or wired wrong
Repair
Poor grounding of regulator F terminal
Repair
Pressure coil open-circuited
Replace
Regulated voltage too high
Replace
3-27
CHAPTER 3 ELECTRICAL SYSTEM Condition
Possible cause Alternator belt
Alternator
Regulator Weak battery Battery
Wiring
Wiring Battery excessive charging Regulator
3-28
Action
Slipping
Adjust the tension
Stator coil grounded or open circuit
Repair or replace
Rotor coil open
Replace
Brushes poorly seating on slip rings
Clean holder and polish slip rings
Brush movement defect
Adjust, replace brushes if worn
Diode short circuit or open circuit
Replace
Regulating voltage is too low
Adjust
Defective or inappropriate electrolyte
Refill or adjust the S.G.
Defective cell plates (internal short-circuit)
Replace
Poor terminal connections due to insufficient tightening torque
Clean and tighten
Open or loose connection between the key switch and regulator IC terminal
Repair
Fuse blown in the above mentioned circuit or poor contact in the holder
Replace fuse or repair the holder's contact part
Open or loose connection between the regulator F terminal and alternator F terminal
Repair
Regulator IC and F terminals shorted or incorrectly wired
Repair
Defective grounding of regulator F terminal
Repair
Pressure coil open circuit
Replace
Regulating voltage too high
Adjust
CHAPTER 4 POWER TRAIN
Chapter 4 POWER TRAIN 1.
Specifications Item
3.5 to 5.5 ton Type
Torque converter
Three-element one-stage two-phase
Manufacturer model
M15
Stall torque ratio
3.2 F/R electrical column shift, H/L automatic transmission
Operation method Transmission
Forward
First: 2.898
First: 5.104 Second: 2.882
Reverse
First: 2.907
First: 5.104 Second: 2.882
Spiral bevel gear
Hypoid gear
4.571
4.857
Transmission ratio
Transmission system
Reduction
Gear type Reduction ratio Housing
Differential
Running gear
6.0 to 7.0 ton
Type and number of gears
Front axle type Front wheel suspension
Banjo-type Large
Straight bevel gear × 2
Small
Straight bevel gear × 4 Full-floating axle tube type Fixed frame type
4-1
CHAPTER 4 POWER TRAIN
2.
Structure (3.5 to 5.5 Ton)
10 4
•
6
5
3
2
1
• •
•
• •
11 9 12
• •
7
8
505715
1. 2. 3. 4. 5. 6.
Engine Flywheel Torque converter (M15) Transmission Input shaft (First axle) Counter shaft (Second axle)
7. 8. 9. 10. 11. 12.
Counter shaft (Third axle) Output shaft (Fourth axle) Reduction differential Front wheel hub Wheel brake Front axle
The transmission system transmits drive power generated by the engine to the drive shaft. It consists of the following equipment: (1) Torque converter The torque converter plays the role of the clutch. It also increases and transmits engine torque to the transmission. (2) Transmission The transmission changes rotational speed when engine torque is transmitted to the universal joint. (3) Reduction differential The Reduction differential Reduces rotational speed and distributes power to the left and right driving wheels. It also prevents slippage by controlling the rotational speed of the two wheels (in turning to the left/right).
4-2
CHAPTER 4 POWER TRAIN
3.
Structure (6.0 to 7.0 Ton)
10 4
6
5
3
2
1
• •
•
•
• •
11 9 12
• •
7
8
505721
1. 2. 3. 4. 5. 6.
Engine Flywheel Torque converter (M15) Transmission Input shaft (First axle) Counter shaft (Second axle)
7. 8. 9. 10. 11. 12.
Counter shaft (Third axle) Output shaft (Fourth axle) Reduction differential Front wheel hub Wheel brake Front axle
The transmission has first and second shifts in FORWARD and REVERSE modes.
4-3
CHAPTER 4 POWER TRAIN 3.1
Reduction Ratio (3.5 to 5.5 Ton)
(25)
(29)
(32)
(37) (7)
(22)
(40)
(32) (51)
505722
Note: Number in parentheses indicates the number of teeth on the gear.
4-4
CHAPTER 4 POWER TRAIN 3.2
Reduction Ratio (6.0 ton 7.0 Ton)
(52) (34)
(24)
(34)
(24)
(18) (52) (7)
(36)
(45)
(34)
505723
Note: Number in parentheses indicates the number of teeth on the gear.
4-5
CHAPTER 4 POWER TRAIN
4.
Removing Engine
Remove the power line in the following sequence: (1) Remove the engine. (2) Remove the transmission and the reduction differential.
4.1
Preparation
(1) Remove the ground button clamp from the battery. (2) Drain cooling water from the radiator. (3) Drain engine oil and oil in the oil cooler piping.
4-6
CHAPTER 4 POWER TRAIN 4.2
Removal Sequence (1)
1
3
5
5
6
10
3
8
5
8 2 7 4 4
7
9
505724
1. 2. 3. 4. 5.
Light harnesses, Overhead guard Engine cover, Seat Radiator cover Floor plate Battery cable, Battery
6. 7. 8. 9. 10.
Reserve tank Steering wheel, Forward/reverse lever assembly Transmission oil hoses Transmission oil cooler, Bracket Cowl
4-7
CHAPTER 4 POWER TRAIN 4.3
Removal Sequence (2)
16 11
14 19 16 15 13
17
12
18
505725
11. 12. 13. 14. 15.
Upper hose Fan belt Tension pulley Fan assembly Lower hose
16. 17. 18. 19.
Exhaust pipe (left and right) Air cleaner hose Air cleaner Engine control cable
Note: Exhaust pipe (left and right) 16 and engine control cable 19 were changed in 2004. Engine control cable 19 is not used, and exhaust pipe (left and right) 16 has the same O-ring and clamping flange on both ends.
4-8
CHAPTER 4 POWER TRAIN 4.4
Removal Sequence (3)
20
24 1)
25
25
22
1)
26
20
25
23
22
21 21
21 505726
20. Engine harnesses 21. Vacuum hoses, Vacuum tank 22. Engine oil hoses
23. 24. 25. 1)
Universal joint Engine mounting bolt, Cushions Engine assembly Lifting lug
Note: Fuel pump and hose 23 were changed in 2004. Lifting lugs were moved to opposite sides of engine.
4-9
CHAPTER 4 POWER TRAIN Suggestions for removal (1) (2) (3) (4)
When removing transmission oil cooler 9, be careful not to spill the oil out of the cooler. Remove fan assembly 14 and tension pulley 13 in subassembled condition. Remove the engine control cable 19 from the engine. Remove engine harnesses 20 from the engine at sockets and terminals. To prevent damage, tack the removed harnesses along the main harness. (5) Remove engine oil hoses 22 from the engine oil filter inlet/outlet. (6) To remove the engine, attach a wire rope on engine lifting lugs 1 and lift the engine using a crane until the wire rope is stretched tight.
1
1 505727 1. Lifting lug
Item Engine unit (service weight)
Value 270 kg (595 lb)
(7) Place wood blocks or a jack under the transmission where the rear leg is removed. (8) Remove the universal joint 24 from the engine.
505728
4-10
CHAPTER 4 POWER TRAIN
5.
Installing Engine
Follow the removal sequence in reverse.
5.1
Suggestions for Installation
(1) When installing the engine mounting nut, tighten the nut a quarter rotation from the position where the nut contacts with the mounting bracket. (2) When installing the engine exhaust pipe, replace the gasket with a new one. (3) To connect battery cables, connect positive cables first. Make sure all cables are connected properly. (4) Refill radiator. Fill the radiator with antifreeze coolant to the specified level. Unless otherwise specified, use 60% antifreeze concentration and 40% soft water. (5) Add engine oil. (6) Check the oil level of the hydraulic tank and the transmission. Refill if necessary. (7) Make sure that the engine is correctly installed. (8) Checking with engine running Start the engine and check for vibration. If the vibration of engine is excessive, tighten the engine mounting bolts and check if the vibration decreases.
1 2 3 505729 1. Bracket 2. Cushion
3. Bracket at frame
4-11
CHAPTER 4 POWER TRAIN
6.
Removing Transmission and Reduction Differential
Remove the transmission and reduction differential after the engine is removed. To remove the engine, see the previous section.
6.1
Preparation
(1) Drain transmission oil. (2) Drain oil from the front axle housing.
4-12
CHAPTER 4 POWER TRAIN 6.2
Removal Sequence
2 1
1
1
2
1 4 8
7
6
3
5
5 505730
1. 2. 3. 4.
6.3
Cords (ground), Harnesses Oil cooler hoses Tube (Brake fluid) Inching cable
5. 6. 7. 8.
Brake pipe Pedal assembly Front axle shaft Transmission and reduction differential
Suggestions for Removal
(1) Remove oil cooler hoses 2 from the transmission. Tack the removed hoses along the right of the frame. (2) Remove inching cable 4 from the transmission. (3) When removing transmission and the reduction differential 8, use two slings. Attach the ropes to the location of center of gravity using a cow hitch.
4-13
CHAPTER 4 POWER TRAIN
7.
Installing Transmission and Reduction Differential
Follow the removal sequence in reverse.
7.1
Suggestions for installation
(1) Adjusting output shaft with shims (unit: mm) Replace the output shaft and the reduction gear as an assembly if the gear teeth are defective. When installing the output shaft, adjust shims and check the tooth contact. Torque converter drive automatic 2-speed transmission Determine the thickness of shims using the equation below before installing the bearing: Dimension “a” is punched on the upper surface of differential carrier.
c
1
Shim thickness C = 1.7 + a/100 – b a: Machining error of differential carrier b: Machining error of bevel pinion gear
±b ±
a 100
505731
1. Centerline of axle
(2) Before installing the differential assembly to the front axle housing, clean the mounting surfaces and apply liquid gasket on the surfaces, and tighten the bolts. (3) After the brake/inching pedal cables are connected, make sure that the level of each pedal and protrusion of the clutch valve plunger comply with the standard value. (4) Fill the transmission and the front axle housing with oil. Check for oil leaks. (5) Bleed air from the brake fluid lines.
4-14
CHAPTER 4 POWER TRAIN
8.
Service Data Unit: liter (U.S.gal) Item
Engine coolant
Engine oil
3.5 to 4.5 ton Engine
7.15 (1.9)
Radiator
3.2 (0.8)
Reserve tank
0.65 (0.2)
Total
11 (2.9)
Oil pan
4.2 (1.1)
Oil filter
0.8 (0.2)
Total
5.0 (1.3)
Transmission/torque converter oil
14 (3.7)
Differential gear oil Hydraulic oil Brake fluid cc (cu.in)
5.5 to 6.0 ton
7.0 ton
15 (3.9) 9.1 (2.4)
46 (12.1)
52 (13.6)
69 (18.2)
130 (7.9)
4-15
CHAPTER 5 POWERSHIFT TRANSMISSION
Chapter 5 POWERSHIFT TRANSMISSION 1. 1.1
Specifications 1-Speed Transmission (3.5 to 5.5 Ton) Item
3.5 to 5.5 ton Type
Torque converter
3 element 1 stage 2 phases
Manufacturer model
M15
Stool torque ratio
3. 2
Operation type
Power transmission Transmission
F/R electric column shift Forward
2.898 (
Backward
2.622 (
Gear ratio
40 32 40 32
×
×
51 22 40 32
)
×
51 22
)
5-1
CHAPTER 5 POWERSHIFT TRANSMISSION
2. 2.1
Structure Torque Converter
1 2
17
3
16
4 5 6 7
15
8
14
9
10
13 1. 2. 3. 4. 5. 6. 7. 8. 9.
5-2
Drive cover Flexible plate Turbine assembly Stator assembly Thrust washer Thrust bearing Thrust washer Spacer Pilot boss
12 , 11 10. 11. 12. 13. 14. 15. 16. 17.
609080
Ball bearing Spring cup Spring Roller Pump boss Ball bearing Stator hub Pump impeller
CHAPTER 5 POWERSHIFT TRANSMISSION 2.2
Transmission 1-Speed b
1
2 •
•
•
a
3
• 9
•
•
c
•
4
•
8 •
7 •
e •
5 •
h
d •
f •
6
g 2nd shaft 1st shaft 3rd shaft
4th shaft
609081
1. 2. 3. 4. 5.
Control valve Oil pump assembly Torque converter assembly Turbine shaft (1st shaft) Flexible plate Range
6. 7. 8. 9.
Output shaft (4th shaft) Countershaft (3rd shaft) Clutch shaft (1st shaft) Countershaft (2nd shaft)
Path
Forward
c6efgh
Reverse
dbaefgh
Note: Illustration shows 3.5 to 5.5 ton.
5-3
CHAPTER 5 POWERSHIFT TRANSMISSION 2.3
Powershift Control
8
1 2
7 4 9 6 1. 2. 3. 4. 5.
2.4
3
5
Transmission shift lever Inching bracket Control valve Solenoid valve (for FOWARD) Solenoid valve (for REVERSE)
609082
6. 7. 8. 9.
Clutch valve plunger Inching lever Cable Inching pedal
Control Valve
1 B
1)
B
2 C
3
4
2) D
D
3) 5 1. 2. 3. 4.
5-4
Accumulator piston Main regulator valve Clutch valve plunger Inching valve
609083
5. 1) 2) 3)
Directional spool Section B-B Section C-C Section D-D
CHAPTER 5 POWERSHIFT TRANSMISSION 2.5
Powershift Transmission Control
4
3
5
PC
2)
6
7
8
R
9
P2 F
7 P1
2
4)
10
PM
3) 11
1)
12
PD
5)
1 13 1. 2. 3. 4. 5. 6. 7. 8. 9.
PL
Oil cooler Torque converter Accumulator valve Main regulator valve Clutch (inching) valve FR filter Last chance filter Solenoid valve Directional valve (Valve top surface) Item
609084
10. 11. 12. 13. 1) 2) 3) 4) 5)
Solenoid valve Gear pump Suction strainer Lubrication oil Torque converter outlet pressure Valve top surface with D stamp Valve top surface with M stamp Torque converter inlet pressure Lubricating circuit Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.05 to 0.29 MPa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
All tests run
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine rpm
5-5
CHAPTER 5 POWERSHIFT TRANSMISSION
3. 3.1 (1) (2) (3) (4) (5) (6)
3.2
Removal and Installation Removal Drain coolant and oil from the engine, transmission, and oil cooler piping. Drain gear oil from the front axle housing. Remove the front axle shafts. Unscrew the torque converter flexible plate mounting bolts and remove the engine from the lift truck. Remove the transmission and the differential as an assembled unit from the lift truck. Separate the transmission from the differential.
Installation
(1) Couple the transmission to the differential. Install the torque converter into the transmission case. Install the torque converter so that the distance between the end face of the housing and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.). (2) Install the transmission and differential assembly on the front axle. (3) Install the front axle shafts. (4) Couple the transmission to the engine and mount it on the lift truck. Make sure the clearance between the flywheel and the flexible plate is approximately 0 to 2 mm (0 to 0.078 in.) when the transmission is coupled to the engine. If the clearance is zero, it is an indication that the torque converter is improperly coupled to the pump gear or splines. Recouple the transmission to the engine correctly. Tighten the flexible plate mounting bolts to the flywheel through the access hole in the case. Note: Tighten the bolts evenly in a criss-cross pattern. (5) Connect pipes to the radiator. (6) Fill the following parts with oil or water. Front axle: Gear oil Transmission: Torque converter oil Radiator, engine: Coolant, anti-freeze coolant Fill engine oil, hydraulic oil, etc. Note: For removal/installation of the engine, and the transmission and differential assembly, See “POWER TRAIN”.
5-6
CHAPTER 5 POWERSHIFT TRANSMISSION
4. 4.1
Disassembling Torque Converter Disassembly Sequence
5
4
6
7 3
6
4 7 1 2 3 608989
1. 2. 3. 4.
4.2
Bolts, Spring washers, Plate Flexible plate, Pilot boss, O-ring Bolts, Drive cover, Ball bearing Spacer, Turbine assembly
5. 6. 7.
Thrust washer, Thrust bearing Stator assembly, Rollers, Hub, Spring, Spring cup Ball bearing, O-ring, Pump boss, Pump impeller, Bolts
Suggestions for Disassembly
The torque converter assembly has no drain plug and cannot be drained completely. Drain oil by turning pump boss 7 downward when the assembly is removed.
5-7
CHAPTER 5 POWERSHIFT TRANSMISSION
5.
After Disassembling Torque Converter
5.1
Pump Impeller
(1) Check for cracks. (2) Check for oil leaks due to loose pump boss bolts at impeller or defective O-ring. (3) Check the face of pump boss for wear in contact with oil seal.
1
608990 1. O-ring
5.2 (1) (2) (3) (4) (5) (6)
Stator Assembly Check the stator assembly blade for cracks and loose fit to the clutch cam. Check the clutch hub and cam for wear or flaws. Check the springs and spring caps for wear, breakage, or distortion. Check the rollers for flaws, distortion, or wear. Check the clutch hub splines for defects. Check the thrust washers for wear or other defects.
4) •
2) 1)
3) 608991
Ref.
Item
Standard
Limit
1)
Outside diameter of clutch hub
65 -0.049mm (2.56 -0.00193 in.)
2)
Diameter of clutch rollers
8.1 -0.015mm (0.32 -0.00059 in.)
3)
Thickness of thrust washer Thickness of thrust washer
4)
5.3
-0.03
-0.0012
6.49 mm (2.555 in.)
0
0
7.985 mm (0.31437 in.)
2.0 -0.05mm (0.08 -0.0020 in.)
0
0
1.75 mm (0.0689 in.)
0 0 3 -0.05mm (0.12 -0.0020 in.)
2.75 mm (0.1083 in.)
Turbine Runner
(1) Check the blades for cracks. (2) Check the fit of turbine boss in the runner. (3) Check the turbine boss splines for wear or other defects.
5-8
CHAPTER 5 POWERSHIFT TRANSMISSION 5.4
Pilot Boss
Check the portion in contact with the pilot bearing for wear or other defects.
1)
608992
Ref.
Item
Standard
1)
Diameter of portion in contact with pilot bearing
20 -0.020mm (0.78 -0.00079 in.)
5.5
-0.007
Limit
-0.00028
19.85 mm (0.781 in.)
Flexible Plate
(1) After installing flexible plate, measure the face runout of the plate with a dial gauge. Replace the plate if the runout exceeds the service limit. Item Face runout of flexible plate
Standard
Limit
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
(2) When the flexible plate is installed on the transmission, make sure the clearance between the end face of the transmission case and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.).
1)
608993
Ref. 1)
Item Distance between T/C housing and surface and Flywheel fitting surface of Flexible plate
Standard 4 to 6 mm (0.157 to 0.236 in.)
Note: After installing the flexible plate, fasten the plate to the transmission case with wire.
5-9
CHAPTER 5 POWERSHIFT TRANSMISSION
6. 6.1
Assembling Torque Converter Assembly Sequence
•
1
11
•
7
12
3
•
2 •
16
•
15
•
•
•
13 14
• •
• ••
• •
•
10 9 8
6
4
5
608994
1. 2. 3. 4. 5. 6. 7. 8.
5-10
Pump impeller Pump boss, O-ring, Bolt, Washer Ball bearing Stator assembly Spring, Spring cap Rollers Stator hub Thrust washer
9. 10. 11. 12. 13. 14. 15. 16.
Thrust bearing Thrust washer Turbine assembly Drive cover, O-ring, Bolt, Washer Spacer Ball bearing Pilot boss, O-ring Flexible plate, Bolt, Washer
CHAPTER 5 POWERSHIFT TRANSMISSION 6.2
Suggestions for Assembly 5 5
Stator assembly (1) Position stator hub 7 in the stator as shown. Put spring 5 and spring cup 5 in each hole, and press in the roller 6 while pushing the spring cap. (2) Install total of ten rollers, and return the stator hub in its original position. (3) Upon assembling, rotate the stator hub by hand, making sure that it rotates in one direction.
6
7
608995
Selection of spacer
A
Measure the dimensions A, B and C, and select spacer D so that the clearance is 0.2 to 0.8 mm (0.0078 to 0.0315 in.) and insert it in place.
D
B
C
608996
Part numbers
Thickness of spacer
91823-01700
2.5 mm (0.098 in.)
91823-01600
2.7 mm (0.106 in.)
91823-01400
3.0 mm (0.118 in.)
Standard dimensions
A
22.1 mm (0.87 in.)
B
16 mm (0.63 in.)
C
3.5 ± 0.05 mm (0.138 ± 0.002 in.)
5-11
CHAPTER 5 POWERSHIFT TRANSMISSION
7.
Disassembling Transmission
7.1
Control Valve and Strainer
Disassembly sequence
3
4
2 1
6
5 6
1) 5 608997
1. 2. 3.
Drain plug, Washer Torque converter thermo unit Control valve
Note: Suction pipe replaced by hose on 3.5 to 5.5 ton models.
5-12
4. 5. 6. 1)
Subplate, Gasket Strainer pipe, Bolts Strainer assembly, Gasket, Bolts New for 3.5 to 5.5 ton models
CHAPTER 5 POWERSHIFT TRANSMISSION 7.2
Pump Body Assembly
Disassembly sequence
6 1 2 4
5
3 4
608998
1. 2. 3.
Pump body, Oil seal, Bushing Internal gear, Drive gear, O-ring Stator shaft, Cap, Dowel pin
4. 5. 6.
Valve, Spring, Washer, Snapring Gasket Turbine shaft, Seal ring, Snapring
Note: It is not unnecessary to remove the cap and dowel pin from the stator shaft or the bushing and oil seal from the pump body unless they are defective. Suggestion for disassembly Removing pump body assembly
1
Unscrew all bolts securing the pump body assembly, and remove the assembly by making use of the jacking bolt holes in the stator shaft.
608999 1. Bolt
Special tool Bolt
Part number 67284-15400
5-13
CHAPTER 5 POWERSHIFT TRANSMISSION 7.3
Countershaft (2nd Shaft)
Disassembly sequence
3 51
2
6 7 4 609000
1. 2. 3. 4.
Snapring Rear cover, O-ring Countershaft Ball bearing
5. 6. 7.
Countergear Ball bearing Countergear, Snapring
Suggestion for disassembly Removing bearings Remove snapring 1 from its groove in advance. Screw a sliding hammer into the tapped hole in shaft 3, pull off the shaft, and remove bearings 4 and 6 from the transmission case.
5-14
CHAPTER 5 POWERSHIFT TRANSMISSION 7.4
Countershaft (3rd Shaft)
Disassembly sequence
7
6
3 4
2
5
1
609001
1. 2. 3. 4.
7.5
Snapring Rear cover, O-ring Countershaft Ball bearing
5. 6. 7.
Countergear Roller bearing (inner) Countergear, Snapring
Countershaft (3rd Shaft)
Disassembly sequence
4
3
2 1 5
609002
1. 2. 3.
Output cover Output shaft subassembly Ball bearing
4. 5.
Output gear Shims
5-15
CHAPTER 5 POWERSHIFT TRANSMISSION Suggestion for disassembly Removing output shaft Using the special tool, pull out the output shaft. The output gear will interfere with the input shaft drum; this makes it necessary to remove the output shaft by tapping the output gear with a copper hammer through the countershaft (3rd shaft) mounting hole.
1 1. Special tool
Special tool Puller
Part number 91868-02100
Shims Reuse the shims removed during disassembly.
5-16
609003
CHAPTER 5 POWERSHIFT TRANSMISSION 7.6
Forward-Reverse Clutch Shaft (Current Production)
Disassembly sequence
1
2
4
3
5
7
6
8 20
2625 27 28 29 30
29
23
16
2214 21
24
15 16
19 18
13 17
11
12
10
9
19
609005
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Servo case, O-ring O-ring Seal ring Ball bearing Thrust washer Forward gear Needle bearing Thrust washer Ball bearing Thrust washer Reverse gear Needle bearing Thrust washer Snapring Pressure plate
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Friction plate, Mating plates Snapring Pressure plate Friction plate, Mating plates Snapring Retainer Spring Clutch piston, Ball, Screw Seal ring Snapring Retainer Spring Clutch piston, Ball, Screw Seal ring Clutch shaft
Note: It is unnecessary to remove the balls and screw from the clutch piston, the screw from the clutch shaft, or the steel ball from the servo case.
5-17
CHAPTER 5 POWERSHIFT TRANSMISSION 7.7
Forward-Reverse Clutch Shaft (First Production)
Disassembly sequence
2
4
3
5
7
6
8 20 28 30
1
2625 2927
29
23
16
14 22 21
24 19
15 16
18
11 13 17
10 12
9
19
609006
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Servo case (O-ring) O-ring Seal ring Ball bearing Thrust washer Forward gear Needle bearing Thrust washer Ball bearing Thrust washer Reverse gear Needle bearing Thrust washer Snapring Pressure plate
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Friction plate, Mating plates Snapring Pressure plate Friction plate, Mating plates Snapring Retainer Spring Clutch piston (Ball, Screw) Seal ring Snapring Retainer Spring Clutch piston (Ball, Screw) Seal ring Clutch shaft
Note: It is unnecessary to remove the balls and screws from the clutch piston, the screw from the clutch shaft, or the steel ball from the servo case.
5-18
CHAPTER 5 POWERSHIFT TRANSMISSION
1
Suggestion for disassembly Disassembling clutch drum Using the special tool or an arbor press, compress return springs 22 and 27, and remove snaprings 20 and 25.
609007 1. Special tool
Special tool
Part number
Piston tool
8.
92267-00300
Inspection and Repair After Disassembling Transmission
8.1 (1) (2) (3) (4)
Oil Pump Install the internal gear and the drive gear in the pump body, and measure top clearance 2. Using a dial gauge, measure side clearance 1 between the gears and the pump case. Measure clearance 3 of the drive gear in the pump boss (notch). Check the relief valve for distortion or other defects.
1 3 2
609008
Ref.
Item
Standard
Limit
1
Side clearance
0.05 to 0.11 mm (0.0019 to 0.0043 in.)
0.20 mm (0.0079 in.)
2
Top clearance
0.6 to 0.66 mm (0.0236 to 0.0259 in.)
0.8 mm (0.031 in.)
3
Drive gear clearance in pump boss notch
0.2 to 0.4 mm (0.008 to 0.016 in.)
1.0 mm (0.039 in.)
5-19
CHAPTER 5 POWERSHIFT TRANSMISSION 8.2
Pump Boss
2
1
Ref.
Item
Standard
1
Diameter of portion in contact with oil seal and bushing
70 -0.0046mm (2.76 -0.00181 in.)
6.90 mm (2.7520 in.)
2
Inside diameter of boss bushing
70.06 to 70.10 mm (2.7583 to 2.7598 in.)
70.3 mm (2.768 in.)
8.3
0
609009
Limit 0
Stator Shaft
(1) Make sure that bearings fit tight to the shaft. (2) Check the splines for wear or damage. (3) Check the oil passages for clogging.
8.4
Clutch Pistons
(1) Shake each piston, making sure that the balls move freely in the piston. Note: Do not overhaul the pistons unless they are defective. (2) Check the seal rings and their grooves for wear or damage.
1 1. Seal ring
8.5
Friction Plates and Mating Plates
(1) Check for sign of seizure, uneven contact, warpage, or excessive wear. (2) Check the splines for wear or damage. (3) Check the oil passages for clogging.
5-20
609010
CHAPTER 5 POWERSHIFT TRANSMISSION 8.6
Clutch Drums
(1) Check the mating plate sliding surfaces for wear or damage. (2) Check the clutch piston sliding surfaces for wear or damage.
8.7
Clutch Gears (Forward and Reverse)
(1) Check the gear and the splines for wear or damage. (2) Check the gear surface in contact with needle roller bearing for wear or damage.
7, 8
6
3
2
1 4
5 Ref.
Item
Standard
Limit
1
Thickness of mating plate
2.3 ± 0.07 mm (0.091 ± 0.028 in.)
2.1mm (0.0028 in.)
2
Thickness of friction plate
2.6 ± 0.1 mm (0.102 ± 0.004 in.)
2.2 mm (0.087 in.)
3
Backlash of friction plate with gear
0.10 to 0.30 mm (0.0039 to 0.0118 in.)
-
4
Width of seal ring
4 -0.03mm (0.16 -0.0012 in.)
5
Width of seal ring groove in piston
6
-0.01
-0.0004
3.5 mm (0.138 in.)
4 +0.1mm (0.16 +0.004 in.)
+0.2
+0.008
4.5 mm (0.177 in.)
Free length of clutch spring spring constant
62.9 mm (2.476 in.) 31.312 N·m (3.193 kgf·m) [178.648 lbf·in.]
62 mm (2.440 in.)
7
Width of clutch piston seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
2.0 mm (0.079 in.)
8
Width of clutch piston seal ring groove
2.5 +0.1mm (0.098 +0.004 in.)
+0.2
+0.008
609011
3.1 mm (0.122 in.)
5-21
CHAPTER 5 POWERSHIFT TRANSMISSION 8.8
Turbine Shaft and Clutch Shaft
Check the seal ring and the contact surface for wear or damage.
1)
4) 5)
6)
2)
3) 609012
Ref.
Item
Standard
Limit
1)
Width of turbine shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
2.0 mm (0.079 in.)
2)
Width of piston seal ring groove in turbine shaft
3)
Inside diameter of turbine shaft in contact with seal ring
4)
Width of clutch shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
5)
Width of clutch shaft seal ring groove
2.5 +0.1mm (0.098 +0.004 in.)
6)
Inside diameter of servocase in contact with seal ring
8.9
+0.2
35
+0.025 +0.00098 0 mm (1.38 0 in.)
+0.2
35
+0.008
+0.025 +0.00098 0 mm (1.38 0 in.)
Clutch Shaft, Countershaft, and Output Shaft
(1) Check the splines for wear or damage. (2) Check oil passages for clogging.
8.10 Gears Check each gear for worn teeth or splines.
8.11 Strainer Assembly Disassemble and clean. Replace the strainer if defective.
5-22
+0.008
2.5 +0.1mm (0.098 +0.004 in.)
3.0 mm (0.118 in.) 35.2 mm (1.386 in.) 2.0 mm (0.079 in.) 3.0 mm (0.118 in.) 35.2 mm (1.386 in.)
CHAPTER 5 POWERSHIFT TRANSMISSION
9. 9.1
Assembling Forward-Reverse Clutch Shaft Subassembly Assembly Sequence
10 6
9 ••
18 19
7 8 •
•
3
8
7
9 10 6
• •
•
•
14 •
•
20
•
13
•
•
•
•
••
• ••
•
•
15 •
• 1 12
21 •
• 17 16
5
4
2
3
11 5
• 2
4 609013
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Input shaft Seal ring, Piston seal Piston Spring Retainer Snapring Mating plates Friction plate Pressure plate Snapring Thrust washer
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Needle bearing Gear (R drive) Thrust washer Ball bearing Thrust washer Needle bearing Gear (F drive) Thrust washer Ball bearing Seal ring
5-23
CHAPTER 5 POWERSHIFT TRANSMISSION
10. Assembling Forward-Reverse Clutch Shaft (1st Shaft) 10.1 Preparation (1) (2)
Install the following parts on the transmission case in advance: Ball bearing B for output shaft Outer race C of roller bearing for countershaft (3rd shaft) Ball bearing D for countershaft (2nd shaft) Put outer gear E in the transmission case.
10.2 Assembly Sequence
2
•
•
D
•
1 •
C •
B •
E
609014
1.
Servo case (O-ring, Bolt, Washer)
2.
10.3 Suggestions for Assembly (1) Install the forward-reverse clutch shaft in an assembled unit. (2) Apply ATF oil on the inside surface of servo case and the seal ring.
5-24
Forward-reverse clutch shaft assembly
CHAPTER 5 POWERSHIFT TRANSMISSION (3) When inserting pistons 3 into clutch drum, put ATF oil on its seal ring portion. (4) Installing return spring Using the special tool or an arbor press, compress springs 4, retainer 5 and install snapring 6.
1
609007 1. Special tool
Special tool Piston tool
Part number 92267-00300
(5) Installing clutch plates Make sure that the combination and number of the plates are correct. Install the plates while putting ATF oil on them. When replacing the friction plates 8, also replace the mating plates 7.
1 2
609015 1. Friction plate
-
2. Mating plate
Installing thrust washers Make sure that the oil-groove side of thrust washers 11, 14, 16, and 19 faces the gear when installed. Put ATF oil on washers before installing thrust washers.
609016
(6) After assembling the clutch, apply air pressure of approximately 98 kPa (1.0 kgf/cm2) [14.2 psi] to the oil hole to make sure that the piston moves smoothly without any sign of air leaks.
5-25
CHAPTER 5 POWERSHIFT TRANSMISSION
11. Assembling Output Shaft (4th Shaft) 11.1 Assembly Sequence
4 6 15 7 12 1011 8 9 13 14 • •
•
•
•• • •
4
• • • 5
1 2
3
609017
1. 2. 3. 4. 5. 6. 7. 8.
Ball bearing Gear Shims Output shaft assembly Bolt, Washer Output shaft Taper roller bearing O-ring
9. 10. 11. 12. 13. 14. 15.
Oil seal race Bearing case Oil seal O-ring Nut Snapring Output cover
11.2 Suggestions for Assembly (1) Install the output shaft as an assembly. (Install 6 through 15 as an assembled unit.) (2) Put LG2 grease on the oil seal. (3) Tighten nut 13 to the specified torque, and stake it in place to prevent loosening. Tightening torque 353 to 392.2 N·m (36 to 40 kgf·m) [79.3 to 88.1 lbf·ft]
Special tool Wrench
5-26
Part number 91868-00300
CHAPTER 5 POWERSHIFT TRANSMISSION
12. Assembling Countershaft (3rd Shaft) 12.1 Assembly Sequence
3
2 7 6 5
• •
•
•
4
• • •
• 1
609018
1. 2. 3. 4.
Countershaft Snapring Snapring, gear Roller bearing inner race (Install 1 to 4 as an assembled unit.)
5. 6. 7.
Gear Ball bearing Cover, O-ring, Bolt, Washer
12.2 Suggestions for Assembly Assemble shaft 1, snapring 2, gear 3, and roller bearing inner race 4 outside the transmission case, without fitting the snapring in its groove. Then fit the shaft to gear 5 inside the case.
2
1
3
4 609019
5-27
CHAPTER 5 POWERSHIFT TRANSMISSION
13. Assembling Countershaft (3rd Shaft) 13.1 Assembly Sequence
6 8 2 7
• •
3
•
•
5
4
•
•
1
• •
•
609020
1. 2. 3. 4. 5.
Ball bearing Countershaft Snapring Snapring, Gear Collar (Install 2 through 5 as an assembled unit.)
6. 7. 8.
Gear Ball bearing Cover, O-ring, Bolt, Washer
13.2 Suggestions for Assembly Install shaft 2 on the transmission case with snapring 3 temporarily fitted on the shaft.
3
2
5
4 •
•
609021
5-28
CHAPTER 5 POWERSHIFT TRANSMISSION
14. Assembling Pump Body Assembly 14.1 Assembly Sequence
5 •
1
2
3
•
•
•
• • • •
6
• 4 609022
1. 2. 3. 4.
Pump body, Oil seal, O-ring Internal gear, Drive gear, O-ring Stator shaft Dowel pin (Install 1 through 4 as an assembled unit.)
5. 6.
Pump body assembly, Gasket, Bolt, Washer Turbine shaft, Snapring, Seal ring
14.2 Suggestions for Assembly (1) (2) (3) (4)
Install the pump body on the transmission case in assembled condition. Put engine oil on the internal gear and drive gear 2 when installing them on pump body 1. Put grease on the oil seal and bushing of pump body 1. After assembly, measure each gear backlash with a dial gauge. Item
Standard
Backlash of countergear with output gear
0.14 to 0.27 mm (0.005 to 0.0106 in.)
Backlash of other gears
0.14 to 0.26 mm (0.0055 to 0.0102 in.)
5-29
CHAPTER 5 POWERSHIFT TRANSMISSION
15. Assembling Control Valve and Strainer To assemble, follow the reverse of disassembly sequence. Replace the gaskets.
16. Disassembling Control Valve 16.1 Disassembly Sequence
9
13
14
4
4
5
12 6 6 11
15
8
7
1
2
3
10 2 1
609023
1. 2. 3. 4. 5. 6. 7. 8. 9.
Solenoid valve, O-ring O-ring, Spring seat, Spring Directional spool Cover, O-ring, Bolt, Washer Accumulator piston, Accumulator spring Regulator valve, Spring seat, O-ring, Main relief spring, Slug Stopper pin, O-ring Clutch valve plunger, Clutch valve spring, Clutch valve, Return spring, Slug Filter, O-ring (last chance filter)
10. 11. 12. 13. 14. 15.
Oil seal Plug, Bearing roller, O-ring Accumulator spring seat, Pin, O-ring Drain plug, Gasket Orifice screw, O-ring Control valve body
Note: Do not remove oil seal 10 unless it is defective. To remove stopper pin 7, use a M4 x 0.7 threaded bolt or screw 25 mm (1 in.) long.
5-30
CHAPTER 5 POWERSHIFT TRANSMISSION
17. After Disassembling Control Valve (1) Check the valve housing for clogged oil passages. (2) Check each plunger for sign of wear, damage, or seizure. (3) Check the oil seals for damaged lips. (4) Check the orifice in the main regulator valve for clogging. Also check the valve spring for weakness or damage.
609024
7) 6) 1) 2) 3) 4) 8)
8)
5)
609025
5-31
CHAPTER 5 POWERSHIFT TRANSMISSION
Ref.
Item
Standard
Limit
1)
Free length of main relief valve inner spring
75 mm (2.95 in.) 2.122 N·m (0.215 kgf·m) [12.050 lbf·in.]
72 mm (2.83 in.)
2)
Free length of main relief valve outer spring
50 mm (1.97 in.) 0.838 N·m (0.0855 kgf·m) [4.783 lbf·in.]
48 mm (1.89 in.)
3)
Free length of clutch valve spring
39 mm (1.54 in.) 2.128 N·m (0.217 kgf·m) [12.141 lbf·in.]
38 mm (1.50 in.)
4)
Free length of clutch valve spring
28 mm (1.10 in.) 0.479 N·m (0.0488 kgf·m) [2.730 lbf·in.]
26.5 mm (1.04 in.)
5)
Free length of torque converter inlet/outlet pressure regulating valve spring
32 mm (1.26 in.) 4.560 N·m (0.465 kgf·m) [26.017 lbf·in.]
31 mm (1.22 in.)
6)
Free length of accumulator valve outer spring
91 mm (3.58 in.) 7.303 N·m (0.0745 kgf·m) [41.666 lbf·in.]
89 mm (3.50 in.)
7)
Free length of accumulator valve inner spring
130 mm (5.12 in.) 0.597 N·m (0.0609 kgf·m) [3.408 lbf·in.]
128 mm (5.04 in.)
8)
Free length of directional spool spring
32.5 mm (1.279 in.) 8.616 N·m (0.8786 kgf·m) [49.158 lbf·in.]
32 mm (1.26 in.)
5-32
CHAPTER 5 POWERSHIFT TRANSMISSION
18. Assembling Control Valve 18.1 Preparation Thoroughly wash the oil passages in the valve, and make sure that they are not clogged.
18.2 Assembly Sequence
Section B-B
1
12 11
4 B
B
2
10
5
12
Section C-C
10
C
C
8 12 7
6
D
15
8
7
13
D
14
15
9 Section D-D
3 609026
1. 2. 3. 4. 5. 6. 7. 8.
Control valve body Orifice screw Filter Accumulator spring seat, O-ring, Pin Plug, O-ring, Bearing roller Oil seal Filter, O-ring (last chance filter) Clutch valve plunger, Clutch valve, Clutch valve spring, Return spring, Slug
9. Stopper pin, O-ring 10. Regulator valve, Slug, Main relief spring, Spring seat, Oring 11. Accumulator piston, Accumulator spring 12. Cover, O-ring, Bolt, Washer 13. Directional spool 14. Spring seat, Spring, O-ring 15. Solenoid valve, O-ring
5-33
CHAPTER 5 POWERSHIFT TRANSMISSION
19. Adjustment 19.1 Oil Pressure Measurement (1) Connect a pressure gauge (20 kgf/cm2) to the main pressure and the clutch pressure taps (Rp1/8) 9206700300.
1
• • •
3
2
609027
1. Torque converter inlet pressure 3. Main pressure 2. Clutch pressure
Special tool
Part number
Connector
92067-00300
* Hose
64309-17722
* Meter
64309-17713
Tools marked with (*) are included in the gauge kit 64309-17700. (2) Start and run the engine at idling speed, and check to make sure that the oil level is correct in the transmission case. (3) Warm up until the torque converter oil temperature gauge indicates the GREEN zone. (4) Run the engine at 1000 to 1500 min-1. Note: Observe the engine tachometer reading. Item
Standard
Main pressure (engine at 1600 ± 100 min-1)
0.98 to1.23 Mpa (10.0 to 12.5 kgf·cm2) [142.2 to 177.8 psi]
Clutch pressure (engine at 1600 ± 100 min-1)
0.98 to1.23 Mpa (10.0 to 12.5 kgf·cm2) [142.2 to 177.8 psi]
Torque converter inlet pressure (engine at 1600 ± 100 rpm)
0.10 to0.49 Mpa (1.0 to 5.0 kgf·cm2) [14.2 to 71.1 psi]
Lubrication pressure (engine at 1600 ± 100 min-1)
0.05 to0.29 Mpa (0.5 to 3.0 kgf·cm2) [7 to 43 psi]
5-34
CHAPTER 5 POWERSHIFT TRANSMISSION Hydraulic pressure test tools (reference) for single speed transmission Special tool
Part number
Remarks
Torque converter inlet
* Connector
64309-17733
PT1/8 thread
z
* Hose
64309-17722
-
z
* Connector
64309-17731
For gauge
z
* Gauge
64309-17714
588 kPa (6 kgf/cm2) [85 psi]
z
Note: Tools marked with (*) are included in the gauge kit 64309-17700.
19.2 Inching Valve Test Preparation (1) Raise the front axle housing with a jack and place wood blocks under the outer mast. Tilt the mast FORWARD to raise the front wheels. (2) Block the rear wheels.
R CAUTION Remember, the front wheels will rotate when the clutch pressure is tested. Adjusting procedure (1) Set the inching pedal stroke to the specified value. (2) Connect a pressure gauge to the clutch pressure tap (Rp1/8) 92067-00300. Use the same special tools. (3) Move the forward-reverse lever to the FORWARD position. (4) Gradually pull out the clutch (inching) valve plunger from its fully pushed position, and plot the oil pressure curve relative to the plunger stroke. Make sure that the pressure curve is identical with the curve shown.
981 (10) [142]
1) 216 (2.2) [31] 0
5 (0.20)
10 (0.39)
2)
609028
1) Torque converter inlet pressure 2) Clutch pressure kPa (kgf/cm2) [psi]
19.3 Stall Speed Measurement (1) (2) (3) (4) (5)
Run the engine at idling speed, and check that the oil level is correct in the transmission case. Warm up the torque convertor oil. Block the front and rear wheels, and apply the parking brake. Run the engine at idling speed. Move the forward-reverse lever to the FORWARD position and depress the brake pedal with left foot and gradually depress the accelerator pedal all the way. Under this condition, observe the engine tachometer reading to measure the stall speed. Item
Stall speed, min-1 (tolerance: ± 100 min-1)
3.5 to 5.5 ton
6.0 to 7.0 ton
2000
2080
5-35
CHAPTER 5 POWERSHIFT TRANSMISSION R CAUTION DO NOT attempt to depress the inching pedal. DO NOT continue “Stall speed” run for more than 10 seconds. Failure to follow this precaution could result in destruction of the torque converter. (6) Read the stall speed for reverse drive the same way. Note: -
Any stall speed within ± 100 min-1 of the specification is satisfactory. If the engine or torque converter is changed, the stall speed will vary since the stall speed is determined by the combination of engine and torque converter.
19.4 10 Meters (33-ft) Starting Acceleration Test (1) (2) (3) (4)
Be ready with the engine idling and the direction lever in the NEUTRAL position. At the signal, shift into FORWARD and, at the same time, depress the accelerator pedal all the way. Measure the amount of time that elapses for the lift truck to travel 10 meters (33 ft) with a stop watch. Measure for reverse travel, too.
Travel time (No load)
5 seconds, maximum
19.5 Adjusting Brake Pedal 1) 2) 3)
Bleed air out of the brake lines from the reserve tank through master cylinder to the wheel cylinder. Adjust and check the clearance between the drum and brake lining. Install locknut 2 (right-hand thread), push rod 3 (righthand thread), locknut 4 (left-hand thread) and clevis 5 (left-hand thread) on push rod 1 of the brake booster. Make sure that L1 dimension is within the standard values. L2 dimension is used for actual check. Screw-in length should be the same for left-hand and right-hand threads.
5
4
3
2
L2
1
L1 609029
1. Push rod 2. Locknut 3. Push rod
5-36
L1
155 mm (6.1 in.)
L2
88 mm (3.46 in.)
4. Locknut 5. Clevis
CHAPTER 5 POWERSHIFT TRANSMISSION 4) 5) 6) 7)
Install the push rod assembly on the brake pedal. Adjust the brake pedal height A to 160 mm (6.3 in.) by turning the stopper bolt, and tighten the locknut. Turn ON the engine. Depress the brake pedal by hand to check play B of the brake pedal.
C
B A
1 2
3
609030 1. Locknut 2. Stopper bolt
Item Brake pedal play B
3. Push rod assembly
Standard 5 mm (6.1 in.)
If the play is not within the standard values, loosen locknuts 2 and 4 and turn push rod 3 to adjust dimension L1. Item Brake pedal stroke C
Standard 37 mm (1.456 in.)
5-37
CHAPTER 5 POWERSHIFT TRANSMISSION 19.6 Adjusting Inching Pedal 1) Connect a pressure gauge to the clutch pressure tap. Note: For the special tools to be used with the pressure gauge, see 5-34 "Oil Pressure Measurement". 2) 3)
4)
F
1
E
Adjust the above-floor height A of the inching pedal to 175 mm (6.89 in.) with the stopper bolt. Adjust clearance B between the inching pedal and the brake pedal contact surface to be 16 mm (0.63 in.) with the stopper bolt and secure this clearance with the locknut. Turn ON the engine, and release the brake pedal. Depress the inching pedal until the brakes start applying (resistance is felt on the pedal). Under this condition, adjust the inching cable length so that spool stroke D becomes 16.5 mm (0.649 in.) (oil pressure: 0 kPa (0 kgf/cm2) [0 psi]).
2 A
3
B
609031 1. Stopper bolt 2. Locknut
Item Inching pedal stroke E (brake functioning) 5)
-
3. Stopper bolt
Standard 82.4 mm (3.24 in.)
Release the inching pedal, and make sure that clutch valve plunger stroke C is 8 to 9.5 mm (0.314 to 0.374 in.) at the pressure of 883 to 1079 kPa (9 to 11 kgf/cm2) [128 to 156 psi]. If plunger stroke C is not within the standard values, adjust the brake and the brake pedal as shown below: The stroke is 9.6 mm (0.378 in.) or more: The shoe to lining clearance is too small. The stroke is 7.9 mm (0.311 in.) or less: The shoe to lining clearance is too large.
1
609032 1. Inching cable
5-38
CHAPTER 5 POWERSHIFT TRANSMISSION
D
C
2)
10 5 (0.39) (0.20)
981 (10) [142] 216 (2.2) [31] 0
1) 609033 1) Clutch valve plunger stroke mm (in.)
Item
2) Clutch oil pressure kPa (kgf/cm2) [psi]
Standard
A
Inching pedal height from frame to top of pedal pad
175 mm (6.89 in.)
B
Clearance between inching pedal stopper bolt and brake pedal
16 mm (0.63 in.)
C
Clutch valve plunger stroke
8 to 9.5 mm (0.314 to 0.374 in.)
D
Clutch valve plunger stroke at brake functioning
16.5 mm (0.649 in.)
E
Inching pedal stroke (brake functioning)
82.4 mm (3.24 in.)
F
Inching pedal stroke
152 mm (5.98 in.)
5-39
CHAPTER 5 POWERSHIFT TRANSMISSION
20. Specifications 20.1 Automatic 2-speed Transmission (6.0 to 7.0 Ton)
Item
Torque converter
6.0 to 7.0 ton Type
3 element 1 stage 2 phases
Manufacturer model
M15
Stool torque ratio
3. 2
Operation type
F/R electric column shift H/L automatic transmission 1-speed 5.104 (
Power transmission
Forward 2-speed 2.882 (
Transmission Gear ratio
1-speed 5.104 ( Backward 2-speed 2.882 (
5-40
45 24 36 34 45 24 36 34
×
×
×
×
49 18 49 18 49 18 49 18
)
)
)
)
CHAPTER 5 POWERSHIFT TRANSMISSION
21. Structure 21.1 Transmission 2-speed
b
1
c
h
•
a
10
•
•
•
•
2 •
g
•
9
•
e
8 •
d
4
•
•
•
k
•
•
•
•
• •
• f
7 12
• 1
2nd shaft
3
•
i
5 j
6
1st shaft
3rd shaft 4th shaft
11
609034
1. 2. 3. 4. 5. 6.
Control valve Torque converter assembly Flexible plate Pump body assembly Speed sensor Magnet strainer
7. 8. 9. 10. 11. 12.
Output shaft (4th shaft) Countershaft (3rd shaft) Input shaft (1st shaft) Countershaft (2nd shaft) Pulse generator Solenoid valve
5-41
CHAPTER 5 POWERSHIFT TRANSMISSION Power flow Range
Path
Forward 1st (F1)
h f i j k
Forward 2nd (F2)
g d i jk
Reverse 1st (R1)
e bc f i j k
Reverse 2nd (R2)
e bad i j k
21.2 Automatic 2-speed Change Mechanism
3
4
2
1 0.5 mm (0.02 n)
7
5 6
1) 2)
8
609035
1. 2. 3. 4. 5.
5-42
Output gear Electronic control unit (ECU) Speed selector switch Speed (solenoid) valve 1st speed clutch
6. 7. 8. 1) 2)
2nd speed clutch Pulse generator Transmission case Electric signal Hydraulic pressure signal
CHAPTER 5 POWERSHIFT TRANSMISSION 21.3 Control System Location of control devices
3
2
1
5
4 1. 2. 3.
ECU (Electronic Control Unit) Power source Speed selector switch
609036
4. 5.
Speed sensor Solenoid valve
The automatic 2-speed transmission consists of an F2-R2 powershift transmission and a control system comprising speed sensor, electronic control unit (ECU) and solenoid valve. Speed can be changed from “Automatic” to “1st speed” mode by means of the speed selector switch. The speed selector switch was moved to the overhead guard pillar in 2006. Selector switch position
Travel speed 1-speed
0 to 9 km/h (0 to 5.6 mph)
2-speed
9 to 24.5 km/h (5.6 to 15.2 mph)
Automatic 2 speeds
1st speed
0 to 14 km/h (0 to 8.7 mph)
5-43
CHAPTER 5 POWERSHIFT TRANSMISSION 21.4 Solenoid Valve
• 4
3
1
2
5
6 609037
1. 2. 3.
Solenoid body Solenoid valve Spring
4. 5. 6.
Cover Cover Solenoid valve (electric)
Note: For the three systems below, see 5-1 "1-Speed Transmission (3.5 to 5.5 Ton)". (1) Torque converter (2) Control system (3) Control valve Removing and Installing Solenoid Valve For removal and installation, see 5-30 "Disassembling Control Valve". Disassembling Solenoid Valve For disassembly, see 5-68 "Disassembling Solenoid Valve".
5-44
CHAPTER 5 POWERSHIFT TRANSMISSION 21.5 Powershift Transmission Hydraulic System Schematic 1-Speed
4
3
5
PC
2)
6
7
8
R
9
P2 F
7 P1
2
4)
10
PM
3) 11
1)
12
PD
5)
1 13 1. 2. 3. 4. 5. 6. 7. 8. 9.
PL
Oil cooler Torque converter Accumulator valve Main regulator valve Clutch (inching) valve FR filter Last chance filter Solenoid valve Directional valve (Valve top surface) Item
609084
10. 11. 12. 13. 1) 2) 3) 4) 5)
Solenoid valve Gear pump Suction strainer Lubrication oil Torque converter outlet pressure Valve top surface with D stamp Valve top surface with M stamp Torque converter inlet pressure Lubricating circuit Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.05 to 0.29 MPa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
All tests run
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine min-1
5-45
CHAPTER 5 POWERSHIFT TRANSMISSION 21.6 Powershift Transmission Hydraulic System Schematic 2-Speed
3 2 1
PO
15
4
1)
PL
5
5)
6)
P1
4)
6
PM
3) 13
2) 7
PC
10 14
9
9
F
R
P2
11
12
8
609038
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Oil cooler air to oil Torque converter Solenoid valve plunger Solenoid valve Accumulator valve Main regulator valve Clutch pressure Solenoid valve Last chance filter FR filter Directional valve Item
12. 13. 14. 15. 1) 2) 3) 4) 5) 6)
Solenoid valve Gear pump Suction strainer with magnet Lubrication oil pressure Torque converter outlet pressure Valve top surface with D stamp Main Pressure Valve top surface with M stamp Torque converter inlet pressure Lubricating circuit
Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.05 to 0.29 MPa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
All tests run
5-46
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine min-1
CHAPTER 5 POWERSHIFT TRANSMISSION 21.7 Hydraulic Control (Forward 1st Speed)
1
2
3
4 8
5
6
7 1) 2) 609039
1. 2. 3. 4. 5.
Pilot pressure Solenoid valve plunger Solenoid valve OFF (open) ECU Transmission
6. 7. 8. 1) 2)
Output gear Pulse generator Solenoid valve Pilot pressure Lubricating circuit
5-47
CHAPTER 5 POWERSHIFT TRANSMISSION 21.8 Hydraulic Control (Forward 2nd Speed)
5
4
1
2 3
6 7 11
10
9
8 1) 2) 3) 609040
1. 2. 3. 4. 5. 6. 7.
5-48
Pilot pressure Solenoid valve plunger Last chance Filter Plunger Signal input Solenoid valve ON (open) ECU
8. 9. 10. 11. 1) 2) 3)
Pulse generator Output gear Transmission Solenoid valve Pilot pressure High-pressure oil Signal
CHAPTER 5 POWERSHIFT TRANSMISSION
22. Disassembling Transmission 22.1 Control Valve and Side Cover Disassembly sequence
4
5
3
6
7 1 2 9 8
609041
1. 2. 3. 4. 5.
Drain plug, Washer Thermo unit Oil level gauge Solenoid valve Control valve
6. 7. 8. 9.
Subplate, O-ring, Gasket Speed sensor, Speed sensor cover, O-ring Strainer assembly, O-ring Side cover, Gasket
5-49
CHAPTER 5 POWERSHIFT TRANSMISSION 22.2 Output Shaft (4th Shaft) Disassembly sequence
2 4
1 3
609042
1. 2.
Output cover Output gear
3. 4.
Output shaft subassembly Tapered roller bearing, Race, Nut, Snapring
Suggestions for disassembly (1) Removing output shaft Use the special tool to remove output shaft subassembly 3. Output gear 2 will interfere with the gear of the countershaft (3rd shaft). This makes it necessary to remove output shaft subassembly 3 by tapping output gear 2 with a copper hammer through the side cover hole
1 1. Special tool
Special tool Special tool
Part number 91868-02100
Note: -
5-50
The same tool is used for 1-speed transmission. The ball bearing remains in the transmission case.
609043
CHAPTER 5 POWERSHIFT TRANSMISSION (2) Disassembling output shaft Usually, it is not unnecessary to disassemble output shaft subassembly 3. When it has to be disassembled, use an arbor press to remove the bearing. Take care not to lose the shims during disassembly. (3) When removing the nut, the caulked area is ground off. Replace the nut with a new one during assembly.
609044
5-51
CHAPTER 5 POWERSHIFT TRANSMISSION 22.3 Pump Body Disassembly sequence
1 1
2
3
609045
1.
Pump body, Roller bearing (outer race), Bushing, Oil seal, Gasket, O-ring
2. 3.
Stator shaft, Valve, Spring washer, Snapring, Steel ball Drive gear, Driven gear
Suggestions for disassembly (1) Removing pump body assembly Unscrew all body mounting bolts. Using the jacking bolts, remove the subassembly.
609046
Special tool Jacking bolt
Part number 67284-15400
(2) It is unnecessary to remove the steel ball and the plug fitted on the pump body or the bushing, oil seal, steel ball, cap, etc. fitted to the stator shaft unless they are defective.
5-52
CHAPTER 5 POWERSHIFT TRANSMISSION 22.4 Countershaft (3rd Shaft) Disassembly sequence
1
8 6 7
4
3
2
5
9 1. 2. 3. 4. 5.
Cover, O-ring Roller bearing (inner race) Spacer Output gear (countergear) Gear (forward 1st speed countergear)
609047
6. 7. 8. 9.
Spacer Gear (forward 2nd speed countergear) Ball bearing Countershaft
Suggestions for disassembly (1) Removing countershaft Attach a sliding hammer to countershaft 9, and remove the shaft complete with ball bearing 8. Roller bearing 2 comes off first. Or install a bearing puller on the backside of output gear 4 to remove bearing inner race 2 and gear out the front of transmission case. Tap end of countershaft 9 to the rear. Then remove gear and countershaft.
5-53
CHAPTER 5 POWERSHIFT TRANSMISSION 22.5 Input Shaft (1st Shaft / Current Production) Disassembly sequence
6 13
5 1
3
2
16 14
15 17
4
13
15 16 12
13
14
8
7
2
9
11
10 12 12
11 12
609048
1. 2. 3. 4. 5. 6. 7. 8.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (forward 2nd speed drive), Needle roller bearing Thrust washer Ball bearing Thrust washer
9. 10. 11. 12. 13. 14. 15. 16. 17.
Gear (forward 1st speed drive), Needle roller bearing Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch ring Clutch piston, Steel ball, Screw, Seal ring Seal ring Input shaft
Note: Do not remove the steel ball fitted on the servo case or the screw fitted on the input shaft.
5-54
CHAPTER 5 POWERSHIFT TRANSMISSION 22.6 Input Shaft (1st Shaft) Disassembly sequence
5 1
3
6
13
2 4
13
17 16
15
12 9 14 13
16
15
14
11
8
7
2
10 12 12
11 12
609049
1. 2. 3. 4. 5. 6. 7. 8.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (forward 2nd speed drive), Needle roller bearing Thrust washer Ball bearing Thrust washer
9. 10. 11. 12. 13. 14. 15. 16. 17.
Gear (forward 1st speed drive), Needle roller bearing Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch ring Clutch piston, Steel ball, Screw, Seal ring Seal ring Input shaft
Note: Do not remove the steel ball fitted to the servo case or the screw fitted to the input shaft.
5-55
CHAPTER 5 POWERSHIFT TRANSMISSION Suggestions for disassembly
1
(1) Removing input shaft ball bearing Use the special tools to remove ball bearing 3 from the input shaft.
2 1. Special tool (Puller)
Special tool
2. Special tool (Plate)
Part number
Puller
91268-13810
Plate
91268-13820
Bolt
F1035-10020
Puller
609050
T24
Disassembling input shaft Using the special tool or a press, compress clutch spring 14, and remove snapring 13.
1
609051 1. Special tool
Special tool Piston tool
Part number 92267-00300
Clutch piston Shake clutch piston 15 and make sure that the balls move freely in the piston. It is unnecessary to disassemble the clutch piston, if the balls move freely.
5-56
CHAPTER 5 POWERSHIFT TRANSMISSION 22.7 Countershaft (2nd Shaft / Current Production) Disassembly sequence
1
23
4
17
5 16
15
12
6
13
14
11
11 12 12
15
1614
9
8
7
3 2
10 13 12
609052
1. 2. 3. 4. 5. 6. 7. 8. 9.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (reverse 2nd speed drive), Needle roller bearing Thrust washer Snapring Thrust washer Gear (reverse 1st speed drive), Needle roller bearing
10. 11. 12. 13. 14. 15. 16. 17.
Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch spring Clutch piston, Seal ring, Steel ball, Screw Seal ring Countershaft
5-57
CHAPTER 5 POWERSHIFT TRANSMISSION 22.8 Countershaft (2nd Shaft / First Production) Disassembly sequence
5 1
2
17
34
15 16 12
3
2
11 6
13
14
12
8
7
9
15
16
14
13
10
11 12
609053
1. 2. 3. 4. 5. 6. 7. 8. 9.
Servo case, O-ring Seal ring Ball bearing Thrust washer Gear (reverse 2nd speed drive), Needle roller bearing Thrust washer Snapring Thrust washer Gear (reverse 1st speed drive), Needle roller bearing
10. 11. 12. 13. 14. 15. 16. 17.
Thrust washer Snapring, Pressure plate Friction plates, Mating plates Snapring, Retainer Clutch spring Clutch piston, Seal ring, Steel ball, Screw Seal ring Countershaft
Suggestions for disassembly To disassemble the countershaft and the clutch piston, See 5-54 "Input Shaft (1st Shaft / Current Production)"5-55 "Input Shaft (1st Shaft)" disassembly of input shaft.
5-58
CHAPTER 5 POWERSHIFT TRANSMISSION
23. After Disassembling Transmission For the following parts, see 5-1 "1-Speed Transmission (3.5 to 5.5 Ton)". (1) Oil pump (2) Pump boss (3) Stator shaft (4) Clutch pistons (5) Friction plates and Mating plates (6) Clutch drums (7) Clutch gears (8) Input shaft, Countershaft, Output shaft (9) Gears (10) Strainer assembly
23.1 Input Shaft, Servo Case, and Seal rings Check the contact surfaces of each part for wear or damage. Note: The dimensions of the seal rings and their grooves for the countershaft (2nd shaft) are identical with those for the input shaft.
1), 2)
4), 5) 6)
3) 609054
5-59
CHAPTER 5 POWERSHIFT TRANSMISSION Ref.
Item
Standard value
Repair limit 2.0 mm (0.079 in.)
1)
Width of input shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
2)
Width of seal ring groove in input shaft
2.5 +0.1mm (0.098 +0.004 in.)
3)
Inside diameter of stator shaft in contact with seal ring
4)
Width of input shaft seal ring
2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
5)
Width of input shaft seal ring groove
2.5 +0.1mm (0.098 +0.004 in.)
6)
Inside diameter of clutch shaft in contact with seal ring
+0.2
35
3.0 mm (0.118 in.)
+0..025 +0.00098 0 mm (1.38 0 in.)
+0.2
35
+0.008
35.2 mm (1.386 in.) 2.0 mm (0.079 in.)
+0.008
3.0 mm (0.118 in.)
+0..025 +0.00098 0 mm (1.38 0 in.)
35.2 mm (1.386 in.)
24. Assembling Transmission 24.1 Ball Bearing and Oil Seals Assembly sequence
2
•
1
609055
1.
Ball bearing
2.
Oil seals
Note: Removal of the output shaft will leave the ball bearing and oil seals in the transmission case. Remove them for replacement only when they are found defective.
5-60
CHAPTER 5 POWERSHIFT TRANSMISSION
1
Suggestions for assembly Use the special tool to install the oil seals. Pay attention that the two oil seals face opposite to each other as shown in the illustration.
2
3
609056 1. Transmission case 2. Oil seals
Special tool
3. Special tool
Part number
Installer
91868-02200
24.2 Countershaft (2nd Shaft) and Input Shaft (1st Shaft) Preparation Assemble the input shaft subassembly. Assemble the countershaft subassembly. Assembly sequence
1 • • 2 1
3
• •
609057
1. 2.
Servo case, O-ring Countershaft subassembly
3.
Input shaft subassembly
5-61
CHAPTER 5 POWERSHIFT TRANSMISSION Assembly of input shaft subassembly and countershaft subassembly Assembly sequence is the same as the forward-reverse clutch shaft subassembly of the 1- speed Transmission.
1
Suggestions for assembly Installing clutch spring (1) Using the special tool or a press, compress clutch spring, and fit snapring.
609007 1. Special tool
Special tool Piston tool
Part number 92267-00300
(2) When inserting clutch piston into the drum of the countershaft or input shaft, put ATF oil on the seal rings. (3) Installing clutch plate Make sure that the combination and number of the plates are correct. Assemble the plates while putting ATF oil on each plate. When replacing the friction plates, replace the mating plates as a set. (4) After assembling, apply air pressure of approximately 98 kPa (1.0 kgf/cm2) [14.2 psi] to the oil hole to make sure that the pistons move freely without any sign of air leaks.
5-62
CHAPTER 5 POWERSHIFT TRANSMISSION 24.3 Countershaft (3rd Shaft) Assembly sequence
5
9 1
•
• • •
2
•
6 • • •
•
8
3
7
4 1. 2. 3. 4. 5.
Countershaft Ball bearing Gear (F2 countergear) Spacer Gear (F1 countergear)
609058
6. 7. 8. 9.
Output gear (counter) Spacer Roller bearing (inner race) Cover, O-ring
Suggestions for assembly (1) Install ball bearing 2 on countershaft 1 and insert it into the transmission case. (2) When placing gear (forward 2nd speed countergear) 3 in the transmission case, slightly pull out the input shaft subassembly and countershaft subassembly (2nd shaft) to prevent interference of these shafts with the gear. (3) Align ball bearing 2 and inner race 8 of roller bearing, which are installed at the ends of countershaft 1, with the end surfaces of the countershaft.
5-63
CHAPTER 5 POWERSHIFT TRANSMISSION 24.4 Pump Body Assembly sequence
1
• • •
2 • 3
609059
1. 2.
Pump body, Outer race of roller bearing, Oil seal, Bushing Pump drive gear, Pump driven gear
3.
Stator shaft, Valve, Spring washer, Snapring
Suggestions for assembly (1) Install the pump body to the transmission case in the assembled state. (2) Put ATF oil in the internal gear and drive gear when installing them to the pump body. (3) Put LG2 grease on the oil seal and bushing of the pump body 1.
5-64
CHAPTER 5 POWERSHIFT TRANSMISSION 24.5 Output Shaft Assembly sequence
3
2
• • • 1 609060
1. 2.
Output gear Output shaft subassembly
3.
Output cover
Suggestions for assembly (1) Install the output shaft subassembly 2. (2) Shim adjustment of output shaft (Unit: mm) Before installing the bearing, determine the required thickness of shims by referring a and b to this formula: c
1) ±b a ± 100
609061
1) Centerline of axle
Thickness of shims (C) =
1.7
+
a 100
-
b
5-65
CHAPTER 5 POWERSHIFT TRANSMISSION (3) (4)
a: machining error indicated in a unit of 1/100 mm on differential carrier by pushing. b: machining error of bevel pinion. Put light grease on the oil seals fitted on the transmission case. Upon assembling, measure each gear backlash with a dial gauge. Item
Standard
Backlash of forward 1st speed gear with forward 2nd speed
0.14 to 0.23 mm (0.0055 to 0.0091 in.)
Backlash of forward gear with reverse gear
0.14 to 0.24 mm (0.0055 to 0.0094 in.)
Backlash of countergear with output gear
0.14 to 0.25 mm (0.0055 to 0.0098 in.)
24.6 Torque Converter
1
2
•
•
•
3 4
609062
1. 2.
5-66
Stator shaft Turbine shaft
3. 4.
Torque converter assembly Pump boss
CHAPTER 5 POWERSHIFT TRANSMISSION Suggestions for assembly (1) Align the splines of the transmission-side stator shaft, turbine shaft, and the pump boss completely. The distance between the end face of the housing and the mating face of the flexible plate is 4 to 6 mm (0.157 to 0.236 in.) if the torque converter is properly placed in the transmission. Apply ATF oil on the sliding surfaces of the oil seal and the bushing. (2) The torque converter is only inserted and not secured. Attach the flexible plate to the housing with a wire. Assembly Install the torque converter assembly into the transmission. 4 to 6 mm (0.157 to 0.236 in.) 609063
25. Assembling Control Valve and Side Cover To assemble, follow the reverse sequence of disassembly.
25.1 Suggestions for Assembly (1) Replace the gaskets and O-rings with new ones.
5-67
CHAPTER 5 POWERSHIFT TRANSMISSION
26. Disassembling Solenoid Valve 26.1 Disassembly Sequence
5 4 6
3
1 2 1 609064
1. 2. 3.
Cover, Gasket Solenoid valve, O-ring Cover, O-ring
4. 5. 6.
Spring Solenoid valve Solenoid body, Gasket
27. After Disassembling Solenoid Valve (1) Check the valve body for clogged oil passages. (2) Check the valve for wear, damage, or seizure. (3) Check the spring for damage or fatigue. Item Free length of solenoid valve spring
5-68
Standard
Limit
65 mm (2.56 in.) 0.183 kgf·m (10.25 lbf·in.)
63 mm (2.48 in.)
CHAPTER 5 POWERSHIFT TRANSMISSION
28. Assembling Solenoid Valve 28.1 Preparation Wash the valve body thoroughly, making sure that all oil passages are free from clogging.
28.2 Assembly Sequence
4
3
1
6
2
5 609065
1. 2. 3.
Solenoid body Solenoid valve Spring
4. 5. 6.
Cover, O-ring, Bolt, Washer Solenoid valve, O-ring Cover, Gasket, Bolt, Washer
29. Adjustment 29.1 Oil Pressure Measurement The taps differ from those for the 1-speed transmission. For the test method and oil pressure specifications, see 5-1 "1Speed Transmission (3.5 to 5.5 Ton)".
2
1
5
• • • •
4 3
•
609066
4. Main pressure 1. Lubrication oil pressure 2. Torque converter inlet pressure 5. Alternate Lubrication oil test port 3. Clutch pressure
5-69
CHAPTER 5 POWERSHIFT TRANSMISSION Item
Value
PM
Main pressure
PC
Clutch pressure
P1
Torque converter inlet pressure
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [14.2 to 71.1 psi]
PL
Lubrication oil pressure
0.01 to 0.15 MPa (0.1 to 1.5 kgf/cm2) [1.42 to 21.3 psi]
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
At 1600 ± 100 engine min-1
All tests run
29.2 Hydraulic Pressure Test Tools Hydraulic pressure test tools for 2-speed transmission
Remarks
Main/clutch
Torque converter inlet/ Lubrication oil
Connector 92067-00300
Rp1/8 thread
z
-
*Connector 64309-17733
Rp1/8 thread
-
z
Connector 91268-02300
Rp1/8 thread
-
-
*Gauge 64309-17714
588 kpa (6 kgf/cm2) [86 psi]
-
z
*Gauge 64309-17713
1961 kpa (20 kgf/cm2) [284 psi]
z
-
*Hose 64309-17722
-
z
z
*Connector 64309-17731
For gauge
z
z
Tool name/ number
Tools marked with (*) are included in the 64309-17700 gauge kit. For the following four items, see 5-1 "1-Speed Transmission (3.5 to 5.5 Ton)". -
Measurement of oil pressure Measurement of stall speed 10 meters (33 ft) starting acceleration Inching pedal adjustment
609067
5-70
CHAPTER 5 POWERSHIFT TRANSMISSION 29.3 2nd Speed/Auto Selector Switch Test Move the selector switch mounted on the side face of the sub panel mounted on the right front overhead guard leg to each position, and make sure that the transmission works properly. In the 1st speed position, the lift truck runs at a maximum speed of 14 km/hr (8.7 mph) and a greater torque is available at the drive axle. In the auto position, the transmission automatically shifts from 1st to 2nd range when the travel speed reaches 9 km/hr (5.6 mph) to allow the lift truck to run at a maximum speed of 24.5 km/hr (15.2 mph).
609068
29.4 2-Speed Transmission Electrical Systems Part Numbers ECU and Pulse Generator / Speed Sensor Parts
Models
Transmissions
ECU 6.0 to 7.0 ton
2-Speed
Pulse Generator / Speed Sensor
Part numbers
System type
16A20-28001
Carburation
16A23-18001
MPFI
69321-08101
Carburation
97433-01100
MPFI
Solenoid Parts
Models
Solenoid types Speed
Solenoids
6.0 to 7.0 ton Directional
Part numbers
Voltage
91828-11200 93728-00901 93728-20701
12V
Type
System type
N/O
Carburation
N/C
MPFI
N/O
Carburation and MPFI
Note: 12 Volt: Working voltage 8 to 16 V The part numbers listed above should be used as reference only. Parts numbers are subject to change without notice. Check parts system for updated part information.
5-71
CHAPTER 5 POWERSHIFT TRANSMISSION 29.5 ECU Self-Diagnostic Test The Electronic Control Unit (ECU) has a self diagnostic feature built in a 1-chip microcomputer. The computer processes the signal received from the pulse generator through the ECU speed selector and automatically selects the speed according to the signal received from the pulse generator. It has two LED indicator fault lights that flash a pattern of flashes for testing the ECU, pulse generator and shift solenoid. The self diagnostic feature is intended to help take the guesswork out of troubleshooting the power shift transmission electrical system. The indicator fault lights are located on the rear mounting face of the ECU. Remove the ECU mounting bolts to access the fault lights. The indicator lights will flash in the following patterns (ECU with no fault, Pulse Generator / Speed Selector Fault and Shift Solenoid Fault) when a problem occurs in the electrical control system of the 2-speed transmission. A fault code will continue to glow until the key switch is turned to the OFF position. If any other blinking pattern of flashes occurs, the ECU is defective and should be replaced.
1
1) 2) 609069
ECU 1. Failure Indicator Lights 1) GREEN
2) RED
R CAUTION It is possible to have a combination of failed components at the same time. BE SURE to check all components (pulse generator, speed and directional solenoids) before replacing the ECU.
29.6 ECU Test (1) Turn the key switch to the ON position. (2) For the first 10 seconds, the GREEN light turns ON and the RED light blinks. (3) For 10 seconds or more, the GREEN light is ON and the RED light is OFF. ECU with no fault
Condition Light Colors GREEN RED
Key Switch ON 0-10 Sec.
Key Switch ON after 10 Sec.
ON
ON
GLOW
OFF
Pulse Generator / Speed Sensor Fault GREEN Light
ON ON
RED Light
OFF
ON OFF
Note: System resets automatically after repair.
5-72
OFF
CHAPTER 5 POWERSHIFT TRANSMISSION 29.7 Pulse Generator Test (1) Set the parking brake and block the rear wheels. (2) Raise the front wheels off the ground either by lifting with a crane or tilting the mast BACKWARD and placing a wood block which can bear the weight of the lift truck under the outer the mast, and tilt FORWARD until the front tires are off the ground. (3) Disconnect the pulse generator (speed sensor) from the wire harness. (4) Connect a digital voltmeter (VOM) to the wires coming from the pulse generator. Note: The pulse generator is not polarity sensitive. (5) Set the VOM to 0 - 20 AC voltage scale. (6) Start the lift truck and place the directional lever to FORWARD or REVERSE. (7) Slowly raise the engine speed while watching the VOM. (8) The minimum reading at shifting point should be 0.860 AC volts. Note: The minimum volt reading will vary depending on the gear ratio of the lift truck. (9) The maximum output reading is 1.004 AC volts. Note: Moving the pulse generator closer or further away from the output gear will change the readings and frequency pattern from the generator. Shift solenoid fault Transmission must be accelerated to shift the speed before fault will appear. GREEN Light
ON ON
RED Light
OFF
ON OFF
OFF
Note: System resets automatically after repair.
29.8 Solenoid Voltage Test Use a voltmeter set on 0 to 40 DC volts to test the solenoid for proper voltage to the shift speed solenoids. Note: 12 V solenoid: working voltage 8 to 16 V. Solenoid
NEUTRAL
FORWARD
REVERSE
-
-
F1
F2
R1
R2
Forward solenoid
OFF
ON
ON
ON
ON
Reverse solenoid
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
1985 - 12/2003 models High speed solenoid 2004 and up models High speed solenoid
5-73
CHAPTER 5 POWERSHIFT TRANSMISSION 29.9 Oscilloscope Shop Test (1) Set the parking brake and block the rear wheels. Raise the front wheels off the ground either by lifting with a crane or tilting the mast BACKWARD and placing a wood block which can bear the weight of the lift truck under the outer mast, and tilting the mast FORWARD until the front tires are off the ground. (2) Disconnect the pulse generator (speed sensor) from the wire harness. Sometimes called speed sensor. (3) Connect an oscilloscope to the wires coming from the pulse generator and check the following reading and frequency pattern to ensure the pulse generator is working properly. Note: The pulse generator is not polarity sensitive. Moving the pulse generator closer or further away from the output gear will change the readings and frequency pattern from the generator. Scope reading
B
A
1) 2)
1) Ref. A: 500 m Volt 2ms
5-74
609070 2) Ref. B: 500 m Volt 2ms
CHAPTER 5 POWERSHIFT TRANSMISSION Meter readings Good
Bad
Ref. A
Ref. B
Histogram
Min/Max
Period
4.23 ms
360 us
Frequency
236 Hz
2.78 kHz
Pos. Pulse Width
2.14 ms
302 us
Neg. Pulse Width
2.09 ms
57.7 us
Rise Time
1.93 ms
9.61 ms
Fall Time
878 us
6.4 us
Pos. Duty Cycle
50.67%
83.96%
Neg. Duty Cycle
49.33%
16.04%
Pos. Overshoot
5.10%
0.00%
Neg. Overshoot
4.46%
0.00%
Peak to Peak
3.44V
800 mV
Amplitude
3.14V
800 mV
High
1.56V
400 mV
Low
-1.58V
-400 mV
Maximum
1.72V
400 mV
Minimum
-1.72V
-400 mV
Mean
-25.3 mV
6.93 mV
Cycle Mean
-4.03 mV
-22 mV
RMS
1.04V
86 mV
AC RMS
1.04V
95.8 mV
Cycle RMS
1.03V
72.7 mV
Cycle AC RMS
1.03V
67.8 mV
Burst Width
17 ms
19.9 ms
Item Measure Mode
5-75
CHAPTER 5 POWERSHIFT TRANSMISSION
30. Troubleshooting 30.1 Torque Converter Drive Transmission Condition Engine
Torque converter
Low output
Transmission
Body
5-76
Possible causes
Corrective action
Low engine output
Adjust the engine
Low engine performance
Adjust the engine
Insufficient oil
Replenish
Air intake from intake side
Retighten or replace pipe and gasket
Spool failure of main regulator valve
Repair or replace
Worn spring of main regulator valve
Replace spring
Worn oil pump (Low or insufficient discharge)
Disassemble or replace defective part
Clogging of magnet strainer
Replace magnet strainer
Worn seal ring and O-ring
Replace after measurement of oil pressure
Seizure of stator free wheel
Replace stator assembly, hub and roller
Damage and contact of impeller
Repair or replace impeller Replace bearing
Air intake from intake side
Retighten or replace
Water inclusion into oil
Replace oil
Insufficient oil
Replenish
Adjustment failure of pedal link (Brake shift and forward-reverse)
Adjust
Clutch slippage due to low main pressure
Adjust pressure after measurement of oil pressure
Worn seal ring and O-ring
Replace after measurement of oil pressure
Damaged clutch piston
Replace piston
Seizure or drag of friction plate
Replace plate
Large driving resistance on underbody parts
Inspect or adjust brake parts
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Torque converter
No transmission of power Transmission
Body
Possible causes
Corrective action
Damaged flexible plate
Replace
Insufficient oil
Replenish
Defective oil pump drive system
Replace
Broken turbine shaft
Replace
Low oil pressure (Main pressure)
Check for wear of the oil pump gear, or replace
Insufficient oil
Replace
Adjustment failure of inching pedal link
Adjust
Worn servo case seal ring
Replace
Worn input shaft O-ring
Replace
Non-removal of input shaft plug
Repair
Seizure of clutch
Replace
Broke shaft
Replace
Damaged clutch drum (Snapring groove)
Replace
Broken snapring for clutch drum
Replace
Clogging of clutch oil circuit
Clean or replace
Worn splines of shaft
Replace
Damaged transmission system (Reduction gear, Differential, Front axle
See each section
5-77
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Torque converter
Transmission
Abnormal noise High abnormal noise
Low abnormal noise
Oil leakage
5-78
Possible causes
Corrective action
Broke flexible plate
Replace
Damaged bearings
Replace
Contact of impeller
Replace
Loose bolt
Retighten or replace bolt
Worn splines
Replace
Worn oil pump
Disassemble or replace
Dragging noise due to clutch seizure
Replace clutch plate
Wear or seizure of bearing
Replace
Damaged gear
Replace
Loose bolt
Retighten or replace bolt
Worn splines
Replace
Clogging of oil strainer
Clean or replace
Failure of main regulator valve spool
Disassemble or replace
Large pipe resistance
Replace
Cold time (High viscosity)
Check applicable lubrication oil before replacement
Failure of instruments
Replace
Use of incorrect oil
Check applicable lubrication oil before replacement
Clogging of oil strainer
Clean or replace
Failure of oil pump
Replace
Excessive oil leakage (1) Failure of main regulator spring (2) Failure of main regulator valve spool
Replace spring
Air intake
Repair or replace spool
Insufficient oil
Retighten or replace packing
From oil seal
Check lip and sliding surface for wear Replace seal
From case connection
Retighten or replace packing
From various joints and pipes
Repair or replace pipe, gasket and Oring
From drain plug
Retighten or replace gasket
From cracks
Replace
Oil leak from transmission case (1) Water inclusion into oil (2) Air intake from intake side joint (3) Oil leak from air breather hole
Replace oil Retighten and replace packing Repair
Excessive oil quantity
Drain oil to the proper level
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Torque converter
Abnormally high oil temperature
Transmission
Body
Abnormally high main pressure
Abnormally low main pressure
Possible causes
Corrective action
Incorrect oil quantity
Replenish or drain
Clogging of oil strainer
Clean or replace
Contact of impeller
Repair or replace impeller
Failure of stator
Replace stator assembly
Air intake
Retighten or replace O-ring
Inclusion of water into oil
Replace oil
Large resistance on pipe (Low circulation flow rate)
Repair or replace
Wear or seizure of bearings
Repair or replace
Failure of instruments
Replace
Drag of clutch
Replace clutch plate
Wear or seizure of bearings
Repair or replace
Failure of control link
Repair or replace
Improper use of body
Use properly
Failure of body (1) Damaged fan belt (2) Clogging of oil cooler (3) Drag of brake
Replace Clean or replace Inspect or adjust
Failure of main regulator valve
Repair or replace valve assembly
Cold time
Check applicable lubrication oil before replacement
Use of incorrect oil
Check applicable lubrication oil before replacement
Clogging of magnet strainer
Clean or replace
Failure of oil pump
Replace
Defective coil spring of main regulator valve
Replace spring
Defective spool of main regulator valve
Repair or replace spool
Intake of air
Retighten or replace packing
Insufficient oil quantity
Replenish
Defective control link
Repair or replace
Defective clutch valve
Repair or replace
5-79
CHAPTER 5 POWERSHIFT TRANSMISSION Condition
Abnormally low clutch oil pressure
Stall speed is not within the standard value
No speed change (2-speed T/M)
5-80
Possible causes
Corrective action
Clogging of magnet strainer
Clean or replace
Failure of oil pump (Wear)
Replace
Defective coil spring of main regulator valve
Replace spring
Defective spool of main regulator valve
Repair or replace spool
Intake of air
Retighten or replace packing
Insufficient oil quantity
Replenish
Defective control link
Repair or replace
Defective clutch valve
Repair or replace
Broken seal ring of servo case
Replace
Broken clutch seal ring
Replace
Low engine output if both forward and reverse speed are a little low
Adjust engine
Failure of stator and free wheel if both forward and reverse speed are abnormally low
Replace stator assembly
Defective inching link or clutch slippage if the value exceeds the standard
Repair or replace
Mode selector switch remains at 1speed
Set the switch to Auto
Failure of solenoid valve
Replace
Clogging of solenoid valve inlet orifice
Clean or replace
Defective solenoid valve spool
Repair or replace spool
Defective solenoid valve spring
Replace spring
Defective ECU control box
Inspect and replace shim
CHAPTER 5 POWERSHIFT TRANSMISSION
31. Service Data 31.1 Torque Converter Drive Transmission Specifications Item -1
3.5 to 5.5 ton
6.0 to 7.0 ton
2000 mm
2080 mm
Stall speed (tolerance ± 100 min )
Standard
Oil pressure standard value
Standard
-
Main oil pressure at Eng. 1600 ± 100 min-1
Standard
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
Clutch oil pressure at Eng. 1600 ± 100 min-1
Standard
0.98 to 1.23 MPa (10.2 to 12.5 kgf/cm2) [142.2 to 177.8 psi]
T/C inlet oil pressure at Eng. 1600 ± 100 min-1
Standard
0.10 to 0.49 MPa (1.0 to 5.0 kgf/cm2) [142.2 to 71.1 psi]
Lubrication oil pressure at Eng. 1600 ± 100 min-1
Standard
10 m (33 ft) standing acceleration (without load) (sec.)
Standard
0.05 to 0.29 Mpa (0.5 to 3.0 kgf/cm2) [7.11 to 42.7 psi]
0.01 to 0.15 Mpa (0.1 to 1.5 kgf/cm2) [1.42 to 21.3 psi]
Within 5
Pump boss Ref. 1
2
Item Oil seal and bushing contact face (inside diameter)
Boss bushing inside diameter
Specifications Standard Limit
0
69.90 mm (2.7520 in.)
Standard Limit
1
0
70 -0.046 mm (2.76 -0.00181 in.)
70.06 to 70.10 mm (2.7583 to 2.7598 in.) 70.3 mm (2.768 in.)
2 609071
5-81
CHAPTER 5 POWERSHIFT TRANSMISSION Pilot boss Ref. 1
Item Diameter of flywheel insertion area
Specifications -0.007
Standard
-0.00028
20 -0.020 mm (0.78 -0.00079 in.)
Limit
19.85 mm (0.781 in.)
1
609072
31.2 Torque Converter Drive Transmission Oil pump Ref.
Item
1
Side clearance
2
Top clearance
Specifications Standard
0.05 to 0.11 mm (0.002 to 0.0043 in.)
Limit
0.20 mm (0.008 in.)
Standard
0.6 to 0.66 mm (0.236 to 0.0259 in.)
Limit 3
Clearance at notch between drive gear and pump boss
0.8 mm (0.031 in.)
Standard
0.2 to 0.4 mm (0.008 to 0.016 in.)
Limit
1.0 mm (0.04 in.)
1 3 2 609073
5-82
CHAPTER 5 POWERSHIFT TRANSMISSION Stator Ref. 1
Item Outside diameter of clutch hub
Specifications -0.03
Standard Limit
2
Outside diameter of clutch roller
64.9 mm (2.555 in.) 0
Standard
Outside diameter of thrust washer
7.985 mm (0.31437 in.) 0
Standard
1.75 mm (0.0689 in.) 0
Standard
Thickness of thrust washer
0
2.0 -0.05 mm (0.08 -0.0020 in.)
Limit 4
0
8.1 -0.015 mm (0.32 -0.00059 in.)
Limit 3
-0.0012
65 -0.049 mm (2.56 -0.00193 in.)
0
3.0 -0.05 mm (0.12 -0.0020 in.)
Limit
2.75 mm (0.1083 in.)
4 • 2
1
3 609074
Flexible plate Ref.
Item
1
Runout of flexible plate (in free condition)
2
Distance between end face of case and mating face of flexible plate
Specifications Standard
0.2 mm (0.008 in.)
Limit
0.5 mm (0.020 in.)
Standard
4 to 6 mm (0.157 to 0.236 in.)
1 2 609075
5-83
CHAPTER 5 POWERSHIFT TRANSMISSION 31.3 Torque Converter Drive Transmission Clutch Ref.
Item
Specifications Standard
1
Thickness of mating plate
2
Thickness of friction plate
3
Backlash between friction plate and gear
4
Width of seal ring
2.3 ± 0.07 mm (0.091 ± 0.0028 in.)
Limit
2.1 mm (0.083 in.)
Standard
2.6 ± 0.1 mm (0.102 ± 0.004 in.)
Limit
2.2 mm (0.087 in.)
Standard
0.1 to 0.3 mm (0.004 to 0.012 in.)
Standard
4 -0.03 mm (0.16 -0.0012 in.)
-0.01
Limit 5
3.5 mm (0.138 in.) +0.2
Standard
Seal ring groove width of piston
4.5 mm (0.177 in.) 62.9 mm (2.476 in.) / 31.312 N·m (3.193 kgf·m) [178.648 lbf·in.]
Standard
Free length of clutch spring
Limit
6
3
+0.008
4 +0.1 mm (0.16 +0.004 in.)
Limit 6
-0.0004
62 mm (2.440 in.)
2 1
4 5
609076
Output shaft (4th shaft) Ref. 1
Item Locknut tightening torque
Specifications Standard
353 to 392.3 N·m (36 to 40 kgf·m) [79.4 to 88.2 lbf·ft]
1
609077
5-84
CHAPTER 5 POWERSHIFT TRANSMISSION 31.4 Torque Converter Drive Transmission (1-Speed Transmission) Main shaft and servo case Specifications Ref.
Item 3.5 to 5.5 ton
1
Seal ring width of turbine shaft
2
Piston seal ring groove width of turbine shaft
Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit
2.0 mm (0.08 in.)
Standard
+0.2
Limit 3
4
5
Seal ring contact surface inside diameter of stator shaft
3.0 mm (0.118 in.)
Standard
+0.2
35.2 mm (1.386 in.) 2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit
Clutch piston seal ring groove width
2.0 mm (0.08 in.)
Standard
+0.2
3.1 mm (0.122 in.)
Standard
Clutch shaft seal ring width
7
Clutch shaft seal ring groove width
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit
2.0 mm (0.08 in.)
Standard
+0.2
Seal ring contact surface inside diameter of servo case
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit 8
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit 6
+0.008
35 +0.1 mm (1.386 +0.004 in.)
Limit Standard
Clutch piston seal ring width
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
3.0 mm (0.118 in.)
Standard Limit
35
+0.025 +0.00098 0 mm (1.38 0
in.)
35.2 mm (1.386 in.)
6, 7
1, 2
8
4,5
3 609078
Gear backlash Specifications Item 3.5 to 5.5 ton Countergear and output gear
Standard
0.14 to 0.27 mm (0.0055 to 0.0106 in.)
Other gears
Standard
0.14 to 0.26 mm (0.0055 to 0.0102 in.)
5-85
CHAPTER 5 POWERSHIFT TRANSMISSION Shaft Specifications Item 3.5 to 5.5 ton Backlash at each shaft spline
Standard
0.036 to 0.206 mm (0.0014 to 0.0081 in.)
31.5 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) Input shaft and servo case Specifications Ref.
Item 6.0 to 7.0 ton
1
2
Seal ring width of input shaft
Seal ring groove width of input shaft
Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit Standard
2.0 mm (0.08 in.) +0.2 +0.008 2.5 +0.1 mm (0.098 +0.004
Limit 3
Seal ring contact surface inside diameter of stator shaft
4
Input shaft seal ring width
5
Input shaft seal ring groove width
Standard
3.0 mm (0.118 in.) +0.025 +0.00098 35 0 mm (1.38 0
Limit Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.) 2.0 mm (0.08 in.) +0.2
Seal ring contact surface inside diameter of servo case
7
Clutch piston seal ring width
8
Clutch piston seal ring groove width
Standard Limit Standard Limit Standard Limit
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit 6
in.)
35.2 mm (1.386 in.)
Limit Standard
in.)
3.0 mm (0.118 in.) 35
+0.025 +0.00098 0 mm (1.38 0
in.)
35.2 mm (1.386 in.) 2.5 ± 0.05 mm (0.098 ± 0.002 in.) 2.0 mm (0.08 in.) +0.2
+0.008
2.5 +0.1 mm (0.098 +0.004 in.) 3.0 mm (0.118 in.)
6
4, 5
5-86
7, 8
3
1, 2 609079
CHAPTER 5 POWERSHIFT TRANSMISSION 31.6 Torque Converter Drive Transmission (Automatic 2-Speed Transmission) Counter shaft and servo case Specifications Ref.
Item 6.0 to 7.0 ton
1
Seal ring width of countershaft
2
Seal ring groove width of countershaft
Standard
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit Standard
2.0 mm (0.08 in.) +0.2
Limit 3
4
5
Seal ring contact surface inside diameter of pump body
Standard
3.0 mm (0.118 in.) 35
Limit Standard
Clutch piston seal ring width
Clutch piston seal ring groove width
Countershaft seal ring width
7
Countershaft seal ring groove width
Standard
2.0 mm (0.08 in.) +0.2
3.1 mm (0.118 in.) 2.5 ± 0.05 mm (0.098 ± 0.002 in.) 2.0 mm (0.08 in.) +0.2
Seal ring contact surface inside diameter of servo case
6, 7
8
4, 5
Standard Limit
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit 8
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
Limit Standard
in.)
2.5 ± 0.05 mm (0.098 ± 0.002 in.)
Limit 6
+0.025 +0.00098 0 mm (1.38 0
35.2 mm (1.386 in.)
Limit Standard
+0.008
2.5 +0.1 mm (0.098 +0.004 in.)
3.0 mm (0.118 in.) 35
+0.025 +0.00098 0 mm (1.38 0
in.)
35.2 mm (1.386 in.)
3
1, 2 609085
5-87
CHAPTER 5 POWERSHIFT TRANSMISSION Gear backlash Specifications Item 6.0 to 7.0 ton Gears for forward 1-speed and 2-speed
Standard
0.14 to 0.23 mm (0.0055 to 0.0090 in.)
Forward and reverse gears
Standard
0.14 to 0.24 mm (0.0055 to 0.0094 in.)
Shaft Specifications Item 6.0 to 7.0 ton Countergear and output gear
Standard
0.14 to 0.25 mm (0.0055 to 0.0098 in.)
Backlash at shaft splines
Standard
0.036 to 0.206 mm (0.0014 to 0.0081 in.)
5-88
CHAPTER 5 POWERSHIFT TRANSMISSION 31.7 Torque Converter Drive Transmission Control valve Ref. 1
2
3
4
5
6
7
8
Item
Specifications
Free length of main relief valve inner spring
Standard
Free length of main relief valve inner spring
Standard
Free length 3 of clutch valve spring
Standard
Free length 3 of clutch valve spring
Standard
75 mm (2.95 in.) / 2.122 N·m (0.215 kgf·m) [12.050 lbf·in.]
Limit
72 mm (2.83 in.) 50 mm (1.97 in.) / 0.838 N·m (0.0855 kgf·m) [4.783 lbf·in.]
Limit
48 mm (1.89 in.) 39 mm (1.54 in.) / 2.128 N·m (0.217 kgf·m) [12.141 lbf·in.]
Limit
38 mm (1.50 in.) 28 mm (1.10 in.) / 0.479 N·m (0.0488 kgf·m) [2.730 lbf·in.]
Limit
26.5 mm (1.04 in.) 32 mm (1.26 in.) / 4.560 N·m (0.465 kgf·m) [26.017 lbf·in.]
Free length of torque converter Standard inlet/outlet oil pressure regulating valve spring Limit Free length of accumulator valve outer spring
Standard
Free length of accumulator valve inner spring
Standard
Free length of directional spool spring
Standard
31 mm (1.22 in.) 91 mm (3.58 in.) / 7.303 N·m (0.0745 kgf·m) [41.666 lbf·in.]
Limit
89 mm (3.50 in.) 130 mm (5.12 in.) / 0.597 N·m (0.0609 kgf·m) [3.408 lbf·in.]
Limit
128 mm (5.04 in.) 32.5 mm (1.279 in.) / 8.616 N·m (0.8786 kgf·m) [49.158 lbf·in.]
Limit
32 mm (1.26 in.)
7 6 1 2 3 4
8
5
8 609086
5-89
CHAPTER 5 POWERSHIFT TRANSMISSION 31.8 Torque Converter Drive Transmission Solenoid valve Specifications Item 6.0 to 7.0 ton 1
Free length of solenoid valve spring
Standard Limit
65 mm (2.56 in.) / 1.795 N·m (0.183 kgf·m) [10.239 lbf·in.] 63 mm (2.48 in.)
1 609087
5-90
CHAPTER 5 POWERSHIFT TRANSMISSION Inching pedal control Ref.
Item
Specifications
1
Inching pedal height (from top of frame to top of pedal pad)
Standard
175 mm (6.89 in.)
2
Clearance between stopper bolt and brake pedal
Standard
16 mm (0.63 in.)
3
Plunger stroke
Standard
8 to 9.5 mm (0.314 to 0.374 in.)
4
Plunger stroke at brake functioning
Standard
16.5 mm (0.649 in.)
5
Inching pedal stroke (brake functioning)
Standard
82.4 mm (3.24 in.)
6
Inching pedal stroke
Standard
15.2 mm (5.98 in.)
6 5 1
2
4
3
609088
5-91
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 1.
Specifications Item Reduction gear
Transmission
Reduction ratio Housing type
Differential gear
Running gear
Gear type
Gear type and quantity
6.0 to 7.0 ton
Spiral bevel gear
Hypoid gear
4.571
4.857 Banjo type
Large
Straight bevel gear x 2
Small
Straight bevel gear x 2
Front axle type Suspension system
3.5 to 5.5 ton
Full-floating axle tube type Front wheel
Frame fixing type
6-1
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
2.
Structure 2
1
•
•
3
4
5
•• •
• •
•
8
7
6 609175
1. 2. 3. 4.
6-2
Front wheel hub drum Reduction bevel pinion Reduction bevel gear Differential case
5. 6. 7. 8.
Differential carrier Axle housing Axle shaft Front axle support
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
3. 3.1
Removing Front Tire Preparation
(1) Set the parking brake, and block the rear wheels. (2) Loosen the wheel nuts about two rotations, and lift the lift truck with a crane or a hydraulic unit.
2
1
609176 1. Wheel nut
2. Front tire
Removal method (1) Lifting the lift truck with a crane Attach a sling on the outer and inner mast crossmembers, and lift the lift truck. Use cloth for the sling for protection. Note: For both methods, place jack stands under the frame to prevent the lift truck from falling off.
609177
(2) Lifting the lift truck with the mast Tilt the mast fully BACKWARD, place wood blocks which can bear the weight under the mast, and tilt the mast FORWARD until the front tires are off the ground.
609178
6-3
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
4.
Installing Front Tire
Follow the removal sequence in reverse. Observe the following key points: Tighten wheel nuts evenly to the specified torque to prevent the wheels from wobbling. After tire replacement, drive the lift truck for a while and then check the torque of the wheel nuts again. Note: Make sure wheel nut mounting holes are free of paint and grease before installing wheel nuts.
1 8
5 3
4 7
6 2
Tightening sequence Item Wheel nut
6-4
Tightening torque 551 ± 55 N·m (56.2 ± 5.6 kgf·m) [406.5 ± 40.6 lbf·ft]
609179
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
5. 5.1
Removing Front Axle Assembly Preparation
(1) Pull the parking brake lever, and place wheel stoppers at the front and rear tires. (2) Remove the mast and the lift bracket assembly. See “MAST AND FORKS”. (3) Loosen the front tire nuts about two rotations, and jack up the lift truck. (4) Place a jack stand under the frame on both sides at the front so that the lift truck becomes level. (5) Remove the front tires. See 6-3 "Removing Front Tire". (6) Drain differential oil. Note: When replacing the front axle housing, carry out the above preparation.
5.2
Removal Sequence
3
2
3
4
1
609180
1. 2.
Axle shaft, Bolt, Spring washer Bolt, Spring washer
3. 4.
Nuts, Spring washers, Bolts Front axle assembly
6-5
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 5.3
Suggestions for Removal
Removing axle support bolts (1) Place wood blocks under the front of the transmission for support.
1 609181 1. Wood block
(2) Attach a sling with protection cloth on the mast fitting in the front axle assembly, and lift the assembly until the wire is braced. Wind the sling twice firmly. (3) To remove bolts, remove the bolts at the top on both sides, and insert a guide bar. Then remove the other bolts.
6.
Installing Front Axle Assembly
Follow the removal sequence in reverse. Be careful with the following key points,: (1) Clean the mounting surface on the differential carrier completely, and apply liquid gasket before installation. (2) Apply liquid gasket to the mounting surface of the axle shaft, and tighten bolts. Item Axle shaft bolts
Tightening torque 128.3 ± 12.8 N·m (13.1 ± 1.3 kgf·m) [94.7 ± 9.4 lbf·ft]
(3) Tighten axle support bolts to the specified torque. Item Axle support bolts
7.
3.5 to 5.5 ton
6.0 to 7.0 ton
693.8 N·m (70.8 kgf·m) [512 lbf·ft]
877.1 N·m (89.5 kgf·m) [647.3 lbf·ft]
Removing and Installing Reduction and Differential
When replacing the reduction gear, replace the gear and pinion as a set. Tooth contact of the reduction gear and the reduction pinion must be adjusted by mating the transmission on the pinion side and the differential carrier on the gear side. Therefore remove the transmission and the differential carrier from the frame before adjusting the tooth contact. Remove the engine before removing or installing the transmission. See “POWER TRAIN”. Place the transmission on a stable work bench, and remove the differential carrier.
6-6
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
8. 8.1
Disassembling Axle Shaft and Hub Preparation
(1) Loosen front wheel nuts about two rotations, and jack up the lift truck. (2) Place jack stands under the frame on both sides at the front so that the lift truck is at the level position when viewed from the front. (3) Remove the front tires. (4) Drain differential oil.
8.2
Disassembly Sequence
6
1
5 4
3 2
609182
1. 2. 3. 4.
Front tire Axle shaft, Bolt, Spring washer Bolt, Lock washer, Locknut Taper roller bearing (inner)
5. 6.
Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal Retainer, O-ring
Note: In general, disassemble the front axle with the axle housing installed on the frame.
6-7
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 8.3
Suggestions for Disassembly
(1) Removing locknut Use the special tool to remove the locknut.
1
609183 1. Special tool
Special tool needed Item Socket wrench
3.5 to 5.5 ton
6.0 to 7.0 ton
100 mm (3.94 in.)
03703-49000
(2) Removing front wheel hub Use a hub puller 1 to remove the front wheel hub. If the taper roller bearing (inner race) is tight, the inner oil seal may fall off and the taper roller bearing may remain in the axle housing.
1
609184 1. Hub puller
(3) Using a bearing puller 1, remove the inner race of tapered roller bearing left on the axle housing, along with the seal retainer.
1
609185 1. Bearing puller
6-8
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
9. 9.1
Inspection and Repair After Disassembling Axle Shaft and Hub Axle Shaft
(1) Check the splines for wear. Install the differential bevel gear on the splined end of axle shaft, and turn the gear back and forth. Measure the free movement of the gear (looseness between mating splines) with a dial gauge as shown.
609186
(2) Measuring axle shaft bend - Attach a dial gauge on the center of the axle shaft, and rotate the axle shaft. Measure bend of the axle shaft. - Attach a dial gauge to the edge of the flange, and rotate the axle shaft. Measure deflection of the flange.
609187
Item
Value
Looseness of axle shaft spline
Standard
Axle shaft bend (1/2 of gauge reading)
Standard Limit Standard
Flange deflection
9.2
Limit
Limit
0.07 to 0.17 mm (0.0028 to 0.0067 in.) 0.5 mm (0.020 in.) 1.0 mm (0.039 in.) or less 2.0 mm (0.079 in.) 0.04 mm (0.0015 in.) 0.5 mm (0.020 in.)
Retainer
Check for wear or damage on the retainer circumference.
9.3
Front Hub Drum
If uneven wear or damage is found on the inner surface of the brake drum, grind and repair. Item Inner diameter of brake drum
Value Standard Limit
317.5
+0.2 +0.078 0 mm (12.5 0 in.)
318.5 mm (12.539 in.)
6-9
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
10. Assembling Axle Shaft and Hub 10.1 Assembly Sequence
6
•
•
4 •• •
5
• •
3 5
• •
•
•
• • ••
•
1
2
609188
1. 2.
6-10
Retainer, O-ring Front hub drum assembly Taper roller bearing (outer), Oil seal, Taper roller bearing, Spacer and Oil seal
3. 4. 5. 6.
Taper roller bearing (inner) Locknut, Lock washer, Bolt Axle shaft, Bolt, Spring washer Front tire, Wheel nut
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 10.2 Suggestions for Assembly Front hub drum assembly (1) Press in the taper roller bearing (outer). (2) Press in a new oil seal. Make sure that the lip is in correct direction. (3) Press in the taper roller bearing (outer). (4) Insert the spacer. (5) Fill the roller holder of the taper roller bearing (inner) with grease. Use your palm to push grease into the roller holder. Insert the taper roller bearing (inner). (6) Press in a new oil seal. Make sure that the lip is in the correct direction. (7) Fill the front hub with grease. (See the illustration on the right.) Apply grease thinly on oil seal lips. Make sure that no grease is in the drum.
1 1) 5 2 3 4 6
609189
Hub bearing preload Wind a wire around the hub bolt twice, attach a spring balance on the wire. Pull and measure the tangential force. Hub bolt pitch: ø260 mm (10.23 in.)
609190
Item Hub bolt
Tangential force 25.5 to 40 N (2.3 to 4.1 kgf) [5.06 to 9.02 lbf]
If the preload is within the standard range, insert the lockring, apply LOCTITE 271, and tighten bolts. Item
Tightening torque 9.8 ± 1.0 N·m (1.0 ± 0.1 kgf·m) [7.2 ± 0.7 lbf·ft]
Bolt
Axle shaft When installing the axle shaft, apply liquid gasket on the mating surface with the hub, and tighten bolts to the specified torque. Item Axle shaft
Tightening torque 128.3 ± 12.8 N·m (13.1 ± 1.3 kgf·m) [94.7 ± 9.4lbf·ft]
Wheel nuts Tighten wheel nuts to the specified torque evenly to prevent tire shimmy. See 6-4 "Installing Front Tire"
6-11
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
11. Disassembling Reduction Differential 11.1 Preparation Remove the differential carrier from the transmission case.
11.2 Disassembly Sequence
3
5 6
4
7 7 8
5
9
7 7
2 1. 2. 3. 4. 5.
6-12
10
1
Bolt, Lockwasher, Lockplate Bolt, Lockwasher, Bearing cap Side bearing nuts Differential carrier Taper roller bearing, Bolt, Spring washer, Differential case (right)
6. 7. 8. 9. 10.
3
609191
Differential bevel gear, Thrust washer Differential bevel pinion, Thrust washer Spider Differential bevel gear, Thrust plate Taper roller bearing, Bolt, Differential case (left), Reduction bevel gear
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 11.3 Suggestions for Disassembly Note: (1) Measure the backlash of the gear before disassembly, and use the measurement for assembly. (2) Put a matchmark across one of the bearing cap adjusting screws and the carrier, and use the mark for assembly.
609192
Item Backlash between Reduction gear and pinion
Standard
3.5 to 5.5 ton
6.0 to 7.0 ton
0.07 to 0.17 mm (0.0028 to 0.0067 in.)
0.07 to 0.17 mm (0.0028 to 0.0067 in.)
11.4 Removing Bearing Remove the inner bearing with a bearing puller.
609193
6-13
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
12. Inspection and Repair After Disassembling Reduction Differential 12.1 Reduction Bevel Gear Check the tooth contact pattern of the reduction bevel gear and pinion. Check the gear teeth for wear, pitting, flaking, or chipping. Minor flaws on the tooth surfaces can be repaired by grinding with an oil stone or sandpaper. If the gear is badly damaged and requires replacement, replace the gear and pinion as a set.
12.2 Differential (1) Check for scoring at the mating part of the differential case and the side bearing inner race. (2) Check for cracks on the differential case, and for wear or damage on the sliding part between the gear and the thrust washer. (3) Check for wear, loss, or scoring on the differential bevel gear and the pinion gear teeth. Check for wear or damage on the thrust washer plate. (4) Check the internal diameter of the differential pinion gear and for wear of the spider shaft. Item Clearance between pinion gear and spider
6-14
Value Standard Limit
0.169 to 0.278 mm (0.0066 to 0.0109 in.) 0.5 mm (0.020 in.)
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
13. Assembling Reduction Differential 13.1 Assembly Sequence
5
7
9
•
•
•
•
• 8
•
11 12
•
•
8
•
•• •
•
11
••
• • •
• • •
10
6
1
•
5 4
3
10
2 609194
1. 2. 3. 4. 5. 6.
Differential case (left) Reduction bevel gear, Bolt Differential gear, Thrust washer Spider Differential bevel pinion, Thrust washer Differential bevel gear, Thrust washer
7. 8. 9. 10. 11. 12.
Differential case (right), Bolt Taper roller bearing Differential carrier Bearing cap, Bolt, Lockwasher Side bearing nut Bolt, Lockplate, Lockwasher
13.2 Suggestions for Assembly Tightening Reduction bevel gear Apply LOCTITE 271 on bolts, and tighten to the specified torque. Item Reduction gear
Tightening torque 225.5 ± 9.8 N·m (23.0 ± 1.0 kgf·m) [166.3 ± 7.2 lbf·ft]
6-15
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL Installing differential bevel pinions The thrust washers of bevel gear are used for adjusting the backlash of the bevel gears with the pinion. Measure the backlash and, if it exceeds the service limit, replace the thrust washers.
609195
Item Backlash of the differential bevel gear
Value Standard
0.20 to 0.40 mm (0.008 to 0.016 in.)
Limit
0.6 mm (0.024 in.)
Installing differential case (1) Assemble the left and right cases by using the matchmark, and tighten bolts. (2) Apply LOCTITE 271 to the threads of the bolts, and tighten the bolts evenly to ensure free gear movement.
609196
Item Differential case
Tightening torque 122.5 ± 9.8 N·m (12.5 ± 1.0 kgf·m) [90.4 ± 7.2 lbf·ft]
Installing differential case assembly (1) After positioning the case assembly on the carrier, fit the bearing caps tentatively by making the cap bolts snug tight. The caps should be secured tight after the bearing preload has been adjusted. (2) Tighten bolts to the specified torque. Note: The bearing caps and the differential carrier are machined together in the factory. Pay attention to the match marks so that they are positioned on the side as they were before disassembly. 609192
Item Bearing cap
6-16
Tightening torque 161.8 ± 9.8 N·m (16.5 ± 1.0 kgf·m) [119.3 ± 7.2 lbf·ft]
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
14. Adjustment 14.1 Adjusting Bearing Preload Wind a coil on a reduction gear bolt, attach a spring scale on the coil and pull. Read the tangential force when the gear starts rotation. Adjust the preload by tightening the side bearing nuts on both sides. Note: Before measuring the preload, tap the back of the bevel gear with a copper hammer while winding the gear by hand. 609197
Item
Tangential force 12.7 to 25.4 N (1.3 to 2.6 kgf) [2.8 to 5.7 lbf]
Side bearing
14.2 Inspecting Back Runout Attach a dial gauge on the back surface of the reduction gear at the largest radius, and measure the back runout while rotating the gear. If the measurement exceeds the standard value, inspect the reduction gear tightening and the taper roller bearing. If the measurement exceeds the standard value, replace together with the pinion gear.
609198
Item Back runout of reduction bevel gear
Value Standard Limit
0.15 mm (0.006 in.) or less 0.20 mm (0.008 in.)
6-17
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 14.3 Adjusting Backlash Adjust the backlash after installing the differential carrier assembly in the transmission case. Attach the dial gauge needle vertically on the tooth surface of the bevel gear. Move the bevel gear forward and backward (in rotating direction) and check the deflection of the needle. Adjust the backlash with the side bearing nut.
609199
1
2)
1)
1)
2)
1 1)
1. Backlash
Item Reduction gear and pinion gear
Standard
2) 609200
1) Small 2) Large
3.5 to 5.5 ton
6.0 to 7.0 ton
0.25 to 0.33 mm (0.0098 to 0.0129 in.)
0.33 to 0.41 mm (0.0129 to 0.0161 in.)
14.4 Adjusting Tooth Contact Apply machinist’s dye on three or four teeth of the reduction gear thinly and evenly. Rotate the reduction gear forward and backward by hand several times. Check tooth contact by the shape of contact area. Adjust faulty tooth contact as follows:
609201
6-18
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL 14.5 Tooth Contact of Reduction Gear Tooth contact conditions
1 500471
Adjusting procedure
Extends from toe to middle portion, covering 50% or more of tooth length.
Good
2
1. Move the gear away from pinion.
Short contact at toe of tooth (Toe).
2
1
500472
502121
2
Short contact at heel of tooth (Heel)
3
502122
2
500474
502123
Heavy contact on flank root portion of tooth (Root)
5 500475
2. Move pinion away from gear by removing shim(s) to secure correct backlash. 1. Slightly move pinion toward gear by adding shims.
1
Heavy contact on flank top portion of tooth (Top)
4
1. Move gear toward pinion. 1
500473
2. Move pinion toward gear by adding shim(s) to secure correct backlash.
1
2. Slightly move gear away from pinion to secure correct backlash. 1. Slightly move pinion away from gear by removing shim(s).
2 502124
2. Slightly move gear toward pinion to secure correct backlash.
Note: “Toe” or “Heel” contact is determined by checking the contact pattern on the outside (convex side) of the reduction gear tooth. For “Top” or “Root” contact, repeat the above adjusting procedure until the correct tooth contact is obtained.
6-19
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
15. Troubleshooting Condition
Continuous gear noise during travel
Irregular noise during travel
Abnormal noise generated at curves
Overheated reduction case after travel
6-20
Possible causes
Corrective action
Wear of reduction gear teeth
Replace the reduction gear
Misadjustment or wear of the reduction gear bearing
Repair or replace the bearing
Breakage of hub bearing
Replace the bearing
Faulty engagement of the reduction pinion gear and the reduction gear of the output shaft
Adjust the tooth contact
Breakage of reduction gear bearing or hub bearing
Replace bearing
Loss of differential gear tooth or wear of thrust washer
Replace the gear or the washer
Mixing of foreign matter in axle housing
Clean the housing and replace oil
Loose axle shaft bolt or differential carrier bolt
Tighten bolts
Wear of contact area between differential gear and differential case
Replace
Loss or wear of the differential gear or the pinion gear teeth, or seizure, wear or tear with the spider
Replace
Breakage of bearing due to excessive preload on bearing
Replace the bearing and adjust the preload
Insufficient backlash of the output shaft reduction gear
Adjust the tooth contact and backlash
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
16. Service Data 16.1 Front Axle Hub and wheel Ref.
Item
3.5 to 5.5 ton Standard
-
0.04 mm (0.0016 in.)
Axle shaft flange deflection Limit
-
Axle shaft bend (1/2 of gauge reading)
6.0 to 7.0 ton
0.5 mm (0.02 in.)
Standard
1.0 mm (0.04 in.) or less
Limit
2.0 mm (0.08 in.)
1
Hub bearing preload Tangential force at the hub bolts position
Standard
2
Axle shaft bolts
Tightening torque
128.3 ± 12.8 N·m (13.1 ± 1.3 kgf·m) [94.7 ± 9.4 lbf·ft]
3
Wheel bolt nuts
Tightening torque
307.9 ± 30.7 N·m (31.4 ± 3.1 kgf·m) [227.1 ± 22.7 lbf·ft]
4
Front axle support bolts
Tightening torque
5
Wheel nuts
Tightening torque
551 ± 55 N·m (56.2 ± 5.6 kgf·m) [406.5 ± 40.6 lbf·ft]
5
Lock ring bolts
Tightening torque
9.8 ± 1.0 N·m (1.0 ± 0.1 kgf·m) [7.2 ± 0.7 lbf·ft]
6
Tire service limit
Limit
22.5 to 40 N (2.3 to 4.1 kgf) [5.06 to 9.02 lbf]
693.8 N·m (70.8 kgf·m) [512 lbf·ft]
877.1 N·m (89.5 kgf·m) [647.3 lbf·ft]
48.3 mm (1.9 in.)
4 5
7
3 •
6
•
•
•
• 2
1
609202
6-21
CHAPTER 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
Ref. 1
Item Differential bevel gear backlash
3.5 to 5.5 ton Standard
6.0 to 7.0 ton
0.20 to 0.40 mm (0.008 to 0.016 in.)
Limit
0.6 mm (0.024 in.)
2
Clearance between Standard differential bevel pinion and Limit spider
0.169 to 0.278 mm (0.0066 to 0.0109 in.)
3
Preload at differential side bearing Tangential force at reduction bevel gear bolt
4
Back runout of reduction bevel gear
5
Backlash between reduction bevel gear and T/M pinion gear
6
Looseness of the axle shaft spline
7
Reduction bevel gear bolts
Tightening torque
225.5 ± 9.8 N·m (23.0 ± 1.0 kgf·m) [166.3 ± 7.2 lbf·ft]
8
Differential case bolts
Tightening torque
122.5 ± 9.8 N·m (12.5 ± 1.0 kgf·m) [90.4 ± 7.2 lbf·ft]
9
Side bearing cap bolts
Tightening torque
161.8 ± 9.8 N·m (16.5 ± 1.0 kgf·m) [119.3 ± 7.2 lbf·ft]
0.5 mm (0.02 in.)
Standard
12.7 to 25.4 N (1.3 to 2.6 kgf) [2.8 to 5.7 lbf]
Standard
0.15 mm (0.006 in.) or less
Limit
0.2 mm (0.08 in.) 0.25 to 0.33 mm (0.0098 to 0.0129 in.)
Standard Standard
0.30 to 0.41 mm (0.0118 to 0.0161 in.)
0.07 to 0.17 mm (0.0028 to 0.0067 in.)
Limit
0.5 mm (0.02 in.)
5
9
6-22
8 1
2 4 7
6
3 609203
CHAPTER 7 REAR AXLE
Chapter 7 REAR AXLE 1.
Specifications Item
3.5 to 5.5 ton
Axle type
Elliot
Suspension
Center pivot Toe-in
Rear axle
Wheel alignment
0 mm (0 in.)
Camber angle
1.0°
Caster angle
0°
Kingpin angle
0°
Steering cylinder inner diameter × Rod external diameter Effective stroke
6.0 to 70 ton
85 × 60 mm (3.34 × 2.36 in.) 155 mm (6.10 in.)
180 mm (7.07 in.)
7-1
CHAPTER 7 REAR AXLE
2. 2.1
Structure Rear Axle (3.5 to 5.5 Ton)
6
5
5
•
4 •
•
• 4
A
• 2
3
•
• •
1
6
A
3 609089
1. 2. 3.
2.2
Rear axle Steering cylinder Tie rods (left and right)
4. 5. 6.
Knuckles (left and right) Stopper bolts (left and right) Rear axle supports (front and rear)
Rear Axle (6.0 to 7.0 Ton)
•
1 • 4
•
2
3
•
6 • • Section A-A 5 1. 2. 3.
7-2
Rear axle Tires (left and right) Rims (left and right)
• 4
609090
4. 5. 6.
Knuckles (left and right) Pins (two pins for each side) Tie rods (left and right)
CHAPTER 7 REAR AXLE Note: The knuckle is operated with a double-action steering cylinder. The rims to which the tires are inserted serve as wheel hubs. Steering cylinder piping is different between 3.5 to 5.5 ton models and 6.0 to 7.0 ton models.
2.3
Steering Cylinder
3 1
4
5
3
2
13
12, 11 10
9
8
7
6 609091
1. 2. 3. 4. 5. 6. 7.
Spherical bushing Stopper ring Cylinder head Piston Bolt Cylinder tube Piston rod
8. 9. 10. 11. 12. 13.
Piston seal Wear ring Bushing Backup ring Oil seal Dust seal
Note: Double-action cylinder is used. The above figure shows a steering cylinder for 6.0 to 7.0 ton models. For 3.5 to 5.5 ton models, the stroke becomes shorter.
7-3
CHAPTER 7 REAR AXLE
3. 3.1
Removing Rear Tires Preparation
(1) Set the parking brake, and block the front wheels. (2) Use the counterweight lifting hole and lift the lift truck, or use a jack. (3) Lift the lift truck until the right and left rear tires are off the ground and rotate freely. (4) Place wood blocks under the flat bottom of the rear axle on both sides, and lower the lift truck.
609092
3.2
Removal Sequence
5
6
6 4
3 2 1
1. 2. 3.
3.3
Cap, Gasket Locknut, Lockplate Taper bearing (inner) Remove 4 through 6 together.
4. 5. 6.
609093
Rim tire assembly Oil seal Taper bearing (outer)
Suggestions for Removal
(1) Since the rim/tire assembly falls easily, prevent fall with a wood block before removal. Be careful not to damage the oil seal on the rim. (2) Knock out the outer race of the taper bearing by attaching a batten on the notch inside the rim.
7-4
CHAPTER 7 REAR AXLE
4.
Installing Rear Tires
Follow the removal sequence in reverse. BE SURE to follow the key points below:
4.1
Suggestions for Installation
(1) Replace the oil seal with a new one. (2) Clean grease off the taper bearing and the rim. Fill in new grease. Apply grease on the oil seal lip.
1 2 •
609094 1. Oil seal
2. Grease
(3) Adjust the hub bearing preload. (4) Tighten the inner nut temporarily. (5) Insert a ø24 round bar to the cast hole of the rim. Attach a spring scale on the round bar, and measure the tangential force.
609095
Item Starting torque of hub rotation (increment from when preload is zero)
Standard value 0.5 to 5 N·m (0.05 to 0.51 kgf·m) [0.369 to 3.688 lbf·in.]
Tighten the inner nut to obtain the specified value.
7-5
CHAPTER 7 REAR AXLE (6) After adjusting the preload, add a new lockwasher and tighten the outer nut to the specified torque.
1 •
•
2 3 609096
1. Lock washer 2. Outer nut
Item Outer nut
3. Inner nut
Tightening torque 157
+20 0
N·m (16
+2 0
kgf·m) [115.7
+14 0 lbf·in.]
(7) Bend the lockwasher to both sides (inward and outward). (8) Fill the cap with grease, and install the cap.
609097
7-6
CHAPTER 7 REAR AXLE
5.
Removing Rear Axle
Remove the rear tires before removing the rear axle. See 7-4 "Removing Rear Tires". BE SURE to carry out the preparation, and follow the key points for removal:
5.1
Suggestions for Removal
(1) Remove the steering hose. Put a plug on the removed hose to prevent oil leakage. Item Plug
05530-30300 (G 3/8)
(2) Before removing the rear axle support bolt, pry the rear axle assembly with a bar, and measure the front and rear clearances. If the total value is 0.8 mm (0.03 in.) or more, insert thrust washers and adjust the clearances when installing the bolt. (3) After removing the rear axle support bolt, remove the rear axle assembly squarely out of the lift truck.
5.2
Removal Sequence
2
3
2
1 609098
1. 2.
Steering hose Rear axle support, Bolt, and Washer
3.
Rear axle assembly, Thrust washer
7-7
CHAPTER 7 REAR AXLE Preparation (1) After removing the rear tires, remove the wood blocks under the rear axle, and insert a carriage. Insert the carriage so that the rear axle can be removed to the side. (2) Place wood blocks under the balance weight on both sides.
609099
6.
Installing Rear Axle
Follow the removal sequence in reverse. Carry out the following procedures.: (1) Adjusting bearing support clearances Adjust the front and rear clearances by using thrust washers so that the total clearance becomes 0.8 mm (0.03 in.) or less. Note: Insert thrust washers evenly.
0.8 mm (0.03 in.) or less
609100
Standard value Item
Thrust washer type
3.5 to 5.5 ton
6.0 to 7.0 ton
1.0 mm (0.039 in.)
3.2 mm (0.125 in.)
-
1.6 mm (0.062 in.)
2.0 mm (0.078 in.)
0.8 mm (0.031 in.)
(2) Removing support bushing Do not remove the bushing in the support if possible. If not, replace the bushing together with the support assembly, or break and remove the bushing. Assemble a new bushing so that the matchmark faces downward (toward the grease nipple). Note: Assemble a new bushing so that the joint faces downward (toward the grease nipple).
1 1. Bushing joint
7-8
609101
CHAPTER 7 REAR AXLE
7. 7.1
Disassembling Rear Axle Assembly Rear Axle (3.5 to 5.5 Ton)
Disassembly sequence
7
14
8 5 5 11
8
2 3
12
10
4
6
10
13
9 1
9
609102
1. 2. 3. 4. 5. 6. 7.
Taper roller bearing (inner), Retainer Bolt, Washer, Tie rod pin, Spacer, Dust seal, Ring, Bearing Tie rod Bolt, Washer, Clamp Oil pipes (L.H., R.H.) Bolt, Spring washer Steering cylinder
8. 9. 10. 11. 12. 13. 14.
Elbows, O-rings Cover, Plate, O-ring, Taper roller bearing (outer), Oil seal, Bolt, Washer Taper roller bearings (inner), Knuckle Plug Oil seal, Taper roller bearing (outer) Bolt, Locknut Rear axle housing
7-9
CHAPTER 7 REAR AXLE 7.2
Rear Axle (6.0 to 7.0 Ton)
Disassembly sequence
5
4
7
5 2
1 3 6 1 609103
1. 2. 3. 4.
Bolt, Washer, Clamp Oil pipes (L.H., R.H.) Bolt, Spring washer Bolt, Washer, Clamp
5. 6. 7.
Elbows, O-rings Bolt, Locknut Rear axle housing
Since different oil pipes are used for 6.0 to 7.0 ton models, clamps of different shapes are used. Elbows are also different.
7-10
CHAPTER 7 REAR AXLE Suggestions for disassembly (1) -
Removing cover Remove the six bolts from cover 9. Remove the plug at the center of the cover. Screw in a cover puller bolt (nominal diameter: 12 mm (0.47 in.), pitch: 1.25 mm (0.049 in.), thread length: 50 mm (1.97 in.) or more), and remove cover 9.
1)
9
609104 1) Puller bolt
(2) Inspect the taper roller bearing (outer) and the oil seal that are pressed into cover 9. Do not disassemble if possible. Do not disassemble the taper roller bearing (outer) and oil seal 12 that are pressed into rear axle 14 if possible. (3) Rings and bearings 2 remain at knuckle 10 and steering cylinder 7 respectively at disassembly. Inspect the rings and bearings, and do not disassemble if possible. (4) Remove oil pipes 5 from the elbows. Then remove elbows 8.
2
2
7
•
•
•
10
• 609105
7-11
CHAPTER 7 REAR AXLE
8.
Assembling Rear Axle Assembly
8.1
Assembly Sequence
12
12 10
13
9
9
B
A
•
B
• A
11
7 1
11
2
• •
•
8
7
5
• •
• •
11
1
••
3
•
•
•
•
14 •
• •
•
•
•
6 3 •
• • •
• •
3
•
4 609106
1. 2. 3. 4. 5. 6. 7.
7-12
Rear axle housing Taper roller bearing (outer), Oil seal Knuckle, Taper roller bearing (inner) Cover, Taper roller bearing (outer), Oil seal, O-ring, Plate, Plug Plug Bearing, Ring Steering cylinder
8. 9. 10. 11.
Bearing, Ring Elbows (L.H., R.H.) Bolt, Spring washer Tie rod, Tie rod pin, Dust seal, Collar, Spacer, Bolt, Spring washer 12. Oil pipes (L.H., R.H.) 13. Bolt, Locknut 14. Taper roller bearing (inner), Retainer
CHAPTER 7 REAR AXLE 8.2
Suggestion for Assembly
(1) Filling grease Fill the taper roller bearing at knuckle 3 with grease. In particular, apply sufficient grease in the roller holder. Apply grease on the oil seal lip, too. The taper roller bearing at knuckle was changed to a greasable type in 2007.
1
• •
2 3 4
• •
609107 1. Grease 2. Oil seal
(2) Tighten bolt 10 of steering cylinder 7 to the specified torque.
3. Oil seal 4. Grease
1)
2)
609108
Ref. 10
Item Bolt
Tightening torque 262 ± 40 N·m (26.7 ± 4 kgf·m) [193.1 ± 28.9 lbf·in.]
7-13
CHAPTER 7 REAR AXLE (3) Adjusting knuckle bearing preload Drive in cover 4 without inserting a plate, and measure the clearance between rear axle housing 1 and the cover. Insert a plate thinner than the clearance by 0.1 mm (0.0039 in.), and tighten the cover with a bolt. Attach a spring scale to the edge of the knuckle arm, and check that the tangential force is the specified value.
1) 1) Clearance
Tightening torque Item
Tangential force
3.5 to 5.5 ton
6.0 to 7.0 ton
30.4 to 79.4 N·m (3.1 to 8.1 kgf·m) [6.82 to 17.82 lbf·in.]
26.5 to 67.6 N·m (2.7 to 6.9 kgf·m) [5.94 to15.18 lbf·in.]
If the specified value is not obtained, adjust the plate.
7-14
609109
CHAPTER 7 REAR AXLE
9.
Disassembling Steering Cylinder
9.1
Disassembly Sequence
5 6
4
A
6 2
1
2
1
A
1
3
609110
1. 2. 3.
Nut, Spring washer, Bolt Cylinder head, Dust seal, Backup ring, Oil seal, O-ring, Bushing Cylinder tube
4. 5. 6.
Piston rod, Piston Wear rings (2 pieces), Piston seal Stopper ring, Bearing
Note: (1) Do not remove bushing 2 from the cylinder head if possible. (2) Do not remove bearing 6 from piston rod 4 if possible.
7-15
CHAPTER 7 REAR AXLE
10. Inspection and Repair After Disassembling Steering Cylinder (1) Cylinder tube 3 Check for wear, damage, or rust inside the cylinder. (2) Piston rod 4 Check for rust, damage, scratches, or impact marks on the rod surface. (3) Rings and gaskets Replace the entire seal kit with new one.
609111
2)
1)
609112
Ref.
Item
Standard value
Repair limit
1)
Internal diameter of cylinder tube
85 mm (3.346 in.)
85.15 mm (3.352 in.)
2)
External diameter of piston rod
60 mm (2.36 in.)
-
7-16
CHAPTER 7 REAR AXLE
11. Assembling Steering Cylinder 11.1 Assembly Sequence
1
3
6
1
5
4
6 2
*
*
*
*
* 609113
1. 2. 3. 4.
Piston rod, Piston Bearing, Stopper ring Wear rings (2 pieces), Piston seal Cylinder tube
5. 6.
Cylinder head, Bushing, O-ring, Oil seal, Backup ring, Dust seal Bolt, Spring washer, Nut
Note: Parts marked with * are included in the seal kit.
11.2 Suggestions for Assembly (1) Replace the seal kit parts shown in the above figure when assembling. (2) Clean the parts completely before assembly, and make sure that they are free of dust. (3) Apply oil on the piston seal, O-ring, gasket, dust seal, and inside the cylinder before assembly. (4) Procedure for installing piston seal Grip the piston seal lightly by hand five or six times to soften the seal before installation. Grip the piston rod in a vice so that the vice does not damage the rod. Apply a little oil on the piston seal. Insert one side of the seal into the fitting groove of the piston, and insert the other side. After installing the piston seal, insert the wear ring.
609114
7-17
CHAPTER 7 REAR AXLE (5) Make sure that seal and rings on the cylinder head are installed in correct directions. (6) Tighten nut 6 to the specified torque.
609115
Item Nut
Tightening torque 59.8 N·m (6.1 kgf·m) [44 lbf·in.]
12. Adjustment 12.1 Adjusting Minimum Turning Radius (1) Measure the turn angle of the rear wheel by using a turning radius gauge. (2) If the turning angle is out of the specified range, adjust the angle with the stopper bolt on the knuckle.
1 2
609116 1. Stopper bolt (left and right)
2. Locknut
Truck Models Item 3.5 to 5.5 ton
6.0 to 7.0 ton
Turning angle (inward)
82°
80°
Turning angle (outward)
59°
55°
-
-
degree
Note: Check clearance between stopper bolt, thread end, and steer cylinder rod when fully turned in both directions.
7-18
CHAPTER 7 REAR AXLE (3) While driving the lift truck at low speed, turn the steering wheel fully in both directions, and check the diameter of the tire tracks at the outside of the rear wheel in both turning operations. (4) Minimum turning radius R is obtained from half of the turning diameter plus the length from the center of the rear tire to the outside edge of the counterweight.
R
609117
Item
Minimum turning radius
Truck Models
Standard value
GC35K
2235 mm (87.99 in.)
GC40K
2285 mm (89.96 in.)
GC40K STR
2090 mm (82.28 in.)
GC45K SWB/STR
2340 mm (92.12 in.)
GC55K
2550 mm (100.39 in.)
GC55K STR
2350 mm (92.52 in.)
GC60K
2570 mm (101.18 in.)
GC70K
2570 mm (101.18 in.)
GC70K STR
2400 mm (94.48 in.)
7-19
CHAPTER 7 REAR AXLE
13. Troubleshooting Condition
Possible causes
Corrective action
Insufficient grease in rear axle or steering parts
Supply grease
Faulty steering system
See “STEERING SYSTEM”.
Slow return of steering wheel
Over-tightening of steering system or rear axle parts
Tighten to the specified torque
Steering wheel prone to move to one side
Gap in external diameters between right Replace with genuine tires and left tires
Heavy steering wheel operation
Shudder of steering wheel
Uneven or early wear of rear tires
7-20
Wear or breakage of taper roller bearing Replace the bearing Faulty steering system
See “STEERING SYSTEM”.
Misalignment of wheels
Realign wheels
Different tire types for right and left wheels
Replace with genuine tires
CHAPTER 7 REAR AXLE
14. Service Data Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Turning angle (L.H., R.H.)
Standard
3°
Toe-in
Standard
0°
Caster
Standard
0°
Camber
Standard
1°
Steering angle Inward
Standard
82°
80°
Steering angle Outward
Standard
59°
55°
Tightening torque
30.4 to 79.4 N·m (3.1 to 8.1 kgf·m) [6.82 to 17.82 lbf·ft]
26.5 to 67.6 N·m (2.7 to 6.9 kgf·m) [5.94 to 15.18 lbf·ft]
41.2 to 49.0 N (4.2 to 5.0 kgf) [9.2 to 11.0 lbf]
44.1 to 52.9 N (4.5 to 5.4 kgf) [9.9 to 11.9 lbf]
1
Tangential force at knuckle bearing
2
Tangential force at hub bearing
Standard
3
Front and back clearance for center pin
Standard
0.8 mm (0.031 in.) or less
Limit
1.2 mm (0.047 in.)
4
Steering cylinder bolt
Tightening torque
262 ± 40 N·m (26.7 ± 4 kgf·m) [193.1 ± 28.9 lbf·ft]
5
Outer nut
Tightening torque
6
Hose
Tightening torque
7
Tire service limit
Tightening torque
4
+20 +2 0 N·m (16 0
kgf·m) [115.7
+14 0 lbf·ft]
49 ± 4.9 N·m (5 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft] 45.7 mm (1.8 in.)
48.3 mm (1.9 in.)
7
1
← ⎯
6
157
←
2
• •
3
•
•
• 5
609118
7-21
CHAPTER 7 REAR AXLE Steering cylinder
Ref.
Item
1
Internal diameter of cylinder tube
2
External diameter of piston rod
3
Bolt
All truck model Standard
85 mm (3.346 in.)
Limit
85.15 mm (3.352 in.)
Standard
60 mm (2.36 in.)
Tightening torque
59.8 N·m (6.1 kgf·m) [44 lbf·ft]
3
2
1
609119
7-22
CHAPTER 8 BRAKE SYSTEM
Chapter 8 BRAKE SYSTEM 1.
Specifications Item
3.5 to 5.5 ton Type Drum diameter
Main brake Brake system
Lining dimension (Length × Width × Thickness Number of unit)
Hydraulic front-wheel braking drum internal expansion duo-servo type 317.5 mm (12.50 in.) 330 × 63 × 10 - 2 mm (13 × 2.48 × 0.39 - 2 in.)
324 × 100 × 10 - 2 mm (12.75 × 3.93 × 0.39 - 2 in.)
Master cylinder internal diameter
28.57 mm (1.125 in.)
Master cylinder internal diameter
31.75 mm (1.250 in.)
Brake booster Parking brake
6.0 to 7.0 ton
Type
Brake booster master back type (Vacuum booster) Hydraulic front-wheel braking drum internal expansion type
8-1
CHAPTER 8 BRAKE SYSTEM
2. 2.1
Structure Brake System 4
2
5
1)
3
6 7
8 1
609120
1. 2. 3. 4. 5.
8-2
Wheel brake Parking brake lever Reserve tank Brake pedal Vacuum tank
6. 7. 8. 1)
Brake booster Master cylinder Wheel cylinder To Engine (intake manifold)
CHAPTER 8 BRAKE SYSTEM 2.2
Master Cylinder and Reserve Tank
1 2 3
11 15
4
12
5
13
6 16
10
7 8
14 9 1)
609121
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder Snapring Secondary cup Piston Spacer Primary cup Thimble Snapring Spring
10. 11. 12. 13. 14. 15. 16. 1)
Piston assembly Cap seal Reserve cap Reserve tank Indicator assembly Cap assembly Reserve assembly 3 ± 2 mm (0.118 ± 0.078 in.) Indicator ON position (energized in emergency)
8-3
CHAPTER 8 BRAKE SYSTEM 2.3
Wheel Brake
4
3
2
5 6
1
7 A
A
8
11
9
10
13 1. 2. 3. 4. 5. 6. 7.
8-4
Parking lever Shoe and lining (primary) Strut Return spring Wheel cylinder Dust shield Shoe and lining (secondary)
Section A-A
12 609122
8. 9. 10. 11. 12. 13.
Fitting link assembly Adjusting lever Adjusting screw Return spring Parking cable Backing plate
CHAPTER 8 BRAKE SYSTEM 2.4
Brake Booster (3.5 to 5.5 Ton)
1
2 3
28 27
4 5 6 7 8 9 1011121314
15 16 17
26 25 24 23 22 21 20 19 18 609123
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Retainer Silencer Filter Retainer Spring Spring Retainer Valve body seal Bearing Retainer Key Reaction disc Pushrod body Rod
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Pushrod seal Plate Retainer Cylinder shell (front) Spring Diaphragm plate Diaphragm plate Diaphragm Cylinder shell (rear) Valve plunger Poppet washer Poppet assembly Valve body guard Operating rod
8-5
CHAPTER 8 BRAKE SYSTEM 2.5
Brake Booster (6.0 to 7.0 Ton)
2
1
22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
8-6
21
20
Silencer Filter Poppet washer Cylinder shell (rear) Diaphragm (rear) Diaphragm plate (rear) Pushrod Diaphragm (front) Diaphragm (front) Pushrod seal Project stud
3
19 18
4
17 16
6
5
15
7
14 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
8
13 Pipe Cylinder plate Cylinder shell (front) Spring Reaction disc Valve plunger Poppet assembly Spring Valve body guard Retainer Operating rod
9
10
12
11
609124
CHAPTER 8 BRAKE SYSTEM
3. 3.1
Disassembling Master Cylinder Disassembly Sequence
2 1
11
5
10
9
8
7
4 3
6
12 609125
1. 2. 3. 4. 5.
Clamp Filler union Snapring Piston Remove piston 4, and parts 6 through 10 as sub-assembly. Spring
6. 7. 8. 9. 10. 11. 12.
S-cup Snapring Thimble P-cup Spacer Cylinder Repair kit
8-7
CHAPTER 8 BRAKE SYSTEM
4. 4.1
Inspection and Repair After Disassembling Master Cylinder Cylinder Body
(1) Check the cylinder bore for rust, erosion, or scoring. (2) Check the condition of the inlet and relief ports. Check joint thread for damage.
4.2
Piston
Check the piston for damage and replace the piston if damaged. Insert the piston to the cylinder. If the clearance between the piston and cylinder exceeds the service limit, replace the master cylinder. Item Clearance between cylinder and piston
4.3
Standard value
Repair limit
0.020 to 0.105 mm (0.0008 to 0.00413 in.)
(Replace every year)
Return Spring
Measure the free length of the return spring. If the measurement exceeds the service limit, replace the return spring. Item Free length of return spring
8-8
Standard value
Repair limit
104 mm (4.09 in.)
(Replace every year)
CHAPTER 8 BRAKE SYSTEM
5.
Assembling Master Cylinder
5.1
Assembly Sequence
10
7
8
6
5 4
3
1
2
9 609126
1. 2. 3. 4. 5.
Piston Secondary cup Spacer Primary cup Thimble
5.2 (1) (2) (3) (4)
6. Snapring 7. Spring 8. Cylinder 9. Snapring 10. Filler union, Clamp Note: Parts 1 through 6 - Piston assembly
Suggestions for Assembly Do not reuse the disassembled piston and cups. Clean metal parts with volatile solvent, and dry with compressed air. Apply brake fluid thinly on the cylinder bore and the piston cup. Tighten the clamp to the specified torque. Item
Clamp
Tightening torque 6.9 to 8.8 N·m (0.7 to 0.9 kgf·m) [5.1 to 6.5 lbf·ft]
8-9
CHAPTER 8 BRAKE SYSTEM
6.
Disassembling Wheel Cylinder
6.1
Disassembling Sequence
1 2
6
*
5
8
3
7
3 1
4
2
609127
1. 2. 3. 4.
Connector ring Boot Piston Piston cup
Note: -
8-10
Parts marked with * are included in the seal kit. Repair kit parts should be replaced periodically.
5. 6. 7.
Return spring Breeder screw, Cap Cylinder body
CHAPTER 8 BRAKE SYSTEM
7. 7.1
Inspection and Repair After Disassembling Wheel Cylinder Cylinder Body
(1) Check the bore of the body for rust, erosion, or scoring. (2) Check the threads of the bleeder screw and oil pipe screw connections for damage.
7.2
Piston
(1) Check the outer surfaces for rust or scoring. (2) Insert the piston in the body. If the clearance between the piston and body exceeds the service limit, replace the wheel cylinder.
609128
Item Clearance between cylinder and piston
7.3
Standard value
Repair limit
0.020 to 0.105 mm (0.0008 to 0.00413 in.)
0.15 mm (0.0059 in.)
Piston Cups
Check each cup for swelling or other defects and replace if any defect is found. Item Fit of the piston cups in cylinder body
7.4
Standard value
Repair limit
1.85 mm (0.0728 in.)
0.65 mm (0.0256 in.)
Boot
Replace the boot if it is damaged or deteriorated due to aging. Replace the boot every year.
8.
Assembling Wheel Cylinder
Follow the disassembly sequence in reverse. Be careful with the following key points: (1) Apply brake fluid evenly to the cylinder bore and the piston cup. (2) Be careful not to damage the lip of the cup. (3) Assemble the cup in correct direction.
8-11
CHAPTER 8 BRAKE SYSTEM
9. 9.1 (1) (2) (3) (4)
9.2
Disassembling Wheel Brake Preparation Remove the front tires. Remove the wheel hub and drum. Separate the parking lever at the lower side of the wheel brake and the parking cable fitting. Remove the brake pipe from the wheel brake assembly.
Disassembly Sequence
6
13
12
11 2
8
2
1
2
4 5 10
6
9
7
3 609129
1. 2. 3. 4. 5. 6.
8-12
Return springs Fitting link assembly, Split pin, Plane washer, Spring and link assembly, Lever and Link Adjusting lever, Adjusting spring Return spring Adjusting screw Hold-down spring, Cup and Pin
7. 8. 9. 10. 11. 12. 13.
Strut, Retainer and Web washer Shoe and lining (secondary) Shoe and lining (primary) Parking lever, Retainer and Web washer Wheel cylinder Parking cable Backing plate
CHAPTER 8 BRAKE SYSTEM 9.3
Suggestions for Disassembly
Removing return springs Use the special tool to remove the return springs from the shoe guide plate.
1
609130 1. Special tool
Special tool Spring remover
Part number 64309-15400
Removing hold-down springs Use the special tool to remove the shoe hold-down springs from the backing plate.
1
609131 1. Special tool
Special tool Spring retainer
Part number 91868-00600
8-13
CHAPTER 8 BRAKE SYSTEM
10. Inspection and Repair After Disassembling Wheel Brake 10.1 Backing Plate (1) Check the backing plate for cracks. (2) Check the tightening torque of mounting bolts. Item
Tightening torque 238.3 to 284.3 N·m (24.3 to 29.3 kgf·m) [53.5 to 63.9 lbf·ft]
Check the mounting bolts
10.2 Shoe and Lining Assembly (1) Check the lining and shoe for cracks or breakage. (2) Replace the lining if severely stained with oil, burned, or deteriorated. (3) Check the lining thickness. If the thickness exceeds the service limit, replace the lining.
609132
Item Lining thickness
Standard value
Repair limit
10 mm (0.39 in.)
4.2 mm (0.16 in.)
10.3 Brake Drums If uneven wear or damage is found inside each brake drum, grind, and repair.
Item Brake drum internal diameter
Standard value 317.5
+0.2 +0.008 0 mm (12.500 0 in.)
Repair limit or Service limit 318.5 mm (12.539 in.)
10.4 Adjusting Screw Check for wear on wheel teeth. Also check if the wheel rotates smoothly.
609133
8-14
CHAPTER 8 BRAKE SYSTEM 10.5 Parking Brake Link (1) Check the lever support pin and pin hole for wear, and replace the link if severely worn. (2) Check the parking cable, and replace if it is stretched, damaged, or rusted.
10.6 Other Inspection Parts (1) Check the shoe return spring for cracks or fatigue. (2) Check the adjusting screw for cracks or fatigue.
8-15
CHAPTER 8 BRAKE SYSTEM
11. Assembling Wheel Brake 11.1 Assembly Sequence
3
13
1
7 5 4
12 8 6 A
A
10 11
9
Section A-A
2 609134
1. 2. 3. 4. 5. 6. 7. 8.
8-16
Backing plate Parking cable Wheel cylinder Parking lever, Retainer and Web washer Shoe and lining (primary) Shoe and lining (secondary) Strut, Retainer and Web washer Hold-down spring, Cup and Pin
9. 10. 11. 12.
Adjusting screw Return spring Adjusting lever, Adjusting spring Fitting link assembly, Link, Lever, Spring and link assembly, Plane washer, and Split pin 13. Return spring
CHAPTER 8 BRAKE SYSTEM 11.2 Suggestions for Assembly Installing wheel cylinder Apply liquid gasket on the mounting surface of cylinder, then tighten the bolt to the specified torque.
609135
Item
Tightening torque 17.6 to 26.4 N·m (1.8 to 2.7 kgf·m) [13.0 to 19.5 lbf·ft]
Bolt
Greasing Apply a thin coat of the specified brake grease on the following parts: -
Shoe ledges (6 places) (Backing plate surface contacting with the shoes) Anchor pin surface in contact with the shoe web Pin surface inner fitting to the automatic adjust lever hole Installing shoes and linings Make sure that the push rod of the wheel cylinder is correctly inserted to the shoe web. Installing return springs Use the special tool to install the return springs to the backing plate pins.
1
609136 1. Special tool
Special tool Spring installer
Part number 64309-15400
8-17
CHAPTER 8 BRAKE SYSTEM Installing automatic adjuster (1) Clean adjusting screw parts and apply grease on the threads and the fitting of screw socket. Make sure the screw rotates smoothly by hand. If the screw rotation is sluggish, replace the screw with a new one. (2) The adjusting screws in L.H. wheel brakes are different from those in R.H. wheel brakes. The L.H. screws are used on the L.H. wheel brake and the R.H. screws are used on the R.H. wheel brake. 609137
Installing parking cable Tighten the parking cable to the specified torque. Item
Tightening torque 41.1 to 54.9 N·m (4.2 to 5.6 kgf·m) [30.3 to 40.5 lbf·ft]
Parking cable
12. Inspecting and Repairing Parking Brake Lever 12.1 Parking Brake Lever Components
1)
2) 1 2
3 4
5 6 609138
1. 2. 3. 4.
8-18
Grip Set screw Stud Lever assembly
5. 6. 7.
Rod assembly Bracket Parking brake wire
CHAPTER 8 BRAKE SYSTEM 12.2 Suggestions for Inspection and Repair (1) Replace the lever support pin if the pin or pin hole is severely worn. (2) Replace the parking brake cable if stretched, damaged, or rusted.
12.3 Installing Parking Brake Lever After connecting the parking brake wire, the operating force of the parking brake lever should be 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]. The operating force of the parking brake lever should be (400 to 445 N (40 to 45 kgf) [90 to 100 lbf] for 7 ton model only)
8-19
CHAPTER 8 BRAKE SYSTEM
13. Adjustment 13.1 Automatic Adjuster Test (1) With all wheel brake components installed correctly, the drum-to-shoe clearance should be within the correct range of 0.4 to 0.6 mm (0.016 to 0.024 in.). Push the cable with thumb to pull the adjusting lever. Observe that the lever turns the adjusting screw by one tooth, and push to observe the adjusting screw returns to the original position.
609139
(2) If the lever fails or is sluggish to turn the adjusting screw in the above test, the possible cause is that the lever is not properly positioned relative to the sprocket wheel. BE SURE that the lever is positioned so that its actuating tip touches the sprocket wheel at a level about 9 mm (0.35 in.) under the center line of the screw as shown. (3) Where the automatic adjusting device is suspected of malfunctioning during normal operation, check the following for possible causes: - Check that springs A and B are correctly installed. - If any of following parts is in bad condition and requires replacement: - Fitting cable - Adjusting lever - Adjusting screw
A
B
9 mm
(0.35 in.) 609140
13.2 Procedure for Manual Adjustment Insert a screw driver in the adjustment hole on the back of the backing plate. Force down and rotate the wheel of adjusting screw to adjust the clearance between the drum and lining.
609141
Item Clearance between drum and lining (one side)
8-20
Standard value 0.14 to 0.6 mm (0.016 to 0.024 in.)
CHAPTER 8 BRAKE SYSTEM 13.3 Brake Fluid Line Bleeding When a part of the brake fluid line is disassembled for repair, or when brake pedal movement is spongy, bleed the brake fluid line. Bleeding work requires two people. Turn ON the engine and keep it idling during bleeding operation. (1) Fill the reserve tank with brake fluid. Always keep the brake fluid level more than half full of the reserve tank during bleeding operation. (2) Insert a vinyl tube on the bleeder screw of the wheel cylinder. Insert the other end of the tube to a container filled with brake fluid. (3) Have one person depress (pump) on the brake pedal several times and while holding the pedal depressed, release the bleeder screw. Before the brake fluid stops flowing in the vinyl tube, tighten the bleeder screw. (4) Repeat the above Steps until there is no air bubbles in the brake fluid. Fill the reserve tank with brake fluid to the specified level.
609142
Note: -
If brake pedal feels soft, a vacuum pump may be needed to bleed all the air out of the master cylinder, lines, and wheel cylinders. BE SURE to maintain sufficient fluid level in the reserve tank. Use brake fluid of the specified brand. Do not mix different types of brake fluids. Start bleeding work of the brake fluid of the wheel cylinder from the right side (far side from the master cylinder).
13.4 Inspecting Reserve Tank Level Sensor The sensor is normal if Brake fluid warning light on the meter panel illuminates when brake fluid level is under MIN. line of the reserve tank.
609143
609290
8-21
CHAPTER 8 BRAKE SYSTEM 13.5 Procedures for Brake Pedal Adjustment (1) Bleed brake fluid of the brake reserve tank from the master cylinder to the wheel cylinder. (2) Adjust and confirm the clearance between the drum and lining. (3) Attach locknut (right-hand thread) 2, push rod (righthand thread) 3, locknut (left-hand thread) 4, and clevis (left-hand thread) 5 to push rod 1 of the brake booster. Make sure that dimension L1 is the specified value. Use dimension L2 for checking. Screw in the right-hand and left-hand threads to the same length.
5
4
3
2
1
L2
L1 609144
Item
Standard value
L1
155mm (6.10 in.)
L2
88 mm (3.46 in.)
(4) Install the push rod assembly on the brake pedal. (5) Rotate the stopper bolt and adjust brake pedal height A to 175 mm (6.9 in.), and fix the stopper bolt with a locknut. (6) Start the engine. (7) Push the brake pedal by hand and check brake pedal free play B.
B
C
1 A
2
3
609145
Item
Brake pedal free play B
Standard value 3.5 to 5.5 ton
6.0 to 7.0 ton
21 to 35 mm (0.83 to 1.83 in.)
23 to 27 mm (0.9 to 1.45 in.)
If the play exceeds specified range, loosen locknuts 2 and 4, then turn push rod 3 to adjust dimension L1. Item Brake pedal stroke C
8-22
Standard value 37 mm (1.456 in.)
CHAPTER 8 BRAKE SYSTEM 13.6 Brake Booster Test Test method without a tester Carry out the following three tests. If no problem is found, the brake booster is in good condition. (1) Run the engine at an idling speed for 1 to 2 minutes, then stop it. Depress the brake pedal with normal stepping force several times. If the pedal stroke decreases every time the pedal is depressed, the brake booster is in good condition. If the stroke does not change, the brake booster is defective. (2) Depress the brake pedal several times while the engine is stopped. Turn ON the engine while the brake pedal is depressed. If the pedal goes down, the booster is in good condition. If not, the booster is defective. (3) Depress the brake pedal while the engine is running. While the pedal is depressed, turn the engine OFF, and keep the pedal depressed for about 30 seconds. If the pedal height does not change, the booster is in good condition. Test method with a simplified tester Use a vacuum gauge, pressure gauge, and force gauge. Bleed the pressure gauge, and proceed as follows: (1) Unloaded air-tightness test Turn ON the engine, and turn the engine OFF when the vacuum gauge reads approx. 66.5 kPa (500 mmHg). The brake booster is in good condition if the vacuum drop in 15 seconds after the engine stops is 3.32 kPa (25 mmHg) or less. (2) Loaded air-tightness test Turn ON the engine, and depress the brake pedal with a stepping force of 20 kg (44 lb). Turn the engine OFF when the vacuum gauge reads approx. 66.5 kPa (500 mmHg). The brake booster is in good condition if the vacuum drop in 15 seconds after the engine stops is 3.32 kPa (25 mmHg) or less. (3) Characteristic test of brake booster Carry out this test after tests (1) and (2). Non-booster action test Make sure that the vacuum gauge reads 0 kPa (0 mmHg) when the engine is stopped. Depress the brake pedal with stepping forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf]. The brake booster is in good condition if the generated hydraulic pressure meets the specified value. Item Generated hydraulic pressure
Stepping force:
Tightening torque
Standard value
98 N·m (10 kgf·m) [22 lbf·ft]
686 kPa (7.0 kgf/cm2) [99.5 psi]
196 N·m (20 kgf·m) [44 lbf·ft]
1373 kPa (14 kgf/cm2) [199 psi]
3
1
4
1)
2 609146 1. Pressure gauge 2. Vacuum gauge 3. Stepping force
4. Vacuum tank 1) To engine
8-23
CHAPTER 8 BRAKE SYSTEM Booster action test Turn ON the engine. Depress the brake pedal with stepping forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf] when the vacuum gauge reads 66.5 kPa (500 mmHg). The brake booster is in good condition if the generated hydraulic pressure meets the specified value. Note: The operation test outlined above is a simplified test. BE SURE to carry out a bench test for the individual booster as specified by the manufacturer if the booster is defective. Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Tightening torque
Generated hydraulic pressure
8-24
3.5 to 5.5 ton
6.0 to 7.0 ton
Standard value
98 N·m (10 kgf·m) [22 lbf·ft]
2354 kPa (24 kgf/cm2) [341 psi] or more
2942 kPa (30 kgf/cm2) [427 psi] or more
196 N·m (20 kgf·m) [44 lbf·ft]
3628 kPa (37 kgf/cm2) [526 psi] or more
5198 kPa (53 kgf/cm2) [757 psi] or more
Stepping force
CHAPTER 8 BRAKE SYSTEM
14. Troubleshooting Item
Condition
Possible causes Oil leakage from master cylinder primary cup Oil leakage from wheel cylinder cup
Insufficient braking force
Action Check cylinder for wear if possible, replace piston cup. If piston cup is deformed, replace cup and brake fluid. Use genuine parts and brake fluid
Oil leakage from oil pipe joint
Retighten or replace pipe and join
Worn lining
Replace
Oil on lining
Clean or replace lining
Air in hydraulic system
Bleed master cylinder and wheel cylinder
Defective master cylinder piston cup
Replace piston cup
Low oil level in reserve tank
Supply oil
Excessive clearance of master cylinder push rod Adjust Excessive pedal stroke
Brake fluid leakage
Check cylinder for wear if possible, replace piston cup. If piston cup is deformed, replace cup and brake fluid. Use genuine parts and brake fluid
Automatic adjuster not activate
Check cable guide and adjusting screw for correct installation. If automatic adjuster still does not activate, replace fitting link assembly, lever, and adjusting screw
Oil or grease on lining or drum
Clean with brake cleaner 21651 and repair. If oil and grease cannot be removed from lining, replace lining
Brake drum shimmy or loose mounting
Replace drum. Adjust and retighten loose mounting
Lining surface too smooth
Scrub lining surface with abrasive paper
Worn lining
Replace shoe and lining assembly
Loose mounting bolt of backing plate
Retighten
Loose wheel bearing
Adjust pre-load and retighten
Dirty drum
Clean drum with brake cleaner 21651
Shoe anchor end contacting with anchor
Repair or replace
Excessive wear of shoe ledge
Replace backing plate
Excessive wear of wheel cylinder piston
Replace wheel cylinder
Wheel brake
Imbalance in braking power
Brake squeaking
Abnormal noise from brake (clicking noise)
8-25
CHAPTER 8 BRAKE SYSTEM Item
Condition
Heavy pedal Wheel brake
Spongy pedal
Insufficient parking brake stroke Abnormal noise from parking brake in driving
Action
Loose connection of vacuum hose
Repair
Squashed or torn vacuum hose
Replace hose
Foreign matter adhesion or damage on Repair or replace vacuum valve or exhaust valve in brake booster Element clogging in brake booster
Clean or replace
Damaged diaphragm of brake booster
Replace
Foreign matter mixing in brake cylinder
Clean cylinder and supply cylinder liquid
Insufficient brake cylinder fluid
Supply
Brake cylinder liquid leakage
Repair or replace
Improper bleeding
Bleed
Insufficient clearance between brake and lining Adjust to standard clearance Insufficient clearance between brake lining and Adjust to standard clearance drum Warped brake drum
Repair brake drum according to repair standard, or replace
Adjust clearance between brake lining and drum. If parking brake still Parking brake cable exceeding specified length does not produce stopping force, check parking brake cable length
Parking brake Parking brake not producing stopping force
8-26
Possible causes
Brake lining worn beyond service limit
Replace shoe and lining assembly
Excessive clearance between brake lining and drum
Adjust clearance between brake lining and drum
Insufficient pulling force of parking brake lever
Adjust pulling force to 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]
CHAPTER 8 BRAKE SYSTEM
15. Service Data Brake system Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
1
Pedal height (between top surface of frame and upper pedal edge)
Standard
2
Free play of brake pedal
Standard
21 to 35 mm (0.83 to 1.38 in.)
23 to 37 mm (0.91 to 1.46 in.)
3
Brake pedal stroke
Standard
45 to 70 mm(1.77 to 2.76 in.)
45 to 70 mm (1.77 to 2.96 in.)
175 mm (6.9 in.)
Master cylinder mounting bolt
Tightening torque
117 N·m (1.2 kgf·m) [8.68 lbf·ft]
Brake booster mounting bolt
Tightening torque
39.2 to 49.0 N·m (4 to 5 kgf·m) [28.9 to 36.1 lbf·ft]
Vacuum pipe union nut mounting bolt
Tightening torque
12.7 to 17.6 N·m (1.3 to 1.8 kgf·m) [9.4 to 13.0 lbf·ft]
Brake pipe union nut mounting bolt
Tightening torque
11.7 N·m (1.2 kgf·m) [8.68 lbf·ft]
3
2
1
609148
8-27
CHAPTER 8 BRAKE SYSTEM Master cylinder Ref.
Item
All truck models
1
Cylinder body internal diameter
Standard
28.57 mm (1.125 in.)
2
Piston external diameter
Standard
28.57 mm (1.125 in.)
Standard
0.020 to 0.105 mm (0.0008 to 0.00413 in.)
Clearance between cylinder and piston
Limit 3
Primary cup lip-side external diameter
4
Secondary cup lip-side external diameter
5
Return spring free-movement length
0.2 mm (0.008 in.) (Replace every year)
Standard
28.57 mm (1.125 in.)
Limit
(Replace every year)
Standard
28.57 mm (1.125 in.)
Limit
(Replace every year)
Standard
104 mm (4.09 in.)
Limit
5
1
3
2
(Replace every year)
4 609149
8-28
CHAPTER 8 BRAKE SYSTEM Wheel cylinder Ref.
Item
All truck models +0.062 +0.00244 0 mm (1.25 0 in.)
1
Cylinder body internal diameter
Standard
31.75
2
Piston external diameter
Standard
31.75 -0.064 mm (1.2500 -0.00252 in.)
Standard
0.020 to 0.105 mm(0.0008 to 0.00413 in.)
Clearance between cylinder and piston
3
4
Limit
-0.00098
0.15 mm(0.006 in.)
Standard
Piston cup lip-side external diameter
Return spring
-0.025
33.6 ± 0.25 mm(1.32 ± 0.0098 in.)
Limit
(Replace every year)
Free-movement length
Standard
33.4 mm(1.31 in.)
Mount length
Standard
14 mm (0.55 in.)
Standard
13 ± 2 N·m (16 ± 0.1 kgf·m) [3.5 ± 0.2 lbf·ft]
Mount weight
Limit
(Replace every year)
5
Wheel cylinder mounting bolt
Tightening torque
18 to 26 N·m (1.8 to 2.7 kgf·m) [13.0 to 20 lbf·ft]
6
Bleeder screw
Tightening torque
6 to 9 N·m (0.6 to 0.9 kgf·m) [4.3 to 6.5 lbf·ft]
6
1
2
3
5
4 609150
8-29
CHAPTER 8 BRAKE SYSTEM Wheel brake Ref. 1
Item
All truck models Standard
Brake drum internal diameter
317.5
Limit 2
Lining thickness
3
Clearance between drum and lining (one-side)
4
Return spring
+0.2 +0.008 0 mm (12.500 0 in.)
318.5 mm(12.539 in.)
Standard
10 mm (0.39 in.)
Limit
4.2 mm (0.17 in.)
Standard
0.4 to 0.60 mm(0.016 to 0.024 in.)
Free-movement length
Limit
Mount length
Standard
101.2 mm(3.98 in.)
Mount weight
Standard
245 N·m (25 kgf·m) [55 lbf·ft]
Free-movement length
Standard
132.2 mm(4.85 in.)
Mount length
Standard
152 mm(5.98 in.)
Mount weight
Standard
78 N·m (8 kgf·m) [18 lbf·ft]
Link (upper)
Standard
Upper: 97 mm (3.82 in.)
Link assembly (lower) length
Standard
Lower: 97.8 mm (3.85 in.)
7
Backing plate mounting bolt
Tightening torque
238 to 284 N·m (24.3 to 29.0 kgf·m) [176 to 210 lbf·ft]
8
Parking cable
Tightening torque
41.1 to 54.9 N·m (4.2 to 5.6 kgf·m) [30.3 to 40.5 lbf·ft]
5
6
Adjusting spring
93 mm(3.66 in.)
1 4 2
4
3 6 7
A 5
A 6
Section A-A 8
8-30
609151
CHAPTER 8 BRAKE SYSTEM Parking brake
Item
All truck models
Lever swing angle A
Standard
Lever operating effort F
Tightening torque
71° to 76° deg 245 to 294 N·m (25 to 30 kgf·m) [55 to 66 lbf·ft]
F A
609152
8-31
CHAPTER 9 STEERING SYSTEM
Chapter 9 STEERING SYSTEM 1.
Specifications Item Steering angle
Steering device
3.5 to 5.5 ton
6.0 to 7.0 ton
Inward
82°
80°
Outward
59°
55°
External diameter of the steering wheel Steering control valve
Full-hydraulic power steering
320 mm (12.9 in.) 23 liter (6.07 U.S. gal)/min.
9-1
CHAPTER 9 STEERING SYSTEM
2. 2.1
Structure Steering System
5
F
4
3
G L
T P
LS
R
B
D
C
E C
D
3
E
2
A
A
6 1) 1. 2. 3.
Hydraulic tank Oil pump Control valve
A
1 B
C
Turning to the left E Turning to the right D 4. 5. 6. 1)
F
G 608816
Steering control valve Steering wheel Power cylinder Oil flow
The steering system reduces the operating effort through hydraulic pressure by using the load sensing mechanism which consists of steering control valve 4 (orbitrol), control valve 3, etc. The operating effort of steering wheel 5 is converted into the hydraulic pressure by steering control valve 4, then into the steering force on the rear axle by power cylinder 6. Control valve 3 supplies hydraulic oil from oil pump 2 to steering control valve 4. Excessive oil is sent to circuits of other devices. When the steering is in the NEUTRAL position, almost all the hydraulic oil can be used to operate other devices.
9-2
CHAPTER 9 STEERING SYSTEM 2.2
Steering Control Valve
13 14 15 16 17 18
Section B-B
T L
R P
B B
1
2 3
4 5 6 7
8
9 10 11 12 608817
1. 2. 3. 4. 5. 6. 7. 8. 9.
Thrust needle bearing Centering spring Pin Drive shaft Valve housing Control sleeve Control spool Wear plate O-ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Gerotor set Spacer End cap Pump port Ball Tank port Cylinder port (Left) Cylinder port (Right) Check ball retainer
9-3
CHAPTER 9 STEERING SYSTEM 2.3
Tilt Steering Assembly
5° 7°
2
1
4
3 608818
1. 2.
Steering column Shaft
3. 4.
Bracket Tilt lock lever
The tilt steering assembly is installed on the bracket under the dashboard. Push down knob 5, and move the steering wheel FORWARD and BACKWARD. Steering column tilt angle is adjustable in the range of 5 degrees FORWARD and 7 degrees BACKWARD.
9-4
CHAPTER 9 STEERING SYSTEM
3.
Removing Tilt Steering and Steering Control Valve Assembly
3.1
Removal Sequence
7 1 2
3
8
6
4
5 10 11 9
12
608819
1. 2. 3. 4. 5. 6.
Steering wheel cap, Nut, and Washer Steering wheel Upper cover (Front) Lower cover (Front) Console box Transmission shift lever assembly
7. 8. 9. 10. 11. 12.
Floor plate Floor plate (Front) Hoses Steering control valve Elbows, Connectors Tilt steering assembly
9-5
CHAPTER 9 STEERING SYSTEM 3.2
Suggestions for Removal
Removing steering wheel
1
Use the special tool to remove the steering wheel.
608820 1. Special tool
Special tool needed Steering wheel puller
91268-10600
R CAUTION DO NOT hit the end of steering shaft when removing the steering wheel.
9-6
CHAPTER 9 STEERING SYSTEM
4. 4.1
Inspection After Installing Tilt Steering and Steering Control Valve Assembly Steering Wheel Play
Check the steering wheel play while idling the engine.
4.2
Steering
(1) Apply the parking brake. Turn ON the engine and warm the hydraulic oil to an operation temperature of 40 to 60°C (104 to 140°F). (2) Attach a spring scale on the rim (or a spoke) of the steering wheel, and measure the steering torque to turn the steering wheel clockwise or counterclockwise.
608821
Item Steering torque Effort
4.3
value 1.96 N·m (0.2 kgf·m) [1.44 lbf·ft] 12.7 N (1.3 kgf) [2.87 lbf]
Air Bleeding
The air in the hydraulic system such as the steering cylinder, the flow divider valve, and the piping may cause a shimmy and abnormal noise. (1) Jack up the rear tires. For procedures, see “REAR AXLE”. (2) Depress and release the accelerator pedal repeatedly to change the engine speed, while turning the steering wheel to lock-to-lock positions.
9-7
CHAPTER 9 STEERING SYSTEM
5. 5.1
Disassembling Steering Control Valve Disassembly Sequence
4 6
11
5 12 7 9 8 10 3
2 1
608822
1. 2. 3. 4. 5. 6.
9-8
End cap, Bolt, O-ring, and Spacer Gerotor set, O-ring Drive shaft, Wear plate, and O-ring Retaining ring Seal gland bushing, O-ring, Oil seal, Dust seal Thrust needle and Race bearing
7. 8. 9. 10. 11.
Control sleeve Control spool Pin Centering spring Check valve, Retainer, Ball, O-ring, Check ball seat, Set screw 12. Valve housing
CHAPTER 9 STEERING SYSTEM 5.2
Suggestions for Disassembly
(1) Removing retaining ring Remove retaining ring 4 from valve housing 12 with a screwdriver.
608823
(2) Removing seal gland bushing Turn the control spool 8 together with the control sleeve 7 until pin 9 is parallel with port face. Remove the seal gland bushing 5.
608824
(3) Removing control spool and control sleeve Remove control spool 8 together with control sleeve 7 from valve housing 12 by pulling them toward the end of the housing, which is the opposite side of the flange. Remove pin 9. Note: Turn control spool 8 and control sleeve 7 in valve housing 12 slowly in both directions, making sure not to bind the spool and sleeve in the housing.
608825
(4) Disassembling control spool and control sleeve Push control spool 8 in control sleeve 7 to the front, and remove centering spring 10. Turn slowly and pull out the control spool from the rear end of the control sleeve. Note: Put a matchmark across the control spool and the control sleeve before disassembly.
608826
9-9
CHAPTER 9 STEERING SYSTEM
6.
Inspection and Repair After Disassembling Steering Control Valve
(1) Inspection on sliding surfaces between the spool and the valve housing and between the spool and the sleeve Check for defective sliding movement in subassembled condition. - If any defective movement is found, check sliding surfaces. - If any defects such as abnormal wear, rust, or scratches are found, replace the steering control valve assembly.
7. 7.1
Assembling Steering Control Valve Assembly Sequence
2
10 9 7
Section B-B
B
8 B
12
4
5 3
6 1 11 608827
1. 2. 3. 4. 5. 6.
Valve housing Check valve, Retainer, Ball, O-ring, Check ball seat, Set screw Control sleeve Control spool Centering spring Pin
Note: Carry out the following preparations before assembly: (1) (2) (3) (4)
9-10
Replace damaged parts. Clean all metal parts and apply compressed air for drying. Replace O-rings and seals with new ones. Apply grease on O-rings.
7. 8. 9. 10. 11. 12.
Thrust needle and Race bearings Seal gland bushing, Oil seal, Dust seal, O-ring Retaining ring Drive shaft, Wear plate, O-ring Gerotor set O-ring End cap, O-ring, Spacer, Bolts
CHAPTER 9 STEERING SYSTEM 7.2
Suggestions for Assembly
(1) Assembling check valve Install the retainer in the housing. Install the seat in the housing with the hole at bottom. Apply Locktite 271 on the threads of the set screw and tighten the screw to the specified torque.
608828
Item
Tightening torque
Set screw
11.3 N·m (1.2 kgf·m) [8.3 lbt·ft]
(2) Assembling control spool and sleeve Put the spool in the sleeve with the spring groove in alignment with the spring groove in the sleeve. Make sure the marks put during disassembly are in alignment. Note: Make sure the spool rotates freely in the sleeve.
2 1
3 608829 1. Spring groove 2. Spring groove
3. Matching marks
(3) Installing centering spring Hold two sets of three springs back to back. Using the spring inserting tool, put these sets of the springs in the groove with the bevel ends at the bottom.
608830
Special tool needed Spring inserting tool
97157-00100
(4) Installing control spool and sleeve assembly on the housing Put the pin in the holes of the spool and sleeve. Install the control spool and sleeve assembly in the housing from the rear side while rotating it in both directions with the pin being on the same level with center of the spool. Note: Make sure the rear end of the spool and sleeve assembly is flush with the rear end of the housing.
608831
9-11
CHAPTER 9 STEERING SYSTEM (5) Installing seal Install the dust seal on the seal gland bushing with its flat side facing down. Also install the oil seal on the bushing.
1 2
3 608832 1. Dust seal 2. Seal gland bushing
3. Quad ring seal
(6) Installing the seal gland bushing - Install the dust seal on the bushing with the flat side facing towards the bushing. - Install the quad ring seal on the bushing by smoothing it into place with your finger. - Install the bushing assembly over the spool end with a twisting motion. Tap it into place with a soft head mallet. Make sure the bushing is flush against the bearing race. 608833
-
1 2 3 4 5
Install the retaining ring in the housing and pry around the ring circumference with a screwdriver to ensure proper seating of the ring.
6
608834 1. Screwdriver 2. Dust seal 3. Retaining ring
9-12
4. Seal gland bushing 5. Quad ring seal 6. O-ring
CHAPTER 9 STEERING SYSTEM (7) Installing the wear plate - Clamp the housing in a vise, equipped with soft jaws or softened with rag. Clamp lightly over the edges of the mounting area. Do not overtighten the vise jaws. Note: Check that the spool and sleeve are flush with or slightly below the surface of the housing.
608835
- Install the O-ring in the housing. Place the wear plate on the housing and align the bolt holes with the tapped holes in the housing.
608836
(8) Installing the drive - Put a match mark across the splined end of the drive to indicate the direction of the slot at the opposite end of the drive. - Rotate the spool and sleeve assembly until the pin is parallel with the port surface. Install the drive and make sure that it engages the pin. The match mark should be parallel to the port surface.
1
2
3 4 1. Port surface 2. Drive
608837
3. Pin parallel with port surface 4. Pin
9-13
CHAPTER 9 STEERING SYSTEM (9) Installing the gerotor set - Install O-ring in the gerotor set. - Align the star valley A with the match mark on the drive B with the O-ring side of gerotor set facing the wear plate. Place A, B, C, and D in parallel, aligning the bolt holes without disengaging the gerotor set from the drive.
1
A B
4
C
2
3 1. Gerotor set star valley 2. Port surface
(10) Installing the end cap - Install the drive spacer in the gerotor set. Install the O-ring in the end cap. Install the end cap in the gerotor set and align the holes.
D
608838 3. Pin 4. Drive (marked)
1 2
4 1. End cap 2. Cap screw
3 608839
3. O-ring 4. Drive spacer
- Tighten all screws until they are snug, then tighten them progressively to the specified torque in the sequence shown in the illustration.
608840
Item
Tightening torque
Initial torque for screws
14.7 N·m (1.5 kgf·m) [10.8 lbf·ft]
Finishing torque for screws
23.5 N·m (2.4 kgf·m) [17.3 lbf·ft]
After installing the end cap, install the steering wheel on the spool and make sure the spool rotates smoothly.
9-14
CHAPTER 9 STEERING SYSTEM
8.
Troubleshooting Item
Possible cause
No steering flow
Stiff steering wheel
Defect in flow divider valve
Oil leak from relief valve
Disassemble and clean
Fatigued or damaged spring in the spool
Replace spring Adjust relief pressure 7355
+490 +5 +71 2 0 kPa (75 0 kgf/cm ) [1066 0 psi]
Damage on valve seating surface
Replace valve assembly
Fatigued or damaged spring
Replace springs and adjust relief pressure
Damaged O-rings on the valve body circumference
Replace O-rings
Clogging in metering section
Disassemble and clean
Malfunction of spool
Disassemble and clean
Faulty bearing
Disassemble and replace
Defect in steering cylinder
Bent piston rod
Repair or replace
Faulty piston seal
Replace
Misalignment
Faulty installation of steering valve or tilt column
Repair
Others
Flattened pipe or mixing of foreign materials
Clean or replace oil line
Defect in control valve
Sticking of spool or sleeve
Repair or replace
Breakage of centering spring
Disassemble and replace
Flattened pipe or mixing of foreign materials
Clean or replace oil line
Faulty piston seal of steering cylinder
Replace
Air trapped in hydraulic fluid
Bleed air
Defect in control valve
Unstable steering
Foreign materials clogged in spool pit
Decline in relief pressure Malfunction of relief valve
Remedy
Others
Abnormal noise
Loose installation of power cylinder and socket end Repair or replace
9-15
CHAPTER 9 STEERING SYSTEM
9.
Service Data Item
3.5 to 5.5 ton
Steering torque at steering wheel rim (While engine is running at low idle, rotate wheel at a rate of one full turn per second, while lift truck is idle.)
6.0 to7.0 ton
Standard
2.0 N·m (0.20 kgf·m) [1.475 lbf·ft]
Inside
Standard
82°
80°
Outside
Standard
59°
55°
Total turns of steering wheel
Standard
4.60 turns
4.27 turns
Steering wheel nut
Standard
Turning angle
9.1
53.9 to 58.8 N·m (5.5 to 6.0 kgf·m) [39.7 to 43.3 lbf·ft]
Steering Control Valve
Ref.
Item Displacement
Standard
Flow rate
3.5 to 5.5 ton
6.0 to7.0 ton
96 cc (5.8 cu.in.)/rev.
120 cc (7.3 cu.in.)/rev.
22.7 liter (5.99 U.S. gal)/min
Maximum operating pressure
Standard
15 MPa (153 kgf/cm2) [2176 psi]
1
End cap bolt
Tightening torque
28.4 N·m (2.9 kgf·m) [20.9 lbf·ft]
2
Check valve set screw
Tightening torque
11.7 N·m (1.2 kgf·m) [8.6 lbf·ft]
3
Steering bracket bolt
Tightening torque
29.4 N·m (3 kgf·m) [21.7 lbf·ft]
3
2
1
608841
9-16
CHAPTER 10 HYDRAULIC SYSTEM
Chapter 10 HYDRAULIC SYSTEM 1.
Specifications Item Gear pump
Rated discharge (Engine direct drive type)
Priority valve
Hydraulic system
Control valve
5.5 ton
6.0 to 7.0 ton
98 liter (25.89 U.S. gal)/2450 min-1
117.6 liter (31.07 U.S. gal)/ 2450 min-1
11768 kPa (120 kgf/cm2) [1706 psi]
14710 kPa (150 kgf/cm2) [2133 psi]
Main relief pressure
19361
+0.482 +5 +70 2 0 kPa (197.6 0 kgf/cm ) [1706 0 psi]
Attachment relief pressure
15503
+0.345 +3.5 +50 2 0 kPa (158 0 kgf/cm ) [2250 0 psi]
Flow regulator valve (Adjustable)
Control flow capacity
Simplex mast
Internal diameter
Lift cylinders
Stroke
Duplex mast
Internal diameter
First lift cylinders Stroke Duplex mast
Internal diameter
Second lift cylinders
Stroke
Triplex mast
Internal diameter
First lift cylinders Stroke Triplex mast
Internal diameter
Second lift cylinders
Stroke
Tilt cylinders
3.5 to 4.5 ton
100 liter/min (26.42 U.S.gal/min)
115 liter/min (30.38 U.S.gal/min)
165 liter/min (43.59 U.S.gal/min)
60 mm (2.36 in.)
70 mm (2.75 in.)
80 mm (3.15 in.)
1650 mm (65 in.) 90 mm (3.54 in.)
110 mm (4.33 in.)
820 mm (32.28 in.)
845 mm (33.27 in.)
55 mm (2.17 in.)
60 mm (2.36 in.)
1590 mm (62.60 in.)
1585 mm (62.40 in.)
90 mm (3.54 in.)
110 mm (4.33 in.)
125 mm (4.92 in.)
820 mm (32.28 in.)
845 mm (33.27 in.)
855 mm (33.66 in.)
60 mm (2.36 in.)
70 mm (2.75 in.)
80 mm (3.15 in.)
1480 mm (58.27 in.)
1530 mm (60.24 in.)
1495 mm (58.86 in.)
-
-
Internal diameter
100 mm (3.937 in.)
110 mm (4.33 in.)
Stroke
120 mm (4.724 in.)
139 mm (5.472 in.)
46 liter (12.1 U.S.gal) 52 liter (13.6 U.S.gal)
69 liter (18.2 U.S.gal)
Hydraulic oil N level
10-1
CHAPTER 10 HYDRAULIC SYSTEM
2. 2.1
Structure Hydraulic Line (6 to 7 Ton)
10 9 8
10
16 11
11 15 14 7 6 B2 B3 B4
A1 LS
12
A2 A3 A4
L
T P
R
5 16
1
•
3 13
2
4 608842
1. 2. 3. 4. 5. 6. 7. 8.
Hydraulic tank Suction strainer Return filter Gear pump Main relief valve Lift spool Tilt spool Flow regulator valve
Note: For the steering control valve, see “STEERING SYSTEM”. For the steering cylinder, see “REAR AXLE”.
10-2
9. 10. 11. 12. 13. 14. 15. 16.
Down safety valve Lift cylinders Tilt cylinders Steering control valve Steering cylinder Attachment spool Attachment relief valve Hydraulic tank
CHAPTER 10 HYDRAULIC SYSTEM 2.2
Hydraulic Tank
6
•
1
1) •
2)
•
2 5
•
4
• •
1. 2. 3. 4.
Cap Level gauge Drain plug Suction strainer
5. 6. 1) 2)
3
608843
Return filter Hydraulic tank (for 6 to 7 ton) From control and priority valves To gear pump
The hydraulic tank has a steel-welded structure and is integrated into the frame. The tank is positioned at the center of the right side frame. Oil in the hydraulic tank is sucked into the gear pump via the suction strainer (100 μ). Return oil from the lift cylinder is combined with return oil from the control valve and the steering control valve, which returns to the hydraulic tank through the return filter (25μ).
10-3
CHAPTER 10 HYDRAULIC SYSTEM 2.3
Gear Pump
4
1
2
7
6
8 3
9
10
5
11
12 608844
1. 2. 3. 4. 5. 6.
Front cover Body Drive gear Driven gear Side plate Rear cover
7. 8. 9. 10. 11. 12.
Bushing Oil seal Snapring Gasket Backup strip Gasket
The gear pump is an external gear pump. It provides hydraulic oil required to operate the hydraulic system.
10-4
CHAPTER 10 HYDRAULIC SYSTEM 2.4
Control Valve
1
7
5
4
3
8
6
2 6
1) 7
B2
B3
B4
T1 T2 P1
PF
5)
4)
A1
A2
A3
A4
3) 10
2)
9 608846
1. 2. 3. 4. 5. 6. 7. 8.
PF relief valve Inlet section assembly Unload valve Lift section assembly Tilt section assembly Attachment section assembly Attachment relief valve Outlet section assembly
9. 10. 1) 2) 3) 4) 5)
Lift lock valve Main relief valve TI-port PI-port LS-port PF-port T2-port
The control valve consists of four sections: inlet, lift, tilt, and attachment, all of which are spool type. The inlet section has a built-in flow divider valve. The tilt section has a built-in tilt lock valve. The attachment section has a built-in shutoff valve or an optional overload relief valve. The main relief valve is in the oil passage from the oil pump and prevents high oil pressure which could damage the pump. The relief valve for flow divider valve controls the oil pressure below the maximum pressure in the steering circuit. The overload relief valve prevents high oil pressure occurring in the attachment circuit.
10-5
CHAPTER 10 HYDRAULIC SYSTEM 2.5
Inlet Section
4
5
6
3 2 7
1 8
609284
1. 2. 3. 4.
10-6
Tank passage Main relief valve FD spool PF passage
5. 6. 7. 8.
P1 port LS port MS passage PF relief valve
CHAPTER 10 HYDRAULIC SYSTEM 2.6
Solenoid Section
3
4
6
5
2
1 8
7
609285
1. 2. 3. 4.
Lift lock valve Lift lock control connecting passage Lift down connecting passage 1 Lift down connecting passage 2
5. 6. 7. 8.
MF passage Unload poppet Unload valve Tank passage
10-7
CHAPTER 10 HYDRAULIC SYSTEM 2.7
Lift Valve Assembly
5
6 7
4
8
3
9
2
10
11
1
609286
1. 2. 3. 4. 5. 6.
10-8
Lift down passage 1 Spring Lift lock control connecting passage Lift lock poppet A1 port Lift down connecting passage 2
7. 8. 9. 10. 11.
Emergency valve Load check Parallel passage Lift spool Tank passage
CHAPTER 10 HYDRAULIC SYSTEM 2.8
Tilt Valve Assembly
4
5
6
7
3
8
2
9
1
10 609287
1. 2. 3. 4. 5.
Pilot spool Spring Shutoff plug A2 port Load check
6. 7. 8. 9. 10.
B2 port Parallel passage Shutoff plug Tilt spool Tank passage
10-9
CHAPTER 10 HYDRAULIC SYSTEM 2.9
Attachment Valve Assembly
3
4
5 6
2
7
1
8
9 609288
1. 2. 3. 4. 5.
Spring Shutoff plug A3 port Load check B3 port
10-10
6. 7. 8. 9.
Parallel passage Shutoff plug Attachment spool Tank passage
CHAPTER 10 HYDRAULIC SYSTEM 2.10 Control Valve Hydraulic Circuit Diagram
Lift valve Tilt valve PF P2
A1
B2 A2
Attachment valve
Attachment valve
B3 A3
B4 A4
P1
T1 T LS T2
2
1
3
3 608848
1. 2.
Main relief valve PF relief valve
3.
Item
3.5 to 5.5 ton
Main relief valve 1 Relief pressure
PF relief valve 2 Attachment relief valve 3
Attachment relief valve
19.4 11.8
6.0 to 7.0 ton
+0.5 +5.1 +72 2 0 MPa (197.8 0 kgf/cm ) [2814 0 psi]
+0.5 +5.1 +72 2 0 MPa (120 0 kgf/cm ) [1711 0 psi]
15.5
+0.5 +5.1 +72 2 0 kPa (150 0 kgf/cm ) [2125 0 psi]
14.7
+0.5 +3.5 +50 2 0 MPa (158 0 kgf/cm ) [2250 0 psi]
10-11
CHAPTER 10 HYDRAULIC SYSTEM 2.11 Lift and Tilt Cylinders Second lift cylinder for simplex mast and triplex mast There are two types for the second lift cylinder: one with a return pipe and the other without a return pipe. The lift cylinder without a return pipe is provided with a check valve in the piston instead of a return pipe. This is called an internal drain type cylinder. Regardless of presence or absence of a return pipe, the bottom of the piston is provided with a cushion mechanism for soft landing. -
Cylinder without a return pipe - Mast used: (1) Simplex mast with raised height of 3.4 m (11.2 ft) or less (2) All triplex masts
Main components
9
10 3
1)
2)
1
3)
2
7 8 5 4) 5)
d ID OD
4 6
Cushion stroke: 23 mm (0.91 in.) 608849
1. 2. 3. 4. 5. 6. 7. 8.
Cylinder tube Piston rod assembly Cylinder head Pipe (integrated with cylinder tube) Cushion bearing Check valve U-ring, Backup ring Bushing
10-12
9. 10. 1) 2) 3) 4) 5)
Wiper ring X-ring Space One side only Groove Groove Inflow and outflow of oil
CHAPTER 10 HYDRAULIC SYSTEM Cushion mechanism when piston descends Action during piston descent
1
2
(B)
Entrapped oil (A)
Passage (a)
2) 1)
3)
5
Passage (b)
4 608850
1) 2)
Descent Groove
3)
Outflow
The above illustration shows a condition in which piston rod assembly 2 descends with its self weight, and pipe 4 and cushion bearing 5 are beginning to fit in. Cushion bearing 5 is pushed upward by entrapped oil (A), and the piston and cushion bearing 5 make surface contact at (B) area. This blocks the passage (a). The only outflow passage for entrapped oil (A) is clearance (b) between the bore of cushion bearing 5 and the outside of pipe 4. This passage (b) becomes narrower as the piston descends further. Therefore, the descending speed of the piston becomes gradually slower and impulsive contact is avoided.
1)
2)
Clearance of approx. 0.1 mm (0.004 in.)
3)
4)
608851
Image of pipe and cushion bearing 1) The inside diameter is further smaller. 2) Outside diameter without step
3) Cushion bearing 4) Pipe
10-13
CHAPTER 10 HYDRAULIC SYSTEM Action during piston ascent (initial stage)
1
2
(B)
Passage (a)
2) 1)
3)
5 1) 2)
Ascent Groove
3)
Passage (b)
4
608852
Inflow
The above illustration shows a condition immediately after the piston rod assembly ascends. Oil that flows in acts on the center of the piston, ascending piston rod assembly 2 slightly. At the same time, cushion bearing 5 descends by being pushed by oil that flows in. This action opens the (B) area, causing the passage (a) to open. Oil from the passage (a) and passage (b), which opens from the beginning flows in the piston bottom, acts on the entire bottom surface of the piston and pushes piston rod assembly 2 upward. Internal drain type cylinder
1
2
1)
3 608853
1.
Entrapped oil and air (Negative pressure tends to exist in this area.)
2. 3.
Groove Check valve
The above illustration shows a condition in which the piston rod assembly ascends to the vicinity of the highest position. When the pressure of oil and air entrapped between the rod and cylinder exceeds the set pressure of the check valve, the check valve opens and discharges oil and air to chamber (internal drain). In the cylinder with a return pipe, the entrapped oil and air are returned to the hydraulic tank.
10-14
CHAPTER 10 HYDRAULIC SYSTEM Lift cylinders of simplex mast with return pipe (A40A)
* * * 6 5 7 4 2
* 10 9
11
* 8
1
3 •• •
•
•
•
•
• ••
608854
1. 2. 3. 4. 5. 6.
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring
7. 8. 9. 10. 11.
Wiper ring U-ring Backup ring Bushing Spacer
Note: Parts marked with * are included in the seal kit. Lift cylinders of simplex mast with return pipe (A45A, A55A, and A70A)
* 2 7
5
* 6 3 4
* 8
* 13 9 10 11 12 1
• • •
•
• •
608855
1. 2. 3. 4. 5. 6. 7.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring
8. 9. 10. 11. 12. 13.
O-ring Piston ring U-ring assembly U-ring holder Stopper Spacer
Note: Parts marked with * are included in the seal kit.
10-15
CHAPTER 10 HYDRAULIC SYSTEM First lift cylinder of duplex mast (B40A, B45A, and B55A)/First lift cylinders of triplex mast (C40A through C70A)
* 6
* 8
3
•
* * * 5 4 7 13,14
2
• •
* 9
1
* 10
•
•
•
11 12
•
• •
608856
1. 2. 3. 4. 5. 6. 7.
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring
8. 9. 10. 11. 12. 13. 14.
O-ring Seal ring assembly Slide ring Check valve Snapring Plug Gasket
Note: Parts marked with * are included in the seal kit. Second lift cylinder of duplex mast (B45A and B55A)
* 6
4
* 7 3 •
* 5 8 •
2 1 18 19 15 9 10
•
•
••
11 13 12
14
• •• • •
• 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
17
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring O-ring Piston Set screw
Note: Parts marked with * are included in the seal kit.
10-16
608857
11. 12. 13. 14. 15. 16. 17. 18. 19.
Slide ring Check valve Cushion spool Spring Snapring Valve Steel ball Spacer Snapring
CHAPTER 10 HYDRAULIC SYSTEM Second lift cylinder of duplex mast (B40A)
* * * * 8 7 6 5 9 4 3 18 17
•
•
• •
1 2
•
•
16 14 12 11 10 13 15
• • • • • •
•
608858
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Backup ring Wiper ring O-ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Piston Slide ring Set screw Check valve Cushion spool Spring Snapring Steel ball Set screw
Note: Parts marked with * are included in the seal kit. Second lift cylinder of triplex mast (C40A)
* * 6 5
* 3 7 4
2
1
16
* * 11 12 10 9 8 15 14 13
608859
1. 2. 3. 4. 5. 6. 7. 8.
Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring U-ring
9. 10. 11. 12. 13. 14. 15. 16.
Backup ring Bushing Spring guide Spring Cushion spool Pin Snapring Spacer
Note: Parts marked with * are included in the seal kit.
10-17
CHAPTER 10 HYDRAULIC SYSTEM Second lift cylinder of triplex mast (C45A and C55A)
7 6 5 4 3
8
2
1
17 13
14 9 10 11 12 16 15
608860
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring O-ring Piston ring
10. 11. 12. 13. 14. 15. 16. 17.
U-ring assembly Holder Stopper Spring guide Spring Cushion rod Spring pin Spacer
Note: Parts marked with * are included in the seal kit. Second lift cylinder of triplex mast (C70A)
7
6 5 8 4 3
2
1
19 14 15 16 18 9 17 10 11 12 13
608861
1. 2. 3. 4. 5. 6. 7. 8. 9.
Cylinder tube Piston rod Cylinder head Bushing Holder U-ring Wiper ring O-ring Piston
Note: Parts marked with * are included in the seal kit.
10-18
10. 11. 12. 13. 14. 15. 16. 17. 18.
Piston ring U-ring assembly Holder Stopper Spring guide Spring Cushion rod O-ring Set screw
CHAPTER 10 HYDRAULIC SYSTEM Tilt cylinder
5
* 9
* 8
* 10
* 7
3
•
•
1
2
12 4
• •
•
•
* 6
11
•
•
13, 14 1. 2. 3. 4. 5. 6. 7.
Cylinder tube Piston rod Guide bushing Piston Tilt socket Piston seal O-ring
608862
8. 9. 10. 11. 12. 13. 14.
Packing Dust seal Buffer ring Self-locknut Collar Bolt Spring washer
Note: Parts marked with * are included in the seal kit.
10-19
CHAPTER 10 HYDRAULIC SYSTEM 2.12 Flow Regulator Valve 3.5 to 5.5 ton
7
3
12
8 10
4 13
6
5 1
14 1. 2. 3. 4. 5. 6. 7.
2
11
9
608863
Valve body Plug Piston Plate Spring Look nut Valve
8. 9. 10. 11. 12. 13. 14.
Spring Washer Spring pin O-ring O-ring Snapring Elbow nut assembly
6.0 to 7.0 ton
10
9 12 7 2
11 13 1. 2. 3. 4. 5. 6. 7.
Valve body Plug Piston Plate Spring Locknut Stopper
3
8
4 14 8. 9. 10. 11. 12. 13. 14.
5
1
6
608864
Valve Spring disc Connector Elbow nut assembly Spring pin O-ring Snapring
The flow regulator valve is located between lift cylinder and control valve. It limits the flow of oil forced out of the cylinder when the loaded forks are lowered in order to keep a constant safe lowering speed regardless of the load.
10-20
CHAPTER 10 HYDRAULIC SYSTEM 2.13 Down Safety Valve
1
3 4
2
2)
1)
3)
608865
1. 2. 3. 4.
Connector Valve Spring Spring pin
1) 2) 3)
Free flow Indication of cut-off flow rate Regulated flow
The down safety valve is located at the bottom of right-side lift cylinder. This valve prevents the load from falling down rapidly in the event of a hose burst. Cut-off flow rate Simplex
A40A
A45A, A55A
A70A
Duplex
B40A
B45A, B55A
-
Triplex
C40A
C45A, C55A
C70A
Cut-off flow rate
0
0
90 -15 liter (23.8 -4 U.S.gal)/min
+5
+1.3
120 -10 liter (31.7 -2.6 U.S.gal)/min 200
+20 +5.3 0 liter (52.8 0 U.S.gal)/min
R WARNING DO NOT reuse the down safety valve after a lift line hose failure.
10-21
CHAPTER 10 HYDRAULIC SYSTEM
3.
Removing Gear Pump
3.1
Preparation for Removal
(1) Remove the counterweight. (2) Loosen the fan belt.
3.2
Removal Sequence
4
3 2 1
5
608866
1. 2. 3.
Universal joint Drive pulley, Locknut, Boss Main hose, Connector, O-ring
10-22
4. 5.
Suction hose, Elbow, O-ring Gear pump
CHAPTER 10 HYDRAULIC SYSTEM 3.3
Suggestions for Removal
(1) Remove the drive pulley locknut 2 with special tools. Special tool needed 91868-00100
Wrench
93768-00100
Note: The drive pulley locknut has left-hand thread. (2) To assemble, follow the reverse of disassembly sequence. Tighten the counterweight bolts, pump outlet joint, and main hose to the specified torque. Ref.
Item
Tightening torque
1
Universal joint
21.6 N·m (2.2 kgf·m) [15.9 lbf·ft]
2
Locknut
78.5 N·m (8.0 kgf·m) [57.9 lbf·ft]
3
Counterweight bolt
4
Connector
167 N·m (17.0 kgf·m) [123 lbf·ft]
5
Main hose
117 N·m (12.0 kgf·m) [87 lbf·ft]
800 to 888 N·m (81.6 to 90.6 kgf·m) [590 to 654 lbf·ft]
10-23
CHAPTER 10 HYDRAULIC SYSTEM
4.
Removing Control Valve
4.1
Preparation for Removal
(1) Remove the floor plate and dashboard cover. (2) Before disconnecting pipes, tilt the mast to VERTICAL position, lower the forks all the way, and relieve the pressure in the pipes.
4.2
Removal Sequence
1
10
4 2 B2
B3
8 T2
LS
A1 A2
9
A3
PF
7
3 P1
6
3
5
4
608867
1. 2. 3. 4. 5. 6.
Clevis pin, Clevis, Boot, Rod Clamp, Return hose, Connector, O-ring Attachment pipe, Connector, O-ring Tilt pipe, Clamp, Connector, O-ring Lift pipe, Connector, O-ring Delivery pipe, Connector, O-ring
10-24
7.
Pipe from the steering control valve (to LS port), Hose, Connector, O-ring 8. Pipe to the steering control valve (to PF port), Hose, Connector, O-ring 9. Hose from the steering control valve (to T2 port), Connector, O-ring 10. Control valve
CHAPTER 10 HYDRAULIC SYSTEM
5. 5.1
Removing Lift Cylinders (Simplex Mast) Removal Sequence
6
7
8
5
3 8
1
4
2 608868
1. 2. 3. 4.
5.2
Nuts Fork, Lift bracket Return (low-pressure) hose Hose guard
5. 6. 7. 8.
High-pressure hose Set bolt, Shims Cylinder clamp, Cushion, Collar, Shims Lift cylinder, Bracket
Suggestions for Removal
Lift bracket removal (1) Tilt the mast FORWARD, and lower the inner mast to the bottom. Slacken the lift chains, and remove the nuts from the anchor bolts. It is unnecessary to remove the forks. (2) Tilt the mast back to VERTICAL position. Raise the inner mast until the lift bracket becomes free. Then, back the lift truck away from the lift bracket and fork assembly.
608869
10-25
CHAPTER 10 HYDRAULIC SYSTEM Removing return hose Lift the mast to the maximum lift position, and turn the key switch OFF. Disconnect the return hose from the right and left lift cylinders at the connectors. (If applicable).
1)
608870 1) To hydraulic tank
Disconnecting high-pressure hoses Slowly push the lift lever FORWARD to lower the lift bracket to the ground. Disconnect the high-pressure hoses at the joints. Prepare a drip pan to catch oil flowing out of the hoses.
1
2
608871 1. Right cylinder
2. Left cylinder
Removing set bolts (1) Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, attach a sling around the mast with a protective rag. Note: The rod end of either lift cylinder is shim adjusted to eliminate the difference in stroke between the cylinders. Before removing the set bolts, make a record of the amount of shims and cylinders to which the shims are fitted. 608872
(2) Tie wood blocks under the inner mast and detach the sling. Make sure the right and left wood blocks are the same in height.
608873
10-26
CHAPTER 10 HYDRAULIC SYSTEM Removing lift cylinders Attach a sling on the lift cylinder from the rear side of the mast, and remove the cylinder. Attach the sling before removing the cylinder clamp.
608874
6. 6.1
Installing Lift Cylinders (Simplex Mast) Installation
To install, follow the reverse of removal sequence, and follow the Steps below after installation is completed: (1) Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly. (2) Check the oil level in the hydraulic tank with an oil level gauge. See 10-3 "Hydraulic Tank". (3) Check to make sure that the lift height is correct. (4) After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders. See “MAST AND FORKS”.
10-27
CHAPTER 10 HYDRAULIC SYSTEM
7.
Removing Lift Cylinders (Duplex and Triplex Mast)
The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full free panoramic mast (Triplex mast) is used to explain.
7.1
Removal Sequence
5
4 2
1
3 608875
1. 2. 3.
Nuts Lift bracket assembly First lift cylinder
10-28
4. 5.
Chain wheel support assembly Second lift cylinder
CHAPTER 10 HYDRAULIC SYSTEM 7.2
Suggestions for Removal
Removing lift bracket assembly 2 (1) Lower lift bracket assembly 2, and place wood blocks under the assembly. Tilt the mast FORWARD, lower the inner mast to the bottom, then remove nuts 1 from the anchor bolts of the first lift chains.
1
608876
(2) Position the mast VERTICAL. Raise the inner mast until main rollers 6 of lift bracket assembly 2 become free. Then, slowly move the lift truck in reverse to separate from lift bracket 2.
6 2 608877
Removing first lift cylinder 3 (1) Attach a sling to first lift cylinder 3, and lift the cylinder with a hoist. Attach the sling securely to prevent slipping. (2) Remove lift cylinder connecting and mounting bolts, and gently remove first lift cylinder 3.
3
608878
10-29
CHAPTER 10 HYDRAULIC SYSTEM Removing second lift cylinders 5 (1) Disconnect hoses from second lift cylinders 5. (2) Remove stopper bolts at the upper sections of second lift cylinders 5, and lift the inner mast (dual-stage full free panoramic mast) or middle mast (triple-stage full free panoramic mast) approximately 550 mm (21.67 in.) using slings.
5
608879
(3) Place wood blocks under the inner mast (dual-stage full free panoramic mast) or middle mast (triple-stage full free panoramic mast). Make sure the right and left wood blocks are the same in height.
608873
(4) Attach a sling to second lift cylinder 5 behind the mast, remove cylinder clamp retaining bolts, and gently remove second lift cylinder 5. Attach the sling securely on the cylinder. The cylinder cannot be lifted straight up since the mast crossmember is located above the cylinder. Tilt the cylinder and move it away from the crossmember to remove. Be careful not have your hands caught between the cylinder and mast.
5
608880
10-30
CHAPTER 10 HYDRAULIC SYSTEM
8.
Installing Lift Cylinders (Duplex and Triplex Mast)
To install, follow the removal sequence in reverse, and observe the Steps below: (1) Install chain wheel support assembly 4 parallel to a line connecting the centers of chain anchor bolt holes on first lift cylinder 3 to prevent chains from twisting. (2) Adjust the chain tensions. See 10-60 "Inspection and Adjustment". (3) Extend and retract the lift cylinders several times under no load condition to bleed air out of the cylinder circuits and to make sure that the cylinders move smoothly. (4) After proper operation is confirmed, check the oil level.
1)
2) 608881
1) Good
2) Bad
10-31
CHAPTER 10 HYDRAULIC SYSTEM
9.
Removing Tilt Cylinders
9.1
Removal Sequence
2
•
4 1 3 1. 2.
Tilt cylinder pin Hoses
9.2
3. 4.
608882
Tilt cylinder pin Tilt cylinder
Preparation
(1) Lower the forks to the bottom, and tilt the mast fully FORWARD. (2) Attach a sling on the top crossmember of outer mast, and support the weight of the mast with a hoist.
608883
9.3
Suggestions for Removal
Retracting piston rod Remove tilt cylinder pin 1. Turn ON the engine, retract the piston rod to the full stroke, and then turn the engine OFF. Disconnecting hoses Disconnect hoses 2 from the cylinder at the connectors. Catch oil that is flowing out of the cylinder in a drip pan. Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of the cylinder when the cylinder is removed.
10-32
CHAPTER 10 HYDRAULIC SYSTEM
10. Disassembling Gear Pump 10.1 Disassembly Sequence
7
* 16 18
17
9
12
8
15 13
6
15
10
11
4
5
3 15
15 14 1
2
608884
1. 2. 3. 4. 5. 6. 7. 8. 9.
Bolt Rear cover Gasket Gasket Backup strip Front cover Gasket Gasket Backup strip
10. 11. 12. 13. 14. 15. 16. 17. 18.
Body Side plate Side plate Drive gear Driven gear Bushing Snapring Oil seal Snapring*
Note: (1) The gear pump should be overhauled by the manufacturer. Where it has to be overhauled in the field, BE SURE to follow the suggestions for disassembly. Remember, field overhauling will release the manufacturer from any guarantee. (2) Do not remove oil seal 17 and bushing 15 unless they are defective. Start by: Remove the fan drive pulley, and then remove snapring 18*.
10.2 Suggestions for Disassembly (1) If gears 13 and14 and side plates 11 and 12 are separated from body 10, it might be difficult to restore them to the original state, resulting in defective pump performance. For this reason, remove the gears, side plates, and body as a set for replacement of the gaskets 3 and 7. (2) Front cover 6 and cover 2 are made of aluminum alloy which is easy to damage; do not use a hammer or pry bar.
10-33
CHAPTER 10 HYDRAULIC SYSTEM
11. Inspection After Disassembling Gear Pump 11.1 Drive and Driven Gears (1) Inspect the gear teeth for wear, chipping, or other defects. Also, inspect the journals and splines for wear, chipping, or other defects. (2) Check the end faces of the gear for wear or damage. (3) Check the journals and splines of the shaft for wear or damage.
608885
11.2 Pump Covers, Body, and Bushings Inspect pump covers, body, and bushing for wear and damage.
10-34
CHAPTER 10 HYDRAULIC SYSTEM
12. Assembling Gear Pump 12.1 Assembly Sequence
4
1 6, 7
13 10
9
8
18
14 2
15
3 4
5
1. 2. 3. 4. 5. 6. 7.
Front cover Oil seal Snapring Bushing Gasket Gasket Backup strip (Assemble 1 through 7 to make a subassembly) 8. Rear cover 9. Bushing 10. Gasket
6 17
11, 12
9
608886
11. Gasket 12. Backup strip (Assemble 8 through 12 to make a subassembly) 13. Body 14. Driven gear 15. Drive gear 16. Side plate 17. Side plate (Install 13 through 17) 18. Bolt (Install front cover subassembly 1 and rear cover subassembly 8 in body 13)
12.2 Suggestions for Assembly (1) (2) (3) (4) (5) (6)
Position rear cover 8 correctly. Clean the mating faces of covers 1, 8, and body 13, making sure that they are free from any oil or grease. Put grease on the lip of oil seal 2. Lubricate bearings, gears, and shafts with clean hydraulic oil before assembling. Take care not to damage the lip of oil seal by the splines of drive gear 15. Tighten all bolts evenly and progressively. Item
Bolts
Tightening torque 98 to 108 N·m (10 to 11 kgf·m) [72 to 80 lbf·ft]
10-35
CHAPTER 10 HYDRAULIC SYSTEM
13. Inspection After Disassembling Control Valve 13.1 Sections, Spools, and Return Springs (1) Check each sliding surface for cracks and defects. Also, check the check-valve seat for wear. (2) Check the spool for burn and distortion. Also, check for operating force. Item Spool operating force
Value 177 to 216N (18 to 22 kgf) [40 to 49 lbf]
(3) Check the tilt lock valve for damaged or sticking valve.
1
608889 1. Tilt lock valve
10-36
CHAPTER 10 HYDRAULIC SYSTEM
14. Assembling Control Valve To assemble, follow the reverse of disassembly sequence, and follow the Steps below: (1) Clean the disassembled parts with high flash-point solvent. Dry all parts (excluding rubber parts) with compressed air. (2) Apply hydraulic oil on the spools when inserting them into the valve blocks. (3) Position the poppet (tilt lock valve) correctly. (4) Apply grease on the O-rings when fitting them between the valve housings to prevent them from twisting. (5) Do not use any type of sealant. (6) Tighten the tie bolts (that hold the valve housings) as evenly as possible to prevent distortion of the housings. Note: Remember, a failure to follow this precaution will result in sluggish movement of the spools.
6.56 (141.3)
1)
2) 608890
Ref.
Item
Tightening torque
1)
bolts
65 N·m (6.6 kgf·m) [48 lbf·ft]
2)
bolt
101 N·m (10.3 kgf·m) [74 lbf·ft]
10-37
CHAPTER 10 HYDRAULIC SYSTEM
15. Disassembling Lift Cylinders (Simplex Mast) 15.1 Disassembly Sequence (A40A)
* 1
2
4 * 7
* 6 5
*
3
* 608891
1. 2. 3. 4.
Cylinder head Wiper ring, U-ring, O-ring Collar Piston rod
5. 6. 7.
U-ring, Backup ring, Bushing Bushing Cylinder tube
Note: -
Parts marked with * are included in the seal kit. Do not remove bushing 6 from cylinder head 1 unless they are defective.
15.2 Suggestions for Disassembly Removing cylinder head To remove the cylinder head, wrap the cylinder tube in cloth and hold it with a vise. Remove the cylinder head using the special tool.
608892
Special tool needed Wrench
10-38
05312-20850
CHAPTER 10 HYDRAULIC SYSTEM 15.3 Disassembly Sequence (A45A, A55A, and A70A)
4
* 1
6
7
* 2
* 5 *
3 608895
1. 2. 3. 4.
Holder, Wiper ring Cylinder head, U-ring, O-ring Collar Piston rod
5. 6. 7.
Piston ring, U-ring, Holder, Stopper Bushing Cylinder tube
Note: -
Parts marked with * are included in the seal kit. Do not remove bushing 6 from cylinder head 2 unless they are defective.
15.4 Suggestions for Disassembly Removing holder To remove the holder from the A70A cylinder, wrap the cylinder in cloth and hold it with a vice. Remove the holder using the special tool. Special tool needed Wrench
05312-10600
Remove the holder from the A45A and A55A cylinders using the spanner. Item Spanner
Value width across flats 85 mm (3.35 in.)
10-39
CHAPTER 10 HYDRAULIC SYSTEM
16. Inspection After Disassembling Lift Cylinders (Simplex Mast) 16.1 Cylinder Tube (1) Check the inner wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
16.2 Piston Rod (1) Place the rod on V-blocks and check for deflection with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
16.3 Packings and Rings Replace all parts contained in the seal kit once disturbed.
17. Assembling Lift Cylinders (Simplex Mast) 17.1 Assembly Sequence
1
6
5
4
3
2
608894
A45A, A55A, and A70A 1. 2. 3.
Piston rod Piston ring, U-ring, Holder, Stopper Collar
4. 5. 6.
Cylinder tube Cylinder head, bushing, U-ring, O-ring Holder, Wiper ring
4. 5.
Cylinder tube Cylinder head, Wiper ring, U-ring, Bushing, O-ring
A40A 1. 2. 3.
Piston rod Bushing, Backup ring, U-ring Collar
10-40
CHAPTER 10 HYDRAULIC SYSTEM 17.2 Suggestions for Assembly (1) (2) (3) (4) (5)
Clean parts completely before assembly, and make sure that parts are free of dust and other particles. To assemble, use new seal kit parts. Apply oil on the U-ring, piston ring, O-ring, bushing, wiper ring, and the cylinder bore before assembly. When holding the cylinder with a vise, be careful not to deform the cylinder by overtightening. Before tightening the cylinder head and the holder, apply liquid gasket (ThreeBond 1901) on the threads. Tightening torque Item
Cylinder head and the holder
A40A
A45A, A55A
A70A
304 N·m (31 kgf·m) [224 lbf·ft]
422 N·m (43 kgf·m) [311 lbf·ft]
490 N·m (50 kgf·m) [362 lbf·ft]
10-41
CHAPTER 10 HYDRAULIC SYSTEM
18. Disassembling Lift Cylinders (Duplex and Triplex Masts) 18.1 Disassembly Sequence for First Lift Cylinders (B55A and C40A Through C70A)
1 *
4
2
*3
7 8 *6 5
608896
1. 2. 3. 4.
Plug, Gasket Cylinder head U-ring, Wiper ring, O-ring, O-ring Piston rod
5. 6. 7. 8.
Check valve, Snapring Slide ring, Seal ring Bushing Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 7 from cylinder head 2 unless they are defective.
18.2 Suggestions for Disassembly Removing cylinder head To remove the cylinder head, hold the lift chain mounting area with a vise. Remove the cylinder head using the wrench. Special tool needed Wrench
10-42
05312-10800 (B40A, C40A) 05312-11000 (B45A, B55A, C45A through C70A)
CHAPTER 10 HYDRAULIC SYSTEM 18.3 Disassembly Sequence for Second Lift Cylinders (B40A)
1 2 6
9
*4
5
10 7
8
3 608897
1. 2. 3. 4. 5.
Valve, Steel ball Holder Cylinder head Wiper ring, U-ring, Backup ring, O-ring Piston rod
6. 7. 8. 9. 10.
Slide ring, Set screw, Piston Snapring, Check valve, Spring, Cushion spool Bushing Steel ball, Screw Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 8 from cylinder head 3 unless they are defective.
18.4 Suggestions for Disassembly Removing holder To remove the holder, wrap the cylinder tube in cloth and hold it with a vice. Remove the holder using the spanner. Item Spanner
Value width across flats 65 mm (2.56 in.)
10-43
CHAPTER 10 HYDRAULIC SYSTEM 18.5 Disassembly Sequence for Second Lift Cylinders (B45A and B55A)
1
6
7
5
10
2 9
*4
8 3
608898
1. 2. 3. 4. 5.
Valve, Steel ball Cylinder head Spacer U-ring, Wiper ring, O-ring Piston rod
6. 7. 8. 9. 10.
Spacer, Snapring Slide ring, Set screw, Piston Snapring, Check valve, Spring, Cushion spool Bushing Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 9 from cylinder head 2 unless they are defective.
18.6 Suggestions for Disassembly Removing cylinder head To remove the cylinder head, hold the mast fitting area of the cylinder tube with a vice. Remove the cylinder head using the wrench.
Special tool needed Wrench
10-44
05312-11000
CHAPTER 10 HYDRAULIC SYSTEM
19. Inspection After Disassembling Lift Cylinders (Duplex and Triplex Masts) 19.1 Cylinder Tube (1) Check the bore wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
19.2 Piston rod (1) Place the rod on V-blocks and check for deflection with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
19.3 Packings and rings Replace all parts contained in the seal kit once disturbed.
20. Assembling Lift Cylinders (Duplex and Triplex Masts) 20.1 First Lift Cylinder (B40A Through B55A, and C40A Through C70A) Assembly sequence
7
6 *
4
1
*
3
2 *
5 1. 2. 3. 4.
Piston rod Check valve, Snapring Slid ring, Seal ring Cylinder tube
608899
5. 6. 7.
Cylinder head, Bushing (Install parts 6 to part 5) U-ring, Wiper ring, O-ring Plug, Gasket
Note: Parts marked with * are included in the seal kit.
10-45
CHAPTER 10 HYDRAULIC SYSTEM 20.2 Second Lift Cylinders (B40A) Assembly sequence
6 1. 2. 3. 4.
1
8
7 *
3
4
5
2
Piston rod Cushion spool, Spring, Check valve, Snapring Piston, Set screw, Slid ring Cylinder tube
5. 6. 7. 8.
608900
Cylinder head, Bushing Holder (Install parts 7 to part 6) Backup ring, U-ring, Wiper ring, O-ring Steel ball, Screw
Note: Parts marked with * are included in the seal kit.
20.3 Second Lift Cylinders (B45A and B55A) Assembly sequence
9 *
10 1. 2. 3. 4. 5.
7
6
5
8
Piston rod Cushion spool, Spring, Check valve, Snapring Piston, Set screw, Slid ring Spacer, Snapring Cylinder tube
Note: Parts marked with * are included in the seal kit.
10-46
1
4
3
2 6. 7. 8. 9. 10.
Spacer Cylinder head (Install parts 8 and 9 to part 7) Bushing U-ring, Wiper ring, O-ring Steel ball, Valve
608901
CHAPTER 10 HYDRAULIC SYSTEM Suggestions for assembly (1) Clean parts completely before assembly, and make sure that parts are free of dust and other particles. (2) Use new seal kit parts and repair kit parts. (3) Apply oil on the seal kit parts such as U-ring, wiper ring, seal ring, and O-ring. Also apply oil on the slide ring and bushing before assembly. Apply oil on the cylinder bore before assembly. (4) When holding the cylinder with a vice, be careful not to deform the cylinder by overtightening. (5) Tighten parts such as the cylinder head, holder, piston, set screw, and the valve to the specified torque. See “Service Data”. (6) Before tightening the cylinder head and the holder, apply liquid gasket (ThreeBond 1901) on the threads. (7) After assembling the first lift cylinder, fill the rod chamber with hydraulic oil. Supply hydraulic oil from the plug, and tighten the plug to the specified torque.
1
2
608902 1. Plug
2. Rod chamber
Specified torque Item
Amount of hydraulic oil
A40A
A45A, A55A
A70A
160 to 180 cc (9.76 to 10.98 cu. in.)
190 to 210 cc (11.59 to 12.81 cu. in.)
260 to 290 cc (15.86 to 17.69 cu. in.)
10-47
CHAPTER 10 HYDRAULIC SYSTEM
21. Disassembling Lift Cylinders (Triplex Masts) 21.1 Second Lift Cylinders (C40A) Disassembly sequence
* 7
* 2
*
*
1
5 6
* 3
4 8
608903
1. 2. 3. 4.
Cylinder head, Bushing Wiper ring, U-ring, O-ring Spacer Piston rod
5. 6. 7. 8.
Snapring, Pin Spring guide, Spring, Cushion spool U-ring, Backup ring, Bushing Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 1 from cylinder head 1 unless they are defective.
10-48
CHAPTER 10 HYDRAULIC SYSTEM 21.2 Second Lift Cylinders (C45A and C55A) Disassembly sequence
* 1
7
*
5
2
6
* 3 8 4
608904
1. 2. 3. 4.
Holder, Wiper ring Cylinder head, U-ring, Bushing, O-ring Spacer Piston rod
5. 6. 7. 8.
Holder, Stopper, Springpin Spring guide, Spring, Cushion rod U-ring assembly, Piston ring Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 2 from cylinder head 2 unless they are defective.
10-49
CHAPTER 10 HYDRAULIC SYSTEM 21.3 Second Lift Cylinders (C70A) Disassembly sequence
* 5
1
* *
*
2
7 *
3
4
8
6
608905
1. 2. 3. 4.
Holder, Wiper ring Cylinder head, U-ring, Bushing, O-ring Spacer Piston rod
5. 6. 7. 8.
Holder, Stopper, U-ring assembly, Piston ring Set screw, Piston, O-ring Spring guide, Spring, Cushion rod Cylinder tube
Note: -
Parts marked with * are included in the repair kit. Do not remove bushing 2 from cylinder head 2 unless they are defective.
10-50
CHAPTER 10 HYDRAULIC SYSTEM Suggestions for disassembly (1) Removing cylinder head or holder To remove the cylinder head or holder, wrap the cylinder tube in cloth and hold it with a vice.
608892
(2) Remove the cylinder head or holder using the wrench or the spanner. Special tool needed Item
C40A
Wrench
05312-10800
Item
C70A
Wrench
05312-11000
Item Spanner
C45A, C55A Width across flats 85 mm (3.35 in.)
22. Inspection After Disassembling Lift Cylinders (Triplex Masts) 22.1 Cylinder Tube (1) Check the inner wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
22.2 Piston Rod (1) Place the rod on V-blocks and check for deflection with a dial gauge as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
22.3 Packings and Rings Replace all parts contained in the seal kit once disturbed.
10-51
CHAPTER 10 HYDRAULIC SYSTEM
23. Assembling Lift Cylinders (Triplex Masts) 23.1 Second Lift Cylinder (C40A) Assembly sequence
14 13 12 15
1
11
10
5
6
2 3
4
9
8
7
608906
1. 2. 3. 4. 5. 6. 7. 8.
Piston rod (Install parts 2 through 9 to part 1) Bushing Backup ring U-ring Spring seat Spring Cushion spool Pin
9. 10. 11. 12.
Snap ring Spacer Cylinder tube Cylinder head kit (Install parts 13 through 15 to part 12) 13. U-ring 14. Wiper ring 15. O-ring
23.2 Second Lift Cylinders (C45A and C55A) Assembly sequence
17 14 16 13 12 15
1
11
10 4
5
2
3
9 8
7
6
608907
1. 2. 3. 4. 5. 6. 7. 8. 9.
Piston rod (Install parts 2 through 9 to part 1) Piston ring U-ring assembly Spring guide Spring Cushion rod Springpin Stopper Holder
10-52
10. Spacer 11. Cylinder tube 12. Cylinder head (Install parts 13 through 15 to part 12) 13. Bushing 14. U-ring 15. O-ring 16. Holder 17. Wiper ring
CHAPTER 10 HYDRAULIC SYSTEM 23.3 Second Lift Cylinders (C70A) Assembly sequence
19 16 18 17 15 14
1
13
12 2 3 4 7 6 5 8 9 11 10
608908
1.
Piston rod (Install parts 2 through 11 to part 1) 2. Spring seat 3. Spring 4. Cushion rod 5. O-ring 6. Piston 7. Set screw 8. Piston ring 9. U-ring assembly 10. Stopper
11. 12. 13. 14. 15. 16. 17. 18. 19.
Holder Spacer Cylinder tube Holder (Install parts 15 through 17 to part 14) Bushing U-ring O-ring Holder Wiper ring
Suggestions for assembly (1) Clean parts completely before assembly, and make sure that parts are free of dust and other particles. (2) Use new seal kit parts and repair kit parts. (3) Apply oil on the seal kit parts such as U-ring, wiper ring, seal ring, and O-ring. Also apply oil on the slide ring and bushing before assembly. Apply oil on the cylinder bore before assembly. (4) When holding the cylinder with a vise, be careful not to deform the cylinder by overtightening. (5) Tighten parts such as the cylinder head, holder, piston, set screw, and valve to the specified torque. See “Service Data”. (6) Before tightening the cylinder head and holder, apply liquid gasket (ThreeBond 1901) on the threads.
10-53
CHAPTER 10 HYDRAULIC SYSTEM
24. Disassembling Tilt Cylinders 24.1 Disassembly Sequence
12 8 7
4 2
5
* *
6
3
*
*
1
13
11
9 1)
10
608909
1. 2. 3. 4. 5. 6. 7.
Bolt, Spring washer Socket (Remove 3 through 7 as a subassembly.) Guide bushing Dust seal Packing Buffer ring O-ring
8. 9. 10. 11. 12. 13. 1)
Piston rod Self-locknut Piston Piston seal Collar Cylinder tube Tilt cylinders for 6.0 to 7.0 ton.
Note: Parts marked with * are included in the seal kit. (1) The illustration shows tilt cylinder for 3.5 to 5.5 ton models. The frame fitting for 6.0 to 7.0 ton models have a different form. (2) Do not disassemble piston 10 unless defective. (3) Collar 12 is for forward tilt angle of 3 degrees. Tilt cylinders with Weber hydraulic stamped into the cylinder are assembled using thread locking compound. The gland nut must be heated to 300 °C (572 °F) before disassembling the cylinders. Use LOCTITE 270 when assembling.
10-54
CHAPTER 10 HYDRAULIC SYSTEM 24.2 Suggestions for Disassembly Removing guide bushing To remove the guide bushing, wrap the tilt cylinder in cloth and hold it with a vise. Remove the guide bushing using the wrench.
608892
Special tool needed Item Wrench
3.5 to 5.5 ton
6.0 to 7.0 ton
05312-10800
05312-11000
Weber hydraulic type cylinders Loosen LOCTITE material by heating up the thread zone (rod guide cylinder barrel) to 300°C (572°F) or higher and loosen the rod guide with a fitting spanner.
25. Inspection After Disassembling Tilt Cylinders 25.1 Cylinder Tube (1) Check the inner wall for wear, grooving, scratches, and rust. (2) Check the welds for cracks.
608893
25.2 Piston Rod (1) Check for deflection as shown. (2) Check for surface flaws such as grooving, scratches, rust, and wear. The rod must be replaced if its threads show a sign of stripping or any other damage.
10-55
CHAPTER 10 HYDRAULIC SYSTEM 25.3 Packings and Rings Replace all parts contained in the seal kit once disturbed. Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
1
Inside diameter of cylinder tube
Standard
100 mm (3.937 in.)
110 mm (4.33 in.)
2
[Guide bushing] Standard Diameter of piston rod
40 mm (1.574 in.)
50 mm (1.968 in.)
3
Inside diameter of tilt Standard socket bushing (fitted)
40 +0.05 mm (1.574 +0.002 in.)
4
Inside diameter of cylinder tube head bushing (fitted)
Standard
5
[Guide bushing] Thread diameter
Standard
5
Guide bushing
Tightening torque
6
[Tilt socket] Thread diameter
Standard
7
Tilt socket bolt
8
Self-locking nut
+0.10
50
+0.004
+0.039 +0.0015 0 mm (1.574 0 in.)
696 ± 69 N·m (71 ± 7 kgf·m) [513 ± 50 lbf·ft]
+0.11 +0.043 0 mm (1.968 0 in.)
785
+98 +10 +7.28 0 N·m (80 0 kgf·m) [578 0 lbf·ft]
M38 × 1.5
M38 × 1.5
Tightening torque
262 ± 13 N·m (27 ± 1.4 kgf·m) [195 ± 10.1 lbf·ft]
262 ± 13 N·m (27 ± 1.4 kgf·m) [195 ± 10.1 lbf·ft]
Tightening torque
588 ± 29 N·m (60 ± 29 kgf·m) [434 ± 21.7 lbf·ft]
981
+98 +10 +72.3 0 N·m (100 0 kgf·m) [723.3 0 lbf·ft]
8 4
2
10-56
+0.004
M115 × 2.0
6
7
50
M105 × 2.0
5 3
+0.10
45 +0.05 mm (1.77 +0.002 in.)
1
608910
CHAPTER 10 HYDRAULIC SYSTEM
26. Assembling Tilt Cylinders Follow the disassembly sequence in reverse.
26.1 Suggestions for Assembly (1) Carefully clean all parts to remove any gritty particle. (2) Assemble the cylinder in the reverse sequence of the disassembling, apply hydraulic oil on the bore wall of the cylinder tube, and also on sealing parts (O-rings, Urings, wiper rings, nylon heels, piston seals, dust seals, and packings) so that they will smoothly slide into the bore. (3) When clamping the cylinder tube in the vise in order to run the head into the cylinder tube, be careful not to distort the tube. 608911
(4) Before fitting the piston seal to the tilt cylinder piston, squeeze the seal by hand 5 or 6 times to soften it. Hold the piston steady by clamping the rod in the vise; apply a small amount of hydraulic oil on the seal; fit a portion of the seal to the groove; and push the other portions just a little at a time into the groove. For Weber hydraulic cylinders, use LOCTITE 270 when installing the rod guide bushing.
608912
Item Rod guide bushing
Tightening torque 400±40 N·m (41±5Kgf·m) [295±29lbf·ft)
10-57
CHAPTER 10 HYDRAULIC SYSTEM
27. Disassembling Flow Regulator Valve 27.1 Flow Regulator Valve (3.5 to 5.5 Ton) Disassembly sequence
3
11
2 1
6
10
9
5
8
7 4
1. 2. 3. 4. 5. 6.
Locknut Plug, O-ring Spring Piston Snapring Spring pin
7. 8. 9. 10. 11.
Washer Spring Plate Valve Body
28. Inspection After Disassembling Flow Regulator Valve (1) Check the springs for fatigue. (2) Check seat and sliding faces of valve and piston. (3) Check the sliding surfaces of the piston and valve body for damage. Note: Replace the flow regulator valve as an assembly if any part is defective.
10-58
608913
CHAPTER 10 HYDRAULIC SYSTEM
29. Assembling Flow Regulator Valve 29.1 Flow Regulator Valve Disassembly sequence
10
4
9
5
11 12
6 1 2 3 8 1. 2. 3. 4. 5. 6.
7
Nut Plug, O-ring Spring Piston Snap spring Pin
608915
7. 8. 9. 10. 11. 12.
Stopper Disc spring Plate Valve Body Elbow
30. Inspection After Disassembling Flow Regulator Valve (1) Check the springs for fatigue. (2) Check seat and sliding faces of valve and piston. (3) Check the sliding surfaces of the piston and valve body for damage. Note: Replace the flow regulator valve as an assembly if any part is defective.
31. Assembling Flow Regulator Valve Follow the disassembly sequence in reverse. Item Control flow rate
Value 165 liter/min (43.6 U.S.gal)
10-59
CHAPTER 10 HYDRAULIC SYSTEM
32. Inspection and Adjustment 32.1 Hydraulic Oil Level
295 mm (11.6 in.)
H N
33 (1.3) 50 (1.97)
L 120 (4.72) 608916
Item
3.5 to 4.5 ton
5.5 ton
6.0 to 7.0 ton
Hydraulic oil level
46 liter (12.1 U.S.gal)
52 liter (13.7 U.S.gal)
69 liter (18.2 U.S.gal)
Level gauge scale
H
N
450 mm (17.72 in.)
415 mm (16.34 in.)
Oil level (from the bottom of tank)
Note: Use level gauge scale N or H to check the oil level. Hydraulic tank (1) Hydraulic oil Check the hydraulic oil in the tank for cleanliness. Oil showing discoloring must be changed (slightly whitish color is allowed as it always appears after the operation). (2) Refill capacities and the amount of oil required. (3) Suction strainer and return filter Check for clogging or damage, and clean or replace the strainer and filter.
10-60
CHAPTER 10 HYDRAULIC SYSTEM 32.2 Test-run of Gear Pump The purpose of a test-run is to break-in the overhauled pump and verify its performance. The use of pump testing equipment, specifically designed as such and commonly used in the service shop is recommended but is not mandatory. The following procedure, however, assumes that the pump is installed on the lift truck. (1) Install a hydraulic pressure gauge with a range of 0 to 35200 kPa (0 to 352 kgf/cm2) [0 to 5000 psi].
1
1)
Installing hydraulic pressure gauge: Remove the plug from the delivery at the hose connector, and install the following tools:
4
3 2 608917 1) R2 PORT
Ref.
Item
1
Connector
2
Hose
3
Connector
4
Gauge
Special tools needed Threaded section (G3/4 MALE O-RING PORT to G3/8 MALE HOSE PORT) 64309-17722 64309-17731 (for gauge mounting) 64309-17712 0 to 35200 kPa (0 to 352 kgf/cm2) [0 to 5000 psi]
Note: Parts 2 through 4 are included in gauge kit 64309-17701. (2) Set the operating control lever in the NEUTRAL position, and run the engine at 500 to 1000 min-1. The hydraulic gauge reading under NEUTRAL condition should become 981 kPa (10 kgf/cm2) [142 psi] or less. Run the pump for 10 minutes and check the pump for abnormal noise. (3) Gradually increase the engine speed to 1500 to 2000 min-1, and run the pump for another 10 minutes under no load. (4) Under the condition of Step (3), loosen the adjusting screw of relief valve, and switch the operating control lever to operating condition. Adjust the adjusting screw and run the pump for 5 minutes with the pressure of 2942 kPa (30 kgf/cm2) [427 psi]. Increase the pressure by 1961 kPa (20 kgf/cm2) [284 psi] and run the pump for 5 minutes. Repeat the 5-minute run while increasing the pressure by the same amount for each run until the pressure reaches the set pressure of relief valve. (5) While increasing the pressure, check the pump surface temperature of the pump and for abnormal noise. If oil and pump are abnormally heated, continue the testrun under no load after lowering the temperature, or disassemble and inspect the pump. (6) After Steps (2) through (5) are completed, adjust the relief valve to the specified set pressure, and make sure that the operation speed is normal.
1 1. Spanner
2
608918 2. Allen wrench
10-61
CHAPTER 10 HYDRAULIC SYSTEM 32.3 Control Valve External oil leaks (1) Check the O-ring between housings for oil leakage. (2) Check the scraper and O-ring for oil leakage. (3) Check the thread connection for oil leakage. Oil leakage It is difficult to carry out an oil leakage check for the control valve individually. Therefore follow the procedures for inspection of cylinders before and after connecting as is described in (1) through (3) below: Measurement indicates the total leakage from the lift spool, tilt spool, tilt lock valve, and the check valves. Oil temperature: approx. 50°C (122°F) (1) Raise the forks with a rated load to approx. 1 m (40 in.). Tilt the mast FORWARD from the vertical position by approx. 3 to 4 degrees, then turn the engine OFF.
3° to 4°
Approx. 1 m (40 in.) 608919
(2) Immediately remove the oil return hose and collect oil from the hose.
608920
Item Standard oil discharge in 15 min.
500 cc (30.5 cu. in.)
(3) If the lift cylinders or tilt cylinders drift (the mast tilts forward or the fork lowers) excessively in spite of that the amount of oil collected for 15 minutes is less than 500 cc (30.5 cu.in.), measure the internal leakage of each cylinder. (The measurement is the assembly standard and not the secure limit).
10-62
CHAPTER 10 HYDRAULIC SYSTEM 32.4 Main Relief Valve Adjustment (1) Install a hydraulic gauge of 35200 kPa (352 kgf/cm2) [5000 psi] to R2 port. Use the same gauge, connector, and the hose used for the test-run of the gear pump. (2) Start the engine, and operate the tilt lever to the BACKWARD position at the maximum engine speed. When the tilt cylinder reaches the maximum BACKWARD position, check the pressure gauge. The main relief valve is in good condition if the oil pressure is relieved and the gauge reading is +0.5
+5.1
+72
19.4 0 MPa (197.8 0 kgf/cm2) [2814 0 psi]. (3) If the relief pressure is incorrect, loosen the relief valve locknut, and while observing the hydraulic gauge, adjust the pressure using the adjusting screw. (4) While pressing the adjusting screw, tighten the locknut to secure. (5) After tightening, check the relief valve set pressure again.
1 1. Spanner
2
608918 2. Allen wrench
Item Main relief valve set pressure
19.4
+0.5 +5.1 +72 2 0 MPa (197.8 0 kgf/cm ) [2814 0 psi]
32.5 Attachment Relief Valve Adjustment (1) Install a hydraulic gauge of 35200 kPa (352 kgf/cm2) [5000 psi] to R2 port. Note: Use the same equipment and tools as used for adjusting the main relief valve. (2) Turn ON the engine, and operate the attachment lever FORWARD or BACKWARD at the maximum engine speed. When the hydraulic pressure of actuator reaches the limit, check the pressure gauge. The secondary relief valve is in good condition if the oil pressure is relieved and the gauge reading becomes the specified value. (3) If the relief pressure is defective, loosen the relief valve locknut, and while observing the hydraulic gauge, adjust the pressure using the adjusting screw. (4) While pressing the adjusting screw, tighten the locknut to secure. (5) After tightening, check the relief valve set pressure again.
608921
10-63
CHAPTER 10 HYDRAULIC SYSTEM 32.6 Priority Relief Valve Function Check (1) Install a hydraulic pressure gauge to the position indicated in the figure to the right.
3 2
1 Ref.
Item
1
Connector
2
Hose
3
Gauge
Special tools needed G3/8 FEMALE O-ring port to G3/8 MALE hose port 64309-17722 64309-17712 35200 kPa (352 kgf/cm2) [5000 psi]
Note: -
Tools 1 through 3 are included in gauge kit. It is desirable to use a hydraulic gauge with a double capacity of the pressure to be measured.
10-64
608922
CHAPTER 10 HYDRAULIC SYSTEM 32.7 Flow Regulator Valve Adjustment Measure the lowering speed under rated load. If the speed is not the standard value, loosen the locknut of set bolt and turn the set bolt in either direction.
608925
Lowering speed
3.5 to 5.5 ton
4.5 to 5.5 ton
6.0 to 7.0 ton
Loaded
550 mm/sec (108 fpm)
440 mm/sec (86.6 fpm)
540 mm/sec (106 fpm)
No load
500 mm/sec (98.4 fpm)
410 mm/sec (81 fpm)
390 mm/sec (77 fpm)
10-65
CHAPTER 10 HYDRAULIC SYSTEM 32.8 Lift and Tilt Cylinders Adjusting mast tilt angle (simplex and duplex) (1) Place the forks on level ground. (2) Tilt the mast BACKWARD to the maximum tilt position for the mast without tilt cylinder spacers, then turn the engine OFF. (3) Measure the BACKWARD angle of the mast at both sides. (4) Loosen the tightening bolt of tilt cylinder socket, rotate the tilt cylinder rod and adjust the cylinder stroke until the right and left masts are tilted at the same angle. Note: It is unnecessary to adjust the forward tilt angle, provided that the backward tilt angle is properly adjusted on the mast without spacers.
608926
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Simplex Forward tilt - Backward tilt degrees
5° to 10°
6° to 9°
Adjusting mast tilt angle (triplex) (1) (2) (3) (4) (5)
Place the forks on level ground. Raise the forks up so when mast is tilted FORWARD to the maximum tilt position the forks will not hit the floor. Measure the forward tilt angle of the mast at both sides. Loosen the tightening bolt of tilt cylinder socket, rotate the tilt cylinder rod and adjust the tilt angle. Tilt mast BACKWARD and then slowly tilt the mast FORWARD, and observe the stopping of piston rod, right and left, at the moment the tilt cylinder reaches its maximum backward tilt. (6) If right to left piston rods stops before and mast cocks, adjust cylinder rod so that right and left stops at the same time. (7) Slowly tilt the mast BACKWARD observing the stopping point at tilt cylinder spacers. (8) Add shims between tilt cylinder socket and spacer, tighten to specified torque. Item
All model
Triplex Forward tilt - Backward tilt degrees
6° to 5°
Lift cylinder stroke adjustment (1) Slowly raise the inner mast, and observe the stopping of piston rod, right and left, at the moment the inner mast reaches its maximum lift height. (2) If the top of mast rolls at that moment, it should be adjusted with shims. Abnormal condition can be detected by a little time lag in stopping between right hand and left hand piston rods and rolling of the rod with a longer cylinder stroke. 608927
10-66
CHAPTER 10 HYDRAULIC SYSTEM Adjusting method (1) Raise the inner mast, tie blocks under the right and left sides of the mast, and lower the mast until it rests on the blocks. (2) Remove the stopper bolt at the top of lift cylinder which stopped first, retract the piston rod, and insert shims at the top of piston rod end.
608873
Note: To retract the piston rod, move the lift lever to the lowering position to let the oil escape from the lift cylinder. (3) Extend the piston rod, and tighten the cylinder stopper bolt. Remove the blocks from under the inner mast. (4) Slowly lower the inner mast to the bottom to ensure the piston rods move smoothly.
1
608928 1. Shims
10-67
CHAPTER 10 HYDRAULIC SYSTEM 32.9 Tests Descent by internal leakages (leakdown) (1) Position the mast VERTICAL with rated load, raise the forks approx. 1 m [40 in.], then turn the engine OFF. (2) Draw a reference line on the mast, and measure the distance of fork lowering after 15 minutes.
608929
Item Load descent test (rated load)
3.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (1.97 in.)
70 mm (2.76 in.)
Forward tilt by internal leakages (leakdown) (1) Position the mast VERTICAL with rated load, raise the forks approx. 50 cm (20 in.), then turn the engine OFF. (2) Measure the amount of tilt cylinder extension after 15 minutes.
608930
Item Load descent test (rated load)
10-68
3.5 to 5.5 ton
6.0 to 7.0 ton
30 mm (1.18 in.)
40 mm (1.57 in.)
CHAPTER 10 HYDRAULIC SYSTEM
33. Hydraulic Circuit Diagram 1 11 2
LS T P
R
L
10
9 4
P2 PF
A1
B2
A2
B3
A3
B4
8
A4
T1
P1
T2 LS
3
5
7
6 608931
1. 2. 3. 4. 5. 6.
Engine Gear pump Main relief valve PF relief valve Lift cylinder Flow regulator valve
7. 8. 9. 10. 11.
Tilt cylinder Control valve ATT relief valve Steering control valve Steering cylinder
10-69
CHAPTER 10 HYDRAULIC SYSTEM
34. Troubleshooting Item
Condition
Possible cause Oil low level
Actions Refill
Relief valve out of order, because of: Will not lift or tilt
(1) Main valve seized
Replace
(2) Valve spring broken
Replace
Oil pump defective
Replace
Relief valve out of order, because of:
Will not lift rated load
Lift speed is too slow Lift and tilt cylinders Lowering speed is too slow
Cylinder vibrates when actuated
Load descends too fast (drift)
Mast tilts forward (drift)
10-70
(1) Relief pressure setting too low
Adjust
(2) Plunger or poppet seat defective
Replace
(3) Spring fatigued
Replace
(4) O-ring in valve case damaged
Replace O-ring
Oil pump defective
Replace
Piston seals worn or damaged
Replace
Engine idle speed too low
Tune up engine
Operating control lever installed loosely, resulting in short spool stroke
Repair or replace
Tank strainer clogged
Clean or replace
Pump not delivering enough oil
Repair or replace
Sleeve seized in flow regulator valve
Repair
Dirt in flow regulator valve
Clean, repair system and replace defective hose
Abnormal resistance to flow due to deformation or partial clogging of hose
Replace hose
Piston rod distorted
Repair or replace
Air in oil circuit
Bleed air by operating cylinders through full strokes
Not enough oil in hydraulic tank
Refill
Control valve spool internally leaking
Replace
Sliding (inside) surface of cylinder tube slightly grooved
Repair or replace cylinder assembly
Sliding (inside) surface of cylinder tube badly grooved
Replace cylinder assembly
Piston seals broken or distorted
Replace seal kit
Oil leakage from piping
Repair or replace
Control valve spool internally leaking
Replace
Foreign particles lodged between packing
Replace packing
CHAPTER 10 HYDRAULIC SYSTEM Item
Lift and tilt cylinders
Condition
Bushing leaks
Hydraulic tank heats excessively
Possible cause
Actions
Foreign particles lodged between sealing members such as oil seals and dust seals
Replace
Oil seals and dust seals defective
Replace
O-rings damaged
Replace
Cylinder distorted
Repair or replace
Oil viscosity improper
Change oil
Overload
Check working conditions and, if overloaded, advise the operator to stay within the load limit
Local overheating of oil line due to a large restriction to flow
Repair or replace Adjust pressure setting
Relief valve adjustment improper 19.12
Hydraulic tank
Cylinders move too slow
Cylinders move too slow
Gear pump
Noise
+0.5 +0.5 +70 2 0 MPa (195 0 kgf/cm ) [2773 0 psi]
Pressure drop due to fatigued or broken springs
Repair or replace and adjust
Gear pump worn
Replace
Outlet pipe or tube deformed, or restricted
Repair or replace
Shortage of oil due to a natural loss
Refill
Oil leakage due to damaged oil line seals
Repair or replace
Oil viscosity too higher
Change oil
Gear pump defective
Check pump and piping; repair or replace
Oil leakage from oil line
Check oil for level and condition; add or change oil
Abnormal oil temperature rise
Check control valve spools for misalignment; repair or replace
Gear pump internally leaking
Replace pump
Poor pumping
Refill Check suction pipe for any flat portion (1) or loose connection; retighten or replace
Cavitation
(2)
Check that shaft oil seal is airtight; replace pump
(3)
Check pump case for any outside interference; repair
10-71
CHAPTER 10 HYDRAULIC SYSTEM Item
Condition
Possible cause Pressure too high
Pump case, drive gear and pump port flange damaged
Actions Replace pump Check to see if relief valve setting is correct Replace pump
Distortion or damage due to external strain or stress
(1) Check to see if return line is restricted Check to see if pipe connections have been externally stressed
(2)
Gear pump
Oil leakage from
Oil leakage past oil seal
Replace oil seal
Oil leakage past sliding surfaces of drive shaft
Replace whole pump assembly
Pump securing bolts loose
Retighten
Excessive internal leakage
Replace O-ring Adjust
Relief pressure setting too low 19.12 Slow or no motion of lift and tilt cylinders
Control valve Load descends or mast tilts forward (drifts) with operating control lever in neutral Oil leakage
10-72
+0.5 +0.5 +70 0 MPa (195 0 kgf/cm2) [2773 0 psi]
Relief valve piston seizure
Clean piston and check to see if it moves smoothly; or replace whole relief valve assembly
O-ring on relief valve body damaged
Replace O-ring
Operating control lever installed loosely, resulting in short spool stroke
Adjust
Control valve internally leaking
Adjust the tilt relief valve to the full closed position or replace the tilt relief valve.
Oil leakage from spool ring cap
Replace O-ring; check spool for flaws and if any, repair or replace a leaky block assembly
Loose plugs
Retighten
CHAPTER 10 HYDRAULIC SYSTEM
35. Service Data
Simplex mast
Item
3.5 to 4.0 ton
4.5 to 5.5 ton
60 to 7.0 ton
Lift speed (rated load/no load) mm (ft)/sec
Standard
540/570 (106.0/112.0)
390/420 (78.0/82.5)
360/390 (71.0/76.0)
Lowering speed (rated load)
Standard
550 (108)
440 (86.5)
540 (106.0)
Forward tilt angle
Standard
5°
6°
Backward tilt angle
Standard
10°
9°
Lift cylinder rod drift (rated load) Oil temperature: 45°C (113°F)
Standard
50 mm (1.97 in.)/15 min.
70 mm (2.76 in.)/15 min.
Tilt cylinder rod drift (forward) (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/15 min.
40 mm (1.57 in.)/15 min.
+0.5 2 0 kPa (197.6 kgf/cm ) [2810 psi]
Standard
Priority relief valve setting
Standard
11713 kPa (120 kgf/cm2) [1700 psi]
14641 kPa (150 kgf/cm2) [2125 psi]
Capacity
Standard
98 liter (25.89 U.S.gal)/2450 min
117.6 liter (31.07 U.S.gal) /2450 min
Flow rate (no load)
Standard
Flow regulator valve Gear pump
Main relief valve setting
Control valve
115 liter (30.38 U.S.gal)/ min
100 liter (26.42 U.S.gal)/ min
165 liter (43.59 U.S.gal)/ min
Tightening torque
49 N·m (5 kgf·m) [36 lbf·ft]
Tie bolts 7/16 inch
Tightening torque
65 N·m (6.6 kgf·m) [48 lbf·ft]
Tie bolts 1/2 inch
Tightening torque
101 N·m (10.3 kgf·m) [74 lbf·ft]
Return filter
Duplex mast
19361
Lift speed (rated load/no load) mm (ft)/sec
Standard
510/540 (100/106)
350/370 (69/73)
-
Lowering speed (rated load)
Standard
560 (110)
440 (86.5)
-
Forward tilt angle
Standard
5°
6°
Backward tilt angle
Standard
10°
10°
Lift cylinder rod drift (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/15 min.
40 mm (1.57 in.)/15 min.
Tilt cylinder rod drift (forward) (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/15 min.
40 mm (1.57 in.)/15 min.
10-73
CHAPTER 10 HYDRAULIC SYSTEM
Triplex mast
Item
3.5 to 4.0 ton
4.5 to 5.5 ton
60 to 7.0 ton
Lift speed (rated load/no load) mm (ft)/sec
Standard
510/550 (100/106)
360/390 (70/77)
330/360 (70/77)
Lowering speed (rated load)
Standard
560 (110)
460 (91)
510 (100)
Forward tilt angle
Standard
6°
Backward tilt angle
Standard
5°
Lift cylinder rod drift (rated load) Oil temperature: 45°C (113°F)
Standard
50 mm (1.97 in.)/ 15 min/70 mm (2.76 in.)/15 min
Tilt cylinder rod drift (forward) (rated load) Oil temperature: 45°C (113°F)
Standard
30 mm (1.18 in.)/ 15 min/40 mm (1.5 in.)/15 min
35.1 Lift Cylinder (Simplex Mast) A40A
A45A A55A
A70A
Standard
60 mm (2.36 in.)
70 mm (2.75 in.)
80 mm (3.15 in.)
Diameter of piston rod
Standard
45 mm (1.77 in.)
50 mm (1.97 in.)
*60 mm (2.36 in.)
3
Holder thread diameter
Standard
M64 × 1.5
M79 × 2.0
M90 × 2.0
4
Width across flat
Standard
-
85 mm (3.35 in.)
-
4
Cylinder head
Tightening torque
304 N·m (31 kgf·m) [224 lbf·ft]
422 N·m (43 kgf·m) [311 lbf·ft]
490 N·m (50 kgf·m) [362 lbf·ft]
Ref.
Item
1
Inside diameter of cylinder tube (Piston)
2
Value marked with * becomes 65 (2.56) for the mast size of 6.5 to 7.0 m (256 to 276 in.).
4
2
3
1
608932
10-74
CHAPTER 10 HYDRAULIC SYSTEM 35.2 Second Lift Cylinders (Duplex Mast Second Cylinders) Ref.
Item
B40A
B45A B55A
1
Inside diameter of cylinder tube (Piston)
Standard
55 mm (2.165 in.)
60 mm (2.362 in.)
2
Diameter of piston rod
Standard
42 mm (1.653 in.)
50 mm (1.968 in.)
3
Holder thread diameter
Standard
M63 x 2
M70 x 2
4
Holder or cylinder head
Tightening torque
304 ± 70.6 N·m (31 ± 7.2 kgf·m) [224 ± 52 lbf·ft]
343 ± 78.5 N·m (35 ± 8.0 kgf·m) [253 ± 57.8 lbf·ft]
5
Piston
Tightening torque
245 ± 44.1 N·m (25 ± 4.5 kgf·m) [180 ± 32.5 lbf·ft]
394 ± 52.9 N·m (30 ± 5.4 kgf·m) [217 ± 39 lbf·ft]
6
Set screw
Tightening torque
3.92 ± 0.98 N·m (0.4 ± 0.1 kgf·m) [2.9 ± 0.7 lbf·ft]
7
Valve
Tightening torque
19.6 ± 4.9 N·m (2 ± 0.5 kgf·m) [14.4 ± 3.6 lbf·ft]
8
Set screw
Tightening torque
B45A, B55A
4
3.92 ± 0.98 N·m (0.4 ± 0.1 kgf·m) [2.9 ± 0.7 lbf·ft]
3
6
2
-
5
1
7 8 B40A
608933
10-75
CHAPTER 10 HYDRAULIC SYSTEM 35.3 First Lift Cylinders (Duplex Mast, Triplex Mast First Cylinder) Ref.
Item
B40A C40A
B45A, B55A C45A, B55A
C70A
1
Inside diameter of cylinder tube (Piston)
Standard
90 mm (3.546 in.)
110 mm (4.33 in.)
125 mm (4.92 in.)
2
Diameter of piston rod
Standard
65 mm (2.56 in.)
75 mm (2.92 in.)
80 mm (3.15 in.)
3
Cylinder head thread diameter
Standard
M95 × 2
M115 × 2
M130 × 2
4
Holder or cylinder head
Tightening torque
530 ± 122 N·m (54 ± 12.4 kgf·m) [390 ± 89.7lbf·ft]
834 ± 191 N·m (85 ± 19.5 kgf·m) [614.8 ± 141 lbf·ft]
1120 ± 275 N·m (123 ± 28 kgf·m) [890 ± 203 lbf·ft]
5
Screw
Tightening torque
3
3.92 ± 0.78 N·m (0.4 ± 0.08 kgf·m) [28.9 ± 0.57 lbf·ft]
5
4
2
1
608934
10-76
CHAPTER 10 HYDRAULIC SYSTEM 35.4 Second Lift Cylinders (Triplex Mast) Ref.
Item
C40A
C45A C55A
C70A
1
Inside diameter of cylinder tube
Standard
60 mm (2.36 in.)
70 mm (2.76 in.)
80 mm (3.15 in.)
2
Diameter of piston rod
Standard
45 mm (1.77 in.)
50 mm (1.97 in.)
60 mm (2.36 in.)
3
Cylinder head or holder thread diameter
Standard
M64 × 1.5
M70 × 2.0
M90 × 2.0
4
Width across flat
Standard
-
85 mm (3.35 in.)
-
5
Holder or cylinder head
Tightening torque
304 ± 70.6 N·m (31 ± 7.2 kgf·m) [224 ± 52.0 lbf·ft]
422 N·m (43 kgf·m) [311 lbf·ft]
490 N·m (50 kgf·m) [362 lbf·ft]
6
Piston
Tightening torque
-
-
294 N·m (30 kgf·m) [217 lbf·ft]
7
Set screw
Tightening torque
-
-
6.86 N·m (0.7 kgf·m) [5.06 lbf·ft]
3
5 C40A
1
2
3
5 C45A, C55A
4
5
2
1
3
7
6
C70A
2
1
608935
10-77
CHAPTER 10 HYDRAULIC SYSTEM 35.5 Tilt Cylinders
Ref.
Item
3.5 to 5.5 ton
6.0 to 7.0 ton
1
Inside diameter of cylinder tube
Standard value
100 mm (3.937 in.)
110 mm (4.33 in.)
2
Diameter of piston rod (Guide bushing)
Standard value
40 mm (1.574 in.)
50 mm (1.968 in.)
3
Inside diameter of tilt socket bushing (fitted)
Standard value
40+0.05 mm (1.574+0.002 in.)
4
Inside diameter of cylinder tube head bushing (fitted)
Standard value
5
Thread diameter (Guide bushing)
5
Guide bushing
6
Thread diameter (Tilt socket)
7
8
+0.10
+0.004
+0.10
+0.004
45+0.05 mm (1.574+0.002 in.)
+0.039 +0.0015 0 mm (1.968 0 in.)
50
Standard value
M105 x 2.0
Tightening torque
696 ± 69 N·m (71 ± 7 kgf·m) [513 ± 50 lbf·ft]
M115 x 2.0
+98 +10 +72.3 0 N·m (80 0 kgf·m) [578 0 lbf·ft]
785
Standard value
M38 x 1.5
Socket bolt
Tightening torque
262 ± 13N·m (27 ± 1.4 kgf·m) [195 ± 10.1 lbf·ft]
Self-locking nut
Tightening torque
3
6
588 ± 29 N·m (60 ± 3 kgf·m) [434 ± 21.7 lbf·ft]
+98 +10 +72.3 0 N·m (100 0 kgf·m) [723.3 0 lbf·ft]
981
8
5
2
4
1
8 608936
10-78
CHAPTER 11 MAST AND FORKS
Chapter 11 MAST AND FORKS 1.
Simplex Mast
1.1
Mast System
The following table shows a combination of truck and mast models: Truck models
Mast
3.5 to 4.0 ton
A40A cc
4.5C ton
A40A cc
4.5 to 5.5 ton
A40A cc
6.0 to 7.0 ton
A40A cc
Note: cc represents maximum lift height. Example: 30 = 3,000 mm (157.5 in.) lift height Mast type and code Code
Mast
A
Simplex mast
Mast serial number location
609227
How to read mast model code
A
40
A
30 4 3 2 1 609228
1. 2.
Indicates the mast type Applicable lift truck class (Example: 4.0 ton)
3. 4.
Mast generation (A6B6C···Z) Maximum lifting height (30: 3000 mm[118.11 in.])
11-1
CHAPTER 11 MAST AND FORKS 1.2
Structure and Functions C
5
C
4
• •
15
1 2
9
6
B
B
13
12
11
A
A
12
11
16
10 14
•
3 7
10
9
D
8
D
Section A-A
1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Section B-B
2)
Outer mast Inner mast Lift bracket Lift cylinder Lift chain Load backrest extension Forks Mast strip Outer mast main roller Lift bracket upper roller Inner mast main roller
Section C-C
3) 12. 13. 14. 15. 16. 1) 2) 3) 4)
Section D-D
4)
609229
Lift bracket lower roller Lift bracket middle roller Side roller Chain wheel Tilt cylinder Detail of lift bracket lower rollers and inner mast main rollers Detail of outer mast main rollers Detail of lift bracket upper rollers Detail of mast strip
Note: For hydraulic lines, see 11-19 "Installing Hydraulic Lines". The simplex mast provides good visibility by placing both lift cylinders behind the outer mast columns. Mast strips are installed at the top end of outer mast in order to support the inner mast when the mast is tilted BACKWARD. All lift cylinders are equipped with a cushion mechanism. For mast operation, see 11-3 "Mast operation".
11-2
CHAPTER 11 MAST AND FORKS Mast operation The forks can reach the maximum free-lift height when the lift cylinders are extended. Further extension of the lift cylinders causes the inner mast to lift at the same speed as the cylinder rods, which causes the forks to lift twice as fast as the inner mast at the same time. See “HYDRAULIC SYSTEM”. Maximum free lift Maximum free lift means the maximum elevation of the forks without raising the mast.
2 3
1 4
4) 1) 1. 2. 3. 4.
Lift cylinder Lift chain Inner mast Outer mast
2) 1) 2) 3) 4)
3)
502138
Forks on the ground Maximum free lift Maximum lift Free lift height
11-3
CHAPTER 11 MAST AND FORKS 1.3
Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the lift truck, see 11-21 "Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck" .
2 5
3
4 6
7 1 1. 2. 3.
1.4
609230
Nut Load backrest extension, Lift bracket, Forks Return hose [4.5 m (14.8 ft.) maximum lift height or above]
4. 5. 6. 7.
High-pressure hose Tilt socket pin Mast support cap, Bushing Inner mast, Outer mast, Lift cylinder
Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly (1) Tilt the mast FORWARD and lower the inner mast to the bottom so that the lift chain is slack. Then remove the nuts 1 from the lift chains. (2) Tilt the mast BACKWARD to the VERTICAL position and lift the inner mast until the lift bracket 2 becomes free. Then, slowly move the lift truck away from the lift bracket. Note: Before overhauling the mast assembly, BE SURE to measure the clearance between the mast and the rollers. This helps to improve work efficiency by understanding which roller is to be replaced or the necessity of shim adjustment. See 11-98 "Adjusting Mast Roller Clearance".
2 1 609231
R CAUTION After the lift bracket is removed from the lift truck, place wood blocks under the lift bracket to prevent it from falling down.
11-4
CHAPTER 11 MAST AND FORKS Disconnecting lift cylinder return hose (1) Turn the engine OFF and disconnect hose at the hose clamp on the return connector side (indicated by the arrow in the figure). (2) Lower the mast.
1)
2
1
2)
3) 502141
1. Return hose 2. Return connector
1) To right lift cylinder 2) To left lift cylinder 3) To tank
Disconnecting lift cylinder high-pressure hoses Lower the mast to the bottom, and then disconnect hose at the location indicated by the arrow.
505780
11-5
CHAPTER 11 MAST AND FORKS Separating tilt cylinders (1) Attach a sling on the rings on the crossmember at the top of the outer mast, then lift the outer mast with a hoist.
609232
R CAUTION When removing and installing the mast assembly with a hoist, BE SURE to use a hoist with enough lift capacity. (2) Place wood blocks under the tilt cylinder mounting section and remove the tilt socket pins, and separate the mast from the tilt cylinders. (3) Start the engine, and retract the tilt cylinder rods with the tilt lever.
609233
R CAUTION -
DO NOT touch any levers except the tilt lever while the engine is running. DO NOT loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps (1) Put a matchmark on each cap. (2) Remove cap mounting bolts from the mast and disconnect the mast assembly from the lift truck by hoisting. Lay the mast assembly horizontally on level ground with the lift bracket side facing up. Note: Lay the mast assembly in a space large enough for disassembly work.
1) 609234 1) Matchmark
11-6
CHAPTER 11 MAST AND FORKS 1.5
Suggestions for Installing Mast and Lift Bracket Assembly
For installation, follow the removal sequence in reverse and observe the instructions below: Mast support (1) Apply a thick coat of grease on the inner surface of the caps and the mast support bushings. (2) Install the mast supports in the same direction as they were removed. (3) For greasing, place wood blocks under the mast so that the mast is off the ground. (4) Tighten the mast support bolts to the specified torque.
1 2
1) 2) 1. Bushing 2. Cap
Item Mast support bolt
505774
1) Bushing internal view 2) Cap internal view
Tightening torque 290 N·m (29.6 kgf·m) [214 lbf·ft]
Adjusting chain tension For chain tension adjustment, see 11-24 "Chain tension inspection and adjustment". Bleeding lift cylinders Move the lift bracket up and down several times to bleed air trapped in the piston end of the lift cylinder. After the proper operation of the lift truck is confirmed, check the oil level in the hydraulic tank.
11-7
CHAPTER 11 MAST AND FORKS 1.6
Removal Sequence of Mast and Lift Bracket
3
16
9
13 8
5 2
16
6 1
5. 6. 7. 8.
1.7
10
11
2
1. 2. 3. 4.
12
15
10 17
7
14
4
Nut Forks, Lift bracket Load backrest extension Lift bracket middle rollers and lower rollers, Shims Lift bracket upper rollers, Snaprings Lift bracket side rollers, Brackets, Shims Lift hose (for high pressure), Rubber hose, T-joint, Down safety valve Return hose (for maximum lift height of 4.5 m [177.165 in.] or more)
609235
9. Snapring, Chain wheel 10. Cylinder clamps, Seats, Shims, Cushion, Collar, Clamp bolt 11. Set bolt, Shims, Washer 12. Mast strip, Shims 13. Outer mast main rollers, Shims 14. Inner mast main rollers, Shims 15. Inner mast 16. Lift cylinder 17. Outer mast, Grease nipple
Suggestions for Disassembling Mast and Lift Bracket
Removing mast strips and main rollers Remove the clamp bolt and set bolt to free the lift cylinders, then cross the two lift cylinders at the top. Slide the inner mast down from the outer mast, and remove the main rollers and the mast strips. Removing inner mast After removing the main rollers from the mast, attach a sling on the crossmember of the inner mast and slide the inner mast upward from the outer mast. Attach a sling on the inner mast again and gently pull out the inner mast from the outer mast by clearing the outer mast roller shafts.
609236
11-8
CHAPTER 11 MAST AND FORKS 1.8
Inspecting Mast and Lift Bracket
Mast (1) Check each roller for binding, wear, and cracks. (2) Check each roller on rolling surface for pitting or other defects. (3) Make sure that rollers rotate smoothly on the rolling face. (4) Check welded joints of mast member, crossmembers, shafts, supports, and tilt brackets for cracks. (5) Check the mast support bushings for wear or other defects. 609237
Lift bracket (1) Check the main rollers and side rollers for binding, wear, and cracks. (2) Check the welded areas of lift bracket for cracks. (3) Check the finger bar for bend or distortion.
1 609238 1. Straight edge
Item Distortion of finger bar
Standard value 5 mm (0.20 in.) or less
Lift chains, chain wheels, and chain wheel supports (1) Measure the length of each chain to make sure that the two chains are equal in length. Also check the chains for wear, indication of breakage and link binding and twisting. (2) Check each chain anchor bolt for cracks or thread damage. (3) Check the chain wheel support and the chain wheel for cracks, wear, and binding. (4) Measure chain length to check for elongation. See 1125 "Checking Chain Elongation". Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20 in.)
523 mm (20.6 in.)
4.5 to 7.0 ton
635 mm (25 in.)
654 mm (25.7 in.)
Mast strip Check for damage, scoring or distortion. See “HYDRAULIC SYSTEM”.
11-9
CHAPTER 11 MAST AND FORKS 1.9
Assembly Sequence of Lift Bracket Roller
1
2
1
6 1)
6)
2
1)
1
9)
3 6
8)
8)
2)
10) 5)
5)
5 3 6)
6 1)
1
3)
4
1
5
5) 4)
6) 5) 1. 2. 3. 4. 5. 6.
4
Lift bracket Lift bracket upper roller Lift bracket middle roller Lift bracket lower roller Side roller Inner mast
1.10 Adjusting Lift Bracket Clearance The lift bracket has three main roller bearings on one side and side rollers on both sides as shown in the illustration. The clearances are necessary so that the lift bracket can move up and down smoothly along the inner mast.
11-10
7)
6) 1)
505770
Clearance between main roller rolling face and mast 2) Clearance between middle roller side face and mast thrust plate 3) Clearance between lower roller side face and mast thrust face 4) Clearance between side roller rolling face and mast 5) Shim (a) 6) Shim (b) 7) Shim (c) 8) Thrust plate 9) No shim required 10) Minimum clearance
inner inner inner inner
CHAPTER 11 MAST AND FORKS Clearances between middle roller side face and thrust plate and between lower roller side face and inner mast The clearance between the side roller face and the inner mast thrust face (right-to-left clearance): Clearance 2) is used to determine the correct amount of shims at the bearing seat. Move the lift bracket to the top of the inner mast and slide the lift bracket to either the left-most or the right-most position. Measure the clearance 2) between the roller side face and the inner mast thrust face on the opposite side. Note: Shim adjustment for clearance 2) is not required for the lift bracket upper rollers. Adjust clearance G to the specified values with shims (a) and (b) for the middle and the lower rollers. Item
Standard value
Clearance between middle roller side face and inner mast thrust plate Clearance between lower roller side face and inner mast thrust face
0.1 to 0.5 mm (0.004 to 0.020 in.)
Clearance between main roller rolling face and inner mast Clearance between roller circumference and inner mast thrust face (back-to-front play): Clearance 1) is used for determining the proper size of the rollers. Select a roller of correct diameter so that the clearance meets the specified value. Check that the rollers rotate smoothly when installed. Item
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Clearance between side roller rolling face and inner mast To determine the clearance between side roller circumference and inner mast side roller thrust face: Move the side roller to the upper end of the inner mast and slide the lift bracket to either the left-most or right-most position. Measure G1 clearance between the roller circumference and inner mast on the opposite side. Adjust the number of shims (c) so that the clearance meets the specified value. Item Clearance between side roller rolling face and inner mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-11
CHAPTER 11 MAST AND FORKS Selecting roller of correct outer diameter Measure the clearance between the upper and lower rollers' rolling faces and the mast. If the measured clearances does not meet the standard value shown in the table replace the roller with a roller of the correct diameter. Use the same sized roller for the upper and the lower rollers and use one size smaller for the middle rollers. Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". Make sure that the rollers rotate smoothly when installed. Specifications Item
Roller size (external diameter)
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
Adjusting clearance between middle roller side face and thrust plate
1
2
Note: The following adjustment is not required for the upper rollers.
4
2)
Measure the clearance between middle roller side face and thrust plate. If the measured clearance does not meet the standard value, adjust the clearance as follows:
3)
3
Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) 1. 2. 3. 4.
1
2)
Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
11-12
1)
2
Measure the clearance between the lower roller side face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows:
(1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) Clearance between middle roller side face and inner mast thrust plate 2) Shim (a) 3) Shim (b)
Inner mast Lift bracket Thrust plate Roller stopper
Clearance between lower roller side face and inner mast thrust face
502152
3) 502153 1. Inner mast 2. Lift bracket
1) Clearance between lower roller side face and inner mast thrust face 2) Shim (a) 3) Shim (b)
CHAPTER 11 MAST AND FORKS Installing rollers To install main rollers on shafts, use a driving tool, and be careful not to strike the outer roller surface with the driving tool. The side of the roller with larger chamfering must face toward the outside. Make sure the rollers rotate smoothly when installed.
502154
Adjusting the clearance between side roller rolling face and inner mast
3
1
2
Measure the clearance between side roller rolling face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows: Note: For clearance measurement, see 11-26 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
4 1)
(1) If the clearance is too large, increase the number of shims (c) as required. Shim (c) is available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.)
2) 1. 2. 3. 4.
Side roller Inner mast Lift bracket Roller mounting bolt
505788 5. Lift bracket 1) Clearance between side roller rolling face and inner mast 2) Shim (c)
11-13
CHAPTER 11 MAST AND FORKS 1.11 Installing Outer/Inner Mast Rollers Mast rollers have the same shape and size as the lift bracket middle roller and the lower roller, and the mast rollers have the same standard value for clearances between the rollers and the masts.
2) 1) 3
6
2
1 2)
4
1) 7
3 5
1. 2. 3. 4. 5.
Outer mast Inner mast Shim (a) Lift bracket lower roller Lift bracket
Item
Standard value
1)
Clearance between main roller rolling face and mast
2)
Clearance between main roller side face and mast
1 mm (0.04 in.) or less 0.1 to 0.5 mm (0.004 to 0.02 in.)
Measuring the clearance between main roller rolling face and mast If the measured clearances do not meet the standard value given in the table below, replace the roller with a roller of the correct diameter. Note: For measurement, see 11-28 "Adjusting Mast Roller Clearance". Specifications Item
Roller size (external diameter)
11-14
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
502156 6. Mast upper side 7. Mast lower side 1) Clearance between main roller rolling face and mast 2) Clearance between main roller side face and mast
CHAPTER 11 MAST AND FORKS Installing rollers Installation of the mast rollers is exactly the same as for the lift bracket rollers. See “Installing Lift Bracket Rollers”. Measuring the clearance between main roller rolling face and mast If measured clearance is larger than the standard value, adjust the clearance by increasing the number of shims (a) and shims (b) under the roller seats. Note: For measurement, see 11-28 "Adjusting Mast Roller Clearance". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1.12 Installing Mast Strips
4
Adjusting the clearance between mast and mast strip Measure the clearance by inserting a feeler gauge between mast and mast strip. Adjust the number of shims (d) so that the clearance is within the range of 0.1 to 0.5 mm (0.004 to 0.02 in.).
1) 2
1 1. Inner mast 2. Mast strip 3. Outer mast
Item 1)
Clearance between mast and mast strip
3
4
502157
4. Shim (d) 1) Clearance between mast and mast strip
Standard value 0.1 to 0.5 mm (0.004 to 0.02 in.)
(1) If the clearance is too large, increase the number of shims (c) as required. (2) After the shim adjustment, slowly move the lift bracket up and down to check for the smooth movement.
11-15
CHAPTER 11 MAST AND FORKS 1.13 Installing Lift Cylinders (1) Install the cylinder brackets on the lift cylinders. (2) Place the lift cylinders between the outer and inner masts. (3) Install each lift cylinder in the mounting hole of the outer mast by aligning the cylinder end with the springpin.
1
502158
1. Springpin
(4) Install the lift cylinder rods on the inner mast as shown in the illustration on the right. Do not forget to install shims if they were installed. Normally shims are not installed. Note: BE SURE to tighten the set bolt securely on the cylinder rod.
3 2 4 1 502159 1. Cylinder bracket 2. Inner mast
(5) Measure the clearance after fully retracting the cylinder rods and placing the cylinders vertically. Add or remove shims (m) so that the clearance is 1.6 mm (0.063 in.) or less. If the clearance is too large, increase the number of shims (m). Normally shims are not installed. If the clearance is 3.2 mm (0.126 in.) or more, BE SURE to insert a 3.2 mm (0.126 in.) thick seat in the shim pack.
3. Set bolt 4. Shim
1 1 1) 1. Seat 2. Shim (m)
Item 1)
Clearance between cylinder bracket and seat
Standard value 1.6 mm (0.063 in.) or less
(6) After assembly, check both lift cylinders for smooth stroke movement, and adjust the stroke as required. See 11-31 "Inspecting and Adjusting Right and Left Lift Cylinder Stroke".
11-16
2
502160
1) Clearance between cylinder bracket and seat
CHAPTER 11 MAST AND FORKS 1.14 Connecting Chains Assemble each chain on the lift bracket as shown in the illustration. Installing chain on lift bracket (A40A mast) Install the chain as shown in the illustration.
5 4 1)
2 3
1 502161 4. Split pin 5. Link 1) Engraved mark
1. Lift bracket 2. Center plate (No engraved mark) 3. Link plate
R CAUTION DO NOT use a center plate without mark on the outer side. Installing chain on lift bracket (A45A to A70A masts)
6
5
(1) When installing the anchor bolt on the lift bracket, maintain a clearance of 1 to 5 mm (0.04 to 0.2 in.) between the lift bracket and the anchor bolt as shown in the illustration on the right. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2) 1) 4
3 2 7
1 7, 8
8
2
502162
1. Lift bracket 2. Anchor bolt 3. Center plate (No engraved mark) 4. Link plate (With engraved mark) 5. Split pin
6. 7. 8. 1) 2)
Link Double nut (upper) Double nut (lower) Engraved mark Clearance for lift chain when installed
R CAUTION DO NOT use a center plate without mark on the outer side. Item 2)
Clearance for lift chain when installed
Standard value
Item
Tightening torque
1 to 5 mm (0.04 to 0.2 in.)
Double nut
290 ± 29 N·m (29.57 ± 2.96 kgf·m) [213.89 ± 21.39 lbf·ft]
11-17
CHAPTER 11 MAST AND FORKS Installing chain to outer mast side
1
(1) Hold the anchor bolt with a spanner wrench, secure the bolt and secure the clip. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2 3 4 1. Anchor bolt 2. Upper nut
Item Double nut (upper and lower)
11-18
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.89 lbf·ft]
4.5C to 7.0 ton
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
3. Double nut (upper) 4. Double nut (lower)
609239
CHAPTER 11 MAST AND FORKS 1.15 Installing Hydraulic Lines General precautions -
Use care not to let abrasive dust or dirt to enter the hydraulic system during installation. Apply hydraulic oil on O-rings before installation. When assembling an elbow connector 6 (connection with straight thread and O-ring), follow the instructions in the “Installation using straight thread and O-ring” on the next page.
-
3) 2) 3 1 2 3 6
1)
2 1 4
1)
5 502165
1) 2)
Lift cylinder Return connector
Item
3)
Return hose (for Masts having 4.5 m (177.165 in.) or above lifting height)
Tightening torque
1
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
2
Nut
118 ± 11.8 N·m (12.03 ± 1.2 kgf·m) [87.03 ± 8.70 lbf·ft]
3
Nut
4
Nut
5
Nut
6
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
11-19
CHAPTER 11 MAST AND FORKS Installation using straight thread and O-ring (1) Apply grease or hydraulic oil on O-ring and O-ring seat on the housing side. (2) Turn locknut so that it moves up against the body of the fitting. Move the backup washer and O-ring up against the locknut. (3) Tighten the fitting by hand. Once O-ring is placed in the correct position of housing and the backup washer comes in contact with the surface of housing, turn it back to adjust the mounting direction. Do not loosen the body fitting more than one turn. (4) Tighten the locknut to the specified torque.
1)
1 3 5
4 6 502164
1. End of fitting body (for hose connection) 2. Fitting body 3. Locknut 4. O-ring seat
11-20
2
5. O-ring 6. Threaded portion to the housing 1) Shape varies by fitting type
CHAPTER 11 MAST AND FORKS 1.16 Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck The mast rollers and strips can only be removed or installed when the inner mast is positioned lower than the outer mast. This can be achieved as follows:
1
(1) Disconnect the lift bracket assembly from the mast. (2) Lift the front side of the lift truck by 15 to 20 cm (5.9 to 7.87 in.) and place wood blocks underneath. Keep the front side of the lift truck off the ground in preparation to lower the inner mast with a hoist.
502166 1. Mast strip
(3) Remove the set bolts located on the top of the lift cylinders. Attach a sling on the inner mast, and lift the inner mast with a hoist to separate the lift cylinder piston rods from the inner mast.
1 4
7
5
3 7
3 6 1. 2. 3. 4.
Lift cylinder set bolt Clamp bolt Cylinder clamp part Cylinder bracket
2
502167
5. Lift cylinder 6. Mast strip 7. Shim
11-21
CHAPTER 11 MAST AND FORKS (4) Remove the lift cylinder clamp bolts, and separate the lift cylinders from the outer mast. Pull out the lift cylinders from the mounting seats at the bottom of the outer mast. Tilt the cylinder tops inward until they rest on the outer mast crossmember. Using a rope, fix the cylinders onto the crossmember. (5) Using the hoist, slowly lower the inner mast until the inner mast contacts the lift cylinders. (6) The main rollers of the inner and outer masts can now be removed. Before attempting to remove the main rollers, remove the mast strips and shims first as they tend to drop easily. (7) Adjust the number of shims for the main rollers and the mast strips as required. Note: To assemble, follow the disassembly sequence in reverse.
11-22
502168
CHAPTER 11 MAST AND FORKS 1.17 Inspection and Adjustment This section covers the inspection/adjustment that does not involve removal or disassembly. Conduct this inspection and adjustment whenever a defect is suspected.
1.18 Inspecting Forks (1) Check the forks for cracks or damage. Special attention should be given to the heel section 1) as well as all weld areas 2). Do not use a fork that has cracks. Magnetic particle inspection which features subsurface detection capability is recommended to check the root of the forks because most of the load weight rests on the root. Liquid penetration inspection is also recommended, however, it is less effective unless the paint on the inspection area is removed.
1)
2)
502169
(2) Check both forks for height 3) difference between the forktips and for any differences in shape. A slight difference between forktips may cause difficulty in inserting the forks into a pallet, which results in load imbalance. The maximum allowable difference in fork tip elevation 3) is 5 mm (0.2 in.) for pallet forks. Replace both forks when the difference in fork tip height exceeds the maximum allowable difference.
3)
502170
(3) Check fork blade thickness 4). If thickness 4) is worn down and exceeds the service limit, do not use.
4)
502171
Item Fork thickness
Standard Limit
3.5 to 4.5C ton
4.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (2 in.)
60 mm (2.4 in.)
65 mm (2.56 in.)
45 mm (1.77 in.)
51 mm (2.00 in.)
58 mm (2.28 in.)
11-23
CHAPTER 11 MAST AND FORKS 1.19 Inspecting and Adjusting Chain Tension R CAUTION -
BE SURE to turn the key switch to the OFF position before inspecting or adjusting lift chains, anchor bolts and nuts in order to prevent serious injury or death caused by a sudden movement of the mast and the lift bracket. BE SURE to place wood blocks under the forks in order to prevent serous injury or death caused by a sudden movement of the forks when they are raised.
Chain tension inspection and adjustment (1) Lower the forks to the ground. Tilt the mast FORWARD to create the slack in the chain. (2) Turn the engine OFF. (3) Loosen the lower nut. Move the upper nut upward. (4) Adjust the chain tension by turning the lower nut. (5) Park the lift truck on level ground and place the mast in a VERTICAL position. Then lower the forks to the ground. Make sure that the lift cylinders are fully retracted. 502172
(6) Raise the forks approximately 100 mm (3.94 in.) off the ground. (7) Turn the key switch to the OFF position. (8) Place wood blocks with the height of approximately 90 mm (3.54 in.) under forks. (9) Push both chains at the midpoint between the chain wheel and the fixed chain end on the lift bracket. Make sure the tension in the right and left chains are the same. If the tension is uneven, adjust the chain tension.
3 2
1 1. Lower nut 2. Upper nut
Item
Tightening torque
3.5 to 4.0 ton Double nut (upper and lower) 4.5C to 7.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
11-24
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
3. Anchor bolt
505815
CHAPTER 11 MAST AND FORKS R CAUTION After adjustment, raise and lower the lift bracket several times. With the mast being tilted BACKWARD and fully retracted, check the position of the lift bracket lower roller. The protrusion of each lower roller must not exceed 40% of the roller diameter from the bottom of inner mast. If it exceeds 40%, elongation of chains is suspected.
2 1
1) 1. Lift bracket lower roller 2. Inner mast
502174
1) 40% or less of roller diameter
Tightening nuts after adjustment (1) Hold the anchor bolt with a spanner wrench, secure the bolt and lower the clip to the anchor. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
1.20 Checking Chain Elongation (1) Pull the chains taut by weighing a load close to the maximum load evenly on both forks. (2) Measure 20 links of chain length. If the length exceeds the limit, replace the chain with a new one.
1) 2)
505791 1) Link
Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 7.0 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
2) 20 links
11-25
CHAPTER 11 MAST AND FORKS 1.21 Adjusting Clearance Between Lift Bracket Roller and Inner Mast Measuring back-to-front clearance on lift bracket main rollers
1)
(1) Slightly lift the forks off the ground. (2) Insert a claw bar between the upper part of the lift bracket and the inner mast, push the inner mast to either side. Measure the clearance between the main roller and the inner mast on the opposite side with a feeler gauge. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-10 "Assembly Sequence of Lift Bracket Roller". Item 1)
1)
502176
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on lift bracket main rollers and side rollers
R CAUTION Place wood blocks under the lift bracket to prevent it from falling. (1) Raise the lift bracket to the inner mast uppermost position. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go over to the opposite side of the mast, and slide the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a claw bar between the inner mast and lift bracket on the dial indicator side, and push the lift bracket to the opposite side. 502177
(5) Measure the clearance between the lift bracket middle roller and the thrust plate. Adjust the number of shims as required. Note: The upper rollers do not require any measurement and adjustment.
1
1 1)
For adjustment, see 11-10 "Adjusting Lift Bracket Clearance".
2
2
502178 1. Upper roller
Item 1)
11-26
Clearance between middle roller side face and inner mast thrust plate
2. Thrust plate
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
CHAPTER 11 MAST AND FORKS (6) Lower the lift bracket slightly from the top so that the side roller comes in contact with the inner mast. Measure the clearance between the side roller and the inner mast. Adjust the number of shims as required. For adjustment, see “Installing Lift Bracket Rollers” .
2) 1
1
502179 1. Side roller
Item 2)
Clearance between side roller rolling face and inner mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
(7) Raise the lift bracket to the top of the inner mast, and measure the clearance between the lower roller and inner mast. Adjust the number of shims as required. For adjustment, see “Installing Lift Bracket Rollers”.
1 3)
502180
1. Lower roller
Item 3)
Clearance between lower roller side face and inner mast thrust face
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-27
CHAPTER 11 MAST AND FORKS 1.22 Adjusting Mast Roller Clearance Measuring back-to-front clearance on mast main rollers (1) Tilt the mast fully BACKWARD. (2) Measure the clearance between the inner mast lower roller and the outer mast's rolling contact face. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-14 "Installing Outer/Inner Mast Rollers".
1)
502181
Item 1)
Standard value
Clearance between main roller rolling face and mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on inner mast main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the inner mast to prevent it from falling. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the inner mast roller against the outer mast's rolling surface. Then go over to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502182
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-14 "Installing Outer/Inner Mast Rollers".
1) Item 1)
11-28
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502183
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on outer mast main rollers (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the outer main roller against the inner mast's rolling surface. Then go to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502184
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-14 "Installing Outer/Inner Mast Rollers".
1)
502185
Item 1)
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-29
CHAPTER 11 MAST AND FORKS 1.23 Inspecting and Adjusting Mast Strip Clearance (1) Measure the clearance with the clearance between the outer mast rollers and the inner mast rolling face adjusted to 0 mm (0 in.) at the maximum lift position. (2) If mast strip clearance deviates from the specified value, adjust the clearance with shims. For adjustment, see 11-15 "Installing Mast Strips".
1)
502186
Item 1)
Standard value
Clearance between mast and mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
(3) After all clearances are adjusted, move the mast and lift bracket slowly, and check whether the full stroke movement is smooth.
1.24 Adjusting Mast Tilt Angle (1) Adjust the tire air pressure and park the lift truck on level ground. (2) Tilt the mast fully backward and turn the engine OFF. (3) Measure the BACKWARD tilt angle of the right and left masts. (4) Adjust the cylinder stroke by loosening the tilt cylinder socket bolt 1 and then turn the tilt cylinder rod so that the backward tilt angle of the mast on each side is the same. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Slowly tilt the mast BACKWARD, and adjust the rod so that both cylinders simultaneously move into their stroke end positions. Item
3.5 to 5.5 ton
6.0 to 7.0 ton
Standard tilt angle
5 ° to 10 °
6 ° to 10 °
1 505772 1. Socket bolt
(5) After tilt angle adjustment, tighten the tilt cylinder socket bolts to the specified torque. Item
Tightening torque
Tilt cylinder socket bolt
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
11-30
CHAPTER 11 MAST AND FORKS 1.25 Inspecting and Adjusting Right and Left Lift Cylinder Stroke Inspection (1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. (2) If the top of the inner mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and shaking of the rod with a longer cylinder stroke. 502188
Adjustment (1) Raise the inner mast, place wood blocks under the right and left sides of the inner mast, and lower the mast until it rests on the wood blocks. (2) Remove the set bolt at the top of lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of piston rod end. Note: When retracting the piston rod, push the lift lever to lowering direction to release the hydraulic oil from the cylinders. 501408
(3) Extend the piston rod, and tighten the lift cylinder set bolt. Remove the wood blocks under the inner mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the inner mast to the bottom. Also check that the left and right lift cylinders come to the end of stroke simultaneously at the maximum lift position of the inner mast.
1
505773 1. Shim
11-31
CHAPTER 11 MAST AND FORKS 1.26 Troubleshooting Condition
Possible cause
Action
Clearance between lift rollers and side rollers is incorrect
Adjust forward/backward and right/ left clearances
Defective roller rotation
Lubricate side rollers and replace other rollers
Incorrect clearance on mast strip
Adjust using shims
Excessive clearance on side roller
Increase shim stack thickness
Uneven tension between chains on right and left side
Adjust chain tension
Shim adjustments are unequal between left and right lift cylinders (at the maximum height)
Adjust shim stack thickness
Defective roller rotation
Adjust or replace rollers after inspection
Lift cylinder packing is damaged
Replace
Sliding (inside) surface of lift cylinder tube is damaged
Replace
Whole mast shakes
Mast support bushing is worn out
Retighten or replace bushing
Mast is distorted
Off-center load or overload
Replace mast assembly
Lift bracket and inner mast do not move smoothly
Lift bracket or inner mast is tilted
Mast makes noise Drift (natural descent) of lift cylinders
Distortion of finger bar Forktips are different in height
Distortion of forks Uneven loading
11-32
Repair or replace
CHAPTER 11 MAST AND FORKS 1.27 Service Data Item
3.5 to 4.0 ton
6.0C to 7.0 ton
Standard
508 mm (20.00 in.)
635 mm (25.00 in.)
Limit
523 mm (20.59 in.)
654 mm (25.75 in.)
S
Standard
117 mm (4.60 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
Standard
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
Standard
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
Standard
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
Chain length (20 links)
Main roller outside diameter
4.5C to 5.5 ton
Side roller external diameter
Standard
52 mm (2.05 in.)
58 mm (2.28 in.)
680 mm(26.77 in.)
800 mm (31.50 in.)
1
Width of outer mast
Standard
2
Width of inner mast
Standard
566 mm (22.28 in.) 556 mm (21.89 in.) 662 mm (20.06 in.)
3
Width of lift bracket
Standard
434 mm (17.09 in.) 422 mm (16.61 in.) 510 mm (20.08 in.)
4
Clearance between main roller rolling face and mast
Standard
1 mm (0.04 in.) or less
5
Clearance between main roller side face and mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
6
Clearance between mast and Standard mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
4
Clearance between main roller rolling face and inner mast
Standard
1 mm (0.04 in.) or less
5
Clearance between middle roller side face and inner mast thrust plate
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
5
Clearance between lower roller side face and inner mast thrust face
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
7
Clearance between side roller rolling face and inner mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
Distortion of finger bar
Standard
5 mm (0.2 in.) or less
Mast support bolt
Tightening torque
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
Tilt cylinder socket bolt
Tightening torque
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
Lift chain nut
Tightening torque
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
Simplex mast size (reference)
Mast
Lift bracket
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
11-33
CHAPTER 11 MAST AND FORKS
4
6
5
5 4
7
4 5
5
2 3
1 502190
Note: The mast is slightly wider at the lower side than at the upper side. Always measure the clearance at the upper side of the mast.
11-34
CHAPTER 11 MAST AND FORKS
2.
Duplex Mast
2.1
Mast System
The following table shows a combination of lift truck and mast models,: Truck models
Mast
3.5 to 4.0 ton
B40A cc
4.5C ton
B45A cc
4.5 to 5.5 ton
B55A cc
Note: cc represents maximum lift height. Example: 30 = 3,000 mm (157.5 in.) lift height Mast type and code Code
Mast
B
Duplex mast
Mast serial number location
505775
How to read mast model code
B
40
A
30 4 3 2 1 505776
1. 2.
Indicates the mast type Applicable truck class (Example: 4.0 ton)
3. 4.
Mast generation (A6B6C···Z) Maximum lifting height (30: 3000 mm [118.11 in.])
11-35
CHAPTER 11 MAST AND FORKS 2.2
Structure and Functions C
C
5 2 1 6 4 7 B
A
14
15
Section A-A
1)
3
B
13
8
A
12 10
Section B-B
Section C-C
2)
3)
1. Outer mast 2. Inner mast 3. Lift bracket 4. First lift cylinder (single) 5. Second lift cylinder 6. Lift chain 7. Load backrest extension 8. Forks 9. Side roller 10. Mast strip Note: For hydraulic lines, see 11-55 "Installing Hydraulic Lines".
11-36
11
3 11. 12. 13. 14. 15. 1) 2) 3) 4)
9 Side roller detail 4)
Lift bracket upper roller Outer mast main roller Lift bracket middle roller Lift bracket lower roller Inner mast main roller Detail of lift bracket lower rollers Detail of lift bracket middle rollers Detail of outer mast main rollers Detail of side roller
505777
CHAPTER 11 MAST AND FORKS On the duplex mast, the first cylinder raises the forks without increasing the overall mast height (free-lift) until the upper edge of the load backrest extension exceeds the top of the mast. The mast assembly consists of inner mast, outer mast, lift bracket, first lift cylinder, and second lift cylinder. The first lift cylinder raises the lift bracket, while the second cylinders raise the inner mast. The first lift cylinder is the internal drain type, and the second lift cylinder is equipped with cushion mechanism. For mast operation, see 11-37 "Mast operation". Mast operation The first lift cylinder extends to raise the forks to the maximum free-lift height. When the first lift cylinder rod is fully extended, the second lift cylinders take over the role to bring the inner mast to the maximum lift height. The mast lowering mechanism is the reverse of lifting. See “HYDRAULIC SYSTEM”. Maximum free lift Maximum free lift means the maximum elevation of the forks without raising the mast.
2 4 1 3 5
4)
1) 1. 2. 3. 4. 5.
First lift cylinder Lift chain Second lift cylinder Inner mast Outer mast
2) 1) 2) 3) 4)
3)
502196
Forks on the ground Maximum free lift Maximum lift Free lift height
11-37
CHAPTER 11 MAST AND FORKS 2.3
Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the lift truck, see 11-57 "Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck" .
8 1 2 1
5
6
7 1 1. 2. 3. 4.
505778
Chain guard, Bolt, Plug Clip Double nut Load backrest extension, Lift bracket, Forks
2.4
5. 6. 7. 8.
High-pressure hose Tilt socket pin Mast support cap, Bushing Inner mast, Outer mast, Lift cylinder
Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly (1) Lower the lift bracket, and place wood blocks under the lift bracket assembly. Tilt the mast FORWARD and lower the inner mast to the bottom to create slack in the lift chains. Then remove upper nut 2 and double nuts 3 from the lift chains. (2) Tilt the mast BACKWARD to the VERTICAL position and lift the inner mast until the lift bracket becomes free. Then, slowly move the lift truck away from the lift bracket. Note: Before overhauling the mast assembly, BE SURE to measure the clearance between the mast and the rollers. This helps to improve work efficiency by understanding which roller is to be replaced or the necessity of shim adjustment. See 11-63 "Adjusting Mast Roller Clearance".
2
3 505779
R CAUTION After the lift bracket is removed from the lift truck, place wood blocks under the lift bracket to prevent it from falling down.
11-38
CHAPTER 11 MAST AND FORKS Disconnecting lift cylinder high-pressure hoses Lower the mast to the bottom, and then disconnect hose at the location indicated by the arrow.
505780
Separating tilt cylinders (1) Attach a sling on the rings on the crossmember at the top of the outer mast, then lift the outer mast with a hoist.
505781
R CAUTION When removing and installing the mast assembly with a hoist, BE SURE to use a hoist with enough lift capacity. (2) Place wood blocks under the tilt cylinder mounting section and remove the tilt socket pins, and separate the mast from the tilt cylinders. (3) Start the engine, and pull back on the tilt lever to retract the tilt cylinder rods.
505782
R CAUTION -
DO NOT touch any levers except the tilt lever while the engine is running. DO NOT loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps (1) Put a matchmark on each cap. (2) Remove cap mounting bolts from the mast and disconnect the mast assembly from the lift truck by hoisting. Lay the mast assembly horizontally on level ground with the lift bracket side facing up. Note: Lay the mast assembly in a space large enough for disassembly work.
1) 505783 1) Matchmark
11-39
CHAPTER 11 MAST AND FORKS 2.5
Suggestions for Installing Mast and Lift Bracket Assembly
For installation, follow the removal sequence in reverse and observe the instructions below: Mast support (1) Apply a thick coat of grease on the inner surface of the caps and the mast support bushings. (2) Install the mast supports in the same direction as they were removed. (3) For greasing, place wood blocks under the mast so that the mast is off the ground. (4) Tighten the mast support bolts to the specified torque.
1 2
1) 2) 1. Bushing 2. Cap
Item Mast support bolt
505774
1) Bushing internal view 2) Cap internal view
Tightening torque 290 N·m (29.57 kgf·m) [213.89 lbf·ft]
Adjusting chain tension For chain tension adjustment, see 11-59 "Inspecting and Adjusting Chain Tension". Bleeding lift cylinders The duplex mast, unlike the other masts, has air bleeding plugs at the top of the second lift cylinders. Move the lift bracket up and down several times to bleed air trapped in the piston end of the lift cylinder. After the proper operation of the lift truck is confirmed, check the oil level in the hydraulic tank.
1
1 502201 1. Air bleeding plug
11-40
CHAPTER 11 MAST AND FORKS 2.6
Removal Sequence of Mast and Lift Bracket
14 15
13 12
5
18
A
2
16
6 7
9
2
11 19
11
A
3
7 B
4
22 9
18 B
C
8
10
22
3
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
11
1 17 CA
21 20
14
18
13
Hose clamps, Bolts, Washers High-pressure hose, pipe (First lift cylinder) Bolt, Washer, Shim First lift cylinder Chain guard, Bolt Chain wheels, Snaprings Chain wheel supports, Bolts, Washers Down safety valve, O-ring High-pressure hose (Second lift cylinder), Connector Cushion, Collar, Shim, Clamp bolt, Washer, Clamp Set bolt, Washer, Shim
16
505784
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Mast strip, Shims Stopper, Shim, Bolt, Washer Main rollers, Shims Inner mast Second lift cylinder Down safety valve, O-ring Elbow, O-ring Cylinder bracket Mast cap, Bolt, Washer Bushing Outer mast, Grease nipple
Note: The lift bracket disassembly procedure is the same as that of the simplex mast.
2.7
Preparation for Disassembling Mast and Lift Bracket
Lay the mast assembly horizontally on wood blocks with the lift bracket side facing up. Place a wood block as a wedge to prevent the inner mast from sliding. Before disassembly, measure and record all clearances between each of the rollers and the lift bracket and between the main rollers and the mast. Recorded measurements will be helpful when replacing rollers or selecting shims to adjust clearances.
11-41
CHAPTER 11 MAST AND FORKS 2.8
Suggestions for Disassembling Mast and Lift Bracket
Removing first lift cylinders (1) Remove the first lift cylinder 4 mounting bolt 3. (2) Tie two slings securely to the first lift cylinder 4, and gently lift the cylinder.
3 505785
Removing main rollers and mast strips (1) Remove the clamp bolts from the second lift cylinders. (2) Remove the set bolts from the top of the second lift cylinder rods. Then place the cylinder rod ends on the outer mast. (3) Count and record the number and thickness of shims that were installed at the top of cylinder rods. (4) Lower the inner mast, then remove mast strips 12 and main rollers 14.
12
14 14 505786
Removing inner mast Attach a sling on the inner mast 15 and gently pull out the inner mast from the outer mast 22 by clearing the outer mast roller shafts.
22
11-42
15
505787
CHAPTER 11 MAST AND FORKS 2.9
Inspecting Mast and Lift Bracket
Mast (1) Check each roller for binding, wear, and cracks. (2) Check each roller on rolling surface for pitting or other defects. (3) Make sure that rollers rotate smoothly on the rolling face. (4) Check welded joints of mast member, crossmembers, shafts, supports, and tilt brackets for cracks. (5) Check the mast support bushings for wear or other defects. 502206
Lift bracket (1) Check the main rollers and side rollers for binding, wear, and cracks. (2) Check the welded areas of lift bracket for cracks. (3) Check the finger bar for bend or distortion.
1
502150
1. Straightedge
Item Distortion of finger bar
Standard value 5 mm (0.20 in.) or less
Lift chains, chain wheels and chain wheel supports (1) Measure the length of each chain to make sure that the two chains are equal in length. Also check the chains for wear, indication of breakage, link binding, and twisting. (2) Check each chain anchor bolt for cracks or thread damage. (3) Check the chain wheel support and the chain wheel for cracks, wear, and binding. (4) Measure chain length to check for elongation. See “Measuring Chain Elongation”. Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 5.5 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
Mast strip Check for damage, scoring or distortion. See “HYDRAULIC SYSTEM”.
11-43
CHAPTER 11 MAST AND FORKS 2.10 Assembly Sequence of Lift Bracket Roller
1
2
1
6 1)
6)
2
1)
1
9)
3 6
8)
8)
2)
10) 5)
5)
5 3 6)
6 1)
1
3)
4
1
5
5) 4)
6) 5) 1. 2. 3. 4. 5. 6.
4
Lift bracket Lift bracket upper roller Lift bracket middle roller Lift bracket lower roller Side roller Inner mast
11-44
7)
6) 1)
505770
Clearance between main roller rolling face and mast 2) Clearance between middle roller side face and mast thrust plate 3) Clearance between lower roller side face and mast thrust face 4) Clearance between side roller rolling face and mast 5) Shim (a) 6) Shim (b) 7) Shim (c) 8) Thrust plate 9) No shim required 10) Minimum clearance
inner inner inner inner
CHAPTER 11 MAST AND FORKS 2.11 Adjusting Lift Bracket Clearance The lift bracket has three main roller bearings on one side and side rollers on both sides as shown in the illustration. The clearances are necessary so that the lift bracket can move up and down smoothly along the inner mast. Clearances between middle roller side face and thrust plate and between lower roller side face and inner mast The clearance between the side roller face and the inner mast thrust face (right-to-left clearance): Clearance 2) is used to determine the correct amount of shims at the bearing seat. Move the lift bracket to the top of the inner mast and slide the lift bracket to either the left-most or the right-most position. Measure the clearance 2) between the roller side face and the inner mast thrust face on the opposite side. Note: Shim adjustment for clearance 2) is not required for the lift bracket upper rollers. Adjust clearance G to the specified values with shims (a) and (b) for the middle and the lower rollers. Item
Standard value
Clearance between middle roller side face and inner mast thrust plate Clearance between lower roller side face and inner mast thrust face
0.1 to 0.5 mm (0.004 to 0.020 in.)
Clearance between main roller rolling face and inner mast Clearance between roller circumference and inner mast thrust face (back-to-front play): Clearance 1) is used for determining the proper size of the rollers. Select a roller of correct diameter so that the clearance meets the specified value. Check that the rollers rotate smoothly when installed. Item Clearance between main roller rolling face and inner mast
Standard value 1 mm (0.04 in.) or less
11-45
CHAPTER 11 MAST AND FORKS Clearance between side roller rolling face and inner mast To determine the clearance between side roller circumference and inner mast side roller thrust face: Move the side roller to the upper end of the inner mast and slide the lift bracket to either the left-most or right-most position. Measure G1 clearance between the roller circumference and inner mast on the opposite side. Adjust the number of shims (c) so that the clearance meets the specified value. Item
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
Selecting roller of correct outer diameter Measure the clearance between the upper and lower rollers' rolling faces and the mast. If the measured clearances does not meet the standard value shown in the table replace the roller with a roller of the correct diameter. Use the same sized roller for the upper and the lower rollers and use one size smaller for the middle rollers. Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". Make sure that the rollers rotate smoothly when installed. Specifications Item
Roller size (external diameter)
11-46
3.5 to 4.0 ton
4.5C to 5.5 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
CHAPTER 11 MAST AND FORKS Adjusting clearance between middle roller side face and thrust plate
1
2
Note: The following adjustment is not required for the upper rollers.
4
2)
Measure the clearance between middle roller side face and thrust plate. If the measured clearance does not meet the standard value, adjust the clearance as follows:
3)
3
Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) 1. 2. 3. 4.
1)
2
Measure the clearance between the lower roller side face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows:
1
2)
Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast" (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) Clearance between middle roller side face and inner mast thrust plate 2) Shim (a) 3) Shim (b)
Inner mast Lift bracket Thrust plate Roller stopper
Clearance between lower roller side face and inner mast thrust face
502152
3) 502153 1. Inner mast 2. Lift bracket
1) Clearance between lower roller side face and inner mast thrust face 2) Shim (a) 3) Shim (b)
11-47
CHAPTER 11 MAST AND FORKS Installing rollers To install main rollers on shafts, use a driving tool, and be careful not to strike the outer roller surface with the driving tool. The side of the roller with larger chamfering must face toward the outside. Make sure the rollers rotate smoothly when installed.
502154
Adjusting the clearance between side roller rolling face and inner mast
3
1
2
Measure the clearance between side roller rolling face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows: Note: For clearance measurement, see 11-61 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
4 1)
(1) If the clearance is too large, increase the number of shims (c) as required. Shim (c) is available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.)
2) 1. 2. 3. 4.
11-48
Side roller Inner mast Lift bracket Roller mounting bolt
505788 1) Clearance between side roller rolling face and inner mast 2) Shim (c)
CHAPTER 11 MAST AND FORKS 2.12 Installing Outer/Inner Mast Rollers Mast rollers have the same shape and size as the lift bracket middle roller and the lower roller, and the mast rollers have the same standard value for clearances between the rollers and the masts.
2) 1) 3
6
2
1 2)
4
1) 7
3 5
1. 2. 3. 4. 5.
Outer mast Inner mast Shim (a) Lift bracket lower roller Lift bracket
Item
502156 6. Mast upper side 7. Mast lower side 1) Clearance between main roller rolling face and mast 2) Clearance between main roller side face and mast
Standard value
1)
Clearance between main roller rolling face and mast
2)
Clearance between main roller side face and mast
1 mm (0.04 in.) or less 0.1 to 0.5 mm (0.004 to 0.020 in.)
Measuring the clearance between main roller rolling face and mast If the measured clearances does not meet the standard value given in the table below, replace the roller with a roller of the correct diameter. Note: For measurement, see 11-63 "Adjusting Mast Roller Clearance". Specifications Item
Roller size (external diameter)
3.5 to 4.0 ton
4.5C to 5.5 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
11-49
CHAPTER 11 MAST AND FORKS Installing rollers Installation of the mast rollers is exactly the same as for the lift bracket rollers. See 11-44 "Assembly Sequence of Lift Bracket Roller". Measuring the clearance between main roller rolling face and mast If measured clearance is larger than the standard value, adjust the clearance by increasing the number of shims (a) and shims (b) under the roller seats. Note: For measurement, see 11-63 "Adjusting Mast Roller Clearance". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
2.13 Installing Mast Strips
4
Adjusting the clearance between mast and mast strip Measure the clearance by inserting a feeler gauge between mast and mast strip. Adjust the number of shims (d) so that the clearance is within the range of 0.1 to 0.5 mm (0.004 to 0.02 in.).
1) 2
1 1. Inner mast 2. Mast strip 3. Outer mast
Item 1)
Clearance between mast and mast strip
Standard value 0.1 to 0.5 mm (0.004 to 0.02 in.)
(1) If the clearance is too large, increase the number of shims (c) as required. (2) After the shim adjustment, slowly move the lift bracket up and down to check for the smooth movement.
11-50
3
4
502157
4. Shim (d) 1) Clearance between mast and mast strip
CHAPTER 11 MAST AND FORKS 2.14 Installing Second Lift Cylinder (1) Install the cylinder brackets to the second lift cylinders. (2) Install the second lift cylinder between the outer and inner masts. (3) Install each lift cylinder to the mounting hole of the outer mast by aligning the cylinder end with the springpin. (4) Install the lift cylinder rods to the inner mast as shown in the illustration on the right. Do not forget to install shims if they were installed. Normally shims are not installed. Note: BE SURE to tighten the set bolt securely to the cylinder rod.
3 2 4
1 502207 1. Cylinder bracket 2. Inner mast
(5) Measure the clearance after fully retracting the cylinder rods and placing the cylinders vertically. Add or remove shims (m) so that the clearance is 1.6 mm (0.06 in.) or less. If the clearance is too large, increase the number of shims (m). Normally shims are not installed. If the clearance is 3.2 mm (0.13 in.) or more, BE SURE to insert a 3.2 mm (0.13 in.) thick seat in the shim pack.
3. Set bolt 4. Shim
1 1 1) 1. Seat 2. Shim (m)
Item 1)
Clearance between cylinder bracket and seat
2
502208
1) Clearance between cylinder bracket and seat
Standard value 1.6 mm (0.063 in.) or less
(6) After assembly, check both lift cylinders for smooth stroke movement, and adjust the stroke as required. See 11-66 "Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke".
11-51
CHAPTER 11 MAST AND FORKS 2.15 Installing First Lift Cylinder (1) With the mast positioned vertically and fully lowered, temporarily install the first lift cylinder to the inner mast with the original shims and mounting bolts. (2) Position the first lift cylinder vertically and measure the clearance between the cylinder brackets and the cylinder mounts on the inner mast. If there is clearance, remove the clearance by adding shims. - To check whether both sides of the cylinder (right-toleft) are vertical against each other, measure to check if the cylinder is parallel to the side face of the inner mast. The parallel difference at the top and the bottom should be plus or minus 1 mm (0.04 in.) - To check whether both sides of the cylinder (front-toback) are vertical against each other, visually check if the cylinder is parallel to the front face of the inner mast. The cylinder should not be inclined FORWARD, not even slightly. The cylinder slightly inclined BACKWARD is acceptable. - Thickness of each adjusting shim is 1 mm (0.04 in.). (3) After shim adjustment, tighten the mounting bolts.
3
2 1 502209 1. First lift cylinder 2. Shim (n)
Item
Tightening torque
First lift cylinder mounting bolt
233 ± 47 N·m (23.76 ± 4.79 kgf·m) [171.85 ± 34.66 lbf·ft]
11-52
3. Mounting bolt
CHAPTER 11 MAST AND FORKS 2.16 Connecting Chains Assemble each chain to the lift bracket as shown in the illustration.
4 5 1) 3
2 1
1. Anchor bolt 2. Center plate (No engraved mark) 3. Link plate
502210
4. Link 5. Split pin 1) Engraved mark
R CAUTION DO NOT use a center plate without mark on the outer side. Installing chain to lift bracket
1 3 4
2 502211 1. Chain 2. Lift bracket
Item
Tightening torque
3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
4.5C to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
Locknut 4.5C to 5.5 ton (double nut side)
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
Locknut (single nut side)
3. Locknut (single nut side) 4. Locknut (double nut side)
11-53
CHAPTER 11 MAST AND FORKS Installing to first lift cylinder side (1) Hold the anchor bolt with a spanner wrench, secure the bolt. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2 3 4 1 1. Anchor bolt 2. Nut
Item Double nut (upper and lower)
11-54
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
4.5C to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
3. Double nut (upper) 4. Double nut (lower)
505818
CHAPTER 11 MAST AND FORKS 2.17 Installing Hydraulic Lines General precautions -
Use care not to let abrasive dust or dirt to enter the hydraulic system during installation. Apply hydraulic oil on O-rings before installation. When assembling an elbow connector 6 (connection with straight thread and O-ring), follow the instructions in the “Installation using straight thread and O-ring” on the next page.
-
9 7 8
2)
5 2
1 A
6
1) B
A
B
1)
8 1) 2)
First lift cylinder Second lift cylinder Item 1
Nut
2
Nut
3
Nut
4
Nut
5
Nut
6
Nut
7
Nut
8
Nut
9
Nut
2)
3
4 3)
505790
Down safety valve
Tightening torque 118 ± 11.8 N·m (12.03 ± 1.2 kgf·m) [87.03 ± 8.70 lbf·ft]
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
11-55
CHAPTER 11 MAST AND FORKS Installation using straight thread and O-ring (1) Apply grease or hydraulic oil on O-ring and O-ring seat on the housing side. (2) Turn locknut so that it moves up against the body of the fitting. Move the backup washer and O-ring up against the locknut. (3) Tighten the fitting by hand. Once O-ring is placed in the correct position of housing and the backup washer comes in contact with the surface of housing, turn it back to adjust the mounting direction. Do not loosen the body fitting more than one turn. (4) Tighten the locknut to the specified torque.
1)
1 3 5
4 6 502164
1. End of fitting body (for hose connection) 2. Fitting body 3. Locknut 4. O-ring seat
11-56
2
5. O-ring 6. Threaded portion to the housing 1) Shape varies by fitting type
CHAPTER 11 MAST AND FORKS 2.18 Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck Preparation (1) Disconnect the lift bracket assembly from the mast. (2) Disconnect the pipes from the first and the second lift cylinders. Removing first lift cylinders (1) Attach a sling on the first lift cylinder, and suspend it with a hoist.Tie the sling securely to the first lift cylinder to prevent the cylinder from slipping. (2) Remove the mounting bolts and slowly remove the first lift cylinder using a hoist.
502214
Place the inner mast lower than the outer mast.
1
(1) Lift the front side of the lift truck by 15 to 20 cm (5.9 to 7.87 in.) and place wood blocks underneath. Keep the front side of the lift truck off the ground in preparation to lower the inner mast with a hoist. (2) Remove the set bolts located on the top of the second lift cylinders. Attach a sling on the inner mast, and lift the inner mast with a hoist to separate the second lift cylinder piston rods from the inner mast.
502166 1. Mast strip
(3) Attach a sling on the inner mast, and lift the inner mast with a hoist to separate the second lift cylinder piston rods from the inner mast. Pull out the second lift cylinders from the mounting seats at the bottom of the outer mast. Tilt the cylinder tops inward until they rest on the outer mast crossmember. Using a rope, fix the cylinders onto the crossmember. (4) Using the hoist, slowly lower the inner mast until the inner mast contacts the second lift cylinders. (5) The main rollers of the inner and outer masts can now be removed. Before attempting to remove the main rollers, remove the mast strips and shims first as they tend to drop easily. (6) Adjust the number of shims for the main rollers and the mast strips as required. Note: To assemble, follow the disassembly sequence in reverse.
502168
11-57
CHAPTER 11 MAST AND FORKS 2.19 Inspection and Adjustment This section covers the inspection/adjustment that does not involve removal or disassembly. Conduct this inspection and adjustment whenever a defect is suspected.
2.20 Inspecting Forks (1) Check the forks for cracks or damage. Special attention should be given to the heel section 1) as well as all weld areas 2). Do not use a fork that has cracks. Magnetic particle inspection which features subsurface detection capability is recommended to check the root of the forks because most of the load weight rests on the root. Liquid penetration inspection is also recommended, however, it is less effective unless the paint on the inspection area is removed.
1)
2)
502169
(2) Check both forks for height 3) difference between the forktips and for any differences in shape. A slight difference between forktips may cause difficulty in inserting the forks into a pallet, which results in load imbalance. The maximum allowable difference in fork tip elevation 3) is 5 mm (0.2 in.) for pallet forks. Replace both forks when the difference in forktip height exceeds the maximum allowable difference.
3)
502170
(3) Check fork blade thickness 4). If thickness 4) is worn down and exceeds the service limit, do not use.
4)
502171
Item Fork thickness
11-58
Standard Limit
3.5 to 4.5C ton
4.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (2 in.)
60 mm (2.4 in.)
65 mm (2.56 in.)
45 mm (1.77 in.)
51 mm (2.00 in.)
58 mm (2.28 in.)
CHAPTER 11 MAST AND FORKS 2.21 Inspecting and Adjusting Chain Tension R CAUTION -
BE SURE to turn the key switch to the OFF position before inspecting or adjusting lift chains, anchor bolts and nuts in order to prevent serious injury or death caused by a sudden movement of the mast and the lift bracket. BE SURE to place wood blocks under the forks in order to prevent serous injury or death caused by a sudden movement of the forks when they are raised.
Chain tension inspection and adjustment (1) Lower the forks to the ground. Tilt the mast FORWARD to create the slack in the chain. (2) Turn the engine OFF. (3) Loosen the lower nut. Move the upper nut upward. (4) Adjust the chain tension by turning the lower nut. (5) Park the lift truck on level ground and place the mast in a VERTICAL position. Then lower the forks to the ground. Make sure that the lift cylinders are fully retracted. 502215
(6) Raise the forks approximately 100 mm (3.94 in.) off the ground. (7) Turn the key switch to the OFF position. (8) Place wood blocks with the height of approximately 90 mm (3.54 in.) under forks. (9) Push both chains at the midpoint between the chain wheel and the fixed chain end on the lift bracket. Make sure the tension in the right and left chains are the same. If the tension is uneven, adjust the chain tension.
2 1
3 1. Lower nut 2. Upper nut
Item Double nut (upper and lower)
505789
3. Anchor bolt
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
4.5C to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
11-59
CHAPTER 11 MAST AND FORKS R CAUTION After adjustment, raise and lower the lift bracket several times. With the mast being tilted BACKWARD and fully retracted, check the position of the lift bracket lower roller. The protrusion of each lower roller must not exceed 40% of the roller diameter from the bottom of inner mast. If it exceeds 40%, elongation of chains is suspected.
2 1
1) 1. Lift bracket lower roller 2. Inner mast
502174
1) 40% or less of roller diameter
Tightening nuts after adjustment (1) Hold the anchor bolt with a spanner wrench, secure the bolt and lower the clip to the anchor. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
2.22 Checking Chain Elongation (1) Pull the chains taut by weighing a load close to the maximum load evenly on both forks. (2) Measure 20 links of chain length. If the length exceeds the limit, replace the chain with a new one.
1) 2)
505791 1) Link
Item Chain length (20 links)
11-60
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 5.5 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
2) 20 links
CHAPTER 11 MAST AND FORKS 2.23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast Measuring back-to-front clearance on lift bracket main rollers
1)
(1) Slightly lift the forks off the ground. (2) Insert a claw bar between the upper part of the lift bracket and the inner mast, push the inner mast to either side. Measure the clearance between the main roller and the inner mast on the opposite side with a feeler gauge. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-44 "Assembly Sequence of Lift Bracket Roller". Item 1)
1)
502176
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on lift bracket main rollers and side rollers
R CAUTION Place wood blocks under the lift bracket to prevent it from falling. (1) Raise the lift bracket to the inner mast uppermost position. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go over to the opposite side of the mast, and slide the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a claw bar between the inner mast and lift bracket on the dial indicator side, and push the lift bracket to the opposite side. 502177
11-61
CHAPTER 11 MAST AND FORKS (5) Measure the clearance between the lift bracket middle roller and the thrust plate. Adjust the number of shims as required. Note: The upper rollers do not require any measurement and adjustment.
1
1 1)
For adjustment, see 11-45 "Adjusting Lift Bracket Clearance".
2
2
502178 1. Upper roller
2. Thrust plate
Item 1)
Standard value
Clearance between middle roller side face and inner mast thrust plate
0.1 to 0.5 mm (0.004 to 0.020 in.)
(6) Lower the lift bracket slightly from the top so that the side roller comes in contact with the inner mast. Measure the clearance between the side roller and the inner mast. Adjust the number of shims as required. For adjustment, see 11-45 "Adjusting Lift Bracket Clearance".
2) 1
1
502179 1. Side roller
Item 2)
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
(7) Raise the lift bracket to the top of the inner mast, and measure the clearance between the lower roller and inner mast. Adjust the number of shims as required. For adjustment, see 11-45 "Adjusting Lift Bracket Clearance".
1 3) 1. Lower roller
Item 3)
11-62
Clearance between lower roller side face and inner mast thrust face
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502180
CHAPTER 11 MAST AND FORKS 2.24 Adjusting Mast Roller Clearance Measuring back-to-front clearance on mast main rollers (1) Tilt the mast fully BACKWARD. (2) Measure the clearance between the inner mast lower roller and the outer mast's rolling contact face. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-49 "Installing Outer/Inner Mast Rollers".
1)
502181
Item 1)
Standard value
Clearance between main roller rolling face and mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on inner mast main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the inner mast to prevent it from falling. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the inner mast roller against the outer mast's rolling surface. Then go over to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502182
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-49 "Installing Outer/Inner Mast Rollers".
1) Item 1)
Clearance between main roller side face and mast
502183
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-63
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on outer mast main rollers
R CAUTION Place wood blocks under the outer mast to prevent it from falling. (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the outer mast with its contact point rested on the inner mast. (3) Using a claw bar, push the outer main roller against the inner mast's rolling surface. Then go over to the opposite side of the mast and set the dial indicator to zero. (4) Insert a claw bar between the outer mast and the inner mast on the dial indicator side, and push the inner mast to the opposite side.
1)
502184
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-49 "Installing Outer/Inner Mast Rollers".
1)
502185
Item 1)
11-64
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
CHAPTER 11 MAST AND FORKS 2.25 Inspecting and Adjusting Mast Strip Clearance (1) Measure the clearance with the clearance between the outer mast rollers and the inner mast rolling face adjusted to 0 mm (0 in.) at the maximum lift position. (2) If mast strip clearance deviates from the specified value, adjust the clearance with shims. For adjustment, see 11-50 "Installing Mast Strips".
1)
502186
Item 1)
Standard value
Clearance between mast and mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
(3) After all clearances are adjusted, move the mast and lift bracket slowly, and check whether the full stroke movement is smooth.
2.26 Adjusting Mast Tilt Angle (1) Adjust the tire air pressure and park the lift truck on level ground. (2) Tilt the mast fully BACKWARD and turn the engine OFF. (3) Measure the backward tilt angle of the right and left masts. (4) Adjust the cylinder stroke by loosening the tilt cylinder socket bolt 1 and then turn the tilt cylinder rod so that the backward tilt angle of the mast on each side is the same. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Slowly tilt the mast BACKWARD, and adjust the rod so that both cylinders simultaneously move into their stroke end positions.
Item
1 505772 1. Socket bolt
Forward tilt angle Backward tilt angle
Standard tilt angle
5°
10 °
(5) After tilt angle adjustment, tighten the tilt cylinder socket bolts to the specified torque. Item
Tightening torque
Tilt cylinder socket bolt
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
11-65
CHAPTER 11 MAST AND FORKS 2.27 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke Inspection (1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. (2) If the top of the inner mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and shaking of the rod with a longer second lift cylinder stroke. 502216
Adjustment (1) Raise the inner mast, place wood blocks under the right and left sides of the inner mast, and lower the mast until it rests on the wood blocks. (2) Remove the set bolt at the top of second lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of piston rod end. Note: When retracting the piston rod, push the lift lever to lowering direction to release the hydraulic oil from the second lift cylinders. 501408
(3) Raise the piston rod, and tighten the second lift cylinder set bolt. Remove the wood blocks under the inner mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the inner mast to the bottom. Also check that the left and right lift cylinders come to the end of stroke simultaneously at the maximum lift position of the inner mast.
1 2 4
3 502217 1. Set bolt 2. Inner mast
11-66
3. Cylinder bracket 4. Shim
CHAPTER 11 MAST AND FORKS 2.28 Troubleshooting Condition
Possible cause
Action
Clearance between lift rollers and side rollers is incorrect
Adjust forward/backward and right/ left clearances
Defective roller rotation
Lubricate side rollers and replace other rollers
Incorrect clearance on mast strip
Adjust using shims
Excessive clearance on side roller
Increase shim stack thickness
Uneven tension between chains on right and left side
Adjust chain tension
Shim adjustments are unequal between left and right lift cylinders (at the maximum height)
Adjust shim stack thickness
Defective roller rotation
Adjust or replace rollers after inspection
Lift cylinder packing is damaged
Replace
Sliding (inside) surface of lift cylinder tube is damaged
Replace
Whole mast shakes
Mast support bushing is worn out
Retighten or replace bushing
Mast is distorted
Off-center load or overload
Replace mast assembly
Lift bracket and inner mast do not move smoothly
Lift bracket or inner mast is tilted
Mast makes noise Drift (natural descent) of lift cylinders
Distortion of finger bar Forktips are different in height
Distortion of forks
Repair or replace
Uneven loading
11-67
CHAPTER 11 MAST AND FORKS 2.29 Service Data Item
3.5 to 4.0 ton
4.5C to 5.5 ton
Standard
508 mm (20.00 in.)
635 mm (25.00 in.)
Limit
523 mm (20.59 in.)
654 mm (25.75 in.)
S
Standard
117 mm (4.60 in.)
129 mm (5.08 in.)
M
Standard
118 mm (4.65 in.)
130 mm (5.12 in.)
L
Standard
119 mm (4.69 in.)
131 mm (5.16 in.)
LL
Standard
120 mm (4.72 in.)
132 mm (5.20 in.)
Chain length (20 links)
Main roller outside diameter
Side roller external diameter
Standard
52 mm (2.05 in.) 680 mm(26.77 in.)
1
Width of outer mast
Standard
2
Width of inner mast
Standard
566 mm (22.28 in.)
556 mm (21.89 in.)
3
Width of lift bracket
Standard
434 mm (17.09 in.)
422 mm (16.61 in.)
4
Clearance between main roller rolling face and mast
Standard
1 mm (0.04 in.) or less
5
Clearance between main roller side face and mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
6
Clearance between mast and mast strip
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
4
Clearance between main roller rolling face and inner mast
Standard
1 mm (0.04 in.) or less
5
Clearance between middle roller side Standard face and inner mast thrust plate
0.1 to 0.5 mm (0.004 to 0.020 in.)
5
Clearance between lower roller side face and inner mast thrust face
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
7
Clearance between side roller rolling face and inner mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
Distortion of finger bar
Standard
5 mm (0.2 in.) or less
Mast support bolt
Tightening torque
290 N·m (29.6 kgf·m) [213.89lbf·ft]
Tilt cylinder socket bolt
Tightening torque
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
Lift chain nut (single)
Tightening torque
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
290 N·m (29.6 kgf·m) [213.89lbf·ft]
Lift chain nut (double)
Tightening torque
-
290 N·m (29.6 kgf·m) [213.89lbf·ft]
Duplex mast size (reference)
Mast
Lift bracket
11-68
CHAPTER 11 MAST AND FORKS
4
6
5
5 4
7
4 5
5
2 3
1 502190
Note: The mast is slightly wider at the lower side than at the upper side. Always measure the clearance at the upper side of the mast.
11-69
CHAPTER 11 MAST AND FORKS
3.
Triplex Mast
3.1
Mast System
The following table shows a combination of truck and mast models. Truck models
Mast
3.5 to 4.0 ton
C40A cc
4.5C ton
C45A cc
4.5 to 5.5 ton
C55A cc
6.0 to 7.0 ton
C70A cc
Note: cc represents maximum lift height. Example: 30 = 3,000 mm (157.5 in.) lift height Mast type and code Code
Mast
C
Triplex mast
Mast serial number location
505792
How to read mast model code
C
40
A
40 4 3 2 1 505793
1. 2.
Indicates the mast type Applicable truck class (example: 4.0 ton)
11-70
3. 4.
Mast generation (A6B6C···Z) Maximum lifting height (40: 4000 mm [157.48 in.])
CHAPTER 11 MAST AND FORKS 3.2
Structure and Functions C
C
6 3 2 1
7 8 5 B
A
4
B
9
A
11
15
16 17 18 Section A-A 1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
13 Section B-B 2)
Outer mast Middle mast Inner mast Lift bracket First lift cylinder Second lift cylinder Lift chain load backrest extension Forks Side roller Mast strip Lift bracket upper roller
12
14 Section C-C 3) 13. 14. 15. 16. 17. 18. 1) 2) 3) 4)
10 4
Side roller detail 4)
505794
Outer mast main roller Middle mast upper roller Lift bracket middle roller Lift bracket lower roller Inner mast main roller Middle mast lower roller Detail of lift bracket, middle mast lower rollers and inner mast main rollers Detail of lift bracket middle rollers Detail of outer mast main rollers and middle mast upper rollers Detail of side roller
Note: For hydraulic lines, see 11-89 "Installing Hydraulic Lines".
11-71
CHAPTER 11 MAST AND FORKS The triplex mast features both triple mast mechanism and full-free mast mechanism. The mast assembly consists of inner mast, middle mast, outer mast, lift bracket, first lift cylinder and second lift cylinder. The first lift cylinder raises the forks. The second cylinder extends the three-stage mast and raises the forks. The first lift cylinder is the internal drain type, and the second lift cylinder is equipped with cushion mechanism and has an internal drain. Therefore, the lift cylinder has no return hose. For mast operation, see 11-72 "Mast operation". Mast operation The first cylinder extends to raise the forks to the maximum free-lift height. When the first lift cylinder rod is fully extended, the second lift cylinder takes over the role to raise the middle mast, and also raise the forks, inner mast, and first lift cylinder as a unit using the second lift chain. The mast lowering mechanism is the reverse of lifting. See “HYDRAULIC SYSTEM”. Maximum free lift Maximum free lift means the maximum elevation of the forks without raising the mast.
3 5 1 6 4
2 4) 1) 1. 2. 3. 4. 5. 6. 7.
First lift cylinder Second lift cylinder First lift chain Second lift chain Inner mast Middle mast Outer mast
11-72
7 2) 1) 2) 3) 4)
3) Forks on the ground Maximum free lift Maximum lift Free lift height
502219
CHAPTER 11 MAST AND FORKS 3.3
Removal Sequence of Mast and Lift Bracket Assembly
For mast roller replacement without removing the mast from the lift truck, see 11-91 "Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck" .
3
4
1
7
5
6
2 505771
1. 2. 3. 4.
3.4
Nut Fork, Lift bracket assembly Tilt socket pin, Collar, Washer, Bolt Low-pressure hose
5. 6. 7.
High-pressure hose for lift cylinders Mast support cap Mast support bushing
Suggestions for Removing Mast and Lift Bracket Assembly
Removing lift bracket assembly (1) Tilt the mast FORWARD and lower the inner mast to the bottom so that the lift chain is slack. Then remove nuts 1 from the lift chains. (2) Tilt the mast BACKWARD to the VERTICAL position and lift the inner mast until the lift bracket becomes free. Then, slowly move the lift truck away from the lift bracket. Note: Before overhauling the mast assembly, BE SURE to measure the clearance between the mast and the rollers. This helps to improve work efficiency by understanding which roller is to be replaced or the necessity of shim adjustment. See 11-98 "Adjusting Mast Roller Clearance".
1 2 502221
R CAUTION After the lift bracket is removed from the lift truck, place wood blocks under the lift bracket to prevent it from falling down.
11-73
CHAPTER 11 MAST AND FORKS Position the mast VERTICALLY. Raise the inner mast until main rollers 8 of the lift bracket become free. Then, slowly move the vehicle in reverse to separate from lift bracket 2.
8 2 505796
Separating tilt cylinders (1) Attach a sling on the crossmember at the top of the outer mast, then lift the outer mast with a hoist.
505797
R CAUTION When removing and installing the mast assembly with a hoist, BE SURE to use a hoist with enough lift capacity. (2) Place wooden blocks under the tilt cylinder mounting section and remove the tilt socket pins 1, and separate the mast from the tilt cylinders. (3) Start the engine, and pull back on the tilt lever to retract the tilt cylinder rods.
1
505798
R CAUTION -
DO NOT touch any levers except the tilt lever while the engine is running. DO NOT loosen the tilt socket bolts except when disassembling the tilt cylinder.
Removing mast support caps (1) Put a matchmark on each cap. (2) Remove cap mounting bolts from the mast and disconnect the mast assembly from the lift truck by hoisting. Lay the mast assembly horizontally on level ground with the lift bracket side facing up. Note: Lay the mast assembly in a space large enough for disassembly work.
1) 505799 1) Matchmark
11-74
CHAPTER 11 MAST AND FORKS 3.5
Suggestions for Installing Mast and Lift Bracket Assembly
For installation, follow the removal sequence in reverse and observe the instructions below: Mast support (1) Apply a thick coat of grease on the inner surface of the caps and the mast support bushings. (2) Install the mast supports in the same direction as they were removed. (3) For greasing, place wood blocks under the mast so that the mast is off the ground. (4) Tighten the mast support bolts to the specified torque.
1 2
1) 2) 1. Bushing 2. Cap
Item
505774
1) Bushing internal view 2) Cap internal view
Tightening torque 3.5 to 5.5 ton
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
6.0 to 7.0 ton
490 N·m (49.7 kgf·m) [361.40 lbf·ft]
Mast support bolt
Adjusting chain tension For chain tension adjustment, see 11-94 "Inspecting and Adjusting Chain Tension". Bleeding lift cylinders Move the lift bracket up and down several times to bleed air trapped in the piston end of the lift cylinder. After the proper operation of the lift truck is confirmed, check the oil level in the hydraulic tank.
11-75
CHAPTER 11 MAST AND FORKS 3.6
Removal Sequence of Mast and Lift Bracket
18
17
11 24
1
9
27
29 12 7
8
5 4
6
25 12
3
7
27
23
1
26 21
14 8
1
28 2 13
10 22 31
28 16
13
19
15
20
19 19
21
30 505800
1. First lift cylinder hose, Clamp, Bolt 2. Bolt, Washer 3. Shim 4. First lift cylinder 5. Bolt, Washer 6. Chain wheel support 7. Chain guard, Plug 8. Snapring, Chain wheel 9. Pulley bracket, Pulley, Bar, Bolt 10. Nut (for second lift cylinder chain) 11. Mast strip, Shims 12. Main roller, Shims 13. Main roller, Shims 14. Inner mast 15. Nut Note: The lift bracket disassembly procedure is the same as that of the simplex mast.
3.7
23. 24. 25. 26. 27. 28. 29. 30. 31.
Lift chain (for second lift cylinder) Chain guard, Bolt Snapring, Chain wheel Hose Joint, Connector, Bolt, Washer Hose, Clamp Cylinder clamps, Seats, Shims, Cushion, Collar, Clamp bolt Cushion, Shims, Bracket Set bolt, Washer, Shim Second lift cylinder Mast strip, Shims Main roller, Shims Main roller, Shims Middle mast Cap, Bolt, Washer Outer mast, Grease nipple
Preparation for Disassembling Mast and Lift Bracket
Lay the mast assembly horizontally on wood blocks with the lift bracket side facing up. Place a wood block so that it stops the inner and middle masts from falling down. Before disassembly, measure and record all clearances between each of the rollers and the lift bracket and between the main rollers and the mast. Recorded measurements will be helpful when replacing rollers or selecting shims to adjust clearances. See 11-98 "Adjusting Mast Roller Clearance".
11-76
16. 17. 18. 19. 20. 21. 22.
CHAPTER 11 MAST AND FORKS 3.8
Suggestions for Disassembling Mast and Lift Bracket
Removing first lift cylinders
4
(1) Remove the first lift cylinder 4 mounting bolt. (2) Tie two slings securely to the first lift cylinder 4, and gently lift the cylinder.
505801
14
Removing main rollers and mast strips Lower inner mast 14 until main rollers can be removed. Remove the middle mast rollers 12, 13, and mast strips 11.
13 11
12
505802
Removing inner mast Using a sling, slightly lift the inner mast 14 to clear the middle mast roller shafts, and separate the inner mast 14 from the middle mast.
14
505803
29
Removing main rollers and mast strips (outer race) Remove the set bolts from the top of the second lift cylinder rods 25. Then place the cylinder rod ends on the outer mast 31. Lower middle mast 29 until main rollers 28 can be removed. Then remove main rollers and mast strips from the outer mast.
28
25
31 27
505804
11-77
CHAPTER 11 MAST AND FORKS 3.9
Inspecting Mast and Lift Bracket
Mast (1) Check each roller for binding, wear, and cracks. (2) Check each roller on rolling surface for pitting or other defects. (3) Make sure that rollers rotate smoothly on the rolling face. (4) Check welded joints of mast member, crossmembers, shafts, supports, and tilt brackets for cracks. (5) Check the mast support bushings for wear or other defects. 505805
Lift bracket (1) Check the main rollers and side rollers for binding, wear, and cracks. (2) Check the welded areas of lift bracket for cracks. (3) Check the finger bar for bend or distortion.
1 505806 1. Straightedge
Item Distortion of finger bar
Standard value 5 mm (0.20 in.) or less
Lift chains, chain wheels and chain wheel supports (1) Measure the length of each chain to make sure that the two chains are equal in length. Also check the chains for wear, indication of breakage, link binding, and twisting. (2) Check each chain anchor bolt for cracks or thread damage. (3) Check the chain wheel support and the chain wheel for cracks, wear, and binding. (4) Measure chain length to check for elongation. See 1195 "Checking Chain Elongation". Item Chain length (20 links)
Standard value
Limit value
3.5 to 4.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
4.5C to 7.0 ton
635 mm (25.00 in.)
654 mm (25.75 in.)
Mast strip Check for damage, scoring, or distortion. See “HYDRAULIC SYSTEM”.
11-78
CHAPTER 11 MAST AND FORKS 3.10 Assembly Sequence of Lift Bracket Roller
1
2
1
6 1)
2
6)
1)
1
9)
3 6
8)
8)
2)
10) 5)
5)
5 3 6)
6 1)
1
3)
4
1
5
5) 4)
6) 5) 1. 2. 3. 4. 5. 6.
4
Lift bracket Lift bracket upper roller Lift bracket middle roller Lift bracket lower roller Side roller Inner mast
7)
6) 1)
505807
Clearance between main roller rolling face and mast 2) Clearance between middle roller side face and mast thrust plate 3) Clearance between lower roller side face and mast thrust face 4) Clearance between side roller rolling face and mast 5) Shim (a) 6) Shim (b) 7) Shim (c) 8) Thrust plate 9) No shim required 10) Minimum clearance
inner inner inner inner
11-79
CHAPTER 11 MAST AND FORKS 3.11 Adjusting Lift Bracket Clearance The lift bracket has three main roller bearings on one side and side rollers on both sides as shown in the illustration. The clearances are necessary so that the lift bracket can move up and down smoothly along the inner mast. Clearances between middle roller side face and thrust plate and between lower roller side face and inner mast The clearance between the side roller face and the inner mast thrust face (right-to-left clearance): Clearance 2) is used to determine the correct amount of shims at the bearing seat. Move the lift bracket to the top of the inner mast and slide the lift bracket to either the left-most or the right-most position. Measure the clearance 2) between the roller side face and the inner mast thrust face on the opposite side. Note: Shim adjustment for clearance 2) is not required for the lift bracket upper rollers. Adjust clearance G to the specified values with shims (a) and (b) for the middle and the lower rollers. Item
Standard value
Clearance between middle roller side face and inner mast thrust plate Clearance between lower roller side face and inner mast thrust face
0.1 to 0.5 mm (0.004 to 0.020 in.)
Clearance between main roller rolling face and inner mast Clearance between roller circumference and inner mast thrust face (back-to-front play): Clearance 1) is used for determining the proper size of the rollers. Select a roller of correct diameter so that the clearance meets the specified value. Check that the rollers rotate smoothly when installed. Item Clearance between main roller rolling face and inner mast
11-80
Standard value 1 mm (0.04 in.) or less
CHAPTER 11 MAST AND FORKS Clearance between side roller rolling face and inner mast To determine the clearance between side roller circumference and inner mast side roller thrust face: Move the side roller to the upper end of the inner mast and slide the lift bracket to either the left-most or right-most position. Measure G1 clearance between the roller circumference and inner mast on the opposite side. Adjust the number of shims (c) so that the clearance meets the specified value. Item
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
Selecting roller of correct outer diameter Measure the clearance between the upper and lower rollers' rolling faces and the mast. If the measured clearances do not meet the standard value shown in the table replace the roller with a roller of the correct diameter. Use the same sized roller for the upper and the lower rollers and use one size smaller for the middle rollers. Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". Make sure that the rollers rotate smoothly when installed. Specifications Item
Roller size (external diameter)
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
11-81
CHAPTER 11 MAST AND FORKS Adjusting clearance between middle roller side face and thrust plate
1
2
Note: The following adjustment is not required for the upper rollers.
4
2)
Measure the clearance between middle roller side face and thrust plate. If the measured clearance does not meet the standard value, adjust the clearance as follows:
3)
3
Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) 1. 2. 3. 4.
1
2)
Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast".
11-82
1)
2
Measure the clearance between the lower roller side face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows:
(1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
1) Clearance between middle roller side face and inner mast thrust plate 2) Shim (a) 3) Shim (b)
Inner mast Lift bracket Thrust plate Roller stopper
Clearance between lower roller side face and inner mast thrust face
502152
3) 503981 1. Inner mast 2. Lift bracket
1) Clearance between lower roller side face and inner mast thrust face 2) Shim (a) 3) Shim (b)
CHAPTER 11 MAST AND FORKS Installing rollers To install main rollers on shafts, use a driving tool, and be careful not to strike the outer roller surface. The side of the roller with larger chamfering must face toward the outside. Make sure the rollers rotate smoothly when installed.
502154
Adjusting the clearance between side roller rolling face and inner mast
3
1
2
Measure the clearance between side roller rolling face and inner mast. If the measured clearance does not meet the standard value, adjust the clearance as follows: Note: For clearance measurement, see 11-96 "Adjusting Clearance Between Lift Bracket Roller and Inner Mast"
4 1)
(1) If the clearance is too large, increase the number of shims (c) as required. Shim (c) is available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.)
2) 1. 2. 3. 4.
Side roller Inner mast Lift bracket Roller mounting bolt
505788 5. Lift bracket 1) Clearance between side roller rolling face and inner mast 2) Shim (c)
11-83
CHAPTER 11 MAST AND FORKS 3.12 Installing Outer/Inner Mast Rollers Mast rollers have the same shape and size as the lift bracket middle roller and the lower roller, and the mast rollers have the same standard value for clearances between the rollers and the masts.
2)
2)
6
1)
1) 4
4 3
2
1)
2)
1
2)
1) 4
7 4 5 1. 2. 3. 4. 5.
6. Mast upper side 7. Mast lower side 1) Clearance between main roller rolling face and mast 2) Clearance between main roller side face and mast
Outer mast Middle mast Inner mast Shim (a) Lift bracket
Item
Standard value
1)
Clearance between main roller rolling face and mast
2)
Clearance between main roller side face and mast
1 mm (0.04 in.) or less 0.1 to 0.5 mm (0.004 to 0.02 in.)
Measuring the clearance between main roller rolling face and mast If the measured clearances does not meet the standard value given in the table below, replace the roller with a roller of the correct diameter. Note: For measurement, see 11-98 "Adjusting Mast Roller Clearance". Specifications Item
Roller size (external diameter)
11-84
502231
3.5 to 4.0 ton
4.5C to 5.5 ton
6.0 to 7.0 ton
S
117 mm (4.61 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
CHAPTER 11 MAST AND FORKS Installing rollers Installation of the mast rollers is exactly the same as for the lift bracket rollers. See 11-79 "Assembly Sequence of Lift Bracket Roller". Measuring the clearance between main roller rolling face and mast If measured clearance is larger than the standard value, adjust the clearance by increasing the number of shims (a) and shims (b) under the roller seats. Note: For measurement, see 11-98 "Adjusting Mast Roller Clearance". (1) If clearance is too large, increase the number of shims (a) as required. (2) Increase the same thickness for shims (b) as shims (a). (3) Shims (a) are available in two thicknesses: 0.5 and 1 mm (0.02 and 0.04 in.) and shim (b) is available in only 1 mm (0.04 in.) thickness. (4) If a 0.5 mm (0.02 in.) thick shim (a) is used, a thickness adjustment using shim (b) is unnecessary.
3.13 Installing Mast Strips Adjusting the clearance between mast and mast strip Measure the clearance by inserting a feeler gauge between mast and mast strip. Adjust the number of shims (d) so that the clearance is within the range of 0.1 to 0.5 mm (0.004 to 0.02 in.).
2
5 1)
4 5
3
1 3 1. Mast strip 2. Inner mast 3. Middle mast
Item 1)
Clearance between mast and mast strip
4
5
502232
4. Outer mast 5. Shim (d) 1) Clearance between mast and mast strip
Standard value 0.1 to 0.5 mm (0.004 to 0.02 in.)
(1) If the clearance is too large, increase the number of shims (c) as required. (2) After the shim adjustment, slowly move the lift bracket up and down to check for the smooth movement.
11-85
CHAPTER 11 MAST AND FORKS 3.14 Installing Second Lift Cylinder (1) Install the cylinder brackets on the second lift cylinders. (2) Install the second lift cylinders between the outer and inner masts. (3) Install the lift cylinder rods on the middle mast as shown in the illustration on the right. Do not forget to install shims if they were installed. Normally shims are not installed. Note: BE SURE to tighten the set bolt securely on the cylinder rod.
2
1
3
505808 1. Middle mast 2. Set bolt
3. Shim
(4) Install each second lift cylinder on the mounting hole of the outer mast by aligning the cylinder end with the springpin.
1
502158
1. Springpin
(5) Measure the clearance after fully retracting the cylinder rods and placing the cylinders vertically. Add or remove shims (m) so that the clearance is 1.6 mm (0.063 in.) or less. If the clearance is too large, increase the number of shims (m). Normally shims are not installed. If the clearance is 3.2 mm (0.126 in.) or more, BE SURE to insert a 3.2 mm (0.126 in.) thick seat in the shim pack.
1 2
1 1) 1. Seat 2. Shim (m)
Item 1)
Clearance between cylinder bracket and seat
Standard value 1.6 mm (0.063 in.) or less
(6) After assembly, check both lift cylinders for smooth stroke movement, and adjust the stroke as required. See 11-103 "Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke".
11-86
502233
1) Clearance between cylinder bracket and seat
CHAPTER 11 MAST AND FORKS 3.15 Installing First Lift Cylinder (1) With the mast positioned VERTICALLY and fully lowered, temporarily install the first lift cylinder to the inner mast with the original shims and mounting bolts. (2) Position the first lift cylinder vertically and measure the clearance between the cylinder brackets and the cylinder mounts on the inner mast. If there is clearance, remove the clearance by adding shims. - To check whether both sides of the cylinder (right-toleft) are vertical against each other, measure to check if the cylinder is parallel to the side face of the inner mast. The parallel difference at the top and the bottom should be plus or minus 1 mm (0.04 in.) - To check whether both sides of the cylinder (front-toback) are vertical against each other, visually check if the cylinder is parallel to the front face of the inner mast. The cylinder should not be inclined FORWARD, not even slightly. The cylinder slightly inclined BACKWARD is acceptable. - Thickness of each adjusting shim is 1 mm (0.04 in.). (3) After shim adjustment, tighten the mounting bolts.
3
2 1 502209 1. First lift cylinder 2. Shim (n)
Item
Tightening torque
First lift cylinder mounting bolt
145 ± 15 N·m (14.8 ± 1.5 kgf·m) [106.94 ± 11.06 lbf·ft]
3. Mounting bolt
11-87
CHAPTER 11 MAST AND FORKS 3.16 Connecting Chains Assemble each chain on the lift bracket. For assembly, see 11-53 "Connecting Chains". After assembly is completed, maintain clearance between chains with locknuts in order to allow for chain tension.
505810
Ref.
Item
1
Locknut (upper)
2
Locknut (upper)
3
Locknut (lower)
4
Locknut (upper)
3.5 to 4.0 ton
4.5C ton
4.5 to 7.0 ton
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft] 210 N·m (21.4 kgf·m) [154.89 lbf·ft]
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
385 ± 39 N·m (39.3 ± 3.9 kgf·m) [289.96 ± 28.8 lbf·ft] 290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
7
4 1)
2 6
1)
8
2) 1
3
5
505809
1. 2. 3. 4. 5.
Locknut (upper) Locknut (upper) Locknut (lower) Locknut (upper) Inner mast
11-88
6. 7. 8. 1) 2)
First lift cylinder Middle mast chain wheel Outer mast 25 mm (0.98 in.) or more 5 mm (0.20 in.)
CHAPTER 11 MAST AND FORKS 3.17 Installing Hydraulic Lines General precautions -
Use care not to let abrasive dust or dirt to enter the hydraulic system during installation. Apply hydraulic oil on O-rings before installation. When assembling an elbow connector 6 (connection with straight thread and O-ring), follow the instructions in the “Installation using straight thread and O-ring” on the next page.
-
1
1) 2)
1
5
2) 6 6 3
2 3) 4 3
1) 2)
First lift cylinder Second lift cylinder Item
3)
505811
Down safety valve
Tightening torque
1
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
2
Nut
118 ± 11.8 N·m (12.03 ± 1.2 kgf·m) [87.03 ± 8.70 lbf·ft]
3
Nut
4
Nut
5
Nut
6
Nut
58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.37 ± 4.35 lbf·ft]
11-89
CHAPTER 11 MAST AND FORKS Installation using straight thread and O-ring (1) Apply grease or hydraulic oil on O-ring and O-ring seat on the housing side. (2) Turn locknut so that it moves up against the body of the fitting. Move the backup washer and O-ring up against the locknut. (3) Tighten the fitting by hand. Once the O-ring is placed in the correct position of housing and the backup washer comes in contact with the surface of housing, turn it back to adjust the mounting direction. Do not loosen the body fitting more than one turn. (4) Tighten the locknut to the specified torque.
1)
1 3 5
4 6 502164
1. End of fitting body (for hose connection) 2. Fitting body 3. Locknut 4. O-ring seat
11-90
2
5. O-ring 6. Threaded portion to the housing 1) Shape varies by fitting type
CHAPTER 11 MAST AND FORKS 3.18 Removing and Installing Mast Rollers and Strips Without Removing Mast From Lift Truck Preparation (1) Disconnect the lift bracket assembly from the mast. (2) Disconnect the pipes from the first and the second lift cylinders. Removing first lift cylinders (1) Attach a sling on the first lift cylinder 1, and suspend it with a hoist. Tie the sling securely on the first lift cylinder to prevent the cylinder from slipping. (2) Remove the mounting bolts and slowly remove the first lift cylinder using a hoist.
1
505812
Removing inner mast main rollers and middle mast upper main rollers
1
(1) Lift the front side of the lift truck by 15 to 20 cm (5.91 to 7.87 in.) and place jack stands underneath. Keep the front side of the lift truck off the ground in preparation to lower the inner mast with a hoist.
502166 1. Mast strip
(2) Attach a sling on the crossmember of the inner mast and suspend the inner mast with a hoist. (3) Remove the chain guard from the second lift chain wheel. (4) Disconnect the second lift chain from the outer mast, and place the chain in front of the inner mast. (5) Lower the inner mast so that the mast rollers can be removed. (6) Support the inner mast with wood blocks. 505813
11-91
CHAPTER 11 MAST AND FORKS (7) The main rollers of the inner mast and upper main rollers of middle mast can now be removed. Before attempting to remove rollers, remove the mast strips and shims from the middle mast as they tend to drop easily. (8) Adjust the number of shims for the main rollers and the mast strips as required.
1 2 3 502239 1. Outer mast 2. Middle mast
3. Inner mast
Removing outer mast main rollers and middle mast lower rollers (1) Lift the inner mast member to the level of middle mast member, and support the inner mast with wood blocks. (2) Lift the middle and the inner masts. (3) Remove the set bolts from the top of the second lift cylinder, and lift the middle and the inner masts.
505814
(4) Remove the cylinder clamp bolts from the second lift cylinder, and secure the cylinder on the outer mast crossmember. (5) Lower the middle and the inner masts until the outer mast main rollers can be removed. (6) Support the middle and inner masts by placing wood blocks underneath. (7) Now that the main rollers of the outer mast and the lower rollers of the middle mast can be removed. Removing mast strips and shims of the outer mast is recommended at this stage because they tend to drop easily. (8) Adjust the number of shims for the main rollers and the mast strips as required.
1 2 3 502241
1. Outer mast 2. Middle mast
Note: To install, follow the removal sequence in reverse.
11-92
3. Inner mast
CHAPTER 11 MAST AND FORKS 3.19 Inspection and Adjustment This section covers the inspection/adjustment that does not involve removal or disassembly. Conduct this inspection and adjustment whenever a defect is suspected.
3.20 Inspecting Forks (1) Check the forks for cracks or damage. Special attention should be given to the heel section 1) as well as all weld areas 2). Do not use a fork that has cracks. Magnetic particle inspection which features subsurface detection capability is recommended to check the root of the forks because most of the load weight rests on the root. Liquid penetration inspection is also recommended, however, it is less effective unless the paint on the inspection area is removed.
1)
2)
502169
(2) Check both forks for height 3) difference between the forktips and for any differences in shape. A slight difference between forktips may cause difficulty in inserting the forks into a pallet, which results in load imbalance. The maximum allowable difference in fork tip elevation 3) is 5 mm (0.2 in.) for pallet forks. Replace both forks when the difference in forktip height exceeds the maximum allowable difference.
3)
502170
(3) Check fork blade thickness 4). If thickness 4) is worn down and exceeds the service limit, do not use.
4)
502171
Item Fork thickness
Standard Limit
3.5 to 4.5C ton
4.5 to 5.5 ton
6.0 to 7.0 ton
50 mm (2 in.)
60 mm (2.4 in.)
65 mm (2.56 in.)
45 mm (1.77 in.)
51 mm (2.00 in.)
58 mm (2.28 in.)
11-93
CHAPTER 11 MAST AND FORKS 3.21 Inspecting and Adjusting Chain Tension R CAUTION -
BE SURE to turn the key switch to the OFF position before inspecting or adjusting lift chains, anchor bolts and nuts in order to prevent serious injury or death caused by a sudden movement of the mast and the lift bracket. BE SURE to place wood blocks under the forks in order to prevent serous injury or death caused by a sudden movement of the forks when they are raised.
Chain tension inspection and adjustment (1) Lower the forks to the ground. Tilt the mast FORWARD to create the slack in the chain. (2) Turn the engine OFF. (3) Loosen the lower nut. Move the upper nut upward. (4) Adjust the chain tension by turning the lower nut. (5) Park the lift truck on level ground and place the mast in a VERTICAL position. Then lower the forks to the ground. Make sure that the lift cylinders are fully retracted. 505810
(6) Raise the forks approximately 100 mm (3.94 in.) off the ground. (7) Turn the key switch to the OFF position. (8) Place wood blocks with the height of approximately 90 mm (3.54 in.) under forks. (9) To check the first lift chain tension, push both chains at the midpoint between the chain wheel and the fixed chain end on the lift bracket. To check the tension of second lift chain, push both chains at the midpoint between the chain wheel and the fixed chain end on the inner mast. Make sure the tension in the right and left chains are the same. If the tension is uneven, adjust the chain tension.
Item
2
1 1. Lower nut 2. Upper nut
Tightening torque 3.5 to 4.0 ton
210 N·m (21.4 kgf·m) [154.89 lbf·ft]
4.5C to 7.0 ton
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft]
Upper nut
11-94
3
3. Anchor bolt
505815
CHAPTER 11 MAST AND FORKS R CAUTION After adjustment, raise and lower the lift bracket several times. With the mast being tilted BACKWARD and fully retracted, check the position of the lift bracket lower roller. The protrusion of each lower roller must not exceed 40% of the roller diameter from the bottom of inner mast. If it exceeds 40%, elongation of chains is suspected.
2
1
1) 505816
1. Lift bracket lower roller 2. Inner mast
1) 40% or less of roller diameter
Tightening nuts after adjustment (1) Hold the anchor bolt with a spanner wrench, secure the bolt and lower the clip on the anchor. (2) Hold the double nut (upper) with a wrench and tighten the double nut (lower) to the specified torque.
3.22 Checking Chain Elongation (1) Pull the chains taut by weighing a load close to the maximum load evenly on both forks. (2) Measure 20 links of chain length. If the length exceeds the limit, replace the chain with a new one.
1) 2)
505817 1) Link
Item
Standard value
Limit value
Chain length 3.5 to 4.0 ton (20 links) 4.5C to 7.0 ton
508 mm (20.00 in.)
523 mm (20.59 in.)
635 mm (25.00 in.)
654 mm (25.75 in.)
2) 20 links
11-95
CHAPTER 11 MAST AND FORKS 3.23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast Measuring back-to-front clearance on lift bracket main rollers
1)
(1) Slightly lift the forks off the ground. (2) Insert a claw bar between the upper part of the lift bracket and the inner mast, push the inner mast to either side. Measure the clearance between the main roller and the inner mast on the opposite side with a feeler gauge. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-79 "Assembly Sequence of Lift Bracket Roller". Item 1)
1)
502176
Standard value
Clearance between main roller rolling face and inner mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on lift bracket main rollers and side rollers
R CAUTION Place wood blocks under the lift bracket to prevent it from falling. (1) Raise the lift bracket to the inner mast uppermost position. (2) Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. (3) Go to the opposite side of the mast, and slide the lift bracket to one side with a bar. Set the indicator to zero. (4) Insert a claw bar between the inner mast and lift bracket on the dial indicator side, and push the lift bracket to the opposite side.
502177
11-96
CHAPTER 11 MAST AND FORKS (5) Measure the clearance between the lift bracket middle roller and the thrust plate. Adjust the number of shims as required. Note: The upper rollers do not require any measurement and adjustment.
1
1 1)
For adjustment, see 11-80 "Adjusting Lift Bracket Clearance".
2
2
502178 1. Upper roller
2. Thrust plate
Item 1)
Standard value
Clearance between middle roller side face and inner mast thrust plate
(6) Lower the lift bracket slightly from the top so that the side roller comes in contact with the inner mast. Measure the clearance between the side roller and the inner mast. Adjust the number of shims as required. For adjustment, see 11-80 "Adjusting Lift Bracket Clearance".
0.1 to 0.5 mm (0.004 to 0.020 in.)
2) 1
1
502179 1. Side roller
Item 2)
Standard value
Clearance between side roller rolling face and inner mast
0.1 to 0.5 mm (0.004 to 0.020 in.)
(7) Raise the lift bracket to the top of the inner mast, and measure the clearance between the lower roller and inner mast. Adjust the number of shims as required. For adjustment, see 11-80 "Adjusting Lift Bracket Clearance".
1 3)
502180
1. Lower roller
Item 3)
Clearance between lower roller side face and inner mast thrust face
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-97
CHAPTER 11 MAST AND FORKS 3.24 Adjusting Mast Roller Clearance Measuring back-to-front clearance on mast main rollers
1)
(1) Tilt the mast fully BACKWARD. (2) Measure the clearance between the inner and middle mast lower roller and the mast rolling surface. (3) If the clearance deviates from the specified value, replace it with a larger size roller. For replacement, see 11-84 "Installing Outer/Inner Mast Rollers".
502243
Item 1)
Standard value
Clearance between main roller rolling face and mast
1 mm (0.04 in.) or less
Measuring right-to-left clearance on inner mast main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the inner mast to prevent it from falling. (2) Set a dial indicator on the inside of the middle mast with its contact point rested on the inner mast. (3) Push the inner mast main roller against the middle mast rolling surface with a claw bar from the opposite side of the dial indicator, and set the dial indicator to zero. (4) Insert a claw bar between the middle mast with dial indicator and the inner mast, and push the middle mast to the opposite side.
1)
502182
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1) Item 1)
11-98
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502245
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on middle mast upper main rollers (1) Raise the mast to the maximum lift position.
R CAUTION Place wood blocks under the middle mast to prevent it from falling. (2) Set a dial indicator on the middle mast with its contact point rested on the inner mast. (3) Push the inner mast main roller against the middle mast rolling surface with a claw bar from the opposite side of the dial indicator, and set the dial indicator to zero. (4) Insert a claw bar between the middle mast with dial indicator and the inner mast, and push the middle mast to the opposite side.
1)
502184
(5) Measure the clearance between the middle mast upper main roller and the inner mast. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1) Item 1)
Clearance between main roller side face and mast
502244
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-99
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on middle mast lower main rollers
R CAUTION Place wood blocks under the middle mast to prevent it from falling. (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the inside of the outer mast with its contact point rested on the middle mast. (3) From opposite side of dial indicator, push the middle mast main roller against the outer mast's rolling surface with a claw bar, and set the dial indicator to zero. (4) Insert a claw bar between the outer mast with the dial indicator and middle mast, and push the middle mast to the opposite side.
1)
502182
(5) Measure the clearance between the middle mast lower main roller and the inner mast. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1) Item 1)
11-100
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
502245
CHAPTER 11 MAST AND FORKS Measuring right-to-left clearance on outer mast main rollers
R CAUTION Place wood blocks under the outer mast to prevent it from falling. (1) Raise the mast to the maximum lift position. (2) Set a dial indicator on the outer mast with its contact point rested on the middle mast. (3) From the opposite side of dial indicator, push the outer mast main roller against the middle mast rolling surface with a claw bar, and set the dial indicator to zero. (4) Insert a claw bar between the outer mast with the dial indicator and middle mast, and push the middle mast to the opposite side.
1)
502184
(5) Measure the clearance between the outer mast and the inner mast main roller. (6) If the clearance deviates from the specified value, increase or decrease shims. For adjustment, see 11-84 "Installing Outer/Inner Mast Rollers".
1)
503983
Item 1)
Clearance between main roller side face and mast
Standard value 0.1 to 0.5 mm (0.004 to 0.020 in.)
11-101
CHAPTER 11 MAST AND FORKS 3.25 Inspecting and Adjusting Mast Strip Clearance (1) Measure the clearance with the clearance between the outer mast rollers and the inner mast rolling face adjusted to 0 mm (0 in.) at the maximum lift position. Measure the clearance between the outer mast main roller and the middle mast rolling surface in a similar manner. (2) If mast strip clearance deviates from the specified value, adjust the clearance with shims. For adjustment, see 11-85 "Installing Mast Strips".
1)
502186
Item 1)
Standard value
Clearance between mast and mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
(3) After all clearances are adjusted, move the mast and lift bracket slowly, and check whether the full stroke movement is smooth.
3.26 Adjusting Mast Tilt Angle (1) Adjust the tire air pressure and park the lift truck on level ground. (2) Tilt the mast fully BACKWARD and turn the engine OFF. (3) Measure the backward tilt angle of the right and left masts. (4) Adjust the cylinder stroke by loosening the tilt cylinder socket bolt 1 and then turn the tilt cylinder rod so that the backward tilt angle of the mast on each side is the same. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Slowly tilt the mast BACKWARD, and adjust the rod so that both cylinders simultaneously move into their stroke end positions.
1 505772 1. Socket bolt
Item
Forward tilt angle
Backward tilt angle
Standard tilt angle
6°
5°
(5) After tilt angle adjustment, tighten the tilt cylinder socket bolts to the specified torque. Item
Tightening torque
Tilt cylinder socket bolt
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
11-102
CHAPTER 11 MAST AND FORKS 3.27 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke Inspection (1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the middle mast reaches its maximum height. (2) If the top of the middle mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and shaking of the rod with a longer second lift cylinder stroke. 502216
Adjustment (1) Raise the middle mast, place wood blocks under the right and left sides of the middle mast, and lower the mast until it rests on the wood blocks. (2) Remove the set bolt at the top of second lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of piston rod end. Note: When retracting the piston rod, push the lift lever to lowering direction to release the hydraulic oil from the second lift cylinders. 501408
(3) Raise the piston rod, and tighten the second lift cylinder set bolt. Remove the wood blocks under the middle mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the middle mast to the bottom. Also check that the left and right lift cylinders come to the end of stroke simultaneously at the maximum lift position of the middle mast.
1
2 3
505808 1. Set bolt 2. Middle mast
3. Shim
11-103
CHAPTER 11 MAST AND FORKS 3.28 Troubleshooting Condition
Possible cause
Action
Clearance between lift rollers and side rollers is incorrect
Adjust forward/backward and right/ left clearances
Defective roller rotation
Lubricate side rollers and replace other rollers
Incorrect clearance on mast strip
Adjust using shims
Excessive clearance on side roller
Increase shim stack thickness
Uneven tension between chains on right and left side
Adjust chain tension
Shim adjustments are unequal between left and right lift cylinders (at the maximum height)
Adjust shim stack thickness
Defective roller rotation
Adjust or replace rollers after inspection
Lift cylinder packing is damaged
Replace
Sliding (inside) surface of lift cylinder tube is damaged
Replace
Whole mast shakes
Mast support bushing is worn out
Retighten or replace bushing
Mast is distorted
Off-center load or overload
Replace mast assembly
Lift bracket and inner mast do not move smoothly
Lift bracket or inner mast is tilted
Mast makes noise Drift (natural descent) of lift cylinders
Distortion of finger bar Forktips are different in height
Distortion of forks Uneven loading
11-104
Repair or replace
CHAPTER 11 MAST AND FORKS 3.29 Service Data Item
3.5 to 4.0 ton
6.0C to 7.0 ton
Standard
508 mm (20.00 in.)
635 mm (25.00 in.)
Limit
523 mm (20.59 in.)
654 mm (25.75 in.)
S
Standard
117 mm (4.60 in.)
129 mm (5.08 in.)
149 mm (5.87 in.)
M
Standard
118 mm (4.65 in.)
130 mm (5.12 in.)
150 mm (5.91 in.)
L
Standard
119 mm (4.69 in.)
131 mm (5.16 in.)
151 mm (5.94 in.)
LL
Standard
120 mm (4.72 in.)
132 mm (5.20 in.)
152 mm (5.98 in.)
Chain length (20 links)
Main roller outside diameter
4.5C to 5.5 ton
Side roller external diameter
Standard
52 mm (2.05 in.)
58 mm (2.28 in.)
780 mm(26.77 in.)
800 mm (31.50 in.)
1
Width of outer mast
Standard
2
Width of middle mast
Standard
666 mm (26.22 in.) 656 mm (25.83 in.) 662 mm (20.06 in.)
3
Width of inner mast
Standard
554 mm (21.81 in.) 536 mm (21.10 in.) 534 mm (21.02 in.)
4
Width of lift bracket
Standard
422 mm (16.61 in.) 402 mm (15.83 in.) 382 mm (15.04 in.)
5
Clearance between main roller rolling face and mast
Standard
1 mm (0.04 in.) or less
6
Clearance between main roller side face and mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
7
Clearance between mast and Standard mast strip
0.1 to 0.5 mm (0.004 to 0.020 in.)
5
Clearance between main roller rolling face and inner mast
Standard
1 mm (0.04 in.) or less
6
Clearance between middle roller side face and inner mast thrust plate
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
6
Clearance between lower roller side face and inner mast thrust face
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
8
Clearance between side roller rolling face and inner mast
Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
Distortion of finger bar
Standard
5 mm (0.2 in.) or less
Mast support bolt
Tightening torque
290 N·m (29.6 kgf·m) [213.89 lbf·ft]
Tilt cylinder socket bolt
Tightening torque
262 ± 13 N·m (26.72 ± 1.33 kgf·m) [193.24 ± 9.59 lbf·ft]
Lift chain nut
Tightening torque
210 N·m (21.4 kgf·m) [154.9 lbf·ft]
Lift chain nut (C45A: inner mast)
Tightening torque
Triplex mast size (reference)
Mast
Lift bracket
-
490 N·m (49.7 kgf·m) [361.40 lbf·ft]
290 ± 29 N·m (29.6 ± 3.0 kgf·m) [213.89 ± 21.4 lbf·ft] 385 ± 39 N·m (39.3 ± 3.9 kgf·m) [283.96 ± 28.76 lbf·ft]
-
11-105
CHAPTER 11 MAST AND FORKS
6
7
5 6 8
5
6
6 6
5
6
3
2
4
1 502246
Note: The mast is slightly wider at the lower side than at the upper side. Always measure the clearance at the upper side of the mast.
11-106
CHAPTER 11 MAST AND FORKS
Model
4.0 ton
4.5 ton
Type
5 to 5.5 ton
Limit value
1
HX**** x 500 (Maker Symbol "HX")
50 x 125
45 mm (1.77 in.)
50 x 122
45 mm (1.77 in.)
2
T**** ("T" Mark)
50 x 122
45 mm (1.77 in.)
3
Without Mark **** or U**** or UQ****
50 x 125
45 mm (1.77 in.)
4
MSI-Fork
50 x 150
45 mm (1.77 in.)
1
HX**** x 500 (Maker Symbol "HX")
50 x 150
45 mm (1.77 in.)
50 x 150
45 mm (1.77 in.)
3
Without Mark **** or U**** or UQ****
55 x 150
50 mm (1.97 in.)
4
MSI-Fork
50 x 150
45 mm (1.77 in.)
1
HX**** x 500 (Maker Symbol "HX")
50 x 150
45 mm (1.77 in.)
3
Without Mark **** or U**** or UQ****
55 x 150
50 mm (1.97 in.)
4
MSI-Fork
60 x 150
55 mm (2.17 in.)
1
HX**** x 500 (Maker Symbol "HX")
60 x 150
55 mm (2.17 in.)
3
Without Mark **** or U**** or UQ****
65 x 150
3
5.00 ton
Blade side
1
2
3
4 Q00581
60 mm (2.36 in.)
11-107
CHAPTER 12 SERVICE DATA
Chapter 12 SERVICE DATA 1.
Maintenance Schedule
Note: Inspection and maintenance should be performed every specified period: months or service hour, whichever comes first.
Brake fluid level
R
Brake hose, pipes and joints
9
Brake pedal free play
9
Parking brake
9
Brake and inching pedal rod (see Note 2)
L
Brake hose and tube
R
Brake wheel cylinder rubber parts
R
Brake booster rubber parts
R
Braking force, brake drum and shoe, and other devices
9
Backing plate, fitting cable, ratchet
9
Radiator fins (see Note 2)
Cooling
C
Cooling fan
9
Engine coolant level
9
Radiator filler cap
9
9
Rubber hose condition
9
9
V-belt (fan and alternator) tension Engine coolant (including reserve tank)
Others (see note 1)
9
Brake fluid
Brake (Dry)
Every 2400 hrs or 12 months
R: Replace Every 1200 hrs or 6 months
Check items
L: Lubricate,
Every 200 hrs or monthly
System
D: Drain,
1st month (200 hrs)
C: Clean,
Every 50 hrs or weekly
9: Check,
Pre-start (daily/10 hours)
Abbreviation
9 R
12-1
9
Battery terminal loosen and damage
9
Driving interlock system
9
Electrical wires
9
Horn
9
Meter panel lights (including seat belt)
9
Mast interlock system
9 9
Starter
9 9
Voltage, current, other electrical system Backup light, stop lights
9
Turn-signal lights (if equipped)
9
Working and head lights
9 9
Warning devices, lights, and meter panel 9
Cylinder head bolt and manifold nut Engine (exhaust, noise, vibration)
9
9
Engine idle speed maximum no-load speed (electronic control engine) Engine oil (dirt and level) Intake and exhaust valve clearance Engine
9 9 9
9 9
Positive crankcase ventilation valves and hoses Engine oil
R
R
Engine oil filter
R
R
Engine mount
9
Compressing and injection pressure
9
Exhaust pipe and muffler
12-2
9
Others (see note 1)
Every 2400 hrs or 12 months
Every 1200 hrs or 6 months 9
9
Battery electrolyte specific gravity (Not required if battery is maintenance free type)
Electrical
Every 200 hrs or monthly
9
Alternator Battery electrolyte level (Not required if battery is maintenance free type)
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
Fuel
Overhead guard
9
Seat adjustment
9
Seat belt
9
Rear view mirror (if equipped)
9
Operator seat
9
Amount of fuel (Lift truck level)
9
Tar in vaporizer (see Note 3)
9
LPG hose, pipes and joints (damage)
9
LPG level (fuel gauge)
9 9
Injection nozzle LPG filter replacement (see Note 3)
R
R
LPG hose
***
Vaporizer rubber parts
R 9
Control valve 9
Hydraulic hose, pipes, and joints Hydraulic oil (dirt and level)
9 9
Hydraulic pump (oil leakage)
Hydraulic
Hydraulic tank strainer
C
Hydraulic tank return filter
9
Hydraulic hose (high-pressure hose)
*
Hydraulic oil Hydraulic tank return oil filter
R R
R 9
Cylinder, safety valve, solenoid valve, and other hydraulic system
Intake
Loading devices and hydraulic system
9
Air cleaner element (see Note 2) (Clean every 2 weeks if note 2 applies)
C
Air cleaner element replacement (see Note 2)
Others (see note 1)
Every 2400 hrs or 12 months
9
Every 1200 hrs or 6 months
9
9
Loosen bolts and nuts Frame and Chassis
Every 200 hrs or monthly
Frame assist grip
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
R
12-3
Lift chain (damage and distortion)
9
Lift and tilt cylinder (oil leakage and damage)
9
Lift cylinder mounting bolts
9
Mast, lift bracket, and forks
9
Lift bracket main roller and side roller
9
Mast strip sliding surfaces
9
Tilt cylinder socket bolts
9
Lift chains (see Note 2)
L
Mast support (see Note 2)
L
Tilt socket pins (see Note 2)
L
L
Tilt cylinder (see Note 2)
L
L
Lift bracket side roller (see Note 2)
L
L
Mast strip sliding surfaces (see Note 2)
L
L
Lift chains
*** 9
Fork lowering speed Load backrest extension
9
Front axle
9
Power steering cylinder
9
Rear axle
9
Rear wheel bearings
9 9
Steering gear box
Steering and Axle
Steering column
9
Steering wheel
9
Rear axle mount bushings (see Note 2)
L
King pins (see Note 2)
L
L
Tie rod pins (see Note 2)
L
L
Power steering cylinder hoses and rubber parts
** 9
Knuckles Tires and rims
12-4
Others (see note 1)
Every 2400 hrs or 12 months
Every 1200 hrs or 6 months
9
Lift and tilt cylinder functions
Mast and Forks
Every 200 hrs or monthly
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
9
Wheel bearings and other traveling devices
9
Wheel steering angle, rod, arm, and other operating devices
9
Accelerator pedal
Transmission drive
9
T/M gear and bearing
9
T/M oil
9
9
Last chance filter (T/M control valve)
C
T/M strainer
C 9
Differential oil
R
Transmission oil
R
Universal joint
L 9
Differential, propeller shaft, and other power flow devices
General
Others (see note 1)
9
Inching pedal
Wheel
Every 2400 hrs or 12 months
Every 1200 hrs or 6 months
Every 200 hrs or monthly
9
Differential oil Inching pedal
1st month (200 hrs)
Check items
Every 50 hrs or weekly
System
Pre-start (daily/10 hours)
CHAPTER 12 SERVICE DATA
Tire and rims
9
Wheel nuts
9
Oil, fuel, and coolant leak (walk around)
9
Hydraulic lines, tubes, and hoses (damage and oil leakage)
9
Grease nipples
L
Note 1: * = Change every 1 to 2 years. ** = Change every 2 years. *** = Change every 2 to 4 years. Note 2: In corrosive or abrasive environments, more frequent cleaning, lubrication, changing, or replacement is required. Note 3: If you have to use poor quality fuel, more frequent checking, draining, cleaning, and changing is required.
12-5
CHAPTER 12 SERVICE DATA
2.
Tightening Torques for Standard Bolts and Nuts
(1) The tables below show the tightening torque for general bolts and nuts. For the tightening torque of the bolts and nuts for specific use, see the torque specified in each section. (2) The table shows the standard value. Bolts and nuts should be tightened within ±10% range of the torque value in the table. When you use an impact wrench, tighten bolts and nuts within ±20% range if the value is 137 N·m (14.0 kgf) [30.80 lbf] or less, and tighten ±15% if the value is more than 137 N·m (14.0 kgf) [30.80 lbf]. (3) Threads and seating faces are in a dry condition.
2.1
Metric Fine Thread With spring washer
Nominal size mm (in.)
Pitch mm (in.)
500244
500245
500246
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
6 (0.24)
1 (0.04)
7.4
0.75
5.4
9.6
0.98
7.1
12.7
1.3
9.4
8 (0.32)
1.25 (0.05)
16.7
1.7
12.3
22.6
2.3
16.6
30.4
3.1
22.4
10 (0.39)
1.25 (0.05)
34.3
3.5
25.3
45.1
4.6
33.3
69.6
7.1
51.4
12 (0.47)
1.25 (0.05)
63.7
6.5
47.0
82.4
8.4
60.8
122.6
12.5
90.4
14 (0.55)
1.5 (0.06)
102.0
10.4
75.2
132.4
13.5
97.6
192.2
19.5
141.8
16 (0.63)
1.5 (0.06)
157.9
16.1
116.5
202.0
20.6
149.0
287.3
29.3
211.9
18 (0.71)
1.5 (0.06)
224.6
22.9
165.6
292.2
29.8
215.5
413.8
42.2
305.2
20 (0.79)
1.5 (0.06)
310.9
31.7
229.3
404.0
41.2
298.0
573.7
58.5
423.1
22 (0.87)
1.5 (0.06)
413.8
42.2
305.2
537.4
54.8
396.4
763.0
77.8
562.7
24 (0.95)
1.5 (0.06)
547.2
55.8
403.6
711.0
72.5
524.4
1006.2
102.6
742.1
27 (1.06)
1.5 (0.06)
794.3
81.0
585.9
1032.6
105.3
761.6
1451.1
148.0
1070.5
30 (1.18)
1.5 (0.06)
1100.3
112.2
811.5
1430.8
145.9
1055.3
2012.3
205.2
1484.2
33 (1.30)
1.5 (0.06)
1467.1
149.6
1082.1
1907.4
194.5
1406.8
2680.2
273.3
1976.8
36 (1.42)
1.5 (0.06)
1918.2
195.6
1414.8
2493.8
254.3
1839.4
3497.1
356.6
2579.3
39 (1.54)
1.5 (0.06)
2461.5
251.0
1815.5
3198.8
326.2
2359.4
4469.9
455.8
3296.8
12-6
CHAPTER 12 SERVICE DATA Without spring washer
Nominal size mm (in.)
Pitch mm (in.)
500244
500245
500246
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
6 (0.24)
1 (0.04)
8.6
0.88
6.4
10.8
1.1
8.0
14.7
1.5
10.8
8 (0.32)
1.25 (0.05)
19.6
2.0
14.5
26.5
2.7
19.5
36.6
3.7
26.8
10 (0.39)
1.25 (0.05)
41.2
4.2
30.4
53.0
5.4
39.1
81.4
8.3
60.0
12 (0.47)
1.25 (0.05)
74.5
7.6
55.0
97.1
9.9
71.6
144.2
14.7
106.3
14 (0.55)
1.5 (0.06)
119.6
12.2
88.2
155.9
15.9
115.0
226.5
23.1
167.1
16 (0.63)
1.5 (0.06)
182.4
18.6
134.5
237.3
24.2
175.0
338.3
34.5
249.5
18 (0.71)
1.5 (0.06)
263.8
26.9
194.6
343.2
35.0
253.2
487.4
49.7
359.5
20 (0.79)
1.5 (0.06)
365.8
37.3
269.8
475.6
48.5
350.8
674.7
68.8
497.6
22 (0.87)
1.5 (0.06)
486.4
49.6
358.8
632.5
64.5
466.5
897.3
91.5
661.8
24 (0.95)
1.5 (0.06)
643.3
65.6
474.5
836.5
85.3
617.0
1183.7
120.7
873.0
27 (1.06)
1.5 (0.06)
934.6
95.3
689.3
1216.0
123.9
896.9
1707.3
174.1
1259.3
30 (1.18)
1.5 (0.06)
1294.5
132.0
954.8
1682.8
171.6
1241.2
2367.3
241.4
1746.0
33 (1.30)
1.5 (0.06)
1726.0
176.0
1273.0
2243.8
228.8
1654.9
3153.8
321.6
2326.1
36 (1.42)
1.5 (0.06)
2256.5
230.1
1664.3
2934.1
299.2
2164.1
4114.0
419.6
3035.0
39 (1.54)
1.5 (0.06)
2896.0
295.3
2135.9
3763.8
383.8
2776.0
5258.3
536.2
3878.3
12-7
CHAPTER 12 SERVICE DATA 2.2
Metric Coarse Thread With spring washer
Nominal size mm (in.)
Pitch mm (in.)
500247
500248
500249
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
10 (0.39)
1.5 (0.06)
33.3
3.4
24.6
43.1
4.4
31.8
67.7
6.9
49.9
12 (0.47)
1.75 (0.07)
58.8
6.0
43.4
76.5
7.8
56.4
115.7
11.8
85.3
14 (0.55)
2 (0.08)
96.4
9.8
70.9
124.5
12.7
91.9
182.4
18.6
134.5
16 (0.63)
2 (0.08)
147.1
15.0
108.5
191.2
19.5
141.0
274.6
28.0
202.5
18 (0.71)
2.5 (0.10)
203.0
20.7
149.7
264.8
27.0
195.3
383.4
39.1
282.8
20 (0.79)
2.5 (0.10)
286.4
29.2
211.2
371.7
37.9
274.1
536.4
54.7
395.6
22 (0.87)
2.5 (0.10)
383.4
39.1
282.8
499.2
50.9
368.2
725.9
74.0
535.2
24 (0.95)
3 (0.12)
492.3
50.2
363.1
640.4
65.3
472.3
924.8
94.3
682.1
27 (1.06)
3 (0.12)
724.7
73.9
534.5
942.2
96.1
695.1
1350.4
137.7
996.0
30 (1.18)
3.5 (0.14)
969.9
98.9
715.3
1259.2
128.4
928.7
1843.7
188.0
1359.8
33 (1.30)
3.5 (0.14)
1328.8
135.5
980.1
1727.0
176.1
1273.7
2477.2
252.6
1827.1
36 (1.42)
4 (0.16)
1676.0
170.9
1236.1
2180.0
222.3
1607.9
3199.9
326.3
2360.1
39 (1.54)
4 (0.16)
2219.2
226.3
1636.8
2884.1
294.1
2127.2
4118.8
420.0
3037.9
42 (16.5)
4.5 (0.18)
2754.7
280.9
2031.8
3581.4
365.2
2641.5
5137.7
523.9
3789.4
12-8
CHAPTER 12 SERVICE DATA Without spring washer
Nominal size mm (in.)
Pitch mm (in.)
500247
500248
500249
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
10 (0.39)
1.5 (0.06)
39.2
4.0
28.9
51.0
5.2
37.6
79.4
8.1
58.6
12 (0.47)
1.75 (0.07)
69.6
7.1
51.4
90.2
9.2
66.5
135.3
13.8
99.8
14 (0.55)
2 (0.08)
112.8
11.5
83.2
146.1
14.9
107.8
215.7
22.0
159.1
16 (0.63)
2 (0.08)
172.6
17.6
127.3
224.6
22.9
165.6
323.6
33.0
238.7
18 (0.71)
2.5 (0.10)
239.3
24.4
176.5
311.9
31.8
230.0
451.1
46.0
332.7
20 (0.79)
2.5 (0.10)
336.4
34.3
248.1
437.4
44.6
322.6
630.6
64.3
465.1
22 (0.87)
2.5 (0.10)
392.3
40.0
289.3
587.4
59.9
433.3
842.4
85.9
621.3
24 (0.95)
3 (0.12)
578.6
59.0
426.7
753.2
76.8
555.5
1088.5
111.0
802.9
27 (1.06)
3 (0.12)
852.2
86.9
628.5
1108.2
113.0
817.3
1588.7
162.0
1771.7
30 (1.18)
3.5 (0.14)
1140.5
116.3
841.2
1481.8
151.1
1092.9
2168.3
221.1
1599.2
33 (1.30)
3.5 (0.14)
1563.2
159.4
1153.0
2031.9
207.2
1498.7
2915.5
297.3
2150.4
36 (1.42)
4 (0.16)
1972.1
201.1
1454.6
2564.4
261.5
1891.4
3765.8
384.0
2777.5
39 (1.54)
4 (0.16)
2610.5
266.2
1925.4
3393.1
3469.0
2502.6
4845.5
494.1
3573.8
42 (16.5)
4.5 (0.18)
3241.1
330.5
2390.5
4212.9
429.6
3107.3
6044.8
616.4
4458.4
12-9
CHAPTER 12 SERVICE DATA
3.
Periodic Replacement Parts
The important parts (marked with *) and elements for safe operation listed below must be replaced at every designated replacement period. Replacement period No.
Periodic replacement parts Year (year)
Service hours (hour)
Month (month)
1
*
Brake booster rubber parts and hoses
1
2000
2
*
Rubber parts for brake wheel cylinder
1
2000
Brake hoses, tube, reserve tube
1
2000
3 4
*
High pressure hoses for loading/unloading operation
1 to 2
2000 to 4000
5
*
Rubber parts for power cylinder
1 to 2
4000
6
*
Power steering hose
2
4000
7
*
Lift chain
2
4000
8
*
LPG hose
2
4000
Remark
9
Engine oil filter element
1
500
Also 1 month after delivery
10
LPG filter element
6
1000
Also 1 month after delivery
11
Hydraulic tank return filter
6
1000
Also 1 month after delivery
12
Air cleaner element
6
1000
Clean every 2 weeks.
13
Engine cooling water
1
2000
Note: "*" indicates safety critical parts.
3.1
Safety Critical Parts
10 *7
*3 *8
*5 *4 *2
*6 *1
*4 *2
609259
12-10
CHAPTER 12 SERVICE DATA
4.
Lubrication Schedule
4.1
Lubrication Chart
1
2
4
3 6
5 7
9
8 10
9
11 609258
Ref.
Lubricating point
1
Lift chains (right and left)
2
Lift bracket side rollers (right and left)
3
Mast strip roller rolling surface (right and left)
4
Tilt sockets (right and left)
5
Tilt cylinder (right and left) * (if equipped)
6
Mast supports (right and left)
7
Pedal bracket
8
Water pump
9
Rear axle center pins (front and rear)
10
Kingpins (4 places)
11
Tie rod pins (4 places)
Lubrication/ greasing
Intervals
Engine oil Every 200 hours or monthly, whichever comes first
MP grease
Every 50 hours or weekly
Every 200 hours or monthly, whichever comes first
12-11
CHAPTER 12 SERVICE DATA 4.2
Fuel and Lubricant Specifications Recommendation for Ambient Temperatures °C [°F] Fuel or Oil
Recommendation
-30 (-22)
-20 (-4)
Fuel
10 (50)
SAE10W or SAE10W-30
API service classification SJ, MIN.
Front axle oil
API service classification multi-purpose type GL-4
Powershift Transmission Oil
Dexron
20 (68)
30 (86)
SAE30 SAE20
SAE80W
SAE90
Consult your authorized Cat lift truck dealer.
Hydraulic Oil
SAE5W F.M.V.S.S. No.116-DOT3 or DOT4 (SAE J1703)
Brake fluid
SAE10W
See Recommended Brands of Lubricants.
Wheel bearings
NLGI No.2 grade multipurpose type (lithium base), consistency: 265-295
Chassis
NLGI No.1 grade multipurpose type (lithium base), consistency: 310-340 Item
Antifreeze solution
0 (32)
Consult your authorized Cat lift truck dealer.
Engine oil
Grease
-10 (14)
Ambient temperature (°C [°F]) (Long Life Coolant) Concentration (%)
Value -45 (-49)
-39 (-38)
-30 (-22)
-25 (-13)
-20 (-4)
-15 (5)
-10 (14)
60
55
50
45
40
35
30
R CAUTION Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with one and the same brand at successive service intervals.
12-12
CHAPTER 12 SERVICE DATA 4.3
Adjustment Value and Oil Capacity
Note: The values in the table below are for the standard model. Class (ton) Item 3.5
4.0
4.5
Alternator drive belt deflectionwhen pushed inward with 98 N (10 kgf) [22 lbf] pressure
5.5
AC-DELCO #41-932
Spark plug gap
1.01 mm (0.040 in.) 750 to 800 min-1
Engine idling speed Steering wheel free play (when measured at rim with engine idling)
15 to 30 mm (0.59 to 1.18 in.)
Brake pedal free play
5 mm (0.20 in.)
Parking brake lever effort
250 to 290 N (25 to 30 kgf) [55 to 65 lbf]
Front tire
22 × 9 × 16
22 × 12 × 16
22 × 12 × 22
Rear tire
18 × 7 × 12-1/8
18 × 8 × 121/8
22 × 8 × 16
Tightening torque of wheel nuts
Front tire
Lift chain elongation limit
551 N·m (56.2 kgf·m) [406.5 lbf·ft] 523 mm (20.6 in.)/20 links
Engine cooling system (0.65 liter [0.17 US gal.] reserve tank included)
Engine oil
7.0
11 to 13 mm (0.43 to 0.51 in.)
Spark plug type
Tire size
6.0
654 mm (25.7 in.)/20 links 17 L (4.5 US gal.)
Crankcase
4.2 L (1.1 US gal.)
Oil filter
0.8 L (0.2 US gal.)
Total
5.0 L (1.3 US gal.)
Transmission oil
14 L (3.7 US gal.)
Differential (P/T) Hydraulic tank Brake fluid reserve tank Battery electrolyte specific gravity, corrected to 20°C (68°F)
15 L (4.0 US gal.)
9.1 L (2.4 US gal.) 45.9 L (12.1 US gal.)
51.6 L (13.6 US gal.)
68.8 L (18.2 US gal.)
149 cc (9.1 cu in.) Consult your battery manufacturer for the specific gravity of your battery.
12-13
CHAPTER 12 SERVICE DATA
5. 5.1
No.
Special Tools Special Service Tools
Name
Part number
Lift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
1
Wrench
93768-00100
Removal/installation of pulley
z
z
2
Wrench
91868-00100
Removal/installation of pulley (used with wrench 93768-00100)
z
z
z
z
3
Bolt Bolt set
F1035-10050 67284-15400
Pulling out the torque converter-drive transmission pump body and the direct-drive transmission shifter case
4
Bevel pinion puller
91868-02100
Pulling out the bevel pinion assembly
z
z
5
Wrench
91868-00300
Tightening the bevel pinion assembly
z
z
6
Installer
91868-02200
Driving in the oil seal of the transmission output shaft
-
z
7
Puller Plate Bolt Puller
91268-13810 91268-13820 F1035-10020 T24
Removing bearing from the torque-drive transmission (to be used in combination with 91268-13820 plate. F1035-10020 bolt and T24 puller) (Commercial)
z
z
12-14
CHAPTER 12 SERVICE DATA
No.
Name
Part number
Lift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
8
Installer
91268-04100
Driving in the ball bearing of the torque-drive transmission
z
z
9
Piston tool Piston tool
92267-00300
Removal/installation of torque-drive transmission clutch return spring
z -
z
10
Ring puller
91268-00500
Removal/installation of torque converter-drive transmission snapring
z
z
11
Gauge kit
64309-17700
Measuring oil pressure of transmission and hydraulic system
z
z
z
z
12
Connector
92067-00300
Measuring oil pressure of torque converter-drive transmission (used with gauge kit)
13
Socket wrench 105 mm
03703-49000
Removal/installation of wheel hub nut
-
z
14
Socket wrench 100 mm
-
Removal/installation of front wheel hub nut
z
-
12-15
CHAPTER 12 SERVICE DATA
No.
Name
Part number
Lift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
15
Spring remover 64309-15400
Removal of return spring
z
z
16
Spring retainer
91868-00600
Removal/installation of brake shoe
z
z
17
Spring hook
64309-15400
Installation of return spring
z
z
18
Puller
91268-10600
Removal of steering wheel
z
z
19
Puller
91268-03200
Removal of steering column needle roller bearing
z
z
91268-01700
Measuring main oil pressure of the steering system (used with gauge kit 64309-00300)
z
z
05312-20850
Removal/installation of tilt cylinder bushing Removal/installation of lift cylinder head (for A40A and B55A)
z
z
20
21
12-16
Connector
Hook wrench
CHAPTER 12 SERVICE DATA
No.
Name
Part number
Lift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
22
Hook wrench
05312-10600
Removal/installation of lift cylinder holder (for A75A)
z
z
23
Hook wrench
05312-10800
Removal/installation of lift cylinder holder (for B40A)
z
z
24
Hook wrench
15312-11000
Removal/installation of lift cylinder holder (for B55A)
z
z
25
Hook wrench
-
Removal/installation of tilt cylinder guide bushing
z
-
26
Hook wrench
-
Removal/installation of tilt cylinder guide bushing
-
z
27
Wheel socket 41 mm
-
Removal/installation of drive wheels
z
z
64309-17722
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
28
Hose
12-17
CHAPTER 12 SERVICE DATA
No.
Name
29
Gauge, 0-5000 psi
30
Gauge, 0-3000 psi
31
Gauge, 0-100 psi
32
Connector
33
Banjo connector
Part number
Lift truck classifications Illustration
Use 3.5 to 5.5 ton
6.0 to 7.0 ton
64309-17712
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17713
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17714
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17714
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
z
z
64309-17733
Measuring oil pressures, hydraulic, transmission, and steering (used with gauge kit)
-
z
Note: Special service tool 4 is a dedicated inspection connector for 91105-00700. Special service tools from 2 through 20 are dedicated inspection connectors and each of them is different in shape and has the different number of connector poles. They are supplied as a set, but individual supply is also available.
12-18
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
Chapter 13 HOW TO READ CIRCUIT DIAGRAMS 1.
Description of Circuit Diagrams
The circuit diagrams consist of the schematic diagrams and connector diagrams.
1.1
Circuit Diagrams
All circuits including the power supply and ground are divided into the power circuit, GND circuit and system circuits. Power circuit diagram The power circuit diagram indicates the power circuit including the battery, fuse, ignition switch, etc. GND circuit diagram The GND circuit diagram indicates the circuits from each electric component to the body ground or from each component to the battery negative terminal. System circuit diagrams The system circuit diagrams indicate the circuits of each system from fuse to GND (earth) excluding the above power supply and GND circuit portions.
1.2
Connector Diagrams
The connector shapes, terminal shapes and terminal arrangements of all connectors in the circuit diagrams are indicated.
13-1
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
2.
How to Read Circuit Diagrams
The circuit of each system from fuse to GND (earth) is indicated. The circuits indicate the direction of signal flow. In figures, it flows from top (positive) to bottom (negative).
1 2 3 4 10
5 6
7
11
15
8 12
16 17
9
13 14
18 19 501952
13-2
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
2.1
Departure equipment name Departure sheet number Cable diameter & color (Description(2)) Circuit number Boundary (Description(4)) Equipment name Terminal number of connector Connector number (Description(3)) Indicates connection with body GND Equipment number
11. 12. 13. 14. 15. 16. 17. 18. 19.
Used place of relay coil (Description(1)) Indicates same connector Indicates connection with GND circuit Sheet number of GND circuit Used place of relay contact (Description (1)) Destination sheet number Destination equipment name Indicates connection with Negative circuit Sheet number of Negative circuit
Symbols
Symbols are used in the figures for easy reading of circuit diagrams. General symbols (1) General use symbols Symbol
Name
Symbol
Name
Negative
GND (Harness)
GND (Body)
(2) Conductors and coupling parts Symbol
Name
Symbol
Name
Connector (Socket/Plug)
Twist wire
Terminal (Socket)
Shield wire
Terminal (Plug)
Branching
Terminal
13-3
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (3) Standard passive parts Symbol
Name
Symbol
Name
Variable resistor
Resistor
(4) Semiconductors and electronic tubes SYMBOL
NAME
SYMBOL
NAME Auto light sensor (Photo diode)
Diode
LED
(5) Generation and conversion of electric energy Symbol
Name
Generator
Three phase Induction motor
DC motor
13-4
Symbol
Name
Stepping motor
Battery
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (6) Switches, control, and protective devices Symbol
Name
Symbol
Name
Switch (N.O)
Oil pressure switch
Switch (N.C)
Magnetic contactor
Fuse
Two position switch
Thermistor
Emergency switch
Magnetic coil
Push button switch
Proximity sensor
Switch (Auto return)
(7) Indicators, lamps, and signal devices Symbol
Name
Lamp
Symbol
Name
Horn
Buzzer
13-5
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS Special symbols The following symbols are used when the representation by general symbols is difficult.
2
This diagram shows that No. 1 and No. 3 terminals are connected when the switch position is placed in N position.
1
F N R 501953
1. Switch position
2.2
2. Terminal
Sheet Symbol
A sheet symbol is provided in each circuit diagram sheet so that the relationship between diagrams can be clarified. The sheet symbol consists of "SH" and two digit numbers, for example, “SH-01" or “SH-02".
13-6
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS Connecting Lines
(1) There are two thicknesses of the line which connect between elements in the circuit diagram. Each line is used as follows: Thick line: Connecting lines for the electric wires size of 20 mm2 (0.78 in2) or above. Thin line: All other connecting lines except the above. (2) Connecting lines are represented by the circuit number, wire diameter and wire color. For the connecting lines of 0.5 mm2 (0.02 in2) wire size, the wire diameter is omitted.
1 2
101(1.25R)
2.3
3 4 501954
1. Wire diameter, wire color 2. Circuit number
3. Wire color 4. Wire diameter
(3) Here are two types of wires: the one having only one color and the one having a colored stripe (combination of two colors).
2 1
3 4
501955 1. Base color 2. Stripe color
3. Base color 4. Stripe color
Color codes Symbol
Color
Symbol
Color
Symbol
Color
B
Black
Br
Brown
P
Pink
W
White
L
Blue
Sb
Sky blue
R
Red
Lg
Light green
V
Purple
G
Green
O
Orange
Y
Yellow
Gr
Gray
13-7
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 2.4
Equipment
(1) Equipment is represented by a box. The symbol of connector that belongs to the equipment is indicated inside the box. (2) The items listed under the item category symbol have a specific symbol (equipment number) for classification of items and identification of identical items. Equipment number system
3
1
4
5
2 6 7 501956
1. 2. 3. 4.
Equipment name Box Connector for harness Connector belongs to equipment
5. 6. 7.
Equipment number Classification number (serial number) Item category symbol
Item category symbol
13-8
Symbol
Item
Symbol
Item
F
Fuse
MC
Contactor
SBF
Slow-blow fuse
R
Resistor
FLW
Fusible link
C
Capacitor
RY
Relay
D
Diode
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 2.5
Relay Contactor and Coil
(1) For the relay contactor, the sheet symbol in which its coil is represented is provided so that you can find its coil easily. However, when the coil is represented in the same sheet, the sheet symbol is omitted.
2 LAMP RELAY
1
3 501957
1. Equipment name 2. Equipment number
(2) For the relay coil (contactor coil), the sheet symbol in which its contact is represented is provided so that you can find the location of contacts. However, when the contact is represented in the same sheet, the sheet symbol is omitted.
3. Sheet symbol where coil is represented
2 LAMP RELAY
1
3 501958 1. Equipment name 2. Equipment number
2.6
3. Sheet symbol where the contact is represented
Connectors
(1) The connectors are represented by the connector number for identification. The connector number is enclosed with a box. (2) The same connector number is allocated to a plug connector (male connector) and its mating socket connector (female connector) as a pair. (3) The connector terminal number is indicated next to the connector symbol. However, for the terminals such as round shape terminal, plug terminal, and flat shape terminal, etc., the terminal number is indicated. (4) When the connectors located side by side are the identical but have a different number, the line between the connectors are indicated by a dotted line.
1
3 2
4
1. 2. 3.
Terminal number Connector number Terminal number
4. 5.
5
501959
Connector number Indicates that the connector is the same.
13-9
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS 2.7
Indication of Connecting Line
(1) When a connecting wire crosses to another sheet, it is indicated by the arrow with the sheet symbol next to it. Also, the name of destination equipment is indicated for better understanding.
1 2 501960 1. Destination sheet symbol
2. Destination equipment name
(2) A connecting wire from another sheet is also indicated by the arrow with the sheet symbol next to it. Also, the name of sender equipment is indicated for better understanding.
1 2
501961 1. Sender equipment name
2.8
2. Sender sheet symbol
Indication of GND (Earth)
The GND (earth), depending on the connection type, is represented as shown below. (1) When connecting directly to the body.
1
2
501962 1. Terminal connector number
13-10
2. Graphic symbol
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (2) When connecting to body or battery negative terminal through GND circuit and negative circuit.
1
1
2 3
2 4 501963
4. This indicates the connection to 1. Graphic symbol negative circuit. 2. Destination sheet symbol 3. This indicates the connection to GND circuit
2.9
Indication of Another Specification
When there is another specification, the portion of circuit, for which another specification is available, is enclosed with an alternate long and two short dashes line, and the circuit of another specification is enclosed by a thick solid line.
1
2
501964
1.
The circuit portion which differs depending on the specification
2.
The circuit of another specification
13-11
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
3.
How to Read Connector Diagrams
For all connectors included in the circuit diagrams; the connector shapes, terminal arrangements, and terminal shapes (plug or socket) are indicated. Socket terminal (female terminal)
4
1
5
2 3
6 501965
1. 2. 3. 4.
Connector number Lock Terminal arrangement terminal number This indicates No.4 terminal of B-01 connector
5. 6.
Socket terminal Plug terminal
Plug terminal (male terminal)
1
502710
1.
Lock (Blackened)
(1) The connector diagram is a view from its mating face. (2) For the connectors that are connected to the equipment, only the wire harness side connector is indicated. (3) For intermediate connectors, the connector diagram of both plug terminal (male) and socket terminal (female) are indicated. (4) The lock portion of the plug terminal (male) is represented by blackening to distinguish from the socket terminal (female). 501966
13-12
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS (5) Unused terminals are represented by the terminal number “-” Also, the terminal number marked with * indicates a gold-plated terminal.
2
1
501967 1. Gold-plated terminal
2. Unused terminal
(6) The terminal shapes are simplified as shown below.
Type
Round shape terminal
“U” shaped end terminal
Plug terminal (Plug)
Plug receptacle terminal (Socket)
Flat shape terminal
Actual shape
Simplified representation
13-13
CHAPTER 13 HOW TO READ CIRCUIT DIAGRAMS
4.
Abbreviation
Abbreviation used in this circuit diagrams are explained in the following table: List of abbreviations (Alphabetical order) Abbreviation COMBI
Explanation COMBINATION
DOC
DIESEL OXIDIZATION CATALYST
DPF
DIESEL PARTICULATE FILTER
ECM
ENGINE CONTROL MODULE
ENG
ENGINE
FC
FINGERTIP CONTROL
FDC
FOOT DIRECTION CONTROL
FNR
FORWARD-NEUTRAL-REVERSE
GND
GROUND
GSE
GROUND SUPPORT EQUIPMENT
HYD
HYDRAULIC
IGN
IGNITION
OCM
OPTION CONTROL MODULE
PS
POWER STEERING
SOL
SOLENOID
SW
SWITCH
TEMP
TEMPERATURE
T/M
TRANSMISSION
VCM
VEHICLE CONTROL MODULE
Different circuit for each market country is explained in the following abbreviations: Abbreviation of market countries
Abbreviation
13-14
Explanation
MCFA
North and South American market
MCFE
European market
SGM
Japanese market
-
-
-
-
CIRCUIT DIAGRAM
CIRCUrr NAME
CIRCurr NAME CONNECTOR
POWER SUPPLY IQN POWER SUPPLY
I
CHARGING
zz
CONNECTOR
04
GND
23
CONNECTOR
05
GND
08
LAMP
07
LAMP
08
TURN SlllNAL
09
HORN & WARNINQ BUZZER
10
STARTER
11
VEHICLE CONTROL
12
VEHICLE CONTROL
13
VEHICLE CONTROL
14
METER PANEL
14A
.
CONNECTOR
03
WARNIN!l LAMP
15
ENGINE HARNESS
18
FOOT DIRECTION
17
FUSE BOX
18
CONNECTOR
19
CONNECTOR
&,5&a1$,,,(
CONTENTS
SH
A1
:
CIRCUrr NAME
"'
'"
-
-
..
-
-
...
-
...
-
-
-
......
c:
a m
I
,.,
,.,
Sl -
a :'l
I
'"
'"
a
21
,.
a
< '-
aa a
a
I2! ., ___
1
202 (1.25W/Q)
203 (1.25W/L)
i:I:"'a <'- 20 (U5W/Ll
!ljlil
"'"' a a !
s
2!
I
c
c
'
00
I
=
0
(3W)
--
L2
a FLW1
(SH-il2)
5 B)a $
aORD a
I I
'
I I
I I
0
RRaRR
FUSE BOX F210A
00
I
I
I
a
ID
Ill
I
a
rn f
,;
I
a
aa ,.
)>
)>
-
-
'"
f-
...
f-
...
"'
f-
-
...
'"
...
!!
I
~
~
0
~
"0 "0
c
(I)
::u
m
~
"0
;;; < 5 z
,.,
,.,
..J
::,
1
Sf!-13
MAST LOCK RELAY
Sf!-08
FLASHER RELAY
TIM CONTROu.ER
'"
DUST INDICATOR LAMP SH-14A
Sf!-15
Sf!-11
Sf!-14
Sf!-07
BACK-UP RELAY
METER PANEL
-··-·
·-· -··-· -··-
T/C OIL TEMP RELAY
~
I
~
00
-
1
32& (0.85R/W)
32(1.25R/W)
2011 (0.85Rl
207 (1.25Rl
101 (R)
81(11)
87 (1.28R)
11a(I.25Rl
I I I
t
I I I
t
-··-
t
t
"
212 (RIQ)
137 (RIG)
18(1.25R/G)
210 (1.25RIQ)
2H1.25RIB)
215 (1.25RIB)
·-· -··-· -··
11 (1.25RIB)
-··-
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99739-94100
Service Manual Options Supplement GC35K GC40K GC40K GC45K GC45K GC55K GC55K GC60K GC70K GC70K
AT87-00001-up AT87-00001-up
STR SWB
AT87-00001-up AT87-00001-up AT88-00001-up AT88-00001-up
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AT88-00001-up AT89-00001-up AT89-00001-up
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AT89-00001-up For use with the Chassis & Mast Service Manual
FOREWORD
This service manual is a guide to servicing of the options for Caterpillar® Lift Truck models from 3.5-ton to 7.0-ton. Long productive life of your lift trucks depends to a great extent on correct servicing – the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Caterpillar reserves the right to change specifications or design without notice and without incurring obligation.
Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions: WARNING
Indicates a specific potential hazard resulting in serious bodily injury or death.
CAUTION
Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the machine.
NOTE
Indicates a condition that can cause damage to, or shorten service life of, the machine.
Pub. No. 99739-94100
WARNING
SAFETY WARNING The proper and safe lubrication and maintenance for this lift truck, recommended by Caterpillar, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance. The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product. 2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welder’s gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. 3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.
WARNING Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.
4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly. 5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. 6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.
10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts. 12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not Operate” tag in the Operator’s Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. 17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
TABLE OF CONTENTS REAR COMBINATION LAMP KIT ......................................................... 1 WARNING LAMP KIT .............................................................................. 2 WORKING LAMP KIT ............................................................................. 4 CREEP SPEED KIT ................................................................................. 6 FOOT DIRECTIONAL CONTROL GROUP ......................................... 8 ENGINE SHUTDOWN KIT (LPG models only) .................................. 10 ENCLOSED ALTERNATOR FIELD KIT ................................................ 12 DISCONNECT SWITCH KIT .................................................................. 13 UL FUEL CAP KIT (Gasoline models only) ........................................ 16 KEY KIT ..................................................................................................... 17 BACK BUZZER KIT ................................................................................. 18 DUAL ELEMENT AIR CLEANER .......................................................... 19 DUST AND FOUNDRY KIT .................................................................... 20 1. Precleaner Kit ....................................................................................... 20 2. Gear Pump Seal Kit .............................................................................. 21 3. Magnetic Plug Kit ................................................................................. 22 4. Dust-Proof Breather Kit ........................................................................ 22
BACK MIRROR KIT ................................................................................. 23
REAR COMBINATION LAMP KIT Description This rear combination stop/back-up lamp alerts traffic approaching from rear to the change of truck’s drive.
Installation 1. Install stop lamp switch to pedal bracket as shown. At this time, do not depress the brake pedal. After installation, check for push rod projection; it must be 2 mm (0.08 in.). 2. Connect harness 6 to main harness B. 3. Route harness 5 inside side cover of frame and connect to harness 6. 4. Route harness 6 along the harness B. (by clip band as required) 5. Mount lamp to bracket using bolts provided with lamp. 6. Mount bracket 2 to overhead guard legs using existing holes. 7. Check that the stop lamps turn on when the brake pedal is depressed a little. Adjust if necessary.
208162
This kit consists of following parts. 1 2 3 4
Rear combination lamp Bracket Bolt Spring washer
5 6 7 8
–1–
Harness (rear combination) Harness (option) Stop lamp switch Band (clip)
WARNING LAMP KIT Unit: mm (in.)
208163
This kit consists of following parts. 1 Strobe Lamp 2 Bracket 3 Bolt 4 Grommet
5 6 7 8*
Terminal (male) Terminal (female) Tube Accessory wiring harness (not included in this kit)
Installation 1. Sheathe wire of strobe lamp with tube 7, then fit terminals 5 and 6 onto the wire. (See View A–A as above.) 2. Fit grommet 4 into the hole in the guard through which accessory wiring harness 8 is inserted (3 places). Pass accessory wiring harness 8 through right rear guard leg. Connect splice on the guard leg side of accessory wiring harness 8 with splice of main harness B. 3. Retrieve portion of accessory wiring harness 8 and protective loom as required from guard tube. 4. After attaching strobe to guard, connect the wire leads. 5. Tape each wire lead connection individually, then tape both connections together. 6. Push excess harness back through grommet into guard tube. NOTE Hardware parts are included in lamp assembly.
–2–
208164
–3–
WORKING LAMP KIT
208165
This kit consists of following parts. 1 2 3
Lamp assembly Bracket Bolt
4 Grommet 5* Accessory wiring harness (not included in this kit)
Installation 1. Fit grommet 4 into the hole in the guard through which accessory wiring harness 5 is inserted (1 place). Pass accessory wiring harness 5 through right rear guard leg. Connect splice on the guard leg side of accessory wiring harness 5 with splice of main harness B. 2. Retrieve portion of accessory wiring harness 5 and protective loom as required from guard tube. 3. After attaching lamp assembly 1 to guard, connect the wire leads. 4. Tape each wire lead connection individually, then tape both connections together. 5. Push excess harness back through grommet into guard tube. NOTE Hardware parts are included in lamp assembly.
–4–
208164
–5–
CREEP SPEED KIT Description A vehicle may move along slowly when the engine is running at a low idle speed with the shift lever (F-N-R) in the F or R position. This phenomenon is called creep. This kit is a device to limit (control) the maximum creep speed.
Installation 1. Remove accelerator pedal linkage, engine throttle cable, cable connecting to inching lever and spring from the existing inching bracket assembly. (Refer to service manual.) 2. Remove the existing inching bracket assembly from top of transmission hydraulic control valve. (Refer to service manual.) 3. Drill two holes through the right side of dash board as shown.
4. Tighten inching bracket assembly together with switch bracket to transmission control valve shown above. 5. Install accelerator switch 1 to bracket 4.
Unit: mm (in.)
208167
208168
6. Install delay timer 2 with hardware as shown.
(Push rod protrudes to turn on switch.)
208169
7. Install and adjust throttle cable. 8. Adjust accelerator switch as follows: After installing and setting cable, adjust the switch push rod position to the dimension marked by * and fix switch by tightening nut.
208166
–6–
208170
9. Route harness 5 along main harness (harness B) and secure with clip band as required. For harness connections, refer to illustration below and wiring diagram.
208172
10. Modify the existing connector 8 of harness B as follows. (1) Disconnect the connector 8. (2) Pull out * marked brown wire shown above from connector 8. (3) Insert ** marked terminal G of harness 5 into connector 8. (4) Bind disconnected * marked brown wire and ** marked terminal together with tape. (5) Re-connect the connector 8. 11. Perform at least the following tests. (1) Operate shift lever (F-N-R) to check that transmission works properly. (2) Check that creep speed is controlled properly.
208171
Harness (5), Delay timer
208173
Wiring diagram –7–
FOOT DIRECTIONAL CONTROL GROUP Description This kit provides foot operated forward/reverse directional control.
Unit: mm (in.)
208174
This kit consists of following parts. 1 2 3 4 5 6 7 8
Pedal assembly Rod (accelerator pedal) Floor plate Stop bolt Stop nut (jam nut) Switch assembly Screw Spring washer
9 10 11 12 13 14 15 16
Band Clip Clip Screw Spring washer Nut Relay bracket Bolt washer assembly
–8–
17 18 19 20 21 22
Relay Relay Bolt (four) Spring washer Harness Harness
Unit: mm (in.)
208175
Installation 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Drill a hole through floor plate as shown in Detail B. Attach clip 10 to floor plate using hardware 12, 13 and 14 supplied. Remove existing floor plate and accelerator pedal. (See illustration above.) Attach foot control pedal assembly 1 to floor plate 3 using existing pin and retaining ring. Attach clip 11 to foot control wiring harness. Install clip 11 under stop nut as shown in Detail C. Carefully route foot control wiring harness as shown in Detail C. Make certain that harness moves freely through rotation of accelerator pedal and does not bind on stop bolt. Tighten down clips so that harness is secured from slipping due to pedal movement. Snap accelerator rod 2 onto foot control pedal 1. Route foot control harness through clip 10. Remove front panel from console and unplug shift lever harness from harness B. Remove shift lever assembly from steering column. Attach switch lever assembly 6 to steering column using hardware 7 and 8 as shown in Detail D. Locate in same position as shift lever. Connect harness 22 as shown in Detail D. Drill holes into cowl support as shown in hole pattern detail. Mount relay bracket 15 to chassis support as shown in Detail E using hardware 16 supplied. Mount relays 17 and 18 to relay bracket using hardware 19 and 20. Connect harness 21 as shown in Detail E. Test foot control for proper function. Secure switch assembly harness onto steering column with band 9 as shown in Detail D.
–9–
ENGINE SHUTDOWN KIT (LPG models only) Description This option will shutdown the engine if the following conditions occur: A: High transmission temperature. B: High coolant temperature. C: Low engine oil pressure. If any of the fault conditions occur a high pitch tone will sound for 30 seconds. If the engine is not turned off before 30 seconds the engine will shutdown and the horn will sound. The engine can be restarted and operated for 30 seconds by recycling the key switch. Unit: mm (in.)
208176
This kit consists of following parts. 1 Module 2 Harness
3 4 5
– 10 –
Bolt, Nut, Lockwasher (2 sets, not shown) Tie wrap (twelve, not shown) Caution film
208177
Module (1) and Harness (2) 1
Module (engine shutdown)
2
Harness (engine shutdown)
Installation 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Drill two 5 mm (0.196 in.) holes in the left-side dash just above the left fender as shown (View A). Mount the module using the hardware 3 provided. Attach the black ground wire to the hardware provided to mount the module. Connect red wire to harness B circuit Black/Yellow wire and Red/Yellow wire to engine harness circuit Purple wire. Connect “Pigtail” wire harness 2 to the module. Connect Orange wire to the horn circuit (Green wire). Located under the dash, behind the steering column. Disconnect the Yellow/Red wire from the transmission sender unit and connect Green wire to the sender. Reconnect the Yellow/Red wire to the piggy back terminal of this wire. Disconnect the Yellow/Green wire from the water temperature sender unit and connect Blue wire to the sender. Reconnect the Yellow/Green wire to the Blue jumper wire. Disconnect the Yellow/Black wire from the engine oil pressure switch and connect Yellow jumper wire to switch. Reconnect the Yellow/Black wire to the piggy back terminal of this wire. Apply caution film 5 to inside right front overhead guard leg (at lowest point possible). NOTE
Route engine shutdown harness along truck main harness (harness B) and tie-wrap as necessary. Test instructions:
A: Start engine. Then, ground the oil pressure switch. This will simulate a hazardous condition. The buzzer will sound and the oil light will illuminate. In approximately 30 seconds the engine will shutdown and the horn will sound. B: To test the engine shutdown warning system, turn the key switch to the on position, but do not engage the starter. The buzzer will immediately sound and the oil pressure light will illuminate. In approximately 30 seconds the horn will sound. – 11 –
ENCLOSED ALTERNATOR FIELD KIT Description This kit provides an alternator of dust proof type or GS/LPS-type of UL standard.
Installation Start by:
(1) Disconnect the existing standard type alternator harness as shown in wiring diagram. (2) Remove the existing standard type alternator. (Refer to service manual.) 1. Install pulley 4 (for enclosed alternator) to the enclosed alternator 3. Torque pulley nut to 60 ± 7 N·m (6.2 ± 0.7 kgf·m) [45 ± 5 lbf·ft]. 2. Install enclosed alternator to the engine. (Refer to Service Manual.) 3. Connect three wires (between alternator and harness B) as shown in wiring diagram.
208178
208179
Wiring diagram of standard alternator
Wiring diagram of enclosed alternator This kit consists of following parts. 1 2 3 4
208180
– 12 –
Wire assembly (ALT-EXC) Wire assembly (ALT D+) Enclosed alternator Pulley
DISCONNECT SWITCH KIT Description 1. This kit provides a manual battery disconnect switch which permits quick disconnection in case of an electrical disturbance. 2. This kit conforms to U.L. standards for type GS and LP rated trucks. 3. This kit cannot be used without enclosed alternator. For details on the installation of enclosed alternator kit, refer to Page 12. Unit: mm (in.)
208181
This kit consists of following parts. 1 2 3 4 5 6 7
Master safety switch (normal close) Bolt (three) Washer (three) Plate Bolt (two) Washer (two) Support
8 9 10 11 12 13
– 13 –
Cable (Master switch to ground) Cable (Battery to master switch) Clip (seven) Bracket (Knob) Bolt (one) Cord
Unit: mm (in.)
Installation Start by:
Remove standard type battery cable (-). 1. Weld clip 10 as shown (7 places, ➉1 to ➉7). 2. Install bracket 11 with one bolt 12 (see previous page.)
208182
Unit: mm (in.)
208183
3. Weld support 7 as shown in View C–C.
208184
4. Install plate 4 to support 7 with bolt 5 and washer 6 (two). 5. Install master safety switch 1 to plate 4 with bolt 2 and washer 3 (three). – 14 –
208185
6. Modify master safety switch: (1) Remove the following parts from master safety switch 1: Signal light system (Signal lamp, Wiring, Fuses and Fuse holders) and Instruction name plate. (2) Apply sealant to fuse holder mounting holes. (3) Cut cable to proper length at switch end, after installation. 7. Connect cord 13 from battery disconnect switch to fusible link which goes to alternator B+; and second terminal of cord 13 back into harness B. Refer to wiring diagram. 8. Dimension “A” in View A–A to be taken as a span for welding clips 10 shall be 10 to 15 mm (0.4 to 0.6 in.) 9. Install battery cable 8 and 9 as shown.
208186
208187
Wiring diagram – 15 –
UL FUEL CAP KIT (Gasoline models only) Description This kit conforms to U.L. standards for type GS and LP rated trucks.
Installation Install this kit in the place of standard fuel cap.
208188
– 16 –
KEY KIT Description This kit makes access to engine compartment be possible only by means of key and tool.
208189
This kit consists of following parts. 1 2
Bolt Washer
3
Key, Padlock
Installation 1. Fastener of engine cover Padlock 3 should be added to bracket of fastener to fix lever. 2. Bolt of the radiator cover Bolt 1 should be used in place of knob bolt to fix radiator cover.
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BACK BUZZER KIT Description This kit works as a warning in drive backward.
Unit: mm (in.)
208190
This kit consists of following parts. 1 2
Back buzzer Bolt
3 4
Installation 1. Threaded hole must be added as shown. 2. Install back buzzer with bolt, plain washer and spring washer. 3. Connect terminal A to harness B.
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Plain washer Spring washer
DUAL ELEMENT AIR CLEANER Description This dual element air cleaner offers the following features: (1) High filtering efficiency. (2) Protection of engine in extremely dusty conditions.
Installation 1. This air cleaner can be installed by the same procedure as standard air cleaner. 2. Parts shown in solid lines are different from the existing standard parts. 3. Apply liquid gasket to the portions of hoses to be clamped to assure air tightness. NOTE 1. Inner element should not be removed. If absolutely needed (to replace, etc.) remove it in clean conditions. 2. Be sure to keep the connections of rubber hose air tight. 3. Rubber hose should be changed periodically. 4. The cleaning and replacement procedures of the elements are the same as for standard type.
Solid line: New parts : Existing standard parts
208191
– 19 –
DUST AND FOUNDRY KIT Description Dust and foundry kit consists of following kits. 1 2 3 4
Precleaner kit Gear pump seal kit Magnetic plug kit Dust-proof breather kit
1. Precleaner Kit Description
This kit is used to minimize foreign materials from entering engine through air intake system.
208192
This kit consists of following parts. 1 2 3
Duct Seal U-clamp
4 5 6 7
Plate Pre-cleaner Nut Washer
Installation
1. Remove existing air louver from guard leg. 2. Install seal 2 with pressure sensitive adhesive against overhead guard leg. 3. Install duct 1 and pre-cleaner 5 with U-clamp 3 and hardware.
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2. Gear Pump Seal Kit Description
This kit is used to minimize foreign materials from damaging the gear pump shaft seal.
208193
208194
This kit consists of following parts. 1 2
Pulley Dust seal
3
Seal (for GC60K-70K only)
Installation for GC35K-55K:
(Refer to Service Manual.) 1. Remove standard pulley 93701-00400. 2. Press dust seal 2 onto drive pulley 1. 3. Install pulley on pump shaft and torque nut to 78 N·m (8 kgf·m) [57.8 lbf·ft]. Installation for GC60K-70K: (Refer to Service Manual.) 1. Remove standard pulley 93701-00400. 2. Press dust seal 2 onto drive pulley 1. 3. Clean pump face with solvent. Remove adhesive backing on seal 3 and apply seal to face of gear pump. 4. Install pulley on pump shaft and torque nut to 78 N·m (8 kgf·m) [57.8 lbf·ft].
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3. Magnetic Plug Kit Description
This kit provides magnetic drain plugs in hydraulic tank and in front drive axle for GC35K-70K. Installation
208195
208196
1. Remove existing plug and gasket from hydraulic tank drain hole.
3. Remove existing plug and gasket from front drive axle drain hole.
2. Install new magnetic plug (M30 × 1.5) and new gasket to drain hole.
4. Install new magnetic plug (M18 × 1.5) and new gasket to drain hole.
Torque to 177 to 196 N·m (18 to 20 kgf·m)
Torque to 50 to 98 N·m (5 to 10 kgf·m)
[130 to 144 lbf·ft]
[36 to 72 lbf·ft]
4. Dust-proof breather kit Description
This kit is used to minimize the entry of foreign particles into the hydraulic tank through its cap assembly. This kit consists of following parts. 1 2
Oil filter cap Oil filter
Installation
1. Remove the existing standard cap assembly from the hydraulic tank, then install oil filter cap 1 in that place. 2. Fit oil filter 2 on top of oil filter cap 1. NOTE Though the oil filter replacement interval depends on the extent of dust accumulations, it is recommended to replace oil filter at every 1,200 service meter hours. 208197
– 22 –
BACK MIRROR KIT Description Back mirrors can help the driver stay aware of other vehicles and pedestrians that may be operating in the vicinity or that may be approaching from behind.
208198
Installation 1. Shown in the illustration is standard dimension for reference. 2. Back mirror is fastened with a U-bolt so that it can be freely moved up and down to set in the desired position. 3. Back mirror can be installed inward as well.
208199
This kit consists of following parts. 1 2 3 4 5
– 23 –
Back mirror Bracket U–clamp Spring washer Nut
®
Lift Trucks
Service Manual GM 4.3L (G6) Fuel System Supplement 003103-up
For use with the GM 4.3L (G6) Engine and GC35K-GC70K Chassis Service Manual.
99789-84111
FORWARD This service manual supplement has instructions and procedures for the GM4.3L (G6) Engine EPA Fuel Systems and is to be used in conjunction with the engine service manual. The information, specifications and illustrations used in this manual are based on information that was current at the time this issue was written. Correct servicing will give the engine a long productive life. Before attempting to start a test, repair or rebuild job be sure that you have read and understood the respective sections of this manual, and know all the components you will be working on. Continuing advancement and improvement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine or this manual, please consult your dealer for the latest available information.
Pub No. 99789-84111
TABLE OF CONTENTS Page General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Fuel Systems Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 English and Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Handling Electrostatic Discharge (ESD) Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 V-Belt Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Serpentine Belt Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Engine Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Engine Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Use of Supplemental Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Synthetic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Changing the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Fuel System Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Propane Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Inspection and Maintenance of the Fuel Storage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Inspection and Maintenance of the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Low Pressure Regulator Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Checking/Draining Oil Build-up in the Low Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . .14 Air Fuel Mixer/Throttle Control Device Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . .15 Exhaust System and Catalytic Converter Inspection and Maintenance . . . . . . . . . . . . . . . . . . .16 Gasoline Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Fuel Tank Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Gasoline Fuel Filter Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Fuel Pump Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fuel Pressure Regulator Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fuel Rails and Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fuel Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Certified Engine Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 LPG Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical LPG Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Descriptions and Operation of the Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Propane Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 LPG Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Service Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Electric Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Low Pressure Regulator (LPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Drive by Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 I
TABLE OF CONTENTS Page Three Way Catalytic Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Propane Closed Loop Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Gasoline Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Multi-Port Fuel Injection System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Gasoline Multi-Port Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Gasoline Fuel Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuel Rail and Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Drive by Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Three Way Catalytic Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Closed Loop Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 LPG Fuel System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Duty Cycle Monitoring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Diagnostic Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Test Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 LPG Fuel System Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Gasoline Fuel System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Test Description - Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Gasoline Fuel System Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LPG Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Important Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Cuts Out, Misses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Backfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Lack of Power, Sluggishness, or Sponginess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 II
TABLE OF CONTENTS Page Rough, Unstable, or Incorrect Idle, Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Surges, Chugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Gasoline Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Important Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Cuts Out, Misses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Backfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Lack of Power, Sluggishness, or Sponginess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Rough, Unstable, or Incorrect Idle, Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Restricted Exhaust System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Exhaust System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Check at heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service Wire Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Connectors and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Micro-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 To Remove a Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Weather Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 4.3L Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 4.3L LPG Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 4.3L Gasoline Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 4.3L Dual Fuel Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 ECM Connector C001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Communication Port C002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Injector Connector C003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Injector Connector C004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Oil Pressure Connector C005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Crank Sensor Connector C006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Module Connector C007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Coil Connector C008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Throttle Connector C009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 EGO Sensor Connector C010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 TMAP Connector C011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 CAM Connector C012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 ECT Connector C013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Starter Solenoid Connector C014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Battery Connector C015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Alternator Connector C016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Alternator Connector C017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Instrument Panel Connector C018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Instrument Panel Connector C019 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 III
TABLE OF CONTENTS Page Instrument Panel Connector C020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Fuel Lockoff C021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Fuel Trim Valve Connector C022 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Pressure Trim Valve Connector C023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Injector 1 Connector C024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 Injector 2 Connector C025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Injector 3 Connector C026 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Injector 4 Connector C027 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Injector 5 Connector C028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Injector 6 Connector C029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of ECM Based Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Diagnostics Overview of the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Malfunction Indicator Lamp (MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Spectrum Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Using a Laptop Computer to Diagnose the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Installing the Diagnostic Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Checking Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Clearing Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Data Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Reading Sensor and Actuator Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Graphing and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 Ignition System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Disabling Ignition Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Injector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Disabling Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Throttle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Using a Diagnostic jumper to Diagnose the ECI System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Diagnostic Procedures for Dual-Fuel Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Injection Driver Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 OBD System Check/Malfunction Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 OBD System Check Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 DTC 111-IAT High Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Conditions for Setting the DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 DTC 111-IAT Voltage High (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .141 DTC 112-IAT Low Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 DTC 112-IAT Voltage Low (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .145 DTC 113-IAT Higher Than Expected 1 (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 DTC 114-IAT Higher Than Expected 2 (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 DTC 115-Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 DTC 115-Oil Pressure Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151 DTC 121-ECT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 DTC 121-ECT High Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 IV
TABLE OF CONTENTS DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
Page 122-ECT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 122-ECT Low Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 123-ECT Higher Than Expected 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 123-ECT Higher Than Expected 1Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 124-ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 124-ECT Higher Than Expected 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 131-MAP High Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 131-MAP High Pressure (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .165 132-MAP Low Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 132-MAP Low Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 134-BP High Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 134-BP High Pressure (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . .173 135-BP Low Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174 135-BP Low Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 142-Crank Sync Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 142-Crank Sync Noise Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 143-Never Crank Synched at Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 143-Never Crank Synched at Start Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 144-Camshaft Sensor Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 144-Camshaft Sensor Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 145-Camshaft Sensor Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 145-Camshaft Sensor Noise Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 211-Closed Loop Multiplier High (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 211-Closed Loop Multiplier High (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .195 212-HO2S Open/Inactive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 212-HO2S Open/Inactive Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 221-Closed Loop Multiplier High (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 221-Closed Loop Multiplier High (Gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .201 222-Closed Loop Multiplier Low (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 222-Closed Loop Multiplier Low (Gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .203 224-Closed Loop Multiplier Low (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 224-Closed Loop Multiplier Low (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .205 241- Adaptive Lean Fault (high limit-gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 241- Adaptive Lean Fault (high limit-gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . .207 242-Adaptive Rich Fault (low limit-gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 242-Adaptive Rich Fault (low limit-gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .211 243-Adaptive Lean High (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212 243-Adaptive Lean High (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213 244-Adaptive Lean Low (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214 244-Adaptive Lean Low (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 261-System Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216 261-System Voltage Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 262-System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218 262-System Voltage High Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219 511-COP Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220 511-COP Failure Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 512-Invalid Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 V
TABLE OF CONTENTS DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
Page 512-Invalid Interrupt Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 513-A/D Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 513-A/D Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 514-RTI 1 Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 514-RTI 1 Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227 515-Flash Checksum Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228 515-Flash Checksum Invalid Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 516-Ram Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 516-Ram Failure Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231 531-External 5 Volt Reference Lower Than Expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 531-External 5 Volt Reference Lower Than Expected Troubleshooting Chart . . . . . . . . . . . . . .233 532-External 5 Volt Reference Higher Than Expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234 532-External 5 Volt Reference Higher Than Expected Troubleshooting Chart . . . . . . . . . . . . .235 555-RTI 2 Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236 555-RTI 2 Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237 556-RTI 3 Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238 556-RTI 3 Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239 611-FPP High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 611-FPP High Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 612-FPP Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 612-FPP Low Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 613-FPP Higher Than IVS Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248 613-FPP Higher Than IVS Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249 614-FPP Lower Than IVS Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 614-FPP Lower Than IVS Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 631-TPS 1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252 631-TPS 1 Signal Voltage High Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253 632-TPS 1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256 632-TPS 1 Signal Voltage Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 633-TPS 2 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 633-TPS 2 Signal Voltage High Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 634-TPS 2 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 634-TPS 2 Signal Voltage Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 635-TPS 1 Higher Than TPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 635-TPS 1 Higher Than TPS 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 636-TPS 1 Lower Than TPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270 636-TPS 1 Lower Than TPS 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 637-Throttle Unable to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274 637-Throttle Unable to Open Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 638-Throttle Unable to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 638-Throttle Unable to Close Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 651-Maximum Governor Speed Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282 651-Maximum Governor Speed Override Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . .283 652-Fuel Rev Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284 652-Fuel Rev Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 653-Spark Rev Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286 653-Spark Rev Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287 721-Transmission Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288 VI
TABLE OF CONTENTS Page Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Low Pressure Lock-Off (LPL) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 Pressure Trim Valve (PTV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 Low Pressure Regulator (LPR) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 Fuel Trim Valve (FTV) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295 Temperature Manifold Absolute Pressure (TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295 Electronic Throttle Control Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 Mixer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 FTV Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Coolant Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Vapor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 Balance Line Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 PTV Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 FTV Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Three Way Catalytic Converter Muffler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Gasoline Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline MPFI Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Gasoline Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 Electronic Throttle Control Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 Fuel Rail Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 Temperature Manifold Absolute Pressure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
VII
SECTION 0A
GENERAL INFORMATION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Fuel Systems Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 English and Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Handling Electrostatic Discharge (ESD) Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . .3 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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Notes, Cautions, And Warnings !
Notes, Cautions, and Warnings are used in this manual to emphasize important and critical instructions. They are used for the following conditions:
Do not allow propane to accumulate in areas below ground level such as in a service pit or underground ventilation systems. Propane is heavier than air and can displace oxygen, creating a dangerous condition.
NOTE
It is important to note that this manual contains various Warnings, Cautions and Notes that must be carefully observed in order to reduce the risk of personal injury during service or repair. Improper service or repair may damage the engine or render it unsafe or fail to make the engine emissions compliant. It is also important to warn of all hazardous consequences that might result from careless treatment of the engine. Failure to observe these items could influence terms of the warranty.
Denotes situations which could influence safety or proper performance of the vehicle or component and to highlight an essential operating procedure or condition.
!
CAUTION
Operating procedures or practices that may result in damage to or destruction of the engine if not strictly observed.
!
To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe reliable operation of all engines. The service procedures recommended and described in this service manual are effective methods of performing service and repair. Some of these procedures require the use of tools specially designed for the purpose.
WARNING
Operating procedures or practices that could result in serious injury or loss of life if not correctly followed.
If part replacement is necessary, the replacement part must be of the same part number or equivalent part. Do not use a replacement part of lesser quality. In the case of replacement parts for the emission control system use only genuine OEM replacement parts.
Fuel Systems Cautions
!
WARNING
Before using a replacement part, service procedure, or a tool which is not recommended by the engine manufacturer, it must first be determined that neither personal safety nor the safe operation of the engine will be jeopardized by the replacement part, service procedure or the tool selected.
Do not smoke, carry lighted tobacco, or use a lighted flame of any type when working on or near any fuel related component. Highly flammable air-fuel mixtures may be present and can be ignited causing personal injury.
!
WARNING
Special service tools shown in this service manual and should be available in your shop.
WARNING
Do not allow propane to contact the skin. Propane is stored in the fuel tank as a liquid. When propane contacts the atmosphere, it immediately expands into a gas, resulting in refrigeration that can cause severe burns. Special Tools which are required to service the LPG fuel system are listed below:
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o
Hand held diagnostic scanner
o
ITK-1 Fuel pressure test kit
first. 5.
Do not remove the solid state component from its protective packaging until you are ready to install the part.
6.
Always touch the solid state components package to a ground before opening. Solid state components can also be damaged if: • They are bumped or dropped. • They are laid on any metal work benches or components that operate electrically, such as a TV, radio, or oscilloscope.
English And Metric Fasteners
!
CAUTION
Late model engines use a combination of English and Metric fasteners. The components affected are the starter motor, engine mounts, and flywheel housing mounting. Other components may also have a combination of fasteners, always verify that the proper fasteners are used whenever removing or replacing any components.
Handling Electrostatic Discharge (ESD) Sensitive Parts Many solid state electrical components can be damaged by electrostatic discharge (ESD). Some will display a label, but many will not. In order to avoid possibly damaging any components, observe the following: 1. Body movement produces an electrostatic charge. To discharge personal static electricity, touch a ground point (metal) on the vehicle. This should be done any time you:
• Slide across the vehicle seat. • Sit down or get up. • Do any walking. 2.
Do not touch exposed electric terminals on components with your finger or any tools. Remember, the connector that you are checking might be tied into .a circuit that could be damaged ‘by electrostatic discharge.
3.
When using a screwdriver or similar tool to disconnect a connector, never let the tool come in contact with or come between the exposed terminals.
4.
Never jumper, ground, or use test equipment probes on any components or connectors unless specified in diagnosis. When using test equipment, always connect the ground lead
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GLOSSARY OF TERMS Air Valve Vacuum (AVV): The vacuum signal taken from below the air valve assembly and above the throttle butterfly. ADP: Adaptive Digital Processor. Air/Fuel Ratio: The amount of air and fuel in the air fuel mixture, which enters the engine, shown in a ratio. Analog Voltmeter: A meter that uses a needle to point to a value on a scale of numbers usually of the low impedance type; used to measure voltage and resistance. Aromatics: Pertaining to or containing the six-carbon ring characteristic of the benzene series. Found in many crude oils. Backfire: Combustion of the air/fuel mixture in the intake or exhaust manifolds. A backfire can occur if the intake or exhaust valves are open when there is a mis-timed ignition spark. Benzene: An aromatic (C6H6). Sometimes blended with gasoline to improve antiknock value. Benzene is toxic and suspected of causing cancer. Bi-Fueled: A vehicle equipped to run on two fuels at the same time such as a fumigated diesel. Blow-By: Gases formed by the combustion of fuel and air, which ordinarily should exert pressure only against the piston crown and first compression ring. When rings do not seal, these gases (blowby) escape down the side of the piston into the crankcase. BTU: British Thermal Unit. A measurement of the amount of heat required to raise the temperature of 1lb. of water 1 degree F. Butane: An odorless, colorless gas, C4H10 found in natural gas and petroleum. One of the five LP gases. CAFE: Corporate Average Fuel Economy. CARB: California Air Resources Board. Carbon Monoxide (CO): A chemical compound of a highly toxic gas that is both odorless and colorless. Carburetor: An apparatus for supplying an internal-combustion engine a mixture of vaporized fuel and air. Cathode Ray Tube: A vacuum tube in which cathode rays usually in the form of a slender beam are projected on a fluorescent screen and produce a luminous spot. Circuit: A path of conductors through which electricity flows before it returns to its source. Closed Loop Operation: Applies to systems utilizing an oxygen sensor. In this mode of operation, the system uses oxygen sensor information to determine air/fuel ratio. Adjustments are made accordingly and checked by comparing the new oxygen sensor to previous signals. No stored information is used. CNG: Compressed Natural Gas. CKP: Crankshaft Position Sensor CMP: Camshaft Position Sensor Conductor: A material, normally metallic, that permits easy passage of electricity. Contaminants: Impurities or foreign material present in fuel. Control Module: One of several names for a solid state microcomputer which monitors engine conditions and controls certain engine functions; i.e. air/fuel ratio, injection and ignition time, etc. Converter: A LPG fuel system component containing varying stages of fuel pressure regulation combined with a vaporizer. Cryogen: A refrigerant used to obtain very low temperatures. Current: The directed flow of electrons through a conductor. Measured in amps. Dedicated Fuel System: A motor fuel system designed to operate on only one fuel type. Diaphragm: A thin, flexible membrane that separates two chambers. When the pressure in one chamber is lower than in the other chamber, the diaphragm will move toward the side with the low pressure. Diaphragm Port: The external port located at the fuel inlet assembly and connected to the vacuum chamber above the air valve diaphragm. Digital Volt/Ohm Meter (DVOM): A meter that uses a numerical display in place of a gauge and is usually of the high impedance type.
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DTC: Diagnostic Trouble Code DST: Diagnostic Scan Tool. DVOM: Digital volt/ohmmeter. ECT: Engine Coolant Temperature. ECM : Electronic Control module EFI: Electronic Fuel Injection. A fuel injection system, which uses a microcomputer to determine and control the amount of fuel, required by, and injected into, a particular engine. EGR: Exhaust gas recirculation. EPA: Environmental Protection Agency: A regulating agency of the Federal government which, among other duties, establishes and enforces automotive emissions standards. Ethanol: Grain alcohol (C2H5OH), generally produced by fermenting starch or sugar crops. Evaporative Emissions Controls: An automotive emission control system designed to reduce hydrocarbon emissions by trapping evaporated fuel vapors from the fuel system. Excess Flow Valve: A check valve that is caused to close by the fuel when the flow exceeds a predetermined rate. FTV: Fuel Trim Valve. FFV: Flexible Fuel Vehicle. Firing Line: The portion of an oscilloscope pattern that represents the total amount of voltage being expended through the secondary circuit. FMVSS: Federal Motor Vehicle Safety Standards. FPP: Foot Pedal Position Sensor Fuel Injector:, a spring loaded, electromagnetic valve which delivers fuel into the intake manifold, in response to electrical from the control module. Fuel Lock: A solenoid-controlled valve located in the fuel line to stop the flow when the engine stops or the ignition switch is off. Gasohol: 10 percent ethanol, 90 percent gasoline. Often referred to as E-10. Gasoline: A motor vehicle fuel that is a complex blend of hydrocarbons and additives. Typical octane level is 89. Greenhouse Effect: A scientific theory that suggests that excessive levels of carbon dioxide from the burning of fossil fuels is causing the atmosphere to trap heat and cause global warming. HD 10: A fuel of not less than 80% liquid volume propane and not more than 10% liquid volume propylene. HD 5: A fuel of not less than 90% liquid volume propane and not more than 5% liquid volume propylene. HDV: Heavy Duty Vehicle. Hg: Chemical symbol for mercury. Used in reference to vacuum (in. of Hg). Hydrocarbon: A chemical compound made up of hydrogen and carbon (HC). A major pollution emission of the internal combustion engine. Gasoline and almost all other fuels are hydrocarbons. Hydrostatic Relief Valve: A pressure relief device installed in the liquid propane hose on a propane fuel system. IAT: Intake Air Temperature Ideal Mixture: The air/fuel ratio at which the best compromise of engine performance to exhaust emissions is obtained. Typically 14.7:1. Ignition Reserve: The difference between available voltage and the required voltage. ILEV: Inherently Low Emission Vehicle. IMPCO: Imperial Machine Products Company. IMPCO Technologies, Inc. A manufacturer of both LPG and Gasoline fuel systems. Impedance: A form of opposition of AC current flow (resistance) measured in ohms. Insulation: A non conductive material used to cover wires in electrical circuits to prevent the leakage of electricity and to protect the wire from corrosion. Intercept: An electrical term for a type of splice where the original circuit is interrupted and redirected through another circuit.
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ITK: IMPCO Test Kit Knock: Sound produced when an engine’s air/fuel mixture is ignited by something other than the spark plug, such as a hot spot in the combustion chamber. Can be caused by a fuel with an octane rating that is too low or maladjusted ignition timing. Also called detonation or ping. Lambda Sensor: A feedback device, usually located in the exhaust manifold, which detects the amount of oxygen present in exhaust gases in relation to the surrounding atmosphere. LDV: Light Duty Vehicle. Lean Mixture: An air to fuel ratio above the stoichiometric ratio; too much air. LEV: Low Emission Vehicle. Limp-in or Limp-home: This term is used to describe the drivability characteristics of a failed computer system Liquefied Petroleum Gas (LPG): A fuel commonly known as propane consisting mostly of propane (C3H8), derived from the liquid components of natural gas stripped out before the gas enters the pipeline, and the lightest hydrocarbons produced during petroleum refining. Octane level is 107. LPG: Liquefied Petroleum Gas. M85: A blend of gasoline and methanol consisting of 85% methanol and 15% gasoline. Measurements of Pressure: 1 PSI=2.06 Hg (mercury) = 27.72” H2O (water column). At sea level atmospheric pressure is 29.92” Hg. Methanol: Known as wood alcohol (CH3OH), a light, volatile, flammable alcohol commonly made from natural gas. Misfire: Failure of the air/fuel mixture to ignite during the power stroke. Mixer: Fuel introduction device that does not include a throttle plate. MPFI: Multi-Point Fuel injection. A fuel injection system that uses one injector per cylinder mounted on the engine to spray fuel near the intake valve area of combustion chamber. MTBE: Methyl Tertiary Butyl Ether. Oxygenate add to gasoline to reduce harmful emissions and to improve the octane rating. Multi-fuel System: A motor fuel system designed to operate on two different fuels, such as LPG and gasoline. Natural Gas: A gas formed naturally from buried organic material, composed of a mixture of hydrocarbons, with methane (CH4) being the dominant component. NGV: Natural Gas Vehicle. Nox: See Oxides of Nitrogen. Octane Rating: The measurement of the antiknock value of a motor fuel. OEM: Original Equipment Manufacturer, the vehicle manufacturer. Open-Loop: An operational mode during which control module memory information is used to determine air/fuel ratio, injection timing, etc., as opposed to actual oxygen sensor input. Orifice: A port or passage with a calibrated opening designed to control or limit the amount of flow through it. Oscilloscope: An instrument that converts voltage and frequency readings into traces on a-cathode ray tube (also see Cathode Ray Tube). Oxides of Nitrogen: Chemical compounds of nitrogen bonded to various amounts of oxygen (Nox). A chief smog forming-agent. Oxygen Sensor: An automotive fuel system that produces a signal in accordance with the oxygen content of the exhaust gas. (See Lambda Sensor). Oxygenate: MTBE, ethanol and methanol. Oxygenates are added to gasoline to increase the oxygen content and therefore reduce exhaust emissions. Ozone: A radical oxygen module (O3) that is found in the upper atmosphere and filters out ultraviolet radiation from the sun. Ground level ozone is formed by Nox, during the formation of photochemical smog. Particulates: Microscopic pieces of solid or liquid substances such as lead and carbon that are discharged into the atmosphere by internal combustion engines. Positive Crankcase Ventilation (PCV): An automotive emission control system designed to reduce hydrocarbon emissions by routing crankcase fumes into the intake manifold rather than to the atmosphere.
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Pressure Differential: The differential between atmospheric pressure and intake manifold (referred to as vacuum) pressure. Pressure Regulator: A device to control the pressure of fuel delivered to the fuel injector(s). Primary Circuit: The low-voltage or input side of the ignition coil. Propane: An odorless, colorless gas, C3H8, found in natural gas and petroleum. PTV: Pressure Trim Valve Reactivity: Refers to the tendency of an HC in the presence of Nox and sunlight to cause a smog-forming reaction. The lighter the HC, the lower reactivity tends to be. Regulator: An assembly used to reduce and control the pressure of a liquid or vapor. Resistance: The opposition to the flow of current in an electrical circuit. Measured in ohms.
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SECTION 0B
MAINTENANCE Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 V-Belt Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Serpentine Belt Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Engine Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Engine Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Use of Supplemental Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Synthetic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Changing the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Fuel System Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Propane Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Inspection and Maintenance of the Fuel Storage Cylinder . . . . . . . . . . . . . . . . . . .13 Inspection and Maintenance of the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Low Pressure Regulator Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . .14 Checking/Draining Oil Build-up in the Low Pressure Regulator . . . . . . . . . . . . . . .14 Air Fuel Mixer/Throttle Control Device Maintenance and Inspection . . . . . . . . . . . .15 Exhaust System and Catalytic Converter Inspection and Maintenance . . . . . . . . .16 Gasoline Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Fuel Tank Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Gasoline Fuel Filter Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .16 Fuel Pump Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fuel Pressure Regulator Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . .17 Fuel Rails and Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Fuel Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Certified Engine Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
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adjust the tension. Do not over tighten the tension of the belt. Over tightening may cause overload on the bearings and pulleys of the drive belt components.
Maintenance The maintenance of the engine and its related components is critical to the life of the engine and optimum performance during its useful life. All engines require a certain amount of maintenance. The suggested maintenance requirements are contained in this section. Industrial engines operate in various environments from extremely dusty environments, to hot and cold temperature environments and clean environments. The recommended schedule is a recommended guide line for the owner and servicing agency to follow, however certain environmental operating conditions may require more frequent inspection and maintenance. In addition the owner may have installed additional equipment to the equipment which may also increase the requirements for service on certain components. Therefore the owner and servicing agent should review the operating condition of the equipment and determine if more frequent inspections and maintenance cycles maybe required.
Serpentine Belt System Serpentine belts utilize a spring-loaded tensioner which keeps the belt properly adjusted. Serpentine belts should be checked according to the maintenance schedule in this section.
NOTE The engine manufacturer does not recommend the use of “belt dressing” or “anti slipping agents” on either belt configuration.
Cooling System !
!
WARNING
WARNING It is important to remember that the cooling system of this engine be maintained properly to insure the longevity of the engine. Maintenance of the cooling system is critical to not only the engine but the fuel system as well. Because the LPG vaporizer is connected into the cooling system low coolant levels and restricted or plugged radiator cores can impact the performance of the fuel system. Therefore proper maintenance of the cooling system should include removing dust, dirt and debris from the radiator core on regular intervals. To properly maintain the cooling system follow the recommend maintenance schedule in this section.
The engine installed in this equipment may use one or both accessory drive belt configurations. The drive belt may be incorporated to drive the water pump, alternator and addition pumps or devices. It is important to note, the drive belt is an integral part of the cooling and charging system and should be inspected at a minimum according to the maintenance schedule in this section and in extremely hot and dirty environments more often. When inspecting the belts check for: • Cracks, •
Chunking of the belt,
•
Splits
•
Material hanging loose from the belt
•
Glazing, hardening
Cooling system inspections should be performed as prescribed when inspecting the cooling system check for the following:
If any of these conditions exist the belt should be replaced with an OEM replacement belt.
V-Belt Systems Check the belt tension by pressing down on the midway point of the longest stretch between two pulleys. The belt should not depress beyond 13 mm (1/2 inch). If the depression is more than allowable
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•
Plugged or restricted radiator core clean with compressed air, blow dust and debris from the core and the fan shroud
•
Check the radiator cap to insure proper sealing if damage replace
•
Check for coolant leaks at the radiator tank seams and inlet joints repair or replace as necessary
•
Check for leaks at the radiator hose connections, tighten hose clamps if necessary
•
Check Radiator hoses for swelling, separation,
timum performance. When inspecting the electrical system check the following:
cracks deterioration in the hoses, or hardening, if any of these conditions exist the hose should be replaced with the OEM replacement parts •
Check coolant level if low add with 50/50 mixture, Do not add plain water
•
Check battery connection clean and insure that connectors are tight.
•
Replace coolant per the recommended schedule at the end of this section
•
Check battery for cracks or damage to the case replace if necessary.
•
Check Positive and Negative cables for corrosion, rubbing, chaffing and insure tight connections at both ends.
•
Check engine wire harness for rubbing, chaffing, pinching, and cracks or breaks in the wiring.
•
Check engine harness connectors, check to insure fitted and locked by pushing the connector together then pull on the connector halves to insure they are locked.
•
Check ignition coil wire for hardening, cracking, arcing, chaffing, separation, split boot covers and proper fit.
•
Check spark plug wires for hardening, cracking, chaffing, separation, split boot covers and proper fit.
•
Replace spark plugs at the required intervals per the recommended maintenance schedule
•
Check to insure all electrical components are securely mounted and retained to the engine or chassis.
•
Check to insure any additional electrical devices installed by the owner are properly installed in the system.
•
Check the MIL, charging, and oil pressure lights for operation by starting the engine and checking that the light illuminates for the prescribe period of time before turning out.
CHECKING THE COOLANT LEVEL !
WARNING
Do not remove the cooling system pressure cap when the engine is hot. Allow the engine to cool and then remove the cap slowly allowing pressure to vent. Hot coolant under pressure may discharge violently. 1.
Check coolant level in coolant recovery tank. Add specified coolant as required.
NOTE The engine manufacturer and the fuel system supplier do not recommend the use of “stop leak” additives to repair leaks in the cooling system. If leaks are present the radiator should be removed and repaired. If the radiator requires repair insure that the radiator core repairs did not result in a significant reduction in the cooling capacity of the radiator. The engine manufacturer recommends the cooling system be filled with a 50/50 mixture of ethylene glycol antifreeze and water. This GM industrial engine can utilize any type of permanent antifreeze or any brand antifreeze solution that meets GM Specification 1825M or 1899M which will not damage aluminum parts.
Engine Crankcase Oil Oil Recommendation
Engine Electrical System Maintenance
Prior to changing the oil, select oil based on the prevailing daytime temperature in the area in which the equipment will be operated. The chart in figure 1 is a guide to selecting the proper crankcase oil.
The engine electrical system incorporates computers to control certain functions of the equipment. The electrical system connections and ground circuits require good connections. Follow the recommended maintenance schedule in this section to maintain op-
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IMPORTANT: Oils containing “solid” additives, nondetergent oils, or low quality oils are not recommended by the engine manufacturer.
Checking/Filling Engine Oil Level NOTE Care must be taken when checking engine oil level. Oil level must be maintained between the “ADD” mark and the “FULL” mark on the dipstick. To ensure that you are not getting a false reading, make sure the following steps are taken before checking the oil level. 1. Stop engine if in use
Figure 1 Engine Oil Viscosity Recommendation
2.
Allow sufficient time (approximately 5 minutes) for the oil to drain back into the oil pan
3.
Remove the dipstick. Wipe with a clean cloth or paper towel and reinstall. Push the dipstick all the way into the dipstick tube.
4.
Remove the dipstick and note the oil level.
5.
Oil level must be between the “FULL” and “ADD” marks.
Use Of Supplemental Additives Use of the oils recommended by the engine manufacturer already contains a balanced additive treatment. The uses of supplemental additives which are added to the engine oil by the customer are not necessary and may be harmful. The engine manufacturer, fuels system suppliers and engine distributors do not review, approve or recommend such products.
Synthetic Oils Synthetic oils have been available for use in industrial engines for a relatively long period of time. Synthetic oils may offer advantages in cold temperature pumpability and high temperature oxidations resistance. However, synthetic oils have not proven to provide operational or economic benefits over conventional petroleum-based oils in industrial engines. Their use does not permit the extension of oil change intervals.
Figure 2 Engine Oil Dip stick (Typical) 6.
If the oil level is below the “ADD” mark, proceed to Step 7 and 8, and reinstall the dipstick into the dipstick tube.
7. Remove the oil filler cap from the valve rocker arm cover
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8.
Add the required amount of oil to bring the level up to but not over the “FULL” mark on the dipstick
9.
Reinstall the oil filler cap to the valve rocker arm cover and wipe any excess oil clean.\
Changing the Engine Oil
Fuel System Inspection and Maintenance
NOTE Propane Fuel System When changing the oil, always change the oil filter. 1.
The Propane fuel system installed on this industrial engine has been designed to meet the emission standard applicable for this equipment for 2004 model year. To ensure compliance to these standards follow the recommended maintenance schedule contained in this section.
Start the engine and run until it reaches normal operating temperature.
NOTE
Inspection and Maintenance Of The Fuel Storage Cylinder
Change oil when engine is warm from operation as it flows more freely, carrying away more impurities.
The fuel storage cylinder should be inspected daily or at the beginning of each operational shift for any leaks, external damage, adequate fuel supply and to insure the manual service valve is open. Fuel storage cylinders should always be securely mounted, inspect the securing straps or retaining devices for damage insure that all locking devices are closed and locked. Check to insure that the fuel storage cylinder is positioned with the locating pin in the tank collar on all horizontally mounted cylinders this will insure the proper function of the cylinder relief valve.
2.
Stop engine.
!
WARNING
Engine oil will be hot. Use protective gloves to prevent burns. Engine oil contains chemicals which may be harmful to your health avoid skin contact. 3.
Remove drain plug and allow the oil to drain.
4.
Remove and discard oil filter and it sealing ring.
5.
Coat sealing ring on the new filter with clean engine oil, wipe the sealing surface on the filter mounting surface to remove any dust, dirt or debris. Tighten filter securely (follow filter manufacturers instructions). Do not overtighten.
6.
When refueling or exchanging the fuel cylinder check the quick fill valve for thread damage. Insure the Oring is in place, check the O-ring for cracking, chunking or separation, replace if damaged before filling. Check the service line quick coupler for any thread damage. Insure the O-ring is in place, check the Oring for cracking, hardening, chunking or separation. Replace if damaged.
NOTE When refueling the fuel cylinder, wipe clean both the female and male connection with a clean rag prior to filling. This will prevent dust, dirt and debris from being introduced to the fuel cylinder and prolong the life of the fuel filter.
Check sealing ring on drain plug for any damage, replace if necessary, wipe plug with clean rag, wipe pan sealing surface with clean rag and re-install plug into the pan. Tighten to specification.
7. Fill crankcase with oil. 8.
Inspection and Replacement Of The Fuel Filter
Start engine and check for oil leaks.
9. Dispose of oil and filter in a safe manner.
The Propane system on this emission certified engine utilizes an in-line replaceable fuel filter element. This element should be replaced, at the intervals specified in the recommended maintenance schedule. When inspecting the fuel filter check the following:
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soapy solution or an electronic leak detector, if leaks are detected make repairs.
• Check for leaks at the inlet and outlet fittings, using a soapy solution or an electronic leak detector, if leaks are detected make repairs
Low Pressure Regulator (LPR) Maintenance and Inspection
• Check to make sure filter is securely mounted. • Check filter housing for external damage or distortion, if damaged replace fuel filter
NOTE
To replace the filter use the following steps: 1. Move the equipment to a well ventilated area and insure all external ignition sources are not present.
The Low Pressure Regulator (LPR) components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine. The regulator should not be disassembled or rebuilt. If the LPR fails to operate or develops a leak the LPR should be replaced with the OEM recommended replacement parts.
2. Start the engine. 3. With the engine running close the manual valve. 4. When the engine runs out of fuel turn OFF the key when the engine stops and disconnect the battery negative cable.
!
When inspecting the regulator check for the following items:
WARNING
• Check for any fuel leaks at the inlet and outlet fittings.
A small amount of fuel may still be present in the fuel line, use gloves to prevent burns, wear proper eye protection. If liquid fuels continues to flow from the connections when loosened check to make sure the manual valve is fully closed.
• Check for any fuel leaks in the regulator body. • Check the inlet and outlet fittings of the coolant supply lines for water leaks. • Check the coolant supply lines for hardening, cracking, chaffing or splits. If any of these conditions exist replace coolant lines.
5. Slowly loosen the inlet fitting and disconnect.
• Check coolant supply hose clamp connections, ensure they are tight.
6. Slowly loosen the outlet fitting and disconnect. 7. Remove the filter housing form the equipment. 8. Check for contamination.
• Check the to ensure the Pressure Trim Valve (PTV) mounting bolts are secure.
9. Tap the opening of the filter on a clean cloth.
• Check PTV for external damage. • Check PTV electrical connection to ensure the connector is seated and locked.
10. Check for debris. 11. Check canister for proper mounting direction.
• Check to ensure the regulator is securely mounted.
12. Reinstall the filter housing to the equipment. 13. Tighten the inlet and outlet fittings to specification.
Checking/Draining Oil Build-up In the Low Pressure Regulator (LPR)
14. Open the manual valve.
NOTE During the course of normal operation oil or “heavy ends” may build inside the secondary chamber of the Low Pressure Regulator (LPR). These oil and heavy ends may be a result of poor fuel quality, contamination of the fuel supply chain, or regional variation of the fuel make up. If the build up of oil becomes significant this can affect the performance of the secondary diaphragm response. The Recommended Maintenance Schedule found in this section recommends that the oil be drained periodically.
The fuel cylinder manual valve contains an “Excess Flow Check Valve” open the manual valve slowly to prevent activating the “Excess Flow Check Valve”. 15. Check for leaks at the inlet and outlet fittings, and the filter housing end connection using a
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clamp.
NOTE
17. Reinstall the fuel inlet line and tighten connection to specification.
Draining the regulator when the engine is warm will help the oils to flow freely from the regulator.
18. Slowly open the manual service valve.
NOTE
To drain the LPR use the following steps: 1. Move the equipment to a well ventilated area and ensure no external ignition sources are present.
The fuel cylinder manual valve contains an “Excess Flow Check Valve” open the manual valve slowly to prevent activating the “Excess Flow Check Valve”.
2. Start the engine. 3. With the engine running close the manual valve.
19. Check for leaks at the inlet and outlet fittings using a soapy solution or an electronic leak detector, if leaks are detected make repairs. Check coolant line connections to ensure no leaks are present.
4. When the engine runs out of fuel turn OFF the key when the engine stops and disconnect the battery negative cable.
!
20. Start engine recheck for leaks at the regulator.
WARNING
21. Dispose of any drained material in safe and proper manner. A small amount of fuel may still be present in the fuel line, use gloves to prevent burns, wear proper eye protection. If liquid fuels continues to flow from the connections when loosened check to make sure the manual valve is fully closed.
Air Fuel Mixer/Throttle Control Device Maintenance and Inspection
5. Slowly loosen the inlet fitting and disconnect. !
6. Loosen the hose clamp at the outlet hose fitting and remove the hose.
CAUTION
The Air Fuel Mixer components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine. The mixer should not be disassembled or rebuilt. If the mixer fails to operate or develops a leak the mixer should be replaced with the OEM recommended replacement parts.
7. Remove and retain the locking pin in the outlet fitting and remove the outlet fitting from the LPR 8. Disconnect PTV connection and disconnect the vacuum hose. 9. Remove the two LPR mounting bolts and retain. 10. Place a small receptacle in the engine compartment.
When inspecting the mixer check for the following items:
11. Rotate the LPR to 90° so that the outlet fitting is pointing down into the receptacle and drain the LPR.
• Check for any fuel leaks at the inlet fitting.
12. Inspect the secondary chamber for any large dried particles and remove.
• Check the fuel inlet hose for cracking, splitting or chaffing, replace if any of these condition exist.
13. Remove the receptacle and reinstall the LPR with the two retaining bolts and tighten to specifications.
• Check to ensure the mixer is securely mounted.
14. Reinstall the outlet fitting and secure with the previously removed locking pin.
• Check air inlet hose connection and insure clamp is tight, check inlet hose for cracking, splitting or chaffing, replace if any of these condition exist.
15. Reconnect the PTV electrical connection push connector until lock “Click”, pull on the connector to ensure it is locked, connect the vacuum line.
• Check air cleaner element according to the Recommended Maintenance Schedule found in this section.
16. Reconnect the outlet hose and secure the hose
• Check fuel line to Throttle body mounted Fuel
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through” repair if necessary.
Trim Valve (FTV) for cracking, splitting or chaffing, replace if any of these condition exist.
• Check any exhaust pipe extension connector for leaks tighten if necessary
• Check Throttle body return action to ensure throttle shaft is not sticking repair if necessary.
• Visually inspect converter to insure muffler is securely mounted and tail pipe is properly aimed.
• Check FTV electrical connection to ensure connector is fully seated and locked.
• Check for any leaks at the inlet and outlet of the converter
• Check for leaks at the throttle body and intake manifold. • Check Throttle cable for damage, rubbing, and kinking and free movement repair if necessary.
Gasoline Fuel Tank Maintenance and Inspection
Exhaust System and Catalytic Converter Inspection and Maintenance
The gasoline fuel tank on most forklifts is integrated into the chassis of the forklift. Gasoline is stored as a liquid in the fuel tank and is drawn from the fuel tank through a pick-up tube by an externally mounted 12 volt electric fuel pump.
NOTE
When inspecting the fuel tank check the following;
The exhaust system on this emission certified engine contains an Exhaust Gas Oxygen Sensor (EGO) which provides feed back to the ECM on the amount of oxygen present in the exhaust stream after combustion. The measurement of oxygen in the exhaust stream is measured in voltage and sent to the ECM. The ECM then makes corrections to the fuel air ratio to ensure the proper fuel charge and optimum catalytic performance. Therefore it is important that the exhaust connections remain secured and air tight.
!
• Check for leaks in the tank. • Check the fill cap sealing ring for cracks, chunking, separation replace if any of these conditions exist. • Check the fill cap for cracks check threads for burrs and distortion ensure cap is tight. • Check outlet hose fitting and connection ensure tight seal. • Check fuel return line connection and fittings for leaks.
CAUTION
• Check fuel return line for cracking, chaffing, separation replace if any of these conditions exist.
The EGO sensor is sensitive to silicone or silicone based products. Do not use silicone sprays or hoses which are assembled using silicone lubricants. Silicone contamination can cause severe damage to the EGO.
Fuel Filter Inspection and Replacement
When inspecting the Exhaust system check the following:
The gasoline fuel system incorporates an inlet replaceable fuel filter to remove dirt, debris and contaminants which may have been introduced into the fuel tank. Replace the filter as prescribed in the Recommended Maintenance Schedule found in this section.
• Check the exhaust manifold at the cylinder head for leaks and that all retain bolts and shields (if used) are in place. • Check the manifold to exhaust pipe fasteners to ensure they are tight and that there are no exhaust leaks repair if necessary.
When inspecting the gasoline fuel filter check the following;
• Check EGO electrical connector to ensure connector is seated and locked, check wires to ensure there is no cracking, splits chaffing or “burn
• Check for leaks at the inlet and outlet connections of the filter.
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harness is secure in its retaining device and that the wire harness is not chaffing or routed improperly.
• Check to ensure the gasoline fuel filter is securely mounted. • Check for any damage to the filter.
• Check to make sure the fuel pump is securely mounted to the chassis.
To replace the Gasoline fuel filter use the following steps:
Fuel Pressure Regulator Maintenance and Inspection
1. Move the forklift to a well ventilated area and insure all external ignition sources are not present. 2. Place a drain receptacle under the forklift to capture any fuel which may drain from the lines.
The gasoline fuel injection system utilizes a single stage pressure regulator to maintain a constant fuel supply to the fuel rails and injectors. The regulator is specifically designed and calibrated to meet the emission requirements of the certified engine. If the regulator fails to operate it should only be replaced with the OEM replacement part.
3. Shut OFF the engine. 4. Disconnect the fuel inlet fitting. 5. Disconnect the fuel outlet fitting. 6. Remove the gasoline fuel filter from the mounting bracket
When inspecting the fuel pressure regulator check the following;
7. Discard the filter in a safe and proper manner 8. Reinstall the fuel filter into the securing bracket and tighten retaining fastener
• Check for leaks at the inlet and outlet fitting of the regulator.
9. Ensure the gasoline fuel filter is mounted in the proper direction arrow should be in the direction of flow.
• Check for external leaks at the regulator
10. Reconnect the inlet and outlet fittings and tighten to specification.
• Check to ensure the regulator is securely mounted
11. Remove drain pan and discard any drained gasoline in a safe and proper manner
• Check the fuel inlet and outlet supply lines for cracks, chaffing or separations replace if any of these conditions exist
12. Start engine and check for leaks, repair if necessary.
Fuel Rails and Injectors Fuel Pump Maintenance and Inspection
The fuel delivery system of the gasoline injection system utilizes two fuel rails to supply fuel to the injectors. The gasoline fuel injectors supply the specific amount of fuel for the combustion cycle. The ECM sends a signal to the injector to open for the calibrated time for fuel delivery to the intake port. The injectors utilized for the emissions certified engines are specifically calibrated if an injector fails to operate it should only be replaced with the OEM replacement parts.
The fuel pump is specifically design to supply the correct fuel pressure to the injector pressure regulator. During normal engine operation excessive fuel from the fuel rails is bypassed back to the fuel tank. If the fuel pump fails to operate replace with the OEM replacement part only, substitute must supply to much fuel and cause excessive pressure in the fuel and damage to the fuel system.
When inspecting the fuel rails and injector check the following:
When inspecting the fuel pump check the following; • Check for leaks at the fuel pump.
• Check the fuel inlet line connections for leaks
• Check the inlet and outlet fittings for leaks.
• Check the fuel return line connections for leaks
• Check the electrical connection to ensure the connector is fully seated and locked.
• Check the fuel rail for leaks or external damage • Check to ensure the fuel rail is securely mounted
• Check the fuel pump wire harness to ensure the
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• Check the fuel rail to injector connections for leaks • Check the base of the injector for leaks • Check the injector wire connections to ensure sure they are fully seated and locked • Check the fuel pressure sender electrical connection to ensure they are fully seated and locked • Check the fuel pressure sender connection at the fuel rail for leaks
Fuel Additives The engine manufacturer does not recommend the use of Injector cleaners or fuel additives which clean fuel system parts. Use of such additives are unnecessary if the fuel system filter is change as required and clean refueling practices are practiced. Avoid storing fuel in containers which are not specifically designed to store gasoline. Avoid storing gasoline in dusty and dirty environments doing so will further prevent contamination of the fuel system.
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CERTIFIED ENGINE MAINTENANCE REQUIREMENTS Install Date General Maintenance Section Visual check for leaks Check engine oil level Check coolant level Change engine oil and filter Check fuel system for leaks Inspect accessory drive belts Inspect engine electrical system Inspect all vacuum lines and fittings Inspect all fuel lines and fitting Engine Coolant Section Check coolant level Clean debris from radiator core Change coolant Inspect coolant hoses for cracks, swelling or deterioration Engine Ignition System Inspect battery case for damage Check battery electrolyte Level Inspect battery cables Check all electrical connectors Check ignition timing and adjust Replace spark plugs Check spark plug wires Fuel System Maintenance Replace fuel filter Inspect lock off for leaks Ensure lock off closing Test LPG/gas regulator pressure Inspect LPR for oil build up Inspect LPR for coolant leaks Check air induction system for leaks Check manifold for vacuum leaks Check FTV electrical connection Check throttle shaft for sticking Check injector & rails for leaks Inspect air cleaner Replace filter element Engine Exhaust System Inspect exhaust manifold for leaks Inspect exhaust piping for leaks Inspect catalyst inlet and outlet Check HEGO sensor connector
Daily
250
500
Interval Hours 750 1000 1250
1500
1750
2000
X X X Every 200 hrs or Monthly, Whichever Comes First Every 10 hrs or Daily (pre-start), Whichever Comes First Every 1200 hrs or 6 Months, Whichever Comes First X X X X Every 100 hours or 60 days of operation Every 1200 hrs or 6 Months, Whichever Comes First X X Every 10 hrs or Daily (Pre-Start), Whichever Comes First X X
X X X X X X X
Every 1200 hrs or 6 Months, Whichever Comes First X X X Annually or every 2000 hours Annually or every 2000 hours X X X X X Every 50 hrs or Weekly, Whichever Comes First Every 1200 hrs or 6 Months, Whichever Comes First X X X X
The maintenance schedule represents manufacturers recommended maintenance intervals to maintain proper engine/equipment function. Specific state and federal regulations may require equipment operators to conduct comprehensive engine/equipment inspections at more periodic intervals than those specified above. This maintenance schedule has no regulatory value and should not be considered representative of any state or federal engine/equipment maintenance requirement.
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SECTION 1A1
LPG FUEL SYSTEM OPERATION LPG Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical LPG Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Descriptions and Operation of the Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Propane Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 LPG Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Service Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Electric Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Low Pressure Regulator (LPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Drive by Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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LPG FUEL SYSTEM Tank Pressure Fuel Cylinder Regulated Pressure Mil Light
Intake Air Fuel Filter
Air/Fuel Mixture Exhaust Gas
Electric Lockoff
Low Pressure PTV Regulator
Air Cleaner
Engine Control Module
Mixer
TPS TMAP
Throttle Body
Speed control motor
FTV FPP
ENGINE
ECT Distributor (Timing) Oil Pressure
Crankshaft Sensor
o2
Catalytic Muffler
Figure 1 Typical Fuel System Schematic -22-
position, fuel flows out of the tank and into the service line. The service valve is also equipped with a safety feature called an “excess flow check valve”. This feature reduces the flow from the service valve in the event of a rupture of the fuel line or any down stream component.
Description And Operation Of The Fuel Systems Propane Fuel System The primary components of the propane fuel system are the fuel storage tank, low pressure regulator (LPR), fuel mixer module with throttle control device, electric fuel lock-off solenoid, engine control module (ECM) fuel trim valve (FTV) pressure trim valve (PTV) and Three Way Catalytic (TWC) converter. The system operates at pressures which range from 355.60 mm (14.0 inches) of water column up to 21.5 BAR (312 psi).Figure 1 Typical Fuel System Schematic.
Service Line Propane flows from the fuel tank to the electric lock via the service line. The service line is connected to the tank utilizing a quick coupler. The other end of the service line is connected to a “bulkhead connector” mounted on the equipment sheet metal. This bulkhead connector allows for a safe means of passing through the equipment engine compartment sheet metal and into the engine compartment. If a bulkhead connector is used a pressure relief device is mounted in the service line or the connector itself to prevent over pressurization of the service line. The service line is made of high pressure hose with special material or possibly tubing which is friendly to the LPG fuel and should always be replaced with an OEM supplied part.
LPG Fuel Tank 1. Liquid Outage valve w/quick disconnect coupling
11. Vapor Withdrawal Tube (when applicable)
2. Filler Valve
12. 80% Limiter Tube
3. Pressure Relief Valve
13. Fuel Level Float
4. Liquid Outage Fill Check Valve
14. Liquid Withdrawal Tube
5. Fuel Gauge
!
CAUTION
The bulkhead assembly should never be removed and a service line run through the sheet metal.
Figure 2 Typical Propane Cylinders Propane is stored in the fuel tank as a liquid. The approximate pressure of the fuel in the tank is 16.5 bar (240 psi) when the tank is full at an ambient temperature of 27° C (81° F). The boiling point, (temperature at which the liquid fuel becomes vapor) is approximately -40° C (-40° F). When the fuel changes from liquid to vapor the fuel expands and creates pressure inside the tank. When the tank service valve is opened the pressure inside the tank forces the liquid fuel out though the pick up tube located near the bottom of the fuel cylinder. Because the Propane is stored under pressure the tank is equipped with a safety valves which are normally set at 25.8 bar (375 psi) to prevent tank rupture due to over-pressurization of the cylinder. The service valve mounted in the end of the cylinder controls the flow of fuel from the tank. By turning the handle to its “open”
Fuel Filter Propane fuel like all other motor fuels is subject to contamination from outside sources. Refueling of the equipment tank and removal of the tank from the equipment can inadvertently introduce dirt and other foreign matter into the fuel system. It is therefore necessary to filter the fuel prior to entering the fuel system components down stream of the tank. A bulkhead type fuel filter has been installed in the fuel system to remove the dirt and foreign matter from the fuel. The filter is replaceable as a unit only. Maintenance of the filter is critical to proper operation of the fuel system and should be replaced as defined in the Recommended Maintenance Schedule. In severe operating conditions more frequent replacement of the filter may be necessary.
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and passes through the primary jet and into the primary/exchanger chamber. As the propane passes through the heat exchanger the fuel expands and creates pressure inside the chamber. The pressure rises as the fuel expands when the pressure rises above 10.34 Kpa (1.5 psi), sufficient pressure is exerted on the primary diaphragm to cause the diaphragm plate to pivot and press against the primary valve pin thus closing off the flow of fuel. This action causes the flow of fuel into the regulator to be regulated. When the engine is cranking, sufficient vacuum will be introduce into the secondary chamber from the mixer drawing the secondary diaphragm down onto the spring loaded lever and opening the secondary valve allowing vaporized fuel to pass to the mixer. Increased vacuum in the secondary chamber increases the downward action on the secondary lever causing it to open wider allowing more fuel to flow to the mixer.
INLET
OUTLET
Figure 3 Fuel Filter
Electric Lock Off The electric lock off device is an integrated assembly. The electric lock assembly is a 12 volt normally closed valve. The solenoid is mounted to the valve body. When energized the solenoid opens the valve and allows the Propane fuel to flow through the device. The valve opens during cranking and run cycles of the engine. The lock off supply voltage is controlled by the engine control module (ECM).
The regulator utilized on this emission certified engine is equipped with a unique Pressure Trim Valve (PTV) which is directly mounted to the regulator. This solenoid is a 12 volt normally closed solenoid. The function of this solenoid is to regulate a specific amount of venture vacuum to the atmospheric side of the secondary diaphragm. By introducing vacuum to the top side of the secondary diaphragm during regulator operation the amount of fuel being delivered to the mixer can be “trimmed” or reduced to allow for correction to the air fuel ratio for closed loop fuel control. The solenoid receives a reference signal from the ECM which causes the solenoid to be pulsed fast or slow depending on the amount of fuel to be trimmed.
Fuel Lockoff
Figure 4 Electric Fuel Lock Off !
CAUTION
Low Pressure Regulator (LPR) The LPR is an emission control device. Components inside the regulator are specifically calibrated to meet the engine emissions requirements and should never be disassembled or rebuilt. If the LPR fails to operate, replace with an OEM replacement part.
The LPR is a combination vaporizer, pressure regulating device. The LPR is a negative pressure two stage regulator that is normally closed when the engine is not running. When the engine is cranking or running a partial vacuum is created in the fuel line which connects the regulator to the mixer. This partial vacuum opens the regulator permitting fuel to flow to the mixer. Propane fuel enters the primary port of the LPR
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Air Fuel Mixer The air valve mixer is an air-fuel metering device and is completely self-contained. The mixer is an air valve design, utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load. The mixer is mounted in the air stream ahead of the throttle control device. When the engine begins to crank it draws in air, with the air valve covering the inlet, negative pressure begins to build. This negative pressure signal is communicated to the top of the air valve chamber through 4 vacuum ports in the air valve assembly. A pressure/force imbalance begins to build across the air valve diaphragm between the air valve vacuum chamber and the atmospheric pressure below the diaphragm. The air valve vacuum spring is calibrated to
Figure 5 Low Pressure Regulator
Electric Lockoff to LPR Adapter Electric Lockoff
PTV Low Pressure Regulator
TMAP LPR Mounting Bracket
Electronic Throttle Control
FTV Mixer to Throttle Adapter
Throttle Body to Manifold Adapter Manifold Gasket Adapter Seal
Figure 6 LPG Fuel System -25-
Mixer
generate from 101.6 mm (4.0 inches) of water column at start to as high as 355.60 mm (14.0 inches) of water column at full throttle. The vacuum being created is referred to as Air Valve Vacuum (AVV). As the air valve vacuum reaches 101.6 mm (4.0 inches) of water column, the air valve begins to lift against the air valve spring. The amount of AVV generated is a direct result of the throttle position. At low engine speed the air valve vacuum is low and the air valve position is low thus creating a small venturi for the fuel to flow. As the engine speed increase the AVV increases and the air valve is lifted higher thus creating a much larger venturi. This air valve vacuum is communicated from the mixer venture to the LPR secondary chamber via the low pressure fuel supply hose. As the AVV increases in the secondary chamber the secondary diaphragm is drawn further down forcing the secondary valve lever to open wider.
Figure 7 Pressure Trim Valve and Fuel Trim Valve
The mixer is equipped with a low speed mixture adjustment which is retained in a tamper proof housing. The mixer has been preset at the factory and should not require any adjustment. In the event that the idle adjustment should need to be adjusted refer to the Section 1E1 of this manual.
!
Drive By Wire Engine speed control is maintained by the amount of pressure applied to the foot pedal located in the engine compartment. In a Drive By Wire (DBW) application there is no direct connection between the operator pedal and the throttle shaft. Speed and load control are determined by the ECM. Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine.
CAUTION
The air/fuel mixer is an emission control device. Components inside the mixer are specifically calibrated to meet the engines emissions requirements and should never be disassembled or rebuilt. If the mixer fails to operate replace with an OEM replacement part.
In a drive by wire application the electronic throttle control device or “throttle body assembly” is connected to the intake manifold of the engine. The electronic throttle control device utilizes an electric motor connected to the throttle shaft. In addition a Foot Pedal Position sensor (FPP) is located in the operator’s compartment. When the engine is running electrical signals are sent from the foot pedal position sensor to the engine ECM when the operator depresses or release the foot pedal. The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air flow to the engine. The electronic throttle control device also incorporates two internal Throttle Position Sensors (TPS) which provide output signals to the ECM
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as to the location of the throttle shaft and blade. The TPS information is used by the ECM to correct for speed and load control as well as emission control.
Three Way Catalytic Muffler The emission certified engine has been designed and calibrated to meet the emission standards in effect for 2004. To help meet the emission requirements the vehicle has been equipped with a Three Way Catalytic (TWC) muffler. The catalyst muffler is a three way catalyst, sound damping and spark arresting unit. Besides controlling the noise created from the combustion process, and preventing sparks from escaping from the exhaust system the most important function is treating the exhaust gases which are created from the combustion process. The three-way catalyst consists of a honeycomb coated with a mixture of platinum, palladium, and rhodium. The hot gases flow through the catalyst sections where an oxidation and reduction reactions take place. These chemical reactions reduce the amount of CO, HC and NOX in the engines exhaust. The Exhaust gas then flows through the outlet.
Also mounted on Electronic throttle body assembly is the Fuel Trim Valve (FTV). The FTV is a 12 volt, normally closed solenoid valve. During closed loop operation the ECM may send a reference signal to the FTV to open or close to allow more or less fuel to be introduced below the throttle blade to correct the air fuel mixture for proper emission control.
Figure 8 Throttle control device “Drive by Wire throttle body assembly”
Figure 9 Three way catalytic converter
LPG ECM INPUTS O2 Sensor Throttle Position RPM Timing Oil Pressure Coolant Temperature Air Temperature Manifold Absolute Pressure Battery
OUTPUTS
ENGINE CONTROL MODULE
Figure 10 LPG Engine Control Module (ECM) -27-
Pressure Trim Valve Fuel Trim Valve Electric Lockoff Valve Governor Speed Control Timing Ignition Gauges Malfunction Indicator Lamp
whether the fuel air ratio is to rich or to lean. If the HEGO sensor signal indicates that the exhaust stream is to rich the ECM will decrease or lean the fuel mixture during engine operation, if the mixture is to lean the ECM will richen the mixture. The ECM continuously monitors the HEGO sensor output if a rich or lean condition is present for an extended period of time and the ECM cannot correct the condition the ECM will set a diagnostic code and turn on the MIL light in the dash.
Engine Control Module To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an on board computer or Engine Control Module (ECM). The ECM is a 32 bit controller which receives in-put data from sensors fitted to the engine and fuel system and then out-puts various signals to control engine operation. One specific function of the controller is to maintain “closed loop fuel control”. Closed loop fuel control is accomplished when the exhaust gas oxygen sensor (HEGO) mounted in the exhaust system sends a voltage signal to the controller. The controller then calculates any correction that may need to be made to the air fuel ratio. The controller then out-puts signals to PTV or the FTV or both mounted in the fuel system to change the amount of fuel being delivered from the regulator or mixer or to the engine.
!
CAUTION
The Heated Exhaust Gas Oxygen Sensor (HEGO) is an emissions control component. If the HEGO fails to operate, replace only with an OEM replacement part. The HEGO sensor is sensitive to silicone and silicone based products and can become contaminated. Avoid using silicone sealers or hoses treated with silicone lubricant in the air stream or fuel supply lines.
The controller also performs diagnostic functions on the fuel system and notifies the operator of malfunctions by turning on a Malfunction Indicator Light (MIL) mounted in the dash. Malfunctions in the system are identified by a Diagnostic Trouble Code (DTC) number. In addition to notifying the operator of the malfunction in the system the controller also stores the information about the malfunction in its memory. A technician can than utilize a computerized diagnostic tool to retrieve the stored diagnostic code and by using the diagnostic charts in this manual determine the cause of the malfunction. In the event a technician does not have the computerized diagnostic tool the MIL light can be used to identify the diagnostic code. By following specific steps the technician can activate the “blink” feature and count the number of blinks to determine the diagnostic code number to locate the fault in the system.
Figure 11 Heated Exhaust Gas Oxygen Sensor (HEGO)
Heated Exhaust Gas Oxygen Sensor The Heated Exhaust Gas Oxygen Sensor (HEGO) is mounted in the exhaust system downstream of the engine. The HEGO is used to measure the amount of oxygen present in the exhaust stream and communicate that to the ECM via an electrical signal. The amount of oxygen present in the exhaust stream indicates
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ENGINE
"Input" Exhaust Gas Oxygen Sensor (HEGO) to ECM
"Output" PTV OR FTV pulses increases or decreases fuel delivery to the engine
ECM Calaculates the change and commands PTV OR FTV signals to increase or decrease
Figure 12 Propane Closed Loop Control Schematic
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SECTION 1A2
GASOLINE FUEL SYSTEM OPERATION Gasoline Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Multi-Port Fuel Injection System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Gasoline Multi-Port Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Gasoline Fuel Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuel Rail and Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Drive by Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Three Way Catalytic Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Closed Loop Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
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4.3 LITER MPFI FUEL SYSTEM AIR FUEL MIXTURE
Fuel Tank FRESH AIR EXHAUST GASES
Mil Light
GASOLINE RETURN GASOLINE FUEL PRESSURE
Fuel Filter GASOLINE FUEL PUMP PRESSURE
Gasoline Fuel Pump
Engine Control Module
Pressure Regulator
Air Induction
Air Cleaner
TPS TMAP Throttle Body
TPS
Speed control motor
Manifold
Injector Oil Pressure
ENGINE
H20 Sensors Distributor (Timing) Magnetic Pick up (RPM)
O2
Catalytic Muffler
Figure 1 Gasoline Multi-Port Fuel Injection System
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Gasoline Multi Port Fuel Injection System (MPFI)
Fuel Rail and Pressure Regulator The fuel flows from the fuel filter to the fuel rails where the fuel is regulated. During engine operation the regulator maintains the proper amount of fuel pressure to the top of the injector. During lower RPM operation excess fuel at the top of the injector is bypassed and returned to the fuel tank for recirculation.
The primary components of the Gasoline Multi Port Fuel Injection (MPFI) fuel system are the gasoline fuel tank, electric fuel pump, fuel filter, fuel rails, fuel pressure regulator, fuel injector, HEGO sensor, engine control module and three way catalytic muffler.
The Fuel pressure regulator has no adjustments and is integrated into the fuel rail assembly. The fuel rail also contains a Schrader valve which is utilized to test the regulated pressure of the fuel system.
Gasoline Fuel Storage Tank The gasoline fuel storage tank location may very on equipment applications. The fuel tank may be integrated into the chassis frame or may be a stand alone vessel mounted on the equipment. For precise location for the equipment application refer to the OEMs vehicle manual.
Pressure Test Port
Pressure Regulator
Fuel Filter Before the fuel is drawn into the fuel pump the fuel flows through the gasoline fuel filter. The fuel filter will trap small particles as the fuel passes through the filter to remove debris and prevent injectors from becoming damaged. Maintenance of the fuel filter is required as indicated in the Recommended Maintenance Schedule. A more frequent replacement of the filter may be required if the equipment operates in a dusty or dirty environment.
Fuel Rail Assy
Figure 2 Gasoline Fuel Rail Assembly
Fuel Injector The fuel supply is maintained on the top of the injector by the fuel pressure regulator. The injector is fed a “pulse” signal through the wire harness which causes the injector to open. During regular operating conditions the ECM controls the opening and duration of opening of the injector. During lower RPM operation the injector signals or “pulses” are less frequent then when the engine is operating at higher RPMs. The certified engine has been calibrated to deliver the precise amount of fuel for optimum performance and emission control.
Gasoline Fuel Pump The Gasoline is stored as a liquid in the fuel tank and in drawn into the fuel system by a 12 volt electric fuel pump. Depending on the vehicle application the fuel pump may be mounted in the fuel tank or as a stand alone component. In either case the fuel pump will receive a signal from the ECM at Key On to prime the fuel system for approximately 2 seconds prior to start. Priming of the fuel system provides for a quicker start, when the engine begins to crank.
!
CAUTION
The fuel pump is an emissions control component. If the fuel pump fails to operate, replace only with an OEM replacement part. The fuel pump is calibrated to supply the correct amount of fuel to the injectors. Replacing the pump with anything other than the OEM replacement could cause damage to the fuel system and or damage to the fuel tank.
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information is used by the ECM to correct for speed and load control as well as emission control.
Drive By Wire
Three Way Catalytic Muffler The emission certified engine has been designed and calibrated to meet the emission standards in effect for 2004. To help meet the emission requirements the vehicle has been equipped with a Three Way Catalytic muffler. The catalyst muffler is a three way catalyst, sound damping and spark arresting unit. Besides controlling the noise created from the combustion process, and preventing sparks from escaping from the exhaust system the most important function is treating the exhaust gases which are created from the combustion process. The three-way catalyst consists of a honeycomb coated with a mixture of platinum, palladium, and rhodium. The hot gases flow through the catalyst sections where an oxidation and reduction reactions take place. These chemical reactions reduce the amount of CO, HC and NOX in the engines exhaust. The Exhaust gas then flows through the outlet
Figure 3 Throttle control device “Drive by Wire” Throttle Body Assembly Engine speed control is maintained by the amount of pressure applied to the foot pedal located in the engine compartment. In a Drive By Wire (DBW) application there is no direct connection between the operator pedal and the throttle shaft. Speed and load control are determined by the ECM. Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine. In a drive by wire application the Electronic Throttle Control device or “throttle body assembly” is connected to the intake manifold of the engine. The electronic throttle control device utilizes an electric motor connected to the throttle shaft. In addition a Foot Pedal Position sensor (FPP) is located in the operator’s compartment. When the engine is running electrical signals are sent from the foot pedal position sensor to the engine ECM when the operator depresses or release the foot pedal. The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air flow to the engine.
Figure 4 Three way catalytic converter
Engine Control Module To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an on board computer or Engine control module (ECM). The ECM is a 32 bit controller which receives in-put data from sensors fitted to the engine and fuel system and then outputs various signals to control engine operation.
The electronic throttle control device also incorporates two internal Throttle Position Sensors (TPS) which provide output signals to the ECM as to the location of the throttle shaft and blade. The TPS
One specific function of the controller is to maintain “closed loop fuel control”. Closed loop fuel control is accomplished when the exhaust gas oxygen sen-
-34-
GASOLINE ECM INPUTS O2 Sensor Throttle Position RPM Timing Oil Pressure Coolant Temperature Air Temperature Manifold Absolute Pressure Battery
OUTPUTS
Gasoline Fuel Pump Governor Speed Control Gasoline Fuel Injector Timing Ignition Gauges Malfunction Indicator Lamp
ENGINE CONTROL MODULE
Figure 5 Gasoline Engine Control Module (ECM) sor (EGO) mounted in the exhaust system sends a voltage signal to the controller. The controller then calculates any correction that may need to be made to the air fuel ratio. The controller then out-puts signals to PTV or the FTV or both mounted in the fuel system to change the amount of fuel being delivered from the regulator or mixer or to the engine.
injectors during engine operation, if the mixture is to lean the ECM will richen the mixture or increase the pulse to the injectors. The ECM continuously monitors the HEGO sensor output if a rich or lean condition is present for an extended period of time and the ECM cannot correct the condition the ECM will set a diagnostic code and turn on the MIL light in the dash.
The controller also performs diagnostic functions on the fuel system and notifies the operator of malfunctions by turning on a Malfunction Indicator Light (MIL) mounted in the dash. Malfunctions in the system are identified by a Diagnostic Code number. In addition to notifying the operator of the malfunction in the system the controller also stores the information about the malfunction in its memory. A technician can than utilize a computerized diagnostic tool to retrieve the stored diagnostic code and by using the diagnostic charts in this manual determine the cause of the malfunction. In the event a technician does not have the computerized diagnostic tool the MIL light can be used to identify the diagnostic code. By following specific steps the technician can activate the “blink” feature and count the number of blinks to determine the diagnostic code number to locate the fault in the system.
!
CAUTION
The Heated Exhaust Gas Oxygen Sensor (HEGO) is an emissions control component. If the HEGO fails to operate, replace only with an OEM replacement part. The HEGO sensor is sensitive to silicone and silicone based products and can become contaminated. Avoid using silicone sealers or hoses treated with silicone lubricant in the air stream or fuel supply lines.
Heated Exhaust Gas Oxygen Sensor The Heated Exhaust Gas Oxygen Sensor (HEGO) is mounted in the exhaust system downstream of the engine. The HEGO is used to measure the amount of oxygen present in the exhaust stream and communicate that to the ECM via an electrical signal. The amount of oxygen present in the exhaust stream indicates whether the fuel air ratio is to rich or to lean. If the HEGO sensor signal indicates that the exhaust stream is to rich the ECM will decrease or lean the fuel mixture by reducing the signals to the
Figure 20 Heated Exhaust Gas Oxygen Sensor (HEGO)
-35-
ENGINE
"Output" Injector pulse increases or decreases fuel delivery to the engine
"Input" Heated Exhaust Gas Oxygen Sensor (HEGO) to ECM
ECM Calculates the change and commands injector signal to increase or decrease
Figure 6 Closed Loop Control Schematic
-36-
SECTION 1B1
LP FUEL SYSTEM DIAGNOSTICS LPG Fuel System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Diagnostic Aids
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Tools Required
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Duty Cycle Monitoring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Diagnostic Scan Tool
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Test Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 LPG Fuel System Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
-37-
Diagnostic Aids
LPG Fuel System Diagnosis
This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify that the vehicle has a sufficient quantity of fuel and that liquid fuel is being delivered to the LPR. Also, ensure that the manual shut off valve on the LPG tank is fully opened and that the excess flow valve has not been activated.
Tools Required: •
7/16 Open end wrench (for test port plugs)
•
Straight Blade screw driver
•
DVOM (Fluke 88 or equivalent).
Duty Cycle Monitoring Tool
Fuel System Description
•
The Engine Control Module (ECM) receives information from various engine sensors in order to control the operation of the fuel control solenoid valves (FTV) and the low-pressure lock-off (LPL) solenoid. The LPL solenoids prevent fuel flow unless the engine is cranking or running. LPG is stored in the tank and delivered under pressure to the system as a liquid. During key on, the LPL receives a two (2) second prime pulse from the ECM which allows LPG to flow from the tank through fuel filter and fuel lines to the low pressure regulator (LPR) at pressures up to 21.5 BAR (312 psi).
Fuel System Analyzer (FSA), or DVOM (Fluke 88 or equivalent).
Diagnostic Scan Tool •
Hand held PDA or equivalent.
Pressure Gauges •
Water Column Gauge / Manometer
•
0-10 PSI Gauge
Test Description The numbers below refer to step numbers on the diagnostic table.
In the (LPR) the fuel is vaporized and the pressure reduced in two stages. The first stage reduces the pressure to approximately 20.68 kilo pascals (3.0 psi). The second stage reduces the pressure to approximately negative 38.1 mm (1.5”) of water column. The fuel is then drawn from the secondary chamber of the LPR by the vacuum generated by air flowing through the mixer. This vacuum signal is also used to generate lift for the mixer air valve. This vacuum signal is most commonly referred to as air valve vacuum. In the mixer, the fuel mixes with the air entering the engine. This air/fuel mixture is then drawn into the engine for combustion.
5.
This step will determine if the PTV and FTV and fuel supply system are functioning properly. The vacuum on the secondary test port will be approximately –1.0 “ to –2.0” w.c.
6.
This step checks the base mechanical LPR output pressure by disabling all fuel control devices.
9. This step checks for proper air valve operation. 19.
-38-
This determines if fuel is available from the fuel tank supply system.
Step 1
2
LPG Fuel System Diagnosis Action Value(s) Were you referred to this procedure by a __ DTC diagnostic chart? Perform the On Board Diagnostic (OBD) System Check.
__
Are any DTCs present in the ECM? 3
4
Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual valve is open and the tank quick connect is fully engaged Does the vehicle have fuel? 1. Connect a water column gauge or a manometer to the secondary test port of the low pressure regulator (LPR). 2. Start the engine and allow it to reach operating temperature.
5
6
Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range? 1. Disconnect the PTV electrical connectors. Note: This action may cause a DTC to be set by the ECM 2. With the engine idling observe the pressure reading on the secondary test port. Is the fuel pressure WITHIN the specified range?
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No
Go to Step 3
Go to Step 2
Go to the applicable DTC Table
Go to Step 3
__
__ Go to Step 4
__
Does the engine start and run? With the engine idling, observe the pressure reading for the LPR secondary pressure.
Yes
Go to Step 5
Go to Step 8
Go to Step 25
Go to Step 6
-1.0” to -2.0” w.c.
-1.0” to -2.0” w.c. Go to Fuel Control System Diagnosis
Go to Step 7
7
8
9
1. Inspect the air intake stream between the mixer assembly and the throttle body for leaks. 2. Inspect the fuel hose connection between the LPR and mixer assembly for damage or leakage. 3. Inspect the vacuum hoses to the FTV solenoid. Was a problem found and corrected? 1. Connect a water column gauge or a manometer to the secondary test port of the low pressure regulator (LPR). 2. Crank the engine and observe the pressure reading for the LPR secondary pressure. Does the fuel pressure indicate a vacuum is present? 1. Remove Air induction hose to the mixer 2. Observe the air valve for movement while the engine is cranking. Note: Movement of the air valve will be minimal at cranking speeds.
__
10
11
Was a problem found and repaired? Inspect the fuel hose connection between the LPR and the mixer assembly for damage or leakage. Was a problem found and repaired?
-40-
Go to Step 22
Go to Step 12
Go to Step 9
Go to Step 11
Go to Step 10
Go to Step 26
Go to Step 24
Go to Step 26
Go to Step 12
__
__
Does the air valve move when the engine is cranked? 1. Inspect the air intake stream to the mixer assembly and the throttle body for vacuum leaks. 2. Inspect the vacuum hoses from the mixer to the PTV solenoids for proper connection and condition.
Go to Step 26
__
__
12
13
1. Connect a 0-10 psi gauge to the primary test port of the low pressure regulator (LPR). 2. Crank the engine and observe the pressure reading for the LPR primary pressure. Is the fuel pressure ABOVE the specified value? 1. Turn OFF the ignition. 2. Disconnect the LPL connector. 3. Install a test light between the pins of the LPL connector. 4. Crank the engine. The test light should illuminate.
2.0 – 4.0 psi
14
Go to Step 13
Go to Step 14
Go to Step 16
Go to Step 15
Go to Step 23
Go to Step 23
Go to Step 17
Go to Step 20
Go to Step 21
__
Does the test light illuminate? Using a DVOM, check the resistance of the low pressure lock-off (LPL).
Go to Step 22
12 - 24
Is the resistance within the specified range? 1. Turn the ignition OFF. 2. Close the manual shut-off valve on the LPG tank. 15 CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Perform this step in a well ventilated area.
__
3. Loosen the fuel inlet hose fitting at the inlet of the LPL.
16
Was fuel present when the fitting was loosened? 1. Turn OFF the ignition. 2. Connect the test light to chassis ground and probe pin A of the LPL connector. 3. Crank the engine. The test light should illuminate. Does the test light illuminate?
-41-
__
17
1. Remove the LPG fuel filter / LPL. 2. Remove the filter from the LPL. 3. Empty the contents of the inlet side of the LPG fuel filter onto a clean surface. 4. Inspect the contents of the LPG fuel filter for an excessive amount of foreign material or water. If necessary, locate and repair the source of contamination. 5. Verify the LPG fuel filter is not restricted or plugged.
__
Go to Step 19
Was a problem found?
18
The fuel supply system or hoses are plugged or restricted, locate and repair the problem.
__
Replace the fuel filter. Refer to Fuel Filter Replacement.
__
Is the action complete?
20
Repair the open in the lock-off ground circuit.
__
Repair the open in the lock-off power (OEM fuel pump) circuit.
__
__ Go to Step 26
Replace the low pressure regulator (LPR). Refer to Low Pressure Regulator Replacement.
__
__ Go to Step 26
Is the action complete? 23
__ Go to Step 26
Is the action complete?
22
__ Go to Step 26
Is the action complete? 21
__ Go to Step 26
Is the action complete? 19
Go to Step 23
Replace the lock-off. Refer to Low Pressure Lock-off (LPL) Replacement. Is the action complete?
__
__ Go to Step 26
-42-
24
Replace the mixer assembly. Refer to Fuel Mixer Replacement.
__
Is the action complete?
25
__ Go to Step 26
The fuel supply system is operating normally, if a failure of the control solenoids is suspected. Refer to Fuel Control System Diagnosis. 1. Install the test plug in the LPR secondary chamber. 2. If you were sent to this routine by another diagnostic chart, return to the previous diagnostic procedure.
__
__
System OK
26
Is the action complete? 1. Disconnect all test equipment 2. Install the primary and secondary test port plugs. 3. Start the engine. 4. Using SNOOP® or equivalent, leak check the test port plugs.
__
__
System OK Is the action complete?
-43-
SECTION 1B2
GASOLINE FUEL SYSTEM DIAGNOSTICS Gasoline Fuel System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Diagnostic Aids
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Test Description - Diagnostic Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Gasoline Fuel System Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
-45-
Gasoline Fuel System Diagnosis
Diagnostic Aids This procedure is intended to diagnose a vehicle operating on Gasoline. If the vehicle will not continue to run on Gasoline, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify that the vehicle has a sufficient quantity of fuel.
GASOLINE INJECTION SYSTEMS
ECM
O-2 SENSOR
COO1
Tools Required: 23456 01 78
PRESSURE REGULATOR
FUEL PRESSURE GAUGE
•
J 34730-1 or equivalent
•
Fuel
Line
shutoff
adapter
Diagnostic Scan Tool •
FUEL SUPPLY FUEL PUMP
Fuel System diagnostic tool.
Test Description
FUEL RETURN LINE
The numbers below refer to step numbers on the diagnostic table.
INJECTOR
FUEL TANK
4.
Connect fuel pressure gage as shown in illustration. Wrap a shop towel around the fuel connection to absorb any small amount of fuel leakage that may occur when installing the gage. With ignition “ON” and the fuel pump running pressure should be 284-325 kPa (4147 psi). This pressure is controlled by spring pressure within the regulator assembly.
6.
When the engine is idling, manifold pressure is low (High Vacuum) and is applied to the pressure regulator diaphragm. Vacuum will offset spring pressure and result in a lower pressure. Fuel pressure at idle will vary somewhat depending on barometric pressure but, should be less then the pressure noted in step 4.
11.
Fuel pressure that drops off during acceleration or cruise may cause a lean condition and result in a loss of power, surging or misfire. This condition can be diagnosed using the Diagnostic Tool. If the fuel in the system is very lean the Heated Exhaust Gas Oxygen (HEGO) will stop toggling and output voltage will drop below 300 mV. Also injector pulse will increase.
14.
Fuel pressure below 284 kPa (41 psi) may cause lean condition and may set a DTC. Driveablity conditions can include hard starting cold, hesitation, and lack of power or misfire.
15.
Restricting the fuel return pipe cause the fuel pressure to build above the regulated pressure.
Fuel System Description The Engine Control Module (ECM) receives information from various engine sensors in order to control the operation of the fuel injectors. The electric fuel pump, prevents fuel flow unless the engine is cranking or running. During key on, electric fuel pump receives a two (2) second prime pulse from the ECM which allows Gasoline to flow from the tank through fuel filter and fuel lines to the fuel rails where the pressure is regulated. With Ignition “ON” and fuel pump running pressure should be 284-325 kPa (41-47 psi). When the engine is idling, manifold pressure is low (high vacuum) and is applied to the pressure regulator diaphragm. Vacuum will offset the spring pressure and result in very low fuel pressure. Fuel pressures at idle will vary somewhat depending on barometric pressure but, should be less then pump pressure. Unused fuel is returned to the fuel tank by a separate return fuel line The fuel pump pressure test port is located on the fuel rail
-46-
• Leaking fuel feed hose
With battery voltage applied to the pump, pressure should rise above 325 kPa (47 psi) as the valve in the return pipe is partially closed.
• Leaking valve/seat within the pressure regulator • Leaking injector
!
CAUTION
26.
Do not allow the pressure to exceed 414 kPa (60 psi) as damage to the regulator may result. 1 7.
18.
21.
23.
A leaking injector can best be determined by checking for a fouled or saturated spark plug(s). If a leaking injector can not be determined by a fouled or saturated plug the following procedure should be used. • Remove the fuel rail but leave the lines connected
Fuel pressure above 325 kPa (47 psi) may cause a rich condition and set a DTC. Driveability may include hard starting, followed by black smoke and a strong sulphur smell in the exhaust.
• Lift the fuel rail out just enough to leave injector nozzle’s in the ports.
This test is to determine if the high fuel pressure is due to a restricted fuel return pipe or a faulty fuel pressure regulator.
!
WARNING
To reduce the risk of fire or personal injury that may result form fuel spray on the engine, make sure fuel rails is positioned over injector port and injector retaining clips are intact.
The pressure regulator may be fitted with a screen which is designed to trap contaminants introduced during engine assembly. If dirty it can be removed with a small pick and discarded without potential harm to the regulator.
• Pressurize the fuel system and observe injector nozzles.
A system that does not hold pressure is caused by one of the following. • Leaking fuel pump check ball
-47-
Step 1
2
Gasoline Fuel System Diagnosis Action Value(s) Yes Were you referred to this procedure by a __ DTC diagnostic chart? Go to Step 3 Perform the On Board Diagnostic (OBD) System Check.
__
Are any DTCs present in the ECM? 3
Verify that the Gasoline fuel tank has a minimum of 1/4 tank of fuel,
__
Does the vehicle have fuel?
4
Go to the applicable DTC Table
No Go to Step 2
Go to Step 3 __
Go to Step 4
1. Connect a fuel pressure gage at the Schrader Valve located on the fuel rail 2. Ignition “ON” fuel pump will run. 3. Note the pressure 4. Turn ignition off pressure may vary slightly then hold steady
285-325 kPa (41-47 psi)
Is pressure within specified values
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 22
Go to 27
Go to Step 7
Go to Step 8
Go to Step 9
Did the fuel pressure hold steady after the pump stopped? 5
6
1. Start engine allow it to warm to normal operating temperature at idle 2. Fuel pressure noted in step 4 should drop.
21-69 kPa (3-10 psi)
Did pressure drop by the specified value?
7
1. Disconnect the vacuum hose from the pressure regulator 2. With the engine idling, apply 12-14 inches of vacuum to the pressure regulator, pressure should drop. Did the pressure drop by the specified value?
-48-
21-69 kPa (3-10 psi)
1. Locate and repair loss of vacuum to the pressure regulator. 8 Is the action complete?
__
Go to Step 27
Replace pressure regulator 9 __
Go to Step 27
285-325 kPa (41-47 psi)
Go to Step 14
Go to Step 11
285-325 kPa (41-47 psi)
Go to Step 12
Go to Step 14
Go to Step 27
Go to Step 13
Is the action complete? Is pressure less then specified value? 10
11
12
1. With the fuel pressure gage installed 2. Start engine and accelerate with load Is pressure less then specified value? 1. Check for restricted fuel filter 2. Check for restricted fuel supply line from pump Was a problem found? 1. Replace fuel pump
__
13 Is this action Complete?
14
Go to Step 27
With the ignition “OFF” 1. Install a 10 amp fused jumper to the B+ 2. Slowly pinch the fuel return line 3. Pressure should rise NOTE: Do not exceed 414 kPa (60 psi) Did Pressure rise?
-49-
325 kPa (47 psi)
Go to Step 9
Go to Step 15
15
1. Check for restricted fuel pump strainer 2. Check for leaking fuel supply line from pump 3. Check to ensure fuel pump is correct
Go to Step 27
Go to Step 16
Was a problem found? 1. Replace fuel pump __ Is this action Complete?
Go to Step 27
16 Is pressure greater then specified value 17
18
19
1. Disconnect the fuel return hose at the fuel rail 2. Attach a length of hose to the return pipe at the rail 3. Place the other end of the hose in an approved Gasoline container 4. Turn ignition “OFF” for 10 seconds 5. Turn ignition “ON” Is pressure within specified value? The fuel return hoses are plugged or restricted, locate and repair the problem.
285-325 kPa (41-47 psi)
Go to Step 15
285-325 kPa (41-47 psi)
Go to Step 19
__
Go to Step 20
__ Go to Step 27
Is the action complete? Check for restricted engine return pipe 20
__ Was a problem found?
21
Remove pressure regulator and check for restriction Was a problem found? -50-
__
Go to Step 27
Go To Step 21
Go to Step 27
Go to Step 9
22
23
Fuel Pressure is within spec but does not hold pressure 1. Install J 37287 fuel line shut off adapter or suitable valve to close off fuel supply 2. Make sure valve is open 3. With the ignition “OFF” 4. Install a 10 amp fused jumper to the B+ 5. Pressure should rise 6. Disconnect the jumper and close valve
__
Go to Step 23
__
Go to Step 24
Go to Step 25
Go to Step 27
Go to Step 13
Go to Step 9
Go to Step 26
__
Did pressure hold? Check for leaking fuel pump supply line. __
24 Was there a problem found?
25
Open valve in fuel pressure pipe Reconnect test jumper and wait for pressure to build Disconnect jumper and close valve in fuel pressure pipe
__
Does Pressure hold 1. Locate and correct leaking injectors 26
27
Is the action complete? 1. Disconnect all test equipment 2. Install the test port cap. 3. Start the engine. 4. Verify engine is in closed loop and no MIL is on. Is the action complete?
-51-
__
Go to Step 27
__
__
System OK
__
SECTION 1B4
SYMPTOM DIAGNOSIS Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LPG Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Important Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Cuts Out, Misses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Backfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Lack of Power, Sluggishness, or Sponginess . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
-53-
LPG Symptom Diagnosis Important Preliminary Checks Checks Before Using This Section
Action Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks are very important. The checks can lead to correcting a problem without further checks that may save valuable time.
LPG Fuel System Check
1. Verify the customer complaint. 2. Locate the correct symptom table. 3. Check the items indicated under that symptom. 4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich. IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at that time. 5. If a scan tool is available, take a snapshot under the condition that the symptom occurs. Go to Engine Scan Tool Data List to verify normal sensor values and parameters.
Visual and Physical Checks
•
Check all ECM system fuses and circuit breakers.
•
Check the ECM ground for being clean, tight and in its proper location.
•
Check the vacuum hoses for splits, kinks and proper connections.
•
Check thoroughly for any type of leak or restriction.
•
Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
•
Check for proper installation of the mixer module assembly.
•
Check for air leaks at the mixer assembly.
•
Check the ignition wires for the following conditions:
•
−
Cracking
−
Hardness
−
Proper routing
−
Carbon tracking
Check the wiring for the following items: −
•
Proper connections, pinches or cuts.
The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan tool readings do not indicate the problems, then proceed in a logical order, easiest to check or most likely to cause first.
-54-
Intermittent Checks
Action
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC). Preliminary Checks
Faulty Electrical Connections or Wiring
•
Refer to Important Preliminary Checks.
•
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.
•
Faulty electrical connections or wiring can cause most intermittent problems.
•
Check the suspected circuit for the following conditions: −
Faulty fuse or circuit breaker
−
Connectors poorly mated
−
Terminals not fully seated in the connector (backed out)
−
Terminals not properly formed or damaged
−
Terminal to wires poorly connected
−
Terminal tension insufficient.
•
Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the connector terminals in the problem circuit in order to ensure the proper contact tension.
•
Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test
If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit.
Intermittent Malfunction Indicator Lamp (MIL)
The following components can cause intermittent MIL and no DTC(s):
Loss of DTC Memory
•
A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
•
The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
•
The ignition secondary voltage shorted to a ground.
•
The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
•
The Control Module grounds.
To check for the loss of the DTC Memory: 1.
Disconnect the TMAP sensor.
2.
Idle the engine until the Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store and remain, the ECM is faulty. Additional Checks
.
-55-
No Start Checks
Action
DEFINITION: The engine cranks OK but does not start. Preliminary Checks
•
Refer to Important Preliminary Checks.
Control Module Checks
•
If a scan tool is available: •
Sensor Checks
Check for proper communication with the ECM
•
Check the 3A inline fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
•
Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for each circuit.
•
Check the TMAP sensor.
•
Check the Magnetic pickup sensor (RPM).
. Fuel System Checks
Ignition System Checks
Important: A closed LPG manual fuel shut off valve will create a no start condition. •
Check for air intake system leakage between the mixer and the throttle body.
•
Verify proper operation of the low pressure lock-off solenoids.
•
Verify proper operation of the fuel control solenoids.
•
Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis.
•
Check for proper mixer air valve operation.
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. •
Check for the proper ignition voltage output with a spark tester.
•
Verify that the spark plugs are correct for use with LPG (R42LTS)
•
Check the spark plugs for the following conditions: −
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
•
Check for bare or shorted ignition wires.
•
Check for loose ignition coil connections at the coil.
-56-
Engine Mechanical Checks
Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than the gasoline fuel supply system. •
Exhaust System Checks
•
•
Check for the following: −
Vacuum leaks
−
Improper valve timing
−
Low compression
−
Bent pushrods
−
Worn rocker arms
−
Broken or weak valve springs
−
Worn camshaft lobes.
Check the exhaust system for a possible restriction: −
Inspect the exhaust system for damaged or collapsed pipes
−
Inspect the muffler for signs of heat distress or for possible internal failure.
Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
-57-
Hard Start Checks
Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks Sensor Checks
Fuel System Checks
Ignition System Checks
•
Refer to Important Preliminary Checks.
•
Make sure the vehicle’s operator is using the correct starting procedure.
•
Check the Engine Coolant Temperature sensor with the scan tool. Compare the engine coolant temperature with the ambient air temperature on a cold engine. IF the coolant temperature reading is more than 5 degrees greater or less than the ambient air temperature on a cold engine, check for high resistance in the coolant sensor circuit. Refer to DTC 111
•
Check the Crankshaft Position (CKP) sensor.
•
Check the Throttle position (TPS) sensor.
Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition. •
Verify the excess flow valve in the LPG manual shut-off valve is not tripped.
•
Check mixer module assembly for proper installation and leakage.
•
Verify proper operation of the low pressure lock-off solenoids.
•
Verify proper operation of the PTV and FTV.
•
Check for air intake system leakage between the mixer and the throttle body.
•
Check the fuel system pressures. Refer to the Fuel System Diagnosis.
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. •
Check for the proper ignition voltage output with a spark tester.
•
Verify that the spark plugs are correct for use with a spark tester.
•
Check the spark plugs for the following conditions: −
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
•
Check for bare or shorted ignition wires.
•
Check for moisture in the distributor cap if applicable.
•
Check for loose ignition coil connections.
Important: 1. If the engine starts but then immediately stalls, Crankshaft Position (CKP). 2. Check for improper gap, debris or faulty connections.
-58-
Engine Mechanical Checks
Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than the gasoline fuel supply system. •
Exhaust System Checks
Check for the following: −
Vacuum leaks
−
Improper valve timing
−
Low compression
−
Bent pushrods
−
Worn rocker arms
−
Broken or weak valve springs
−
Worn camshaft lobes.
•
Check the intake and exhaust manifolds for casting flash.
•
Check the exhaust system for a possible restriction:
•
−
Inspect the exhaust system for damaged or collapsed pipes
−
Inspect the muffler for signs of heat distress or for possible internal failure.
Check for possible plugged catalytic converter.
-59-
Cuts Out, Misses Checks Action DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks
•
Refer to Important Preliminary Checks.
Ignition System Checks
•
Start the engine.
•
Wet down the secondary ignition system with water from a spray bottle, and look/listen for arcing or misfiring as you apply water.
•
Check for proper ignition output voltage with a spark tester.
•
Check for a cylinder misfire.
•
Verify that the spark plugs are correct for use with LPG (R42LTS)
•
Remove the spark plugs in these cylinders and check for the following conditions:
Engine Mechanical Checks
Fuel System Checks
Additional Check
−
Insulation cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
−
Visually/Physically inspect the secondary ignition for the following:
−
Ignition wires for arcing, cross-firing and proper routing
−
Ignition coils for cracks or carbon tracking
•
Perform a cylinder compression check.
•
Check the engine for the following: −
Improper valve timing
−
Bent pushrods
−
Worn rocker arms
−
Worn camshaft lobes.
−
Broken or weak valve springs.
•
Check the intake and exhaust manifold passages for casting flash.
•
Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
•
Check the condition of the wiring to the low pressure lock-off solenoid.
Check for Electromagnetic Interference (EMI). •
EMI on the reference circuit can cause a missing condition.
•
Monitoring the engine RPM with a scan tool can detect an EMI.
•
A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
•
If the problem exists, check the routing of the secondary wires and the ground circuit.
-60-
Hesitation, Sag, Stumble Checks
Action
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks
Refer to Important Preliminary Checks.
Fuel System Checks
•
Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
•
Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a faulty low pressure regulator or a restriction in the fuel system.
•
Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
•
Check LPL electrical connection
•
Check the mixer air valve for sticking or binding.
•
Check the mixer module assembly for proper installation and leakage.
•
Check the PTV and FTV.
Ignition System Checks
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly. •
Check for the proper ignition voltage output with a spark tester or the equivalent.
•
Verify that the spark plugs are correct for use with LPG (R42LTS)
•
Check for faulty spark plug wires
•
Check for fouled spark plugs.
• Additional Check
•
Check for manifold vacuum or air induction system leaks
•
Check the generator output voltage.
-61-
Backfire Checks
Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Check
•
Ignition System Checks
Important!
Refer to Important Preliminary Checks.
LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
Engine Mechanical Check
•
Check for the proper ignition coil output voltage using a spark tester or the equivalent.
•
Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires.
•
Check the connection at each ignition coil.
•
Check for deteriorated spark plug wire insulation.
•
Check the spark plugs. The correct spark plugs for LPG are (R42LTS)
•
Remove the plugs and inspect them for the following conditions: −
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
Important! The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than a gasoline fuel supply system. •
Fuel System Checks
Check the engine for the following: −
Improper valve timing
−
Engine compression
−
Manifold vacuum leaks
−
Intake manifold gaskets
−
Sticking or leaking valves
−
Exhaust system leakage
•
Check the intake and exhaust system for casting flash or other restrictions.
•
Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
-62-
Lack of Power, Sluggishness, or Sponginess Checks
Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks
Fuel System Checks
Sensor Checks
Exhaust System Checks
Engine Mechanical Check
Additional Check
•
Refer to Important Preliminary Checks.
•
Refer to the LPG Fuel system OBD System Check
•
Compare the customer’s vehicle with a similar unit. Make sure the customer has an actual problem. Do not compare the power output of the vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics
•
Remove the air filter and check for dirt or restriction.
•
Check the vehicle transmission Refer to the OEM transmission diagnostics.
•
Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis.
•
Check for the proper ignition output voltage with a spark tester or the equivalent.
•
Check for proper installation of the mixer module assembly.
•
Check all air inlet ducts for condition and proper installation.
•
Check for fuel leaks between the LPR and the mixer.
•
Verify that the LPG tank manual shut-off valve is fully open.
•
Verify that liquid fuel (not vapor) is being delivered to the LPR.
•
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper operation of the MAP sensor.
•
Check for proper operation of the TPS sensor.
•
Check the exhaust system for a possible restriction:
•
−
Inspect the exhaust system for damaged or collapsed pipes
−
Inspect the muffler for signs of heat distress or for possible internal failure.
−
Check for possible plugged catalytic converter.
Check the engine for the following: −
Engine compression
−
Valve timing
−
Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
•
Check the ECM grounds for being clean, tight, and in their proper locations.
•
Check the generator output voltage.
•
If all procedures have been completed and no malfunction has been found, review and inspect the following items:
•
Visually and physically, inspect all electrical connections within the suspected circuit and/or systems.
•
Check the scan tool data.
-63-
Poor Fuel Economy Checks
Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by an by refueling records. Preliminary Checks
•
Refer to Important Preliminary Checks.
•
Check the air cleaner element (filter) for dirt or being plugged.
•
Visually (Physically) check the vacuum hoses for splits, kinks, and proper connections.
•
Check the operators driving habits for the following items: −
Is there excessive idling or stop and go driving?
−
Are the tires at the correct air pressure?
−
Are excessively heavy loads being carried?
−
Is their often rapid acceleration?
•
Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
•
Suggest that a different operator use the equipment and record the results.
•
Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
•
Check the fuel system for leakage.
Sensor Checks
•
Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
Ignition System Checks
•
Verify that the spark plugs are correct for use with LPG (R42LTS)
•
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
Fuel System Checks
•
−
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
Check the ignition wires for the following items: −
Cracking
−
Hardness
−
Proper connections
Cooling System Checks
•
Check the engine thermostat for always being open or for the wrong heat range
Additional Check
•
Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
•
Check for dragging brakes.
-64-
Rough, Unstable, or Incorrect Idle, Stalling Checks
Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Preliminary Check
•
Refer to Important Preliminary Checks.
Sensor Checks
•
Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating. The sensor will result in a high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe driveability problem.
•
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
•
Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
•
Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem.
•
Check for a sticking mixer air valve.
•
Verify proper operation of the PTV and FTV.
•
Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
•
Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
•
Check mixer module assembly for proper installation and connection.
•
Check for the proper ignition output voltage using a spark tester or the equivalent.
•
Verify that the spark plugs are correct for use with LPG (R42LTS)
•
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
Fuel System Checks
Ignition System Checks
• Additional Checks
−
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Blistered insulators
−
Heavy deposits
Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires.
Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than the gasoline fuel supply system. •
Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
•
Check the ECM grounds for being clean, tight, and in their proper locations.
•
Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality..
-65-
Engine Mechanical Check
•
Check the engine for the following: −
Broken motor mounts
−
Improper valve timing
−
Low compression
−
Bent pushrods
−
Worn rocker arms
−
Broken or weak valve springs
−
Worn camshaft lobes
-66-
Surges/Chugs Checks
Action
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. Preliminary Checks
•
Refer to Important Preliminary Checks.
•
Be sure the driver understands the Torque Converter Clutch operation.
Sensor Checks
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Fuel System Checks
•
Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem.
•
Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
•
Verify proper fuel control solenoid operation.
•
Verify that the LPG manual shut-off valve is fully open.
•
Check the in-line fuel filter for restrictions.
•
Check for the proper ignition output voltage using a spark tester or the equivalent.
•
Verify that the spark plugs are correct for use with LPG (R42LTS)
•
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
Ignition System Checks
Additional Check
−
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
−
Check the Crankshaft Position (CKP) sensor.
•
Check the ECM grounds for being clean, tight, and in their proper locations.
•
Check the generator output voltage.
•
Check the vacuum hoses for kinks or leaks.
•
Check Transmission
-67-
Gasoline Symptom Diagnosis Important Preliminary Checks Checks Before Using This Section
Action Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks are very important. The checks can lead to correcting a problem without further checks that may save valuable time.
Fuel System Check
1. Verify the customer complaint. 2. Locate the correct symptom table. 3. Check the items indicated under that symptom. 4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich. IMPORTANT! Normal HEGO switching indicates the Gasoline fuel system is in closed loop and operating correctly at that time. 5. If a scan tool is available, take a snapshot under the condition that the symptom occurs. Go to Engine Scan Tool Data List to verify normal sensor values and parameters.
Visual and Physical Checks
•
Check all ECM system fuses and circuit breakers.
•
Check the ECM ground for being clean, tight and in its proper location.
•
Check the vacuum hoses for splits, kinks and proper connections.
•
Check thoroughly for any type of leak or restriction.
•
Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
•
Check for proper installation of the Throttle Body assembly.
•
Check for fuel leaks at the fuel rail and injectors.
•
Check the ignition wires for the following conditions:
•
−
Cracking
−
Hardness
−
Proper routing
−
Carbon tracking
Check the wiring for the following items: −
•
Proper connections, pinches or cuts.
The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan tool readings do not indicate the problems, then proceed in a logical order, easiest to check or most likely to cause first.
-68-
Intermittent Checks
Action
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC). Preliminary Checks
Faulty Electrical Connections or Wiring
•
Refer to Important Preliminary Checks.
•
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.
•
Faulty electrical connections or wiring can cause most intermittent problems.
•
Check the suspected circuit for the following conditions: −
Faulty fuse or circuit breaker
−
Connectors poorly mated
−
Terminals not fully seated in the connector (backed out)
−
Terminals not properly formed or damaged
−
Terminal to wires poorly connected
−
Terminal tension insufficient.
•
Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the connector terminals in the problem circuit in order to ensure the proper contact tension.
•
Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test
If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit.
Intermittent Malfunction Indicator Lamp (MIL)
The following components can cause intermittent MIL and no DTC(s):
Loss of DTC Memory
•
A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
•
The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
•
The ignition secondary voltage shorted to a ground.
•
The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
•
The Control Module grounds.
To check for the loss of the DTC Memory: 1. Disconnect the TMAP sensor. 2. Idle the engine until the Malfunction Indicator Lamp illuminates. The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store and remain, the ECM is faulty.
Additional Checks
.
-69-
No Start Checks
Action
DEFINITION: The engine cranks OK but does not start. Preliminary Checks
•
Refer to Important Preliminary Checks.
Control Module Checks
•
If a scan tool is available: −
Sensor Checks
Fuel System Checks
Ignition System Checks
Engine Mechanical Checks
Check for proper communication with the ECM.
•
Check the 3A inline fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
•
Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for each circuit.
•
Check the TMAP sensor.
•
Check the Magnetic pickup sensor (RPM).
•
Check for fuel pump electrical circuit
•
Verify proper fuel pump pressure.
•
Verify proper Fuel rail pressure.
•
Refer to the Gasoline Fuel System Diagnosis.
•
Check Electrical connections at the injectors.
•
Check for the proper ignition voltage output with a spark tester or the equivalent.
•
Verify that the spark plugs are correct use (R42LTS)
•
Check the spark plugs for the following conditions: −
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
•
Check for bare or shorted ignition wires.
•
Check for loose ignition coil connections at the coil.
•
Check for the following: −
Vacuum leaks
−
Improper valve timing
−
Low compression
−
Bent pushrods
−
Worn rocker arms
−
Broken or weak valve springs
−
Worn camshaft lobes.
-70-
Exhaust System Checks
•
•
Check the exhaust system for a possible restriction: −
Inspect the exhaust system for damaged or collapsed pipes
−
Inspect the muffler for signs of heat distress or for possible internal failure.
Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
-71-
Hard Start Checks
Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks Sensor Checks
Fuel System Checks
•
Refer to Important Preliminary Checks.
•
Make sure the vehicle’s operator is using the correct starting procedure.
•
Check the Engine Coolant Temperature sensor with the scan tool. Compare the engine coolant temperature with the ambient air temperature on a cold engine. IF the coolant temperature reading is more than 5 degrees greater or less than the ambient air temperature on a cold engine, check for high resistance in the coolant sensor circuit. Refer to DTC 111
•
Check the Crankshaft Position (CKP) sensor.
•
Check the Throttle position (TPS) sensor.
•
Check for fuel pump electrical circuit
•
Verify proper fuel pump pressure.
•
Verify proper Fuel rail pressure.
•
Refer to the Gasoline Fuel System Diagnosis. Check Electrical connections at the injectors
Ignition System Checks
•
Check for the proper ignition voltage output with J 26792 or the equivalent.
•
Verify that the spark plugs are correct use (R42LTS)
•
Check the spark plugs for the following conditions: −
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
•
Check for bare or shorted ignition wires.
•
Check for moisture in the distributor cap if applicable.
•
Check for loose ignition coil connections.
Important: 1. If the engine starts but then immediately stalls, Crankshaft Position (CKP). 2. Check for improper gap, debris or faulty connections. Engine Mechanical Checks
•
•
Check for the following: −
Vacuum leaks
−
Improper valve timing
−
Low compression
−
Bent pushrods
−
Worn rocker arms
−
Broken or weak valve springs
−
Worn camshaft lobes. Ref
Check the intake and exhaust manifolds for casting flash.
-72-
Exhaust System Checks
•
•
Check the exhaust system for a possible restriction: −
Inspect the exhaust system for damaged or collapsed pipes
−
Inspect the muffler for signs of heat distress or for possible internal failure.
Check for possible plugged catalytic converter.
-73-
Cuts Out, Misses Checks
Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks
•
Refer to Important Preliminary Checks.
Ignition System Checks
•
Start the engine.
•
Wet down the secondary ignition system with water from a spray bottle, and look/listen for arcing or misfiring as you apply water.
•
Check for proper ignition output voltage with a spark tester.
•
Check for a cylinder misfire.
•
Verify that the spark plugs are correct use (R42LTS)
•
Remove the spark plugs in these cylinders and check for the following conditions:
•
Engine Mechanical Checks
Fuel System Checks
Additional Check
−
Insulation cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
Visually/Physically inspect the secondary ignition for the following: −
Ignition wires for arcing, cross-firing and proper routing
−
Ignition coils for cracks or carbon tracking
•
Perform a cylinder compression check.
•
Check the engine for the following: −
Improper valve timing
−
Bent pushrods
−
Worn rocker arms
−
Worn camshaft lobes.
−
Broken or weak valve springs.
•
Check the intake and exhaust manifold passages for casting flash.
•
Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to Gasoline Fuel System Diagnosis.
•
Check the condition of the wiring to the fuel pump and injectors.
Check for Electromagnetic Interference (EMI). •
EMI on the reference circuit can cause a missing condition.
•
Monitoring the engine RPM with a scan tool can detect an EMI.
•
A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
•
If the problem exists, check the routing of the secondary wires and the ground circuit.
-74-
Hesitation, Sag, Stumble Checks Action DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks
Refer to Important Preliminary Checks.
Fuel System Checks
•
Check for fuel pump electrical circuit
•
Verify proper fuel pump pressure.
•
Verify proper Fuel rail pressure.
•
Refer to the Gasoline Fuel System Diagnosis.
•
Check Electrical connections at the injectors
•
Check for the proper ignition voltage output with a spark tester or the equivalent.
•
Verify that the spark plugs are correct use (R42LTS)
•
Check for faulty spark plug wires
•
Check for fouled spark plugs.
Ignition System Checks
• Additional Check
1. Check for manifold vacuum or air induction system leaks •
Check the generator output voltage.
-75-
Backfire Checks
Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Check
•
Refer to Important Preliminary Checks.
Ignition System Checks
•
Check for the proper ignition coil output voltage using a spark tester or the equivalent.
•
Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires.
•
Check the connection at each ignition coil.
•
Check for deteriorated spark plug wire insulation.
•
Check the spark plugs. The correct spark plugs are (R42LTS)
•
Remove the plugs and inspect them for the following conditions:
Engine Mechanical Check
Fuel System Checks
−
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
•
Check the engine for the following: −
Improper valve timing
−
Engine compression
−
Manifold vacuum leaks
−
Intake manifold gaskets
−
Sticking or leaking valves
−
Exhaust system leakage
•
Check the intake and exhaust system for casting flash or other restrictions.
•
Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
-76-
Lack of Power, Sluggishness, or Sponginess Checks
Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks
Fuel System Checks
•
Refer to Important Preliminary Checks.
•
Refer to the Gasoline Fuel system OBD System Check
•
Compare the customer’s vehicle with a similar unit. Make sure the customer has an actual problem.
•
Remove the air filter and check for dirt or restriction.
•
Check the vehicle transmission Refer to the OEM transmission diagnostics.
•
Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to Gasoline Fuel System Diagnosis.
•
Check for the proper ignition output voltage with a spark tester or the equivalent.
•
Check for fuel pump electrical circuit
•
Verify proper fuel pump pressure.
•
Verify proper Fuel rail pressure.
•
Refer to the Gasoline Fuel System Diagnosis. Check Electrical connections at the injectors
Sensor Checks
Exhaust System Checks
Engine Mechanical Check
Additional Check
•
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper operation of the MAP sensor.
•
Check for proper operation of the TPS sensor.
•
Check the exhaust system for a possible restriction: −
Inspect the exhaust system for damaged or collapsed pipes
−
Inspect the muffler for signs of heat distress or for possible internal failure.
−
Check for possible plugged catalytic converter.
Check the engine for the following: •
Engine compression
•
Valve timing
•
Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
•
Check the ECM grounds for being clean, tight, and in their proper locations.
•
Check the generator output voltage.
•
If all procedures have been completed and no malfunction has been found, review and inspect the following items:
•
Visually and physically, inspect all electrical connections within the suspected circuit and/or systems.
•
Check the scan tool data.
-77-
Poor Fuel Economy Checks
Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by an by refueling records. Preliminary Checks
•
Refer to Important Preliminary Checks.
•
Check the air cleaner element (filter) for dirt or being plugged.
•
Visually (Physically) check the vacuum hoses for splits, kinks, and proper connections.
•
Check the operators driving habits for the following items: −
Is there excessive idling or stop and go driving?
−
Are the tires at the correct air pressure?
−
Are excessively heavy loads being carried?
−
Is their often rapid acceleration?
•
Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
•
Suggest that a different operator use the equipment and record the results.
•
Check the fuel Rail pressure. Refer to Gasoline Fuel System Diagnosis.
•
Check the fuel system for leakage.
Sensor Checks
•
Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
Ignition System Checks
•
Verify that the spark plugs are correct use (R42LTS)
•
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
Fuel System Checks
•
−
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Heavy deposits
Check the ignition wires for the following items: −
Cracking
−
Hardness
−
Proper connections
Cooling System Checks
•
Check the engine thermostat for always being open or for the wrong heat range
Additional Check
•
Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
•
Check for dragging brakes.
-78-
Rough, Unstable, or Incorrect Idle, Stalling Checks
Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Preliminary Check
•
Refer to Important Preliminary Checks.
Sensor Checks
•
Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating. The sensor will result in a high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe driveability problem.
•
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
•
Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
•
Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem.
•
Check for a sticking mixer air valve.
•
Verify proper operation of the Injectors.
•
Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
•
Check the fuel Rail pressure. Refer to the Gasoline Fuel System Diagnosis.
•
Check injector electrical connections.
•
Check for the proper ignition output voltage using a spark tester or the equivalent.
•
Verify that the spark plugs are correct use (R42LTS)
•
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
Fuel System Checks
Ignition System Checks
Additional Checks
−
Wet plugs
−
Cracks
−
Wear
−
Improper gap
−
Burned electrodes
−
Blistered insulators
−
Heavy deposits
•
Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires.
•
Check the ECM grounds for being clean, tight, and in their proper locations.
•
Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality..
-79-
Engine Mechanical Check
•
Check the engine for the following: −
Broken motor mounts
−
Improper valve timing
−
Low compression
−
Bent pushrods
−
Worn rocker arms
−
Broken or weak valve springs
−
Worn camshaft lobes
-80-
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)
Restricted Exhaust System Diagnosis
1.
Carefully remove the HEGO
Exhaust System Description
2.
Install exhaust backpressure tester in place of the HEGO (See Illustration)
The emission certified engine has been designed and calibrated to meet the emission standards in effect for 2004. To help meet the emission requirements the vehicle has been equipped with a Three Way Catalytic (TWC) muffler. The catalyst muffler is a three way catalyst, sound damping and spark arresting unit. Besides controlling the noise created from the combustion process, and preventing sparks from escaping from the exhaust system the most important function is treating the exhaust gases which are created from the combustion process. The three-way catalyst consists of a honeycomb coated with a mixture of platinum, palladium, and rhodium. The hot gases flow through the catalyst sections where an oxidation and reduction reactions take place. These chemical reactions reduce the amount of CO, HC and NOX in the engines exhaust. The Exhaust gas then flows through the outlet.
3.
With the engine idling at normal operating temperature, observe the exhaust system back pressure reading on the gage. Reading should not exceed 8.6 kPa (1.25 psi)
4.
Increase engine speed to 2000 RPM and observe gage. Reading should not exceed 20.7 kPa (3 psi)
5.
If the back pressure at either speed exceeds specification, a restricted exhaust system is indicated.
6.
Inspect the entire exhaust system for a collapsed pipe, heat distress or possible internal muffler failure.
7. If there are no obvious reasons for the excessive back pressure, the catalytic converter is suspected to be restricted and should be replaced using current recommended procedures
During normal operation the exhaust system could become damaged. Damage which reduces the flow of the exhaust gas will create increased back pressure in the engine. Reduction in exhaust flow can result from crushed muffler outlets or melted catalyst brick inside the converter. It may be necessary to measure the back pressure in the exhaust system. To determine if the back pressure in the engine is correct use the following procedure.
Diagnostic Aids Tools Required: •
Exhaust Back Pressure Gauge
Diagnostic Scan Tool •
Fuel System diagnostic tool.
Figure 1 Exhaust Back Pressure Test
-81-
SECTION 1C2
SCHEMATICS Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service Wire Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Connectors and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Micro-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 To Remove a Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Weather Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 4.3L Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 4.3L LPG Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 4.3L Gasoline Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 4.3L Dual Fuel Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 ECM Connector C001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Communication Port C002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Injector Connector C003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Injector Connector C004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Oil Pressure Connector C005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Crank Sensor Connector C006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Module Connector C007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Coil Connector C008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Throttle Connector C009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 EGO Sensor Connector C010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 TMAP Connector C011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 CAM Connector C012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 ECT Connector C013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Starter Solenoid Connector C014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Battery Connector C015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Alternator Connector C016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Alternator Connector C017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Instrument Panel Connector C018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Instrument Panel Connector C019 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Instrument Panel Connector C020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Fuel Lockoff C021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Fuel Trim Valve Connector C022 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Pressure Trim Valve Connector C023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Injector 1 Connector C024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 Injector 2 Connector C025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Injector 3 Connector C026 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Injector 4 Connector C027 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Injector 5 Connector C028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Injector 6 Connector C029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
-83-
SECTION 1C2
SCHEMATICS Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service Wire Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Connectors and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Micro-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 To Remove a Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Weather Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 4.3L Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 4.3L LPG Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 4.3L Gasoline Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 4.3L Dual Fuel Jump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 ECM Connector C001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Communication Port C002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Injector Connector C003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Injector Connector C004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Oil Pressure Connector C005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Crank Sensor Connector C006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Module Connector C007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Coil Connector C008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Throttle Connector C009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 EGO Sensor Connector C010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 TMAP Connector C011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 CAM Connector C012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 ECT Connector C013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Starter Solenoid Connector C014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Battery Connector C015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Alternator Connector C016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Alternator Connector C017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Instrument Panel Connector C018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Instrument Panel Connector C019 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Instrument Panel Connector C020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Fuel Lockoff C021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Fuel Trim Valve Connector C022 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Pressure Trim Valve Connector C023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Injector 1 Connector C024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 Injector 2 Connector C025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Injector 3 Connector C026 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Injector 4 Connector C027 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Injector 5 Connector C028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Injector 6 Connector C029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
-83b-
jumper wires between connectors, for circuit checking. NEVER probe through the Weather-Pack seals. Use a tachometer adapter which provides an easy hook up of the tach lead. The connector test adapter kit J 35616, or equivalent, contains an assortment of flexible connectors, used to probe terminals during diagnosis. Fuse remover and test tool BT 8616, or equivalent, is used for removing a fuse and to adapt fuse holder, with a meter, for diagnosis.
ON-VEHICLE SERVICE WIRE HARNESS REPAIR The ECM/PCM harness electrically connects the ECM/ PCM to the various solenoids, electrically and sensors in vehicle engine and passenger compartment. Wire harnesses should be replaced with proper part number harnesses. When signal wires are spliced, into a harness, use wire with high temperature insulation only.
When diagnosing, open circuits are often difficult to locate by sight, because oxidation, or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor, or in the wiring harness, may correct the open circuit condition. This should always be considered, when an open circuit, or failed sensor is indicated. Intermittent problems may, also, be caused by oxidized or loose connections.
With the low current and voltage levels found in the system, it is important that the best possible bond at all wire splices be made by soldering the splices, as shown in Figure 1. Molded on connectors require complete replacement of the connector. This means splicing a new connector assembly into the harness.
Before making a connector repair, be certain of the type of connector. Weather-Pack and Meter Pack connectors look similar, but are serviced differently.
Refer to Figure 1 for wiring diagrams.
CONNECTORS AND TERMINALS Use care when probing a connector or replacing terminals in them. It is possible to short between opposite terminals. If this happens to the wrong terminal pair, it is possible to damage certain components. Always use
FIGURE 1 WIRE HARNESS REPAIR
-84-
Micro-Pack
If reusing the terminal, reshape the locking tang (2).
Refer to Figure 2 and repair procedure for replacement of a :Micro-Pack terminal.
Weather-Pack A Weather-Pack connector can be identified by a rubber seal, at the rear of the connector. This connector, which is used in the engine compartment, protects against moisture and dirt, which could create oxidation and deposits on the terminals. This protection is important, because of the very low voltage and current levels found in the electronic system.
FIGURE 2 MICRO-PACK CONNECTOR
Metri-Pack Some connectors use terminals called Metri-Pack Series 150. (Figure 3). ‘These may be used at the coolant sensor, as well as TBI units. They are also called “Pull-To-Seat” terminals, because, to install a terminal on a wire, the wire is fi rst inserted through the seal (5) and connector (4). The terminal is then crimped on the wire and the terminal pulled back into the connector to seat it in place.
To remove a terminal: 1.
Slide the seal back on the wire.
2. Insert tool (3) BT-8518, or J 35689, or equivalent, as shown in insert “A” and “B,” to release the terminal locking tab (2).
FIGURE 4 WEATHER PACK TERMINAL REPAIR
3. Push the wire and terminal out through the connector.
FIGURE 3 METRI-PACK SERIES 150 TERMINAL REMOVAL
-85-
Repair of a Weather-Pack terminal is shown in Figure 3-23. Use tool J M28742, or BT8234-A to remove the pin and sleeve terminals. If removal is attempted with an ordinary pick, there is a good chance that the terminal will be bent, or deformed. Unlike standard blade type terminals, these terminals cannot be straightened once they are bent. Make certain that the connectors are properly seated and all of the sealing rings in place, when connecting leads. The hinge type flap provides a backup, or secondary locking feature for the connector. They are used to improve the connector reliability by retaining the terminals, if the small terminal lock tangs are not positioned properly. Weather-Pack connections cannot be replaced with standard connections. Instructions are provided with Weather-Pack connector and terminal packages.
-86-
ECM CONNECTOR C001
INJ + INJ 1 INJ 2 AUX OUT 2A AUX ANA PD1 MAP FPP IAT ECT IVS AUX ANA PU1 POWER GROUND POWER GROUND ANA_RTN 5 VOLT REF VSW EGO 1 KNK + KNK CRANK + CRANK CAM + CAM VBAT VBAT STARTER LOCKOUT FUEL LOCKOFF FUEL PUMP2 RELAY CONTROL TPS1 TPS2 DBW + DBW OIL PRESSURE TACH MIL AUX ANA PD2 AUX OUT 1A FUEL SELECT AUX ANA PU2 GOV SELECT FTV CAN + CAN RS 232 TX RS 232 RX COIL 1 INJ 3 INJ 4 INJ 5 INJ 6 PTV CHARGE LAMP AUX OUT 3
-96-
18 16 17 5 35 33 38 32 31 39 36 19 20 49 50 21 55 41 42 11 12 13 14 22 23 9 8 3 10 53 54 24 25 37 56 26 47 4 40 48 34 15 43 44 51 52 27 29 30 28 1 2 7 6
ORANGE/BLUE 16 BROWN/BLUE 16 BROWN/GREEN 16 LT BLUE/WHITE 18 TAN/DK GREEN 18 LT GRN 18 DK BLUE 18 TAN 18 YELLOW/GRAY 18 PURPLE/YELLOW 18 DK BLUE/YELLOW 18 BLACK 16 BLACK 16 BLACK/LT GREEN 18 LT GREEN/RED 18 PINK/TAN 18 DK GREEN/ORANGE 18
PURPLE/WHITE 18 WHITE/PURPLE 18 GRAY/BROWN 18 PURPLE/ORANGE 18 RED/TAN 16 RED/TAN 16 GRAY/ORANGE 18 WHITE/BLACK 18 TAN/BLACK 18 WHITE/LT BLUE 18 PURPLE/LT BLUE 18 LT BLUE/DK BLUE 18 PINK/WHITE 18 TAN/ORANGE 18 LT GREEN/BLACK 18 YELLOW/LT GREEN 18 LT BLUE/BLACK 18 BLACK/WHITE 18 PURPLE/DK BLUE 18 TAN/BROWN 18 YELLOW/DK BLUE 18 GRAY/DK BLUE 18 WHITE/RED 18 BLUE/PINK 18 BLUE/WHITE 18 DK GREEN 18 ORANGE 18 YELLOW 18 BROWN/WHITE 16 BROWN/YELLOW 16 BROWN/ORANGE 16 TAN/LT BLUE 16 RED/WHITE 18 ORANGE/YELLOW 18
-87-
COMMUNICATION PORT C002
Pin A B C D
Wire Color Orange Dark Green Lt Green/Red Black/Lt Green
A
B
D
C
Function RS232 RX RS232 TX 5 Volt Ref Ana Rtn
-97-
INJECTOR CONNECTOR C003
A B C D E F
Pin A B C D E F
Wire Color Brown/Blue Brown/Green Brown/White Brown/Yellow Brown/Orange Tan/Light Blue
Function Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6
-98-
INJECTOR CONNECTOR C004
C A F E D
Pin A Not Used C D E F
Wire Color Orange/Blue
Function Injector +
Red/White White/Black White/Red Pink/Tan
Injector 7 Fuel Lockoff Gaseous Trim VSW
-99-
OIL PRESSURE CONNECTOR C005
A
Pin A
Wire Color Function Lt Green/Black Oil Pressure
-100-
CRANK SENSOR CONNECTOR C006
A
Pin A B C
Wire Color Lt Green/Red White/Purple Purple/White
B
C
Function 5 Volt Ref Crank Crank +
-101-
MODULE CONNECTOR C007
A B C D
Pin A B C D
Wire Color Pink/Dk Green Yellow Black Yellow/Black
Function Coil Coil Power Ground Coil
-102-
COIL CONNECTOR C008
A
Pin A B C
Wire Color Pink/Dk Green Yellow/Black Not Used
B
C
Function EGO Module
-103-
THROTTLE CONNECTOR C009
A E
Pin A B C D E F G H
Wire Color Black/Lt Green Lt Green/Red Purple/Lt Blue Lt Blue/Dk Blue Pink/White Tan/Orange Not Used Dk Blue
B F
C G
Function Analog Return 5 Volt Reference TPS 1 TPS 2 DBW + DBW FPP
-104-
EGO SENSOR CONNECTOR C010
Pin A B C D
A
B
C
D
Wire Color Blk/Lt Green Dk Green/Orange Pink/Dk Green Black
Function Power Ground EGO Coil Power Ground
-105-
TMAP CONNECTOR C011
1
Pin 1 2 3 4
Wire Color Black/Lt Green Tan Lt Green/Red Lt Green
2
3
4
Function Analog Return IAT 5 Volt Reference MAP
-106-
CAM CONNECTOR C012
A
Pin A B C
Wire Color Purple/Orange Grey/Brown Lt Green/Red
B
C
Function Cam – Cam + 5 Volt Ref
-107-
ECT CONNECTOR C013
A
Pin A B
Wire Color Yellow/Gray Black/Lt Green
-108-
B
Function ECT Analog Return
STARTER SOLENOID CONNECTOR C014
Pin A
Wire Color White
Function Starter Relay
-109-
BATTERY CONNECTOR C015
Pin A
Wire Color Red
Function Battery +
-110-
ALTERNATOR CONNECTOR C016
Pin A
Wire Color Red
Function Battery +
-111-
ALTERNATOR CONNECTOR C017
A
Pin A B
Wire Color Red Pink/Dk Green
-112-
B
Function Battery Power Relay
INSTRUMENT PANEL CONNECTOR C018
Pin A B C D E F G H J K
A B C D
E
F G H
K
Wire Color Pink Dk Blue Purple/Yellow Black/Lt Green Orange/Yellow Lt Blue/Black Lt Green/Red Not Used Lt Blue/Pink Pink/Black
J
Function VSW FPP IVS Ana Return Charge Lamp MIL VREF Start In (Interrupt Type) Start In (Autocranking)
-113-
INSTRUMENT PANEL CONNECTOR C019
Pin A B C D E F G H
A
B
C
D
E
F
G
H
Wire Color Lt Blue/White Tan/Dk Green Yellow/Lt Green Tan/Brown Grey/Dk Blue Blue/Pink Blue/White Purple/Dk Blue
-114-
Function Aux Out 2A Aux In PD1 Tach Fuel Select Gov Select Can + Can Aux Out 1
INSTRUMENT PANEL CONNECTOR C020
A B C D E F
Pin A B C D E F
Wire Color Black/White Yellow/Dk Blue Dk Blue/Yellow Pink/Yellow Black Pink/Dk Green
Function Aux In PD2 Aux In PU2 Aux In PU1 Fuel Pump Ground Relay Fused Power
-115-
FUEL LOCKOFF CONNECTOR C021
A
Pin A B
Wire Color White/Black Pink/Tan
-116-
B
Function Fuel Lockoff VSW
FUEL TRIM VALVE CONNECTOR C022
A
Pin A B
Wire Color White/Red Orange/Blue
B
Function Gaseous Trim Injector +
-117-
PRESSURE TRIM VALVE CONNECTOR C023
A
Pin A B
Wire Color Red/White Orange/Blue
B
Function INJ 7 INJ +
-118-
INJECTOR 1 CONNECTOR C024
A
Pin A B
B
Wire Color Function Orange/Lt Blue Fuel Trim Valve Brown/Lt Blue Injector 1
-119-
INJECTOR 2 CONNECTOR C025
A
Pin A B
B
Wire Color Function Orange/Lt Blue Fuel Trim Valve Tan/Lt Blue Injector 2
-120-
INJECTOR 3 CONNECTOR C026
A
Pin A B
B
Wire Color Function Orange/Lt Blue Fuel Trim Valve Brown/Orange Injector 3
-121-
INJECTOR 4 CONNECTOR C027
A
Pin A B
B
Wire Color Function Orange/Lt Blue Fuel Trim Valve Brown/Yellow Injector 4
-122-
INJECTOR 5 CONNECTOR C028
A
Pin A B
B
Wire Color Function Orange/Lt Blue Fuel Trim Valve Brown/White Injector 5
-123-
INJECTOR 6 CONNECTOR C029
A
Pin A B
B
Wire Color Function Orange/Lt Blue Fuel Trim Valve Brown/Green Injector 6
-124-
4.3L MAIN HARNESS COO3 BROWN/BLUE 16 BROWN/GREEN 16 BROWN/WHITE 16 BROWN/YELLOW 16 BROWN/ORANGE 16 TAN/LT BLUE 16
ORANGE/BLUE 16
COO1 ECM INJ + INJ 1 INJ 2 AUX OUT 2A AUX ANA PD1 MAP FPP IAT ECT IVS AUX ANA PU1 POWER GROUND POWER GROUND ANA_RTN 5 VOLT REF VSW EGO 1 KNK + KNK CRANK + CRANK CAM + CAM VBAT VBAT STARTER LOCKOUT FUEL LOCKOFF FUEL PUMP2 RELAY CONTROL TPS1 TPS2 DBW + DBW OIL PRESSURE TACH MIL AUX ANA PD2 AUX OUT 1A FUEL SELECT AUX ANA PU2 GOV SELECT FTV CAN + CAN RS 232 TX RS 232 RX COIL 1 INJ 3 INJ 4 INJ 5 INJ 6 PTV CHARGE LAMP AUX OUT 3
RED/WHITE 18 WHITE/BLACK 18 WHITE/RED 18 PINK/TAN 18 18 16 17 5 35 33 38 32 31 39 36 19 20 49 50 21 55 41 42 11 12 13 14 22 23 9 8 3 10 53 54 24 25 37 56 26 47 4 40 48 34 15 43 44 51 52 27 29 30 28 1 2 7 6
ORANGE/BLUE 16 BROWN/BLUE 16 BROWN/GREEN 16 LT BLUE/WHITE 18 TAN/DK GREEN 18 LT GRN 18 DK BLUE 18 TAN 18 YELLOW/GRAY 18 PURPLE/YELLOW 18 DK BLUE/YELLOW 18 BLACK 16 BLACK 16 BLACK/LT GREEN 18 LT GREEN/RED 18 PINK/TAN 18 DK GREEN/ORANGE 18
SHD A B C D E F TWR A B C D E F
MTRSHD6 FUEL SYSTEM INTERFACE
MTRTWR6
COO4
CO13 YELLOW GRAY 18
A
BLACK/LT GREEN 18
B
ECT
CO11 PURPLE/WHITE 18 WHITE/PURPLE 18 GRAY/BROWN 18 PURPLE/ORANGE 18 RED/TAN 16 RED/TAN 16 GRAY/ORANGE 18 WHITE/BLACK 18 TAN/BLACK 18 WHITE/LT BLUE 18 PURPLE/LT BLUE 18 LT BLUE/DK BLUE 18 PINK/WHITE 18 TAN/ORANGE 18 LT GREEN/BLACK 18 YELLOW/LT GREEN 18 LT BLUE/BLACK 18 BLACK/WHITE 18 PURPLE/DK BLUE 18 TAN/BROWN 18 YELLOW/DK BLUE 18 GRAY/DK BLUE 18 WHITE/RED 18 BLUE/PINK 18 BLUE/WHITE 18 DK GREEN 18 ORANGE 18 YELLOW 18 BROWN/WHITE 16 BROWN/YELLOW 16 BROWN/ORANGE 16 TAN/LT BLUE 16 RED/WHITE 18 ORANGE/YELLOW 18
LT GREEN 18 LT GREEN/RED 18 TAN 18 BLACK/LT GREEN 18
4 3 2 1
G2 BOSCH_TMAP
BLACK 12
ALTERNATOR GROUND
BLACK 16 BLACK 16
BLACK 12
G1
RED/TAN 16 RED/TAN 16
GROUND
F1
PINK/TAN 18
PINK 18
5A
CO12 THIS JUNCTION TO BE WITHIN 3-6 INCHES OF CONN
PURPLE/ORANGE 18 GRAY/BROWN 18 LT GREEN/RED 18
TWR A B C
VEHICLE INTERFACE DIST/CAM
CO18 PINK 18 DK BLUE 18 PURPLE/YELLOW 18 BLACK/LT GREEN 18 ORANGE/YELLOW 18 LT BLUE/BLK 18 LT GREEN/RED 18
LT GREEN/RED 18
BLK/LT GREEN 18
CO10
COO2 BLK/LT GREEN 18
D
LT GREEN/RED 18
C
DK GREEN 18
B
ORANGE 18
A
TWR A B C D
BLK/LT GREEN 18 DK GREEN/ORANGE 18 PINK/DK GREEN 16 BLACK 18
TWR
RTN
LT BLUE/PINK 16 PINK/BLACK 16
TWR A B C D E F G H J K
VSW FPP1 IVS ANA RTN CHARGE LAMP MIL VREF START IN (INTERUPT TYPE) START IN (AUTOCRANKING)
EGO MTRTWR10
CO19
5V TX
LT BLUE/WHITE 18 TAN/DK GREEN 18 YELLOW/LT GREEN 18 TAN/BROWN 18 GRAY/DK BLUE 18 BLUE/PINK 18 BLUE/WHITE 18 PURPLE/DK BLUE 18
RX
COMM
COO5 LT GREEN/BLACK 18
OIL PRES
TWR A B C D E F G H
AUX OUT 2 SPEED INPUT TACH FUEL SELECT GOV SELECT CAN + CAN AUX OUT 1
MTRTWR8
COO6 LT GREEN/RED 18 WHITE/PURPLE 18 PURPLE/WHITE 18
TWR A B C
CO14
STARTER_RELAY WHITE 16
STARTER SOLENOID
87A
LT BLUE/PINK 16
87
PINK/BLACK 16
F2
RED/TAN 14
30
CRANK PINK/TAN 18
86
GRAY/ORANGE 18
85
RED 14
CO20
RED 12
20A BLACK/WHITE 18 YELLOW/DK BLUE 18 DK BLUE/YELLOW 18 PINK/YELLOW 16 BLACK 16 PINK/DK GREEN 16
CO15
MTRTWR6
COO7 YELLOW/BLACK 18 BLACK 16 YELLOW 18 PINK/DK GREEN 16
RED 12
D C
50A
RED 12
MAXI-FUSE
BATT+ 1 MODULE
B A
FUEL_PUMP_RELAY RED 14
30 87 PINK/YELLOW 16
COO8 PINK/DK GREEN 16 YELLOW/BLACK 18 PLUG
A B C
PINK/TAN 18
86
TAN/BLACK 18
85
F4
PINK/YELLOW 16
15A
COIL
CO16 RED 12 RED 16
ALTERNATOR
CO17 POWER_RELAY
COO9
RED 16 RED 14
30 87
BLK/LT GREEN 18 LT GREEN/RED 18 PURPLE/LT BLUE 18 LT BLUE/DK BLUE 18 PINK/WHITE 18 TAN/ORANGE 18
-88-
2 3 6 5 4 1
RED/TAN 14
86
PINK/DK GREEN 16
F3 15A
BOSCH THROTTLE WHITE/BLUE 18
85
-89-
TWR A B C D E F
PINK/DK GREEN 16
PINK/DK GREEN 16
A B
ALTERNATOR
AUX IN PD2 AUX IN PU2 AUX IN PU1 FUEL PUMP GROUND RELAY FUSED POWER
4.3L LPG JUMP HARNESS
C022 FUEL TRIM WHITE/RED 18 ORANGE/BLUE 16
A B
C023 PRESSURE TRIM RED/WHITE 18 ORANGE/BLUE 16
A B
C021 LOCKOFF WHITE/BLACK 18 PINK/TAN 18
C004 A B
ORANGE/BLUE 16 RED/WHITE 18 WHITE/BLACK 18 WHITE/RED 18 PINK/TAN 18
-90-
-91-
SHD A B C D E F
4.3L GASOLINE JUMP HARNESS
COO4 SHD C B E D F A
ORANGE/LT BLUE 16 ORANGE/LT BLUE 16
ORANGE/LT BLUE 16
ORANGE/LT BLUE 16
COO3 TWR A E C B D F
BROWN/LT BLUE 16 BROWN/ORANGE 16 BROWN/WHITE 16 BROWN/GREEN 16 BROWN/YELLOW 16 TAN/LT BLUE 16
BROWN/LT BLUE 16
CYL 1
CO24
BROWN/ORANGE 16
CYL 3
BROWN/WHITE 16
CYL 5
CO26
CO28
BROWN/GREEN 16 BROWN/YELLOW 16 TAN/LT BLUE 16
ORANGE/LT BLUE 16
CYL 2
-92-
CO25
ORANGE/LT BLUE 16
CYL 4
ORANGE/LT BLUE 16
CYL 6
CO27
-93-
CO29
4.3L DUAL FUEL JUMP HARNESS
C021 WHITE/BLACK 18 PINK/TAN 18
FUEL LOCKOFF
C022 RED/WHITE 18 ORANGE/LT BLUE 16
A B
A B
C023
FUEL TRIM WHITE/RED 18 ORANGE/LT BLUE 16
A B
PRESSURE TRIM
C004 SHD C B E D F A
RED/WHITE 18 WHITE/RED 18 WHITE/BLACK 18 PINK/TAN 18 ORANGE/LT BLUE 16 ORANGE/LT BLUE 16
ORANGE/LT BLUE 16
ORANGE/LT BLUE 16
C003 TWR A E C B D F
BROWN/LT BLUE 16 BROWN/ORANGE 16 BROWN/WHITE 16 BROWN/GREEN 16 BROWN/YELLOW 16 TAN/LT BLUE 16
BROWN/LT BLUE 16
CYL 1
C024
BROWN/ORANGE 16
CYL 3
BROWN/WHITE 16
CYL 5
C026
C028
BROWN/GREEN 16 BROWN/YELLOW 16 TAN/LT BLUE 16
ORANGE/LT BLUE 16
CYL 2
-94-
C025
ORANGE/LT BLUE 16
CYL 4
C027
ORANGE/LT BLUE 16
CYL 6
C029
-95-
SECTION 1C4
DIAGNOSTIC TROUBLE CODES Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of ECM Based Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Diagnostics Overview of the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Malfunction Indicator Lamp (MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Spectrum Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Using a Laptop Computer to Diagnose the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Installing the Diagnostic Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Checking Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Clearing Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Data Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Reading Sensor and Actuator Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Graphing and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 Ignition System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Disabling Ignition Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Injector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Disabling Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Throttle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Using a Diagnostic jumper to Diagnose the ECI System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Diagnostic Procedures for Dual-Fuel Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Injection Driver Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 OBD System Check/Malfunction Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 OBD System Check Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 DTC 111-IAT High Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Conditions for Setting the DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 DTC 111-IAT Voltage High (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .141 DTC 112-IAT Low Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 DTC 112-IAT Voltage Low (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .145 DTC 113-IAT Higher Than Expected 1 (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 DTC 114-IAT Higher Than Expected 2 (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 DTC 115-Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 DTC 115-Oil Pressure Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151 DTC 121-ECT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 DTC 121-ECT High Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
-127-
SECTION 1C4
DIAGNOSTIC TROUBLE CODES DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
122-ECT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 122-ECT Low Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 123-ECT Higher Than Expected 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 123-ECT Higher Than Expected 1Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 124-ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 124-ECT Higher Than Expected 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 131-MAP High Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 131-MAP High Pressure (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .165 132-MAP Low Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 132-MAP Low Voltage (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 134-BP High Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 134-BP High Pressure (Bosch® TMAP) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . .173 135-BP Low Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174 135-BP Low Pressure (Bosch® TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 142-Crank Sync Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 142-Crank Sync Noise Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 143-Never Crank Synched at Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 143-Never Crank Synched at Start Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 144-Camshaft Sensor Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 144-Camshaft Sensor Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 145-Camshaft Sensor Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 145-Camshaft Sensor Noise Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 211-Closed Loop Multiplier High (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 211-Closed Loop Multiplier High (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .195 212-HO2S Open/Inactive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 212-HO2S Open/Inactive Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 221-Closed Loop Multiplier High (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 221-Closed Loop Multiplier High (Gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .201 222-Closed Loop Multiplier Low (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 222-Closed Loop Multiplier Low (Gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .203 224-Closed Loop Multiplier Low (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 224-Closed Loop Multiplier Low (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . .205 241- Adaptive Lean Fault (high limit-gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 241- Adaptive Lean Fault (high limit-gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . .207 242-Adaptive Rich Fault (low limit-gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 242-Adaptive Rich Fault (low limit-gasoline) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .211 243-Adaptive Lean High (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212 243-Adaptive Lean High (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213 244-Adaptive Lean Low (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214 244-Adaptive Lean Low (LPG) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 261-System Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216 261-System Voltage Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 262-System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218 262-System Voltage High Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219 511-COP Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220 511-COP Failure Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 512-Invalid Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
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SECTION 1C4
DIAGNOSTIC TROUBLE CODES DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
512-Invalid Interrupt Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 513-A/D Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 513-A/D Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 514-RTI 1 Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 514-RTI 1 Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227 515-Flash Checksum Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228 515-Flash Checksum Invalid Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 516-Ram Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 516-Ram Failure Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231 531-External 5 Volt Reference Lower Than Expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 531-External 5 Volt Reference Lower Than Expected Troubleshooting Chart . . . . . . . . . . . . . .233 532-External 5 Volt Reference Higher Than Expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234 532-External 5 Volt Reference Higher Than Expected Troubleshooting Chart . . . . . . . . . . . . .235 555-RTI 2 Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236 555-RTI 2 Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237 556-RTI 3 Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238 556-RTI 3 Loss Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239 611-FPP High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 611-FPP High Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 612-FPP Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 612-FPP Low Voltage Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 613-FPP Higher Than IVS Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248 613-FPP Higher Than IVS Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249 614-FPP Lower Than IVS Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 614-FPP Lower Than IVS Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 631-TPS 1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252 631-TPS 1 Signal Voltage High Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253 632-TPS 1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256 632-TPS 1 Signal Voltage Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 633-TPS 2 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 633-TPS 2 Signal Voltage High Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 634-TPS 2 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 634-TPS 2 Signal Voltage Low Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 635-TPS 1 Higher Than TPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 635-TPS 1 Higher Than TPS 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 636-TPS 1 Lower Than TPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270 636-TPS 1 Lower Than TPS 2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 637-Throttle Unable to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274 637-Throttle Unable to Open Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 638-Throttle Unable to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 638-Throttle Unable to Close Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 651-Maximum Governor Speed Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282 651-Maximum Governor Speed Override Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . .283 652-Fuel Rev Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284 652-Fuel Rev Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 653-Spark Rev Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286 653-Spark Rev Limit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287 721-Transmission Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .288
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DESCRIPTION OF ECM BASED DIAGNOSTICS DEFINITION OF TERMS Active Gov Mode
Speed is governed by one of two modes. Isochronous, which maintains an exact speed, or Droop, which allows speed to drop a predetermined amount based on current engine load
AL
Adaptive Learn
AL Mult
Adaptive Learn Multiplier. The adaptive learn multiplier is a correction to the fuel delivery which is expressed as a percentage (%) and stored in the ECM’s RAM.
Analog
0 to 5 volt or 0 to 12 volt signals
Batt
Battery Voltage
BP
Barometric Pressure. The pressure of the outside air
CHT
Cylinder Head Temperature
CL
Closed Loop
CL Mult
Closed Loop Multiplier. The closed loop multiplier is a fast acting adjustment to the fuel delivery based on feedback from the HEGO. The closed loop multiplier is expressed as a percentage (%) and is not stored in the ECM’s memory.
Closed Loop
Fuel and timing modified based on feedback from the O2 sensor
DBW
Drive by wire
DTC
Diagnostic Trouble Code. A code which is stored in the ECM when an ECM initiated test fails.
ECT
Engine Coolant Temperature.
ECM
Engine Control Module. The computer, which controls the fuel and ignition system on the engine
EGO
See HO2S
Forced Idle
ECM commands electronic throttle controller to an idle position.
FPP
Foot Pedal Position
HO2S
Heated Oxygen Sensor
IAT
Intake Air Temperature
IVS
Idle Validation Switch
Low Rev Limit
Secondary engine speed control, only used to limit speed when throttle positioning is not maintaining desired speed
MAP
Manifold Absolute Pressure. The pressure of the air in the intake manifold.
MAT
Manifold Air Temperature. The temperature of the air in the intake manifold
MIL
Malfunction Indicator Light. A dash mounted light that illuminates when the ECM senses a system fault
ms
Milli-seconds. 1/1000 of a second
Open Loop
Fuel and timing based strictly on tables stored in the ECM
Power Derate Level 1 ECM has detected condition in throttle control and limits throttle blade opening to 50% Power Derate Level 2 ECM has detected condition in throttle control and limits throttle blade opening to 20% PSIA
Pounds per square inch absolute. 14.7 psia = 0 psig
RAM
Random Access Memory. The portion of computer memory within the ECM, which changes as the engine is running and is stored while the engine is off
TPS
Throttle Position Sensor. The throttle position sensor measures the opening of the throttle
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DIAGNOSTICS OVERVIEW OF THE SPECTRUM FUEL SYSTEM The Spectrum Fuel system has built-in diagnostics for trouble shooting. The system has a dash mounted Malfunction Indicator Lamp (MIL) for indication of system problems.
MALFUNCTION INDICATOR LAMP (MIL) Most engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC) Diagnostic Trouble Code and illuminate the Malfunction Indicator Lamp. The MIL has the following functions: 1. It notifies the driver of a problem with the fuel system, ignition system, or emission control system so the driver can arrange for service as soon as possible. 2. It will display DTC’s that have been stored due to a system malfunction. The lamp should come on when the key is in the ON position and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not come on with the vehicle key on/engine off, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp illuminates while the engine is in the start or run mode, there is a current Diagnostic Trouble Code.
SPECTRUM DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Trouble Codes are set when the Spectrum ECM (Electronic Control Module) runs a diagnostic self-test and the test fails. When a DTC is set, the ECM will illuminate the Malfunction Indicator Lamp on the instrument panel and save the code in memory. The ECM will continue to run the self-test unless the DTC is an oxygen sensor lean, oxygen sensor rich, or an internal ECM related DTC. If the system continues to fail the test, the lamp will stay illuminated and the DTC is current (ACTIVE). All DTC’s are stored as historical faults until they are cleared. All DTC’s except the ECM related DTC’s will automatically clear from memory if the DTC does not reset within 50 consecutive engine run cycles. While a Diagnostic Trouble Code is current for a sensor, the ECM may assign a default “limp home” value and use that value in its control algorithms. All of the system diagnostic self-tests run continuously during normal vehicle operation. The Diagnostic Trouble Codes can be read by using either the MIL lamp or a laptop computer. Refer to Using a Laptop Computer to Diagnose the Spectrum System and Using a Diagnostic Jumper to Diagnose the ECI System, located in this section. Diagnostic Trouble Codes can be cleared from memory with a laptop computer or by turning the ignition key to the OFF position and removing the system main power fuse (F3) for 15 seconds. If more than one DTC is detected, always begin with the lowest number DTC and diagnose each problem to correction unless directed to do otherwise by the fault tree. The DTC’s are numbered in order of importance. Having DTC 112 and DTC 122, both concerning the oxygen sensor, is possible. By repairing DTC 112 first, the problem causing the DTC 122 may also be corrected.
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USING A LAPTOP COMPUTER TO DIAGNOSE THE SPECTRUM SYSTEM A laptop computer is the preferred tool for performing diagnostic testing of the Spectrum system. A laptop computer, with the system diagnostic cable and diagnostic software, is used to read and clear Diagnostic Trouble codes. It is also used to monitor sensor and actuator values. The diagnostic software also performs several special tests. The following procedures will assist you in using a laptop computer to diagnose the Spectrum system: INSTALLING THE SPECTRUM DIAGNOSTIC SOFTWARE Loading Software and Connecting the Computer •
Start Windows
•
Insert the Diagnostic Interface software CD.
•
Click on the START button.
•
From the Start menu, select RUN.
•
In the command-line text box, type the letter of your CD-ROM drive, followed by: \setup (for example, e:\setup), then click OK.
•
Follow the on screen instructions.
Connecting a Laptop Computer to the Spectrum System •
Connect the system diagnostic cable to the RS232 port on the back of the computer. If you do not have a RS-232 port use the USB to RS232 adapter cable.
•
Connect the diagnostic cable to the diagnostic connector on the engine harness. The diagnostic connector is a square 4-pin connector located near the Spectrum system ECM.
•
Turn the computer ON.
•
Start Windows.
•
From the Start menu select Programs.
•
Select IMPCO Display.
•
Place the ignition key in the ON position.
•
The system Gauge screen should now appear and a green banner in the upper left hand will read “Connected”.
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DIAGNOSTIC TROUBLE CODES
The System Fault screen is used to view and clear DTC’s, which have been set. Checking Diagnostic Trouble Codes The System Fault screen contains a listing of all of the Historic and Active DTC’s set within the system. If a DTC is stored in memory, the screen will display that fault in the History column. If the fault is active it will also show up in that column. Clearing Diagnostic Trouble Codes To clear a DTC from memory use the arrow keys or mouse to move the Press the Enter key to clear the fault from memory. NOTE: Record faults before erasing them for reference during diagnostics.
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DATA STREAM
Reading Sensor and Actuator Values Most applicable sensor and actuator values are displayed on the Gauges screen. The display shows the value for sensors, voltages and the sensor values in engineering units. NOTE: If a DTC for a sensor is current, the engineering value for that sensor may be a default, limp home value and the voltage value will be the actual sensor voltage. Use the voltage value when performing diagnostics unless directed to do otherwise by the diagnostic trouble tree.
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GRAPHING AND DATA LOGGING
Graphing the values and voltages can be a very useful tool in doing intermittent diagnosis. The system diagnostic monitoring software includes graphing and data logging capability. These features enhance the ability to diagnose and repair possible problems with the system. The graphing feature allows sensor inputs and select control output variables to be plotted in real-time while the engine is running. To plot a variable you must first “TAG” the variable you wish to plot. To do this, use the mouse to highlight the variable, and then right click. Next press the “P” key or double click the Plot/Log button to invoke the plotting feature. You may change the desired time interval for each display screen. The default is 10 seconds. This can be increased or decreased as necessary to display the desired results. You can also change the sample rate. You are now ready to plot. Simply click the “START” button to observe the plotted variables. The plot sweeps across the screen from left to right. To pause the display screen press the “SPACE BAR” at any time during plotting. To continue plotting simply press the “SPACE BAR” again. To stop the plotting feature simply click the “STOP” button. To exit the plotting screen click the “CLOSE” button. The range of each variable is listed along the left side of the display and the time is listed along the bottom of the screen.
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IGNITION SYSTEM TEST
The Spark Kill diagnostic mode allows the technician to disable the ignition on individual cylinders. If the Spark Kill diagnostic mode is selected with the engine running below 1000 RPM, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Spark System Test mode is selected with the engine running above 1000 RPM, the throttle will continue to operate normally. Disabling Ignition Outputs To disable the ignition system for an individual cylinder, use the mouse to highlight the “Spark Kill” button and select the desired coil. The spark output can be re-enabled by using the mouse to highlight the “Spark Kill” button and selecting “Normal”. If the engine is running below 1000 RPM, the spark output will stay disabled for 15 seconds and then re-set. If the engine is running above 1000 RPM, the spark output will stay disabled for 5 seconds and then re-set. This test mode has a timeout of 10 minutes. Record the rpm drop related to each spark output disabled. The Spark outputs are arranged in the order which the engine fires, not by cylinder number.
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INJECTOR TEST
The Injector Kill mode is used to disable individual fuel injectors. If the Injector Kill mode is selected with the engine running below 1000 RPM, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Injector Kill mode is selected with the engine running above 1000 RPM, the throttle will continue to operate normally. Disabling Injectors To disable an injector, use the mouse to select the desired. The word “Normal” will change to the Injector you have selected. The injector driver can be re-enabled by selecting again. If the engine is running below 1000 RPM, the injector driver will stay disabled for 15 seconds and then re-set. If the engine is running above 1000 RPM, the injector driver will stay disabled for 5 seconds and then reset. Record the change in rpm or closed loop multiplier while each driver is disabled.
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THROTTLE TEST
To select this test mode the engine must be off but the key must be in the ON position. The DBW (Drive By Wire) test mode allows the technician to control the throttle directly with the foot pedal or throttle input and is used during the diagnostic routines specified for FPP and TPS for Spectrum systems that use DBW. FPP position displays the current position of the foot pedal as a percentage. FPP volts display the voltage which the ECM is reading from the FPP sensor. TPS Command displays the commanded throttle position expressed as a percentage, which is being sent to the throttle. TPS Position is the actual percent of throttle opening being sent to the ECM from the throttle. TPS volts display the actual TPS signal voltage the ECM is receiving from the throttle. Using a Diagnostic Jumper to Diagnose the ECI System If you do not have access to a laptop computer, it is still possible to access the Diagnostic Trouble Codes stored in the memory of the Spectrum system ECM using a diagnostic jumper and the Malfunction Indicator Lamp. With the key off connect the diagnostic jumper to the ECI system diagnostic connector located near the ECM. The jumper will connect diagnostic pins A and D. Turn the ignition on but do not start the vehicle. The Malfunction Indicator Lamp (MIL) will begin to flash. The MIL displays three digit codes by flashing the first digit, pausing, then flashing the second digit, -136-
pausing, and then flashing the third digit. There will be a long pause between codes. For example, a code 143 would be one flash followed by four flashes followed by three flashes. The MIL will first display a 116 three times. Code 116 indicates that the ECM based diagnostic routines are functioning. Then, any Diagnostic Trouble Codes stored in memory will display three times each. The MIL will then start over with the code 116. If the vehicle is started while the diagnostic jumper is in place, the MIL will flash rapidly. Diagnostic Trouble Codes may be cleared from the system ECM memory by moving the ignition key to the OFF position and removing the (F1) system battery fuse for at least 15 seconds. Note: This will erase all of the memory in the computer including the adaptive learn.
DIAGNOSTIC PROCEDURES FOR DUAL-FUEL APPLICATIONS Diagnostic Trouble Codes (DTC) will set in both propane and gasoline fuel modes. Some DTC’s are specific to either gasoline or propane, but are described in the DTC charts as such. When dealing with a fuel specific DTC, it is advised to run the diagnostic test in the fuel mode that the code was originally set. In the case of a fuel specific DTC, the diagnostic test procedures must be performed running in the fuel mode that is described for that particular DTC. An example of this would be DTC 243 Adaptive Learn High (LPG) The diagnostic test must be run in the LPG mode for a successful repair. In the presence of multiple DTC codes always begin with the lowest number DTC and diagnose each problem to correction, unless directed to do otherwise by the DTC chart. The DTC’s are numbered in order of importance. Having DTC 112 and DTC 122, both concerning the oxygen sensor, is possible. By repairing DTC 112 first, the problem causing the DTC 122 may also be corrected. When a DTC is set, the ECM will illuminate the Malfunction Indicator Lamp on the instrument panel and save the code in memory. The ECM will continue to run the self-test unless the DTC is an oxygen sensor lean, oxygen sensor rich, Injector Driver Diagram or an internal ECM related DTC. If the system continues to fail the test, the lamp will stay illuminated and the DTC is current (ACTIVE). ECM All DTC’s are stored as historical C 003 O R N /LT BLU O R N /BLU Injector Power 18 A faults until they are cleared. All DTC’s except the ECM related BR N /LT BLU BR N /BLU Injector D river A 16 #1 DTC’s will automatically clear Inj T AN /LT BLU BR N /G R N Injector D river 17 F from memory if the DTC does #2 Inj not reset within 50 consecutive BR N /W H T BR N / O R N Injector D river 29 E #3 engine run cycles. Inj BR N /YEL
BR N / YEL D
30
Injector D river #4
28
Injector D river #5
1
Injector D river #6
Inj
BR N /O R N
BR N /W H T C
Inj
T AN /LT BLU
BR N /G R N B
Inj
C 004
R EV A
-137-
While a Diagnostic Trouble Code is current for a sensor, the ECM may assign a default “limp home” value and use that value in its control algorithms. All of the system diagnostic self-tests run continuously during normal vehicle operation.
OBD System Check/Malfunction Indicator Lamp
ECM
M IL
C 02 2 L T B L U E /B L K F
26
H o t in S ta rt a n d Run
Circuit Description The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has a dash mounted MIL (Malfunction Indicator Lamp) for the indication of system problems. Engine control system problems that affect emissions or driveability of the vehicle will set a DTC (Diagnostic Trouble Code). The ECM will then provide a path to ground and illuminate the MIL (Malfunction Indicator Lamp) The MIL has the following functions: 1. It notifies the driver of a problem with the fuel system, ignition system, or emission control system so the driver can arrange for service as soon as possible. 2. It will display DTC’s that have been stored due to a system malfunction. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not come on with the vehicle key on/engine off, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp illuminates while the engine is in the start or run mode, a current Diagnostic Trouble Code may be set. Always use the OBD System Check chart on the next page of this manual to verify proper MIL operation before proceeding with a DTC diagnostic code repair.
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OBD System Check Step 1 2
3
4 5
6
7 8
9
10
11
Action • Key ON Engine OFF Does the MIL illuminate? • Start the engine • Does the MIL lamp turn off?
Value(s)
• •
Key ON engine OFF Check for voltage between MIL power source and engine ground Do you have voltage?
Replace MIL lamp Did that solve the problem? • Key OFF • Disconnect ECM wire harness connector C001 • Using a DVOM check for continuity between MIL ground and ECM terminal 26 Do you have continuity? • Inspect the MIL lamp socket, connector C022 and ECM terminal 26 for damage, corrosion or contamination Did you find a problem? • Replace ECM Is the replacement complete? •
Back probe the MIL and ECM terminal F in connector C022 • Using a DVOM check for continuity through connector C022 Do you have continuity? • Inspect the MIL lamp socket, connector C022 and ECM terminal 26 for damage, corrosion or contamination Did you find a problem?
Active DTC (Diagnostic trouble code) is stored in memory. Proceed with DTC diagnosis. If no active DTC is found in ECM memory return to this page Step (11) • Key OFF • Disconnect ECM wire harness connector C001 • Using a DVOM check for continuity between ECM terminal 26 and battery voltage • Do you have continuity?
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Yes Go to Step (2)
No Go to Step (3)
Go to Step (10) MIL is working properly. OBD System Check is complete Go to Step (4) Repair MIL voltage source. Refer to OEM body and chassis wiring diagrams Go to step (1) Go to Step (5) Go to Step (6)
Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (1)
Go to Step (7)
Go to Step (9)
Go to Step (9)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical. -
-
Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
-
Go to Step (7)
DTC 111-IAT High Voltage (Bosch£ TMAP)
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC x x x x x x
Intake Air Temperature Check Condition-Engine Running Fault Condition-IAT Sensor Voltage greater than 4.95 MIL-On during active fault and for 2 seconds after active fault Adaptive-Disabled during active fault Closed Loop-Enabled
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. The IAT is a calculated value based mainly on the IAT sensor at high airflow, and influenced more by the ECT (Engine Coolant Temperature) at low airflow. This fault will set if the signal voltage is more than 4.95 volts anytime the engine is running. The ECM will use the default value for the IAT sensor in the event of this fault.
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DTC 111- IAT VOLTAGE HIGH (BOSCH®) TMAP Step 1
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
2
3
Go to step (3) • Key On • DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display IAT voltage of 4.95 or greater? • Key Off • Disconnect the TMAP sensor connector from the wiring and harness and jumper pins 1 and 2 together • Key On Does the DST display IAT voltage of 0.1 volts or less? • •
4
5
6
7
8
9
Yes Go to Step (2)
Key OFF Jumper TMAP sensor connector signal pin 2 to engine ground • Key ON • Does DST display IAT voltage of 0.1 volts or less? Replace TMAP sensor. Is the replacement complete? • Key OFF • Disconnect the ECM wire harness connector. • Check for continuity between TMAP sensor connector signal pin 2 and ECM IAT signal pin 32. Do you have continuity between them?
Go to step (9)
Go to step (4)
Go to Step (7)
Go to Step (6)
Go to Step (11)
_
Go to step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. _
__
•
Check for continuity between TMAP sensor connector ground circuit pin 1 and ECM sensor ground circuit pin 49. Do you have continuity between them?
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? • Re-check wire harness and TMAP sensor connectors for damage corrosion or contamination Were any problems found?
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__
Go to step (10)
_
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to step (11)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
Go to Step (5)
• 10
11
Re-check wire harness and TMAP sensor connectors for damage corrosion or contamination Were any problems found?
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-111 check for any stored codes. Does the engine operate normally with no stored codes?
-142-
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical System OK
Go to Step (8)
Go to OBD System Check
-143-
DTC 112-IAT Low Voltage (Bosch£ TMAP)
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC x x x x x x
Intake Air Temperature Check Condition Engine Cranking or Running Fault Condition-IAT Sensor Voltage less than 0.05 MIL-On during active fault and for 2 seconds after active fault Adaptive-Disabled during active fault Closed Loop-Enabled and allowed to stay at limit if required but will then also set the limiting fault.
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. The IAT is a calculated value based mainly on the IAT sensor at high airflow, and influenced more by the ECT (Engine Coolant Temperature) at low airflow. This fault will set if the signal voltage is less than 0.05 volts anytime the engine is cranking or running. The ECM will use the default value for the IAT sensor in the event of this fault.
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DTC 112- IAT VOLTAGE LOW (BOSCH®) TMAP Step Action 1 Did you perform the On-Board (OBD) System Check?
Value(s) _
2
Yes Go to Step (2)
Go to step (3)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to step (4)
Go to step (5)
Go to Step (9)
_
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to step (6)
• Key On • DST (Diagnostic Scan Tool) connected in System Data Mode
3
4
5
6
7
8
Does DST display IAT voltage of 0.05 or less? • Key Off • Disconnect the TMAP sensor wire harness connector • Key ON Does the DST display IAT voltage of 4.9 volts or greater? Replace TMAP sensor. Is the replacement complete? • Key OFF • Disconnect ECM wire harness connector. • Check for continuity between TMAP sensor connector ground pin 1 and TMAP sensor connector signal pin 2 Do you have continuity between them? • Check for continuity between TMAP sensor connector signal circuit pin 2 and engine ground. Do you have continuity?
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? • Remove all test equipment except the DST. • Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-112 check for any stored codes. Does the engine operate normally with no stored codes?
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__
Go to step (7) __
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
_
Go to step (8)
System OK
_
Go to OBD System Check
DTC 113-IAT Higher Than Expected 1 (Bosch® TMAP)
BLK/LT GRN
1
49 TAN
2 3 4
32
LT GRN/RED
LT GRN
Sensor Ground IAT Signal 5V
50
5 Volts
33
MAP Signal ECM
Conditions for Setting the DTC Intake Air Temperature Check Condition-Engine Running Fault Condition-Intake Air Temperature greater than 210 degrees F. and engine RPM greater than 1000 MIL- On during active fault Adaptive-Disabled during active fault Closed Loop-Enabled Power Derate (Level 1) Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. The IAT is a calculated value based mainly on the IAT sensor at high airflow, and influenced more by the ECT (Engine Coolant Temperature) at low airflow. This fault will set if the Intake Air Temperature is greater than 210 degrees F. and engine RPM is greater than 1000 and Power Derate 1 will be enforced. During this fault, maximum throttle position is 50% and the MIL light will flash twice per second.
Diagnostic Aids * This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged. * Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system
-146-
DTC 113-IAT Higher Than Expected 1 Bosch® TMAP
Diagnostic Aids * This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged. * Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system • If none of the above can be found, Follow the diagnostic steps for DTC 112-IAT Low Voltage Bosch® TMAP.
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DTC 114-IAT Higher Than Expected 2 (Bosch£ TMAP)
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC x x x x x x x
Intake Air Temperature Check Condition-Engine Running Fault Condition-Intake Air Temperature greater than 220 degrees F. and engine RPM greater than1000 MIL-On for active fault and for 15 seconds after active fault Adaptive-Disabled during active fault Closed Loop-Enabled Engine Shut Down Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. The IAT is a calculated value based mainly on the IAT sensor at high airflow, and influenced more by the ECT (Engine Coolant Temperature) at low airflow. This fault will set if the Intake Air Temperature is greater than 220 degrees F and engine RPM is greater than 1000. The MIL light will be on during this active fault and the engine will shut down.
-148-
DTC 114-IAT Higher Than Expected 2 (Bosch® TMAP)
Diagnostic Aids * This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged. * Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system * If none of the above can be found, Follow the diagnostic steps for DTC 112-IAT Low Voltage.
-149-
DTC 115-Oil Pressure Low
ECM + 5 volts LT GRN/BLK 37
Oil Pressure Voltage
To Oil Pressure Switch
Conditions for Setting the DTC Engine Oil Pressure low Check Condition-Engine running for 5 seconds. Fault Condition- closed circuit/voltage low MIL-On during active fault and for 3 seconds after active fault Adaptive-Enabled Closed Loop-Enabled Engine Shut Down Circuit Description The Oil Pressure Switch is used to communicate a low oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM uses an analog voltage input with an internal 5 volt reference. If the oil pressure circuit is grounded, the input voltage will be near zero. If it is open, the input will be near 5 volts. The switch is normally closed, and the fault will set if the switch remains closed with the engine running. The engine will shut down in the event of this fault to help prevent possible engine damage.
-150-
DTC 115- Oil Pressure Low Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
•
Go to Step (3)
Repair faulty Oiling System
•
Key On, Engine Running DST connected in System Data Mode • Clear DTC 115 • Warm the engine by idling until the ECT temperature is above 160 degrees F. and has been running for at least one minute • Increase engine speed above 1300 RPM Does DTC115 reset and cause the engine to shut down?
Go to Step (4)
Intermittent problem Go to Intermittent section
• •
Key OFF Disconnect oil pressure switch harness connector C005 • Clear DTC 115 • Start engine, let idle for at least one minute with ECT over 160 degrees F. • Increase engine speed above 1300 RPM Does DTC 115 reset?
Go to Step (6)
Go to Step (5)
• Replace oil pressure switch Is the replacement complete?
Go to Step (9)
-
• • •
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceeding with this chart. See Engine Specifications Section 1F.
Does the engine have oil pressure above 2 psi? 3
4
5
6
• 7
•
8
• •
Key OFF Disconnect ECM harness connector C001 Using a DVOM check for continuity between oil pressure switch connector LT GRN/BLK wire and engine ground. Do you have continuity between them?
Inspect ECM connector pin 37 for damage corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Replace ECM Is the replacement complete?
Go to Step (9)
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Go to Step (8)
-
9
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-115 check for any stored codes. Does the engine operate normally with no stored codes?
-152-
System OK
Go to OBD System Check
-153-
DTC 121-ECT / High Voltage
Signal
YEL/GRY
31
BLK/LT GRN
49
5 volts
A
B
Sensor Ground
ECM
Conditions for Setting the DTC Engine Coolant Temperature Check Condition-Engine Running Fault Condition-ECT sensor voltage exceeds 4.95 MIL-On during active fault and for 2 seconds after active fault Adaptive-Disabled during active fault Closed Loop-Enabled Circuit Description The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant. It is used for the engine airflow calculation, gasoline cold enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is greater than 4.95 volts anytime the engine is running. The ECM will use a default value for the ECT sensor in the event of this fault.
-154-
ECT Data: Temp (deg F)
Ohms
242.4
101
231.9
121
211.6
175
201.4
209
181.9
302
163.1
434
144.9
625
127.4
901
102.4
1,556
78.9
2,689
49.9
5,576
23.5
11,562
-5.7
28,770
-21.2
49,715
-30.8
71,589
-40.0
99,301
DTC 121- ECT VOLTAGE HIGH Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
Go to step (3)
Intermittent problem Go to Intermittent section
Go to step (4)
Go to Step (8)
Go to Step (6)
Go to step (5)
2 • •
Key On DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display ECT voltage of 4.95 or greater?
3
• •
4
•
5
• Replace ECT sensor Is the replacement complete?
Go to Step (14)
-
6
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• • •
Key Off Disconnect the ECT sensor from the wiring harness and Jumper connector terminals A and B together • Key On Does the DST display ECT voltage of 0.05 volts or less? Using a DVOM check the resistance between the two terminals of the ECT sensor and compare the resistance reading to the chart Is the resistance value correct?
Inspect the ECT wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
•
Key OFF Disconnect ECM wire harness connector Inspect ECM connector pins 31 and 49 for damage corrosion or contamination Did you find a problem?
See resistance chart vs. temperature in the DTC 121 circuit description
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Intermittent problem Go to Intermittent section
8
•
Jumper the ECT signal pin A at the ECT connector to engine ground Does DST display ECT voltage of 0.05 or less?
Go to Step (9)
Go to Step (12)
9
• • •
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between ECT sensor ground pin B and ECM connector pin 49 Do you have continuity between them?
-155-
10
•
Inspect ECM connector pins 31 and 49 for damage, corrosion or contamination
Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (11)
-
11
• Replace ECM Is the replacement complete?
Go to Step (14)
12
• • •
Key OFF Disconnect ECM wire harness connector Using A DVOM check for continuity between ECT connector signal pin A and ECM connector terminal 31 Do you have continuity between them?
Go to Step (13)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
13
•
Inspect ECM connector pins 31 and 49 for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (11)
• •
System OK
14
Go to OBD System Check
• • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature
• • • •
Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-121 check for any stored codes. Does the engine operate normally with no stored codes?
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-157-
DTC 122-ECT Low Voltage
Signal
YEL/GRY
31
BLK/LT GRN
49
5 volts
A
B
Sensor Ground
ECM
Conditions for Setting the DTC z Engine Coolant Temperature z Check Condition-Engine Running z Fault Condition- ECT sensor voltage less than 0.05 z MIL-On during active fault and for 2 seconds after active fault z Adaptive-Disabled during active fault z Closed Loop-Enabled
Circuit Description The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant. It is used for the engine airflow calculation, gasoline cold enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm This fault will set if the signal voltage is less than 0.05 volts anytime the engine is running. The ECM will use a default value for the ECT sensor in the event of this fault.
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DTC 122- ECT VOLTAGE LOW Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
_
Go to Step (2)
Go to OBD System Check Section
2
Go to step (3) • Key On • DST (Diagnostic Scan Tool) connected in • System Data Mode Does DST display ECT voltage of 0.05 or less?
Intermittent problem Go to Intermittent section
• Key Off • Disconnect the ECT wire harness connector • Key ON Does the DST display ECT voltage of 4.9 volts or greater?
Go to step (4)
Go to step (5)
Replace ECT sensor. Is the replacement complete?
Go to Step (8)
_
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to step (6)
5
• • •
6
•
3
4
Key OFF Disconnect ECM wire harness connector Check for continuity between ECT sensor connector signal pin A and ECT sensor ground pin B Do you have continuity between them?
Check for continuity between ECT sensor connector signal circuit pin A and engine ground. Do you have continuity?
7
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
8
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature
• • • •
Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-122 check for any stored codes. Does the engine operate normally with no stored codes?
-159-
__
Go to step (7) __
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
_
Go to step (8)
System OK
_
Go to OBD System Check
DTC 123-ECT Higher Than Expected 1
Signal
YEL/GRY
31
BLK/LT GRN
49
5 volts
A
B
Sensor Ground
ECM
Conditions for Setting the DTC Engine Coolant Temperature Check Condition-Engine Running Fault Condition-Engine Coolant Temperature reading or estimate greater than 220 deg. F and engine RPM greater than 500 for 60 seconds MIL- On during active fault and for 15 seconds after active fault Adaptive-Disabled during active fault Closed Loop-Enabled Power Derate (level1) Circuit Description The Engine Coolant Temperature sensor is a thermistor (temperature sensitive resistor) located in the engine coolant. The ECT (Engine Coolant Temperature) sensor that is located in the coolant near the thermostat. The ECT is used for engine airflow calculation, fuel enrichment, ignition timing control, to enable certain features, and for engine protection. The ECM provides a voltage divider circuit so when the sensor reading is cool the sensor reads higher voltage, and lower when warm. This fault will help protect the engine in the event of over temperature. When the coolant exceeds 220 degrees F. and engine RPM exceeds 500 this fault will set and Power Derate 1 will be enforced. During this fault, maximum throttle position is 50% and the MIL light will turn on.
-160-
DTC 123- ECT Higher Than Expected 1 Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On • DST (Diagnostic Scan Tool) connected in System Data Mode • Warm Engine to normal operating temperature, then run the engine above 500 rpm for 60 seconds Does DST display ECT temperature of 220 degrees F. or greater with the engine running over 500 rpm?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Repair Cooling system.
Go to step (4)
4
Verify ECT circuit function. Follow diagnostic test procedure for DTC-122 ECT Low Voltage
-
-
Verify with a temperature gauge that the engine coolant is over 220 degrees F. Does the temperature gauge indicate 220 degrees F. or greater?
-161-
DTC 124-ECT Higher Than Expected 2
Signal
YEL/GRY
31
BLK/LT GRN
49
5 volts
A
B
Sensor Ground
ECM
Conditions for Setting the DTC Engine Coolant Temperature Check Condition-Engine Running Fault Condition-Engine Coolant temperature reading or estimate greater than 235 deg. F and engine RPM greater than 500 for 60 seconds MIL-On for active fault and for 15 seconds after active fault Adaptive-Enabled Closed Loop-Enabled Engine Shut Down
Circuit Description The Engine Coolant Temperature sensor is a thermistor (temperature sensitive resistor) located in the engine coolant. The ECT (Engine Coolant Temperature) sensor that is located in the coolant near the thermostat. The ECT is used for engine airflow calculation, ignition timing control, fuel enrichment, to enable certain features, and for engine protection. The ECM provides a voltage divider circuit so when the sensor reading is cool, the signal reads higher voltage, and lower when warm. This fault will set if coolant temperature reaches 235 degrees F. and engine RPM exceeds 500 rpm, then engine will shut down.
-162-
DTC 124 ECT Higher Than Expected 2 Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On • DST (Diagnostic Scan Tool) connected in System Data Mode • Warm Engine to normal operating temperature, then run the engine above 500 rpm for 60 seconds • Does DST display ECT temperature of 235 degrees F. or greater with the engine running over 500 rpm?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Repair Cooling system.
Go to step (4)
4
Verify ECT circuit function. Follow diagnostic test procedure for DTC-122 ECT Low Voltage
-
-
Verify with a temperature gauge that the engine coolant is over 235 degrees F. Does the temperature gauge indicate 235 degrees F. or greater?
-163-
DTC 131-MAP High Pressure
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC x x x x x x x
Manifold Absolute Pressure Check Condition-RPM greater than 800, Throttle Command less than 10%, steady MAP and TPS Fault Condition-MAP greater than 18 psia, TPS less than 10% and engine RPM greater than 1800. MIL-On for remainder of key on cycle Adaptive-Disabled for remainder of key on cycle Closed Loop-Enabled and allowed to stay at limit Misc.-Fueling is based on RPM and TPS Limp-Home Condition during this fault.
Circuit Description The TMAP is a combined inlet manifold temperature and pressure sensor connected to the intake manifold. It is used to measure the pressure of air in the manifold prior to induction into the engine. The pressure reading is used in conjunction with other inputs to determine the airflow rate to the engine, which also determines the fuel flow rate. This fault will set when the MAP reading is higher than it should be for the given TPS, and RPM. When the fault is set, the Adaptive Learn will be disabled for the remainder of the key on cycle and the MIL will be on. The engine will operate on a default MAP during this active fault. Diagnostic Aids If the engine is running rough, unstable or missing due to a suspected mechanical problem, vacuum leak or other issue causing misfire these problems must be taken care before using the MAP diagnostic chart. Failure to follow this recommendation will result in a false MAP diagnostic and repair procedure.
-164-
DTC 131- MAP HIGH PRESSURE (Bosch TMAP®) Step 1
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
2
Yes Go to Step (2)
Go to step (3) • Key On, Engine running. • DST (Diagnostic Scan Tool) connected in System Data Mode
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Does DST display MAP pressure of 13.0 psia or greater with the engine idling? 3
4 5
6
7
• Key OFF • Disconnect the TMAP sensor connector • Key ON Does the DST display MAP pressure less than 0.05 psia? • Probe TMAP sensor connector ground circuit pin 1 with a test light connected to battery voltage. Does the test light come on? • Check TMAP mechanical connection for correct mounting or possible damage causing leakage. Is the TMAP sensor mechanical connection OK? • Key OFF • Disconnect ECM connector and inspect terminals for damage corrosion or contamination. Is the connection OK?
Go to step (4)
Go to step (6)
Go to step (5)
Go to step (8)
Go to step (6)
Go to Step (10)
Go to step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. -
Replace TMAP sensor. Is the repair complete? __
Go to step (11)
8
•
Disconnect ECM connector and check for continuity between TMAP connector sensor ground pin 1 and ECM sensor ground PIN 49. Do you have continuity between them?
Go to step (9)
9
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? • Correct TMAP mechanical connection
Go to step (11)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. -
Go to Step (11)
-
10
Has TMAP mechanical connection been corrected?
-165-
11
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature
• • •
Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-131 check for any stored codes. Does the engine operate normally with no stored codes?
-166-
System OK
Go to OBD System Check
-167-
DTC 132-MAP Low Voltage (Bosch TMAP£)
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC z Manifold Absolute Pressure z Check Condition-Cranking or Running z Fault Condition-MAP voltage less than 0.05,Throttle Position greater than 2% and engine RPM less than 7000. z MIL-On for remainder of key on cycle z Adaptive-Disabled for remainder of key on cycle z Closed Loop-Enabled z Misc.-Fueling is based on RPM and TPS Limp-Home Condition during this fault.
Circuit Description The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake manifold. It is used to measure the pressure of air in the manifold prior to induction into the engine. The pressure reading is used in conjunction with other inputs to determine the airflow rate to the engine, which determines the fuel flow rate. This fault will set when the MAP reading is lower than the sensor should normally produce. When this fault is set the Adaptive Learn will be disabled for the remainder of the key on cycle and the MIL will be on.
-168-
DTC 132- MAP Low Voltage (Bosch® TMAP) Step 1
Action Did you perform the On-Board (OBD) System Check?
2
Value(s) -
Yes Go to Step (2)
Go to Step (3) • Key On, Engine running. • DSC (Diagnostic Scan Tool) connected in System Data Mode
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Does DST display MAP voltage of 0.05 or less with the engine idling?
3
• • • •
Key OFF Disconnect the TMAP sensor from the wiring harness Jumper the 5 volt reference pin 3 and MAP signal circuit pin 4 together Key ON
Go to Step (4)
Go to step (8)
Does the DST display MAP voltage of 4.5 volts or greater? 4
•
5
• • •
6
Inspect TMAP connector and pins for corrosion, contamination or mechanical damage Any problems found?
Key OFF Disconnect ECM connector Check for continuity between TMAP sensor connector signal pin 4 and ECM MAP signal pin 33. Do you have continuity between them? • Check for continuity between TMAP sensor connector 5 volt supply signal pin 3 and ECM 5 volt supply pin 50 Do you have continuity between them?
7
•
8
•
Check for continuity between TMAP sensor connector ground pin 1 and ECM sensor ground pin 49 Do you have continuity between them?
Probe MAP connector signal circuit pin 4 with a test light connected to battery voltage
Does the DST display MAP voltage of 4.0 or greater?
-169-
Repair the circuit Go to step (5) as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to step (17)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (13)
Go to Step (9)
9
10
• • •
Key OFF Disconnect ECM connector Check for continuity between TMAP sensor connector pin 3 and ECM 5 volt reference pin 50. Do you have continuity between them? • Check for continuity between TMAP sensor connector 5 volt reference pin 3 and engine ground Do you have continuity?
11
•
12
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? • Disconnect ECM connector • Check for continuity between TMAP sensor connector signal circuit pin 4 and ECM signal PIN 33 Do you have continuity between them?
13
Inspect ECM and TMAP wire harness connector and terminals for corrosion, contamination or mechanical damage Any problems found?
Go to step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Repair the circuit Go to Step (11) as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit Go to Step (16) as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (17) -
Go to Step (14)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
14
•
15
•
16
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (18)
-
Replace TMAP sensor Is the replacement complete? • Remove all test equipment except the DSC. • Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature
Go to step (17)
-
17 18
Check for continuity between TMAP sensor connector signal pin 4 and engine ground Do you have continuity?
Inspect ECM connector and wire harness connector terminals for corrosion, contamination or mechanical damage Any problems found?
• • •
Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-132 check for any stored codes. Does the engine operate normally with no stored codes?
-170-
Repair the circuit Go to step (15) as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit Go to Step (16) as necessary. Refer to Wiring Repairs in Engine Electrical.
System OK
Go to OBD System Check
-171-
DTC 134-BP High Pressure (Bosch£ TMAP)
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC
z Barometric Pressure z Check Condition-Key On z Fault Condition-BP greater than 16 psia z MIL-On for active fault and for 2 seconds after active fault z Adaptive-Disabled for remainder of key on cycle z Closed Loop-Enabled Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of the normal range.
-172-
DTC 134- BP High Pressure (Bosch® TMAP) Step 1
Action Did you perform the On-Board (OBD) System Check?
2 • • •
Value(s) -
Yes Go to Step (2)
Go to step (3)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to Step (4)
-
System Ok
Go to OBD System Check
Key On DST (Diagnostic Scan Tool) connected in System Data Mode
Does DST display MAP pressure of 16 psia or greater? 3
Replace TMAP sensor. Is the repair complete?
4
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature
• • •
Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-134 check for any stored codes. Does the engine operate normally with no stored codes?
-173-
DTC 135-BP Low Pressure (Bosch£ TMAP)
BLK/LT GRN
1
49
Sensor Ground IAT Signal
2 3 4
TAN
32
LT GRN/RED
LT GRN
5V
50
5 Volts
33
MAP Signal
ECM
Conditions for Setting the DTC
z Barometric Pressure z Check Condition-Key On z Fault Condition-BP less than 8.3 psia z MIL-On for active fault and for 2 seconds after active fault z Adaptive-Disabled for remainder of key on cycle z Closed Loop-Enabled Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of the normal range.
-174-
DTC 135- BP Low Pressure (Bosch® TMAP) Step 1
Action Did you perform the On-Board (OBD) System Check?
2
Value(s) -
Yes Go to Step (2)
Go to Step (3) • Key On. • DST (Diagnostic Scan Tool) connected in System Data Mode
3
4
5
6
Does DST display BP pressure of 8.3 psia or less? • Key OFF • Disconnect the TMAP sensor from the wiring harness • Jumper the 5 volt reference pin 3 and MAP signal pin 4 together • Key ON Does the DST display BP pressure of 16.00 psia or greater? • Inspect TMAP connector and wire harness connector terminals for corrosion, contamination or mechanical damage Any problems found? • • •
Key OFF Disconnect ECM connector Check for continuity between TMAP sensor connector pin 4 and ECM connector pin 33 Do you have continuity between them? • Check for continuity between TMAP sensor connector 5 volt supply pin 3 and ECM connector pin 50 Do you have continuity between them?
7
•
8
• •
Check for continuity between TMAP sensor connector ground pin 1 and ECM connector pin 49 Do you have continuity between them?
Remove Jumper that was installed during step 3 Probe TMAP connector signal circuit pin 4 with a test light connected to battery voltage
Does the DST display BP pressure of 16.00 psia or greater?
-175-
Go to Step (4)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to step (8)
Repair the circuit Go to step (5) as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to step (17)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (13)
Go to Step (9)
9
10
• • •
Key OFF Disconnect ECM connector Check for continuity between TMAP sensor connector pin 3 and ECM connector pin 50 Do you have continuity between them? • Check for continuity between TMAP sensor connector 5 volt reference pin 3 and engine ground Do you have continuity?
Go to step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Repair the circuit Go to Step (11) as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit Go to Step (16) as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step(17) -
11
•
12
13
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? • Disconnect ECM connector C001 • Check for continuity between TMAP sensor connector pin 4 and ECM pin 33 Do you have continuity between them?
14
•
15
•
16
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (18)
-
Replace TMAP sensor Is the replacement complete? • Remove all test equipment except the DST. • Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-135 check for any stored codes. Does the engine operate normally with no stored codes?
Go to step (17)
-
17 18
Inspect TMAP and ECM connector pins for corrosion, contamination or mechanical damage Any problems found?
Check for continuity between TMAP sensor connector pin 4 and engine ground Do you have continuity?
Inspect ECM connector and wire harness connector pins for corrosion, contamination or mechanical damage Any problems found?
-176-
Go to Step (14)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Repair the circuit Go to step (15) as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit Go to Step (16) as necessary. Refer to Wiring Repairs in Engine Electrical.
System OK
Go to OBD System Check
-177-
DTC 142-Crank Sync Noise
ECM 5 volts +
LT GRN/RED
50
A
Crankshaft Crankshaft
Crank Sensor
WHT/PPL B PPL/WHT C
12
11
Crank -
Crank +
Conditions for setting the DTC z z z z z z
Crankshaft Position sensor Check Condition- Engine running Fault Condition- 1 invalid crank re-sync MIL- On during active fault and for 10 seconds after active fault Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled
Circuit Description The Crankshaft Position sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. It determines crankshaft position by monitoring the pulse wheel. The Crankshaft Position sensor is used to measure engine RPM and its signal is used to synchronize the ignition and fuel systems. The ECM must see a valid Crankshaft position signal while running. If no signal is present for 800ms or longer, this fault will set.
-178-
DTC 142 Crank Sync Noise Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
2
•
3
• •
Go to OBD System Check Section Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • •
Check that the ECM ground terminals G1 and G2 are clean and tight Are the ground terminals G1 and G2 clean and tight?
Key On, Engine OFF Disconnect the CKP (Crankshaft position) Sensor connector C009 • Using A DVOM check for voltage at the CKP sensor connector pin A and engine ground Do you have voltage?
Go to Step (3)
5.0 volts
Go to Step (4
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin B and ECM connector pin 12 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Using a DVOM check for continuity between CKP connector pin C and ECM connector pin 11 Do you have continuity between them?
• 5
•
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Go to Step (7)
7
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
•
Replace CKP sensor using R&R procedure in Section 1E. Pay special attention to CKP sensor reluctor wheel inspection. Is the replacement complete?
Go to Step (10)
-
9
• •
Go to Step (11)
-
Inspect the CKP connector C009 terminals for damage, corrosion or contamination Did you find a problem?
Inspect the ECM connector C001 terminals 11,12 and 50 for damage, corrosion or contamination Did you find a problem
Replace ECM Is the replacement complete?
-179-
Go to step (8)
10
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-142 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• • • • •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-142 check for any stored codes. Does the engine operate normally with no stored codes?
-180-
-181-
DTC 143-Never Crank Synced At Start
ECM 5 volts +
LT GRN/RED
50
A
Crankshaft Crankshaft
Crank Sensor
WHT/PPL B PPL/WHT C
12
11
Crank -
Crank +
Conditions for Setting the DTC z z z z z z
CKP (Crankshaft Position Sensor) Check Condition- Engine cranking or running Adaptive- Enabled Fault Condition- 4 cranking revs without sync and engine RPM greater than 90 MIL- On during active fault Closed Loop- Enabled
Circuit description The CKP (Crankshaft Position Sensor) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. It determines crankshaft position by monitoring the pulse wheel. The Crankshaft position sensor is used to measure engine RPM and its signal is used to synchronize the ignition system. The ECM must see a valid Crankshaft Position signal while cranking before it starts. If no signal is present within 4 cranking revs, this fault will set.
-182-
DTC 143 Never Crank Sync At Start Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
2
•
3
• •
Go to OBD System Check Section Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • •
Check that the ECM ground terminals G1 and G2 are clean and tight Are the ground terminals G1 and G2 clean and tight?
Key On, Engine OFF Disconnect the CKP (Crankshaft position) Sensor connector C009 • Using A DVOM check for voltage at the CKP sensor connector pin A and engine ground Do you have voltage?
Go to Step (3)
5.0 volts
Go to Step (4
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin B and ECM connector pin 12 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Using a DVOM check for continuity between CKP connector pin C and ECM connector pin 11 Do you have continuity between them?
• 5
•
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Go to Step (7)
7
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
•
Replace CKP sensor using CKP R&R procedure in Section 1E. Pay special attention to CKP reluctor wheel inspection Is the replacement complete?
Go to Step (10)
-
9
• •
Go to Step (11)
-
Inspect the CKP connector C009 terminals for damage, corrosion or contamination Did you find a problem?
Inspect the ECM connector C001 terminals 11,12 and 50 for damage, corrosion or contamination Did you find a problem
Replace ECM Is the replacement complete?
-183-
Go to step (8)
10
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-143 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• • • • •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-143 check for any stored codes. Does the engine operate normally with no stored codes?
-184-
-185-
DTC 144-Camshaft Sensor Loss
PPL/ORN A Dist./Cam Sensor
GRY/BRN B
14
Cam -
13
Cam + 5 volts
LT GRN/RED 50
C
ECM
Conditions for Setting the DTC
z CMP (Camshaft Position Sensor) z Check Condition-Engine Cranking or Running z Fault Condition-No cam pulse in 3 cycles z MIL-On for active fault and for 10 seconds after active fault z Adaptive-Disabled for remainder of key-on cycle z Closed Loop-Enabled
Circuit Description The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems. This fault will set if the ECM does not detect a cam pulse in 3 engine cycles whenever the engine is cranking or running. The engine will not run with this fault present.
-186-
DTC 144 Camshaft Sensor Loss Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
2
•
3
• •
Go to OBD System Check Section Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • •
Check that the ECM ground terminals G1 and G2 are clean and tight Are the ground terminals G1 and G2 clean and tight?
Key On, Engine OFF Disconnect the CMP (Camshaft position) Sensor connector C011 • Using A DVOM check for voltage at the CMP sensor connector pin C and engine ground Do you have voltage?
Go to Step (3)
5.0 volts
Go to Step (4
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CMP connector pin A and ECM connector pin 14 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Using a DVOM check for continuity between CMP connector pin B and ECM connector pin 13 Do you have continuity between them?
• 5
•
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Go to Step (7)
7
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
•
Replace CMP sensor using R&R procedure in Section 1E. Pay special attention to CMP sensor reluctor wheel inspection. Is the replacement complete?
Go to Step (10)
-
9
• •
Go to Step (11)
-
Inspect the CMP connector C011 terminals for damage, corrosion or contamination Did you find a problem?
Inspect the ECM connector C001 terminals 13,14 and 50 for damage, corrosion or contamination Did you find a problem
Replace ECM Is the replacement complete?
-187-
Go to step (8)
10
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-144 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• • • • •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-144 check for any stored codes. Does the engine operate normally with no stored codes?
-188-
-189-
DTC 145-Camshaft Sensor Noise
PPL/ORN A Dist./Cam Sensor
GRY/BRN B
14
Cam -
13
Cam + 5 volts
LT GRN/RED 50
C
ECM
Conditions for Setting the DTC
z Camshaft position sensor z Check Condition-Cranking or Running z Fault Condition-One invalid cam re-sync z MIL-On for active fault and for 10 seconds after active fault z Adaptive-Disabled for the remainder of the key-on cycle z Closed Loop-Enabled
Circuit Description The camshaft position sensor is used to synchronize the fuel and ignition systems. This fault will set if the ECM detects erroneous pulses from the camshaft position sensor causing invalid cam resync. The engine will not run with this fault present.
-190-
DTC 145 Camshaft Sensor Noise Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
2
•
3
• •
Go to OBD System Check Section Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • •
Check that the ECM ground terminals G1 and G2 are clean and tight Are the ground terminals G1 and G2 clean and tight?
Key On, Engine OFF Disconnect the CMP (Camshaft position) Sensor connector C011 • Using A DVOM check for voltage at the CMP sensor connector pin C and engine ground Do you have voltage?
Go to Step (3)
5.0 volts
Go to Step (4
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CMP connector pin A and ECM connector pin 14 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Using a DVOM check for continuity between CMP connector pin B and ECM connector pin 13 Do you have continuity between them?
• 5
•
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Go to Step (7)
7
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
•
Replace CMP sensor using R&R procedure in Section 1E. Pay special attention to CMP sensor reluctor wheel inspection. Is the replacement complete?
Go to Step (10)
-
9
• •
Go to Step (11)
-
Inspect the CMP connector C011 terminals for damage, corrosion or contamination Did you find a problem?
Inspect the ECM connector C001 terminals 13,14 and 50 for damage, corrosion or contamination Did you find a problem
Replace ECM Is the replacement complete?
-191-
Go to step (8)
10
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-145 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• • • • •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-145 check for any stored codes. Does the engine operate normally with no stored codes?
-192-
-193-
DTC 211- Closed Loop Multiplier High (LPG)
-
DK G RN/O RN
+
B
Sensor
55
BLK/LT GRN A
49
HO2S
Sensor G round
BLK D
Heater C
PNK/DK G RN
ECM
To Engine G round
To System Power Relay
Conditions for Setting the DTC z z z z z z
Heated Oxygen Sensor Check Condition- Engine running Fault Condition- Closed Loop multiplier out of range (greater than 35%) MIL- Disabled Adaptive- Enabled but not updated when Closed Loop is at limit Closed Loop- Enabled
Circuit description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation and cannot correctly modify the fuel flow within its limits. Diagnostic Aids Always diagnose any ECM codes that are present before beginning this diagnostic procedure. x Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold. x Vacuum leaks can cause a lean exhaust condition, especially at light load and idle conditions. x Exhaust leaks can cause a lean exhaust condition, especially at light load and idle conditions x A poor ECU ground to the engine block or battery negative x Problems with the fuel system causing lean fuel mixtures such as low fuel pressure, faulty mixture control solenoid or damaged fuel mixer assembly. Never solder HO2S wires. For the correct repair procedure refer to Wiring Repairs in the Engine Electrical Section.
-194-
DTC 211- Closed Loop Multiplier High (LPG) Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section Intermittent problem Go to Intermittent section
2
Go to step (3) • •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Run engine to full operating temperature and then idle for a minimum of 2 minutes Does DST display HO2S voltage fixed below 0.35 volts after 2 minutes of idle run time? 3
• • • •
Key OFF Disconnect ECM connector Disconnect HO2S wire harness connector Using a high impedance DVOM check for continuity between HO2S connector signal pin B and engine ground
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
Do you have continuity? 4
• •
Using a high impedance DVOM check for continuity between HO2S connector signal pin B and HO2S connector sensor ground pin A Do you have continuity between them?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
5
• Refer to Diagnostic aids for DTC 211 Did you check the diagnostic Aids for DTC 211?
Go to Step (6)
6
• Replace HO2S sensor Is the replacement complete?
Go to Step (7)
7
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-211 check for any stored codes. Does the engine operate normally with no stored codes?
-195-
System OK
Go to Step (5)
Go to OBD System Check
DTC 212-HO2S Open/Inactive
-
DK G RN/O RN
+
B
Sensor
55
BLK/LT GRN A
49
HO2S
Sensor G round
BLK D
Heater C
PNK/DK G RN
ECM
To Engine G round
To System Power Relay
Conditions for Setting the DTC
Heated Oxygen Sensor
Check condition- Engine running Fault condition- HO2S cold persistently more than 120 seconds MIL- On during active fault and for 1 second after active fault Adaptive- Disabled during active fault Closed Loop- Disabled during active fault
Circuit Description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the Adaptive multiplier. This fault will set if HO2S is cold, non-responsive, or inactive for 120 seconds or longer.
-196-
DTC 212- HO2S Open/Inactive Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
Go to Step (5) • • •
Go to Step (3)
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Run engine to full operating temperature and then idle for a minimum of 2 minutes
Does DST display HO2S voltage fixed between 0.4 and 0.5 volts after 2 minutes of idle run time?
3
4
5
6
7
Go to step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
•
Back probe HO2S wire harness connector and check for voltage between HO2S connector heater power pin C and engine ground. Do you have power?
Go to step (7)
Repair the circuit as necessary. Check System Power Relay circuit. Refer to Wiring Repairs in Engine Electrical.
• • • •
Key OFF Disconnect HO2S connector and ECM connector. Key ON Check for continuity between HO2S sensor connector ground pin A and ECM HO2S sensor ground PIN 49. Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
•
Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
• Back probe HO2S wire harness connector and check for voltage between HO2S connector heater ground pin D and battery voltage positive. Do you have power?
Check for continuity between HO2S sensor connector signal pin B and ECM connector HO2S signal pin 55 Do you have continuity between them?
Replace HO2S Sensor Is the replacement complete?
Go to Step (9)
-197-
-
8
• •
Inspect ECM connector pins 49 and 55 for damage, corrosion or contamination Inspect HO2S connector terminals A, B, C and D for damage, corrosion or contamination
Did you find a problem? 9
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-212 check for any stored codes. Does the engine operate normally with no stored codes?
-198-
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
System OK
Go to OBD System Check
-199-
DTC 221-Closed Loop Multiplier High (Gasoline)
-
+
D K G R N /O R N B
55
Sensor
BLK/LT G R N A
49
H O 2S
Sensor G round
BLK D H eater
PN K/D K G R N
C
T o System Power R elay
ECM
T o Engine G round
Conditions for Setting the DTC z Heated Oxygen Sensor z Functional Fault-Closed Loop multiplier out of range (at limit of 35%) z MIL-On during active fault z Adaptive-Enabled z Closed Loop-Enabled
Circuit Description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the Adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation. When the multiplier cannot correctly modify the fuel flow within its limits, the limit is enforced.
-200-
DTC 221 Closed Loop Multiplier High (Gasoline) Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
Go to step (3) • • •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Run engine to full operating temperature and then idle for a minimum of 2 minutes
Intermittent problem Go to Intermittent section
Does DST display HO2S voltage fixed below 0.35 volts after 2 minutes of idle run time? 3
• • • •
Key OFF Disconnect HO2S sensor wire harness connector Disconnect ECM connector Using a high impedance DVOM Check for continuity between HO2S connector signal pin B and engine ground Do you have continuity?
Repair the circuit as required Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
4
•
Using a high impedance DVOM Check for continuity between HO2S connector signal pin B and HO2S sensor ground pin A Do you have continuity?
Repair the circuit as required Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Refer to Diagnostic aids for DTC 221 Did you check the diagnostic Aids for DTC 221?
Go to Step (6)
-
6
• Replace HO2S sensor Is the replacement complete?
Go to Step (7)
-
7
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-221 check for any stored codes. Does the engine operate normally with no stored codes?
-201-
DTC 222- Closed Loop Multiplier Low (Gasoline)
-
+
D K G R N /O R N B
Sensor
55
BLK/LT G R N A
49
H O 2S
Sensor G round
BLK D H eater C
PN K/D K G R N
ECM
T o Engine G round
T o System Power R elay
Conditions for Setting the DTC z Heated Oxygen Sensor z Functional Fault-Closed Loop multiplier out of range (at limit of -35%) z MIL-On during active fault and for one update after active fault z Adaptive-Enabled z Closed Loop-Enabled Circuit Description The HO2S (Heated Oxygen Sensor) sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation. When the multiplier cannot correctly modify the fuel flow within its limits, it is limited at -35%. Diagnostic Aids Always diagnose any other ECM codes that are present before beginning this diagnostic procedure. Fuel System The system will be rich if an injector fails in an open manner. High fuel pressure due to a faulty fuel regulator or obstructed fuel return line will cause the system to run rich. Ignition noise open or poor ground circuit to or in the ignition system or ECM may cause EMI (Electromagnetic interference). This noise could be interpreted by the ECM as ignition pulses, and the sensed RPM becomes higher than the actual speed. The ECM then delivers too much fuel, causing the system to run rich. TMAP Sensor A higher manifold pressure than normal can cause the system to go rich. Temporarily disconnecting the MAP Sensor will allow the ECM to set a default value for MAP. IAT Sensor Check for a shifted sensor that could cause the ECM to sense lower than actual temperature of incoming air. This can cause a rich exhaust condition.
-202-
DTC 222- Closed Loop Multiplier Low (Gasoline) Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section Intermittent problem Go to Intermittent section
2
Go to step (3) • •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Run engine to full operating temperature and then idle for a minimum of 2 minutes Does DST display HO2S voltage fixed above 0.7 volts after 2 minutes of idle run time? 3
• • • • •
Key OFF Disconnect HO2S wire harness connector Disconnect ECM wiring harness connector Key ON Using a high impedance DVOM check for voltage between HO2S connector signal pin B and engine ground Do you have voltage?
-203-
Repair the circuit as required Refer to Wiring Repairs in Engine Electrical.
Refer to Diagnostic Aids for DTC 222
DTC 224- Closed Loop Multiplier Low (LPG)
-
+
D K G R N /O R N B
Sensor
55
BLK/LT G R N A
49
H O 2S
Sensor G round
BLK D H eater C
PN K/D K G R N
ECM
T o Engine G round
T o System Power R elay
Conditions for Setting the DTC z Heated Oxygen Sensor z Functional Fault-Closed Loop multiplier out of range (at limit of -35%) z MIL Disabled z Adaptive-Disabled z Closed Loop-Enabled Circuit Description The HO2S (Heated Oxygen Sensor) sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation. When the multiplier cannot correctly modify the fuel flow within its limits, it is limited at -35%. Diagnostic Aids Always diagnose any other ECM codes that are present before beginning this diagnostic procedure. Fuel System High secondary fuel pressure can cause the system to run rich. A worn fuel mixer, faulty PTV (pressure trim valve) or FTV (fuel trim valve) can also cause the system to run rich. Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is used.
-204-
DTC 224- Closed Loop Multiplier Low (LPG) Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section Intermittent problem Go to Intermittent section
2
Go to step (3) • • •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Run engine to full operating temperature and then idle for a minimum of 2 minutes
Does DST display HO2S voltage fixed above 0.7 volts after 2 minutes of idle run time? 3
• • • • •
Key OFF Disconnect HO2S wire harness connector Disconnect ECM wiring harness connector Key ON Using a high impedance DVOM check for voltage between HO2S connector signal pin B and engine ground Do you have voltage?
-205-
Refer to Repair wire harness shorted Diagnostic Aids for DTC 224 signal to voltage Refer to Wiring Repairs in Engine Electrical.
DTC 241-Adaptive Lean Fault (high limit-gasoline)
-
+
D K G R N /O R N B
Sensor
55
BLK/LT G R N A
49
H O 2S
Sensor G round
BLK D H eater C
PN K/D K G R N
ECM
T o Engine G round
T o System Power R elay
Conditions for Setting the DTC z Heated Oxygen Sensor z Functional Fault-Adaptive multiplier out of range (greater than 30%) z MIL-On during active adaptive limit condition z Adaptive-Enabled z Closed Loop-Enabled Circuit Description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the Adaptive multiplier. This fault sets if the Adaptive multiplier exceeds the limits of normal operation. Diagnostic Aids If any other DTCs are present, diagnose those first Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold. Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition at especially at light load. Injectors System will be lean if an injector driver or driver circuit fails open. The system will also be lean if an injector fails in a closed manner or is dirty. Fuel Pressure Low fuel pressure, faulty fuel injector or damaged fuel pump assembly can cause fuel system to run lean Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past the 02 sensor causing a false lean condition. Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean. Ground Problem ECM grounds must be good battery or engine ground.
-206-
DTC 241 Adaptive Lean Fault (High Limit Gasoline) Step
Action
Value(s)
Yes
No Go to Step (2)
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
2
Visually and physically check the following items: • The air intake duct for being collapsed or restricted • The air filter for being plugged • The HO2S sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires • ECM grounds for being clean and tight. Refer to Section 1C Engine Electrical Power and Ground Distribution • Fuel System Diagnostics. Refer to Section 1B Fuel System Diagnostics Was a repair made?
Go to Step (8)
3
•
Go to Step (8)
Go to step (4)
4
• •
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired?
• •
Key ON Engine running Back probe the HO2S sensor connector heater terminals D for negative and C for positive Using a DVOM check for voltage Do you have voltage?
Battery voltage
Go to Step (4)
5
• • • • •
Key OFF Disconnect HO2S sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a high impedance DVOM check for continuity between HO2S connector signal pin B and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
Go to Step (8)
-
•
7
Using a high impedance DVOM check for continuity between HO2S connector sensor ground pin A and HO2S signal pin B Do you have continuity?
• Replace HO2S sensor Is the replacement complete?
-207-
8
• • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-241 check for any stored codes. Does the engine operate normally with no stored codes?
-208-
System OK
Go to OBD System Check
-209-
DTC 242-Adaptive Rich Fault (low limit-gasoline)
-
+
D K G R N /O R N B
Sensor
55
BLK/LT G R N A
49
H O 2S
Sensor G round
BLK D H eater C
PN K/D K G R N
ECM
T o Engine G round
T o System Power R elay
Conditions for Setting the DTC z Heated Oxygen Sensor z Functional Fault-Adaptive multiplier out of range (at limit of -30%) z MIL-On during active adaptive limit condition z Adaptive-Enabled z Closed Loop-Enabled Circuit Description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the Adaptive multiplier. This fault sets if the Adaptive multiplier exceeds the limits of normal operation. Diagnostic Aids Always diagnose any other ECM codes that are present before beginning this diagnostic procedure. Fuel System The system will be rich if an injector fails in an open manner. High fuel pressure due to a faulty fuel regulator or obstructed fuel return line will cause the system to run rich. Ignition noise open or poor ground circuit to or in the ignition system or ECM may cause EMI (Electromagnetic interference). This noise could be interpreted by the ECM as ignition pulses, and the sensed RPM becomes higher than the actual speed. The ECM then delivers too much fuel, causing the system to go rich. TMAP Sensor A higher manifold pressure than normal can cause the system to go rich. Temporarily disconnecting the MAP Sensor will allow the ECM to set a default value for MAP. IAT Sensor Check for a shifted sensor that could cause the ECM to sense lower than actual temperature of incoming air. This can cause a rich exhaust condition. ECT Sensor Check for a skewed sensor that could cause the ECM to sense engine temperature colder than it actually is. This could also cause a rich exhaust condition.
-210-
DTC 242 Adaptive Rich Fault (Low Limit Gasoline) Step
Action
Value(s)
Yes
No Go to Step (2)
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
2
Visually and physically check the following items: • The air intake duct for being collapsed or restricted • The air filter for being plugged • The HO2S sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires • ECM grounds for being clean and tight. Refer to Section 1C Engine Electrical Power and Ground Distribution • Fuel System Diagnostics. Refer to Section 1B Fuel System Diagnostics Was a repair made?
Go to Step (6)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired?
Go to Step (6)
Go to step (4)
4
• • • • •
Key OFF Disconnect HO2S sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage at HO2S connector signal pin B and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Replace HO2S sensor Is the replacement complete?
Go to Step (6)
-
6
• • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-242 check for any stored codes. Does the engine operate normally with no stored codes?
-211-
System OK
Go to Step (4)
Go to OBD System Check
DTC 243-Adaptive Learn High (LPG)
-
D K G R N /O R N
+
B
Sensor
55
B L K /L T G R N A
49
HO 2S
S e n s o r G ro u n d
BLK D H e a te r C
P N K /D K G R N
ECM
T o E n g in e G ro u n d
T o S ys te m P o w e r R e la y
Conditions for Setting the DTC z z z z z z
Heated Oxygen Sensor Check Condition- Engine Running Fault Condition- Adaptive multiplier out of range (greater than 30%) MIL- Disabled Adaptive- Enabled Closed Loop- Enabled
Circuit Description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier exceeds the limits of normal operation. Diagnostic Aids If any other DTCs are present, diagnose those first Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold. Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition at especially at light load. Injectors System will be lean if an injector driver or driver circuit fails open. The system will also be lean if an injector fails in a closed manner or is dirty. Fuel Pressure Low fuel pressure, faulty fuel injector or damaged fuel pump assembly can cause fuel system to run lean Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past the 02 sensor causing a false lean condition. Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean. Ground Problem ECM grounds must be good battery or engine ground.
-212-
DTC 243 Adaptive Learn High (LPG) Step
Action
Value(s)
Yes
No Go to Step (2)
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
2
Visually and physically check the following items: • The air intake duct for being collapsed or restricted • The air filter for being plugged • The HO2S sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires • ECM grounds for being clean and tight. Refer to Section 1C Engine Electrical Power and Ground Distribution • Fuel System Diagnostics. Refer to Section 1B Fuel System Diagnostics Was a repair made?
Go to Step (7)
3
•
Go to Step (7)
Go to step (4)
4
• •
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired?
•
Key ON Engine running Using a DVOM back probe the HO2S sensor connector heater circuit pin C for positive and D for negative. check for voltage Do you have voltage?
Battery voltage
Go to Step (4)
5
• • • • •
Key OFF Disconnect HO2S sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage at HO2S connector signal pin B and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
• Replace HO2S sensor Is the replacement complete?
Go to Step (7)
-
7
• • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-243 check for any stored codes. Does the engine operate normally with no stored codes?
-213-
System OK
Go to OBD System Check
DTC 244-Adaptive Learn Low (LPG)
-
+
D K G R N /O R N B
Sensor
55
BLK/LT G R N A
49
H O 2S
Sensor G round
BLK D H eater C
PN K/D K G R N
ECM
T o Engine G round
T o System Power R elay
Conditions for Setting the DTC z z z z z z
Heated Oxygen Sensor Check Condition- Engine running Fault Condition- Adaptive multiplier out of range (at limit of -30%) MIL-Disabled Adaptive- Enabled Closed Loop- Enabled
Circuit Description The HO2S sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier exceeds the limits of normal operation. Diagnostic Aids Always diagnose any other ECM codes that are present before beginning this diagnostic procedure. Fuel System High secondary fuel pressure will cause the system to run rich. A worn fuel mixer, faulty PTV (pressure trim valve) or FTV (fuel trim valve) can also cause the system to run rich. Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is used.
-214-
DTC 244 Adaptive Learn Low (LPG) Step
Action
Value(s)
Yes
No Go to Step (2)
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
2
Visually and physically check the following items: • The air intake duct for being collapsed or restricted • The air filter for being plugged • ECM grounds for being clean and tight. Refer to Section 1C Engine Electrical Power and Ground Distribution • Fuel System Diagnostics. Refer to Section 1B Fuel System Diagnostics Was a repair made?
Go to Step (7)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired?
Go to Step (7)
Go to step (4)
4
• • • • •
Key OFF Disconnect HO2S sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage at HO2S connector signal pin B and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Replace HO2S sensor Is the replacement complete?
Go to Step (7)
-
7
• • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-244 check for any stored codes. Does the engine operate normally with no stored codes?
-215-
System OK
Go to Step (4)
Go to OBD System Check
DTC 261-System Voltage Low
ECM
BLK
19
GROUND BLK
20
RED/TAN
22
RED/TAN 23
VBAT
Conditions for Setting the DTC z System Voltage to ECM z Check Condition-Key on and RPM greater than 1500 z Fault Condition-Battery voltage at ECM less than 9.0 volts continuously for 5 seconds z MIL-On for active fault and for 10 seconds after active fault z Adaptive-Disabled for remainder of key on cycle z Closed Loop-Enabled Circuit Description The battery voltage powers the ECM and must be measured to correctly operate injector drivers, fuel trim valves and ignition coils. This fault will set if the ECM detects system voltage less than 9.0 for 5 seconds or longer while the alternator should be charging. The adaptive learn is disabled.
-216-
DTC 261- System Voltage Low Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display system voltage greater than 9.0 volts?
Intermittent problem Go to Engine Electrical Intermittent section
Go to Step (3)
3
• Check battery condition Is it OK?
-
Go to Step (4)
Replace Battery
4
• Check charging system Is it Ok?
-
Go to Step (5)
Repair charging System
5
• •
-
Repair ECM Ground circuit. Go to Power and Ground section in engine Electrical
Go to Step (6)
-
Repair ECM power circuit. Go to Power and Ground section in engine Electrical
Go to step (7)
Back probe ECM connector pins 22 and 23 Measure voltage with DVOM between each pin and engine ground Is the voltage greater than 9.0 volts?
6 • •
Back probe ECM connector pins 19 and 20 Measure voltage with DVOM between each pin and battery voltage Is the voltage greater than 9.0 volts? 7
Replace ECM Is the replacement complete?
-
Go to Step (8)
-
8
• •
-
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-261 check for any stored codes. Does the engine operate normally with no stored codes?
-217-
DTC 262-System Voltage High
ECM
BLK
19
GROUND BLK
20
RED/TAN
VBAT
22
RED/TAN
23
Conditions for Setting the DTC z System Voltage to ECM z Check Condition-Cranking or Running z Fault Condition-Switched battery voltage at ECM greater than 18 volts for 3 seconds z MIL-On for active fault and for 5 seconds after active fault z Adaptive-Disabled for remainder of key on cycle z Closed Loop-Enabled
Circuit Description The battery voltage powers the ECM and must be measured to correctly operate injector drivers, trim valves and ignition coils. This fault will set if the ECM detects voltage greater than 18 volts for 3 seconds at anytime the engine is cranking or running. The adaptive learn is disabled. The ECM will shut down with internal protection if the system voltage exceeds 26 volts. The ECM fuse will then open.
-218-
DTC 262- System Voltage High Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• • •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Run engine greater than 1500 rpm.
Intermittent problem Go to Engine Electrical Intermittent section
Go to Step (3)
Does DST display system voltage less than 18 volts? 3
•
Check voltage at battery terminals with DVOM with engine speed greater than 1500 rpm Is it greater than 18 volts?
-
Go to Step (4)
Go to Step (5)
4
• Repair the charging system Has the charging system been repaired?
-
Go to Step (6)
-
5
• Replace ECM Is the replacement complete?
Go to Step (6)
-
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-262 check for any stored codes. Does the engine operate normally with no stored codes?
-219-
-
DTC 511-COP Failure
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-220-
DTC 511 COP Failure Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 511 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-511 check for any stored codes. Does the engine operate normally with no stored codes?
-221-
Intermittent problem Go to Intermittent section
DTC 512-Invalid Interrupt
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM has checks that must be verified each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-222-
DTC 512 Invalid Interrupt Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 512 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-512 check for any stored codes. Does the engine operate normally with no stored codes?
-223-
Intermittent problem Go to Intermittent section
DTC 513-A/D Loss
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM has checks that must be verified each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-224-
DTC 513 A/D Loss Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 513 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-513 check for any stored codes. Does the engine normally with no stored codes?
-225-
Intermittent problem Go to Intermittent section
DTC 514-RTI 1 Loss
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM runs checks that must be verified each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-226-
DTC 514 RTI 1 Loss Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 514 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-514 check for any stored codes. Does the engine operate normally with no stored codes?
-227-
Intermittent problem Go to Intermittent section
DTC 515-Flash Checksum Invalid
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-228-
DTC 515 Flash Checksum Invalid Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 515 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-515 check for any stored codes. Does the engine operate normally with no stored codes?
-229-
Intermittent problem Go to Intermittent section
DTC 516-Ram Failure
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Random Access Memory Check Condition- Key-On Fault Condition- Internal ECM memory access failure MIL- On until fault is cleared Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2) enforced
Circuit Description Random Access Memory is located within the microprocessor that can be read from or written to at any time. The System Fault Codes and the Adaptive Learn Table are among the data stored in RAM. This fault will set if the ECM detects a problem accessing or writing information to RAM. This fault will not self erase and must be cleared manually.
-230-
DTC 516 Ram Failure Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 516 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-516 check for any stored codes. Does the engine operate normally with no stored codes?
-231-
Intermittent problem Go to Intermittent section
DTC 531-External 5V Ref Lower Than Expected
LT GRN/RED 50
+5 Volts
ECM
Conditions for Setting the DTC z External 5V reference z Check Condition-Cranking with battery voltage greater than 8 volts and engine running z Fault Condition-5V reference voltage lower than 4.6 volts z MIL-On during active fault and for 2 seconds after active fault z Adaptive-Disabled during active fault z Closed Loop-Enabled
Circuit Description The External 5 Volt supply powers some of the sensors and other components in the system. The accuracy of the 5 Volt supply is very important to the accuracy of the sensors and therefore controlled by the ECM. The ECM monitors the 5 volt supply to determine if it is overloaded, shorted, or otherwise out of specification. This fault will set if the 5 Volt reference is below 4.6 volts.
-232-
DTC 531 External 5V Reference Lower Than Expected Action
Step
Value(s)
Yes
No
-
Go to Step (2)
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine Running • DST (Diagnostic Scan Tool) connected in System Fault Mode Does DST display DTC 531?
Go to Step (3)
3
• • •
Go to Step (5)
Go to OBD System Check Section Intermittent problem Go to Intermittent section Go to Step (4)
Go to Step (7)
-
Go to Step (6)
-
Go to step (7)
-
System OK
Go to OBD System Check
4 5
Key OFF Disconnect ECM connector Using DVOM check for continuity between ECM 5 volt reference LT GRN/R pin 50 and engine ground Do you have continuity? • Replace ECM Is the replacement complete? • While monitoring DVOM for continuity between ECM 5 volt reference and engine ground disconnect each sensor (below) one at a time to find the shorted 5 volt reference. When continuity to ground is lost the last sensor disconnected is the area of suspicion. Inspect 5volt reference supply wire leads for shorts before replacing the sensor. • IAT • ECT/CHT • TMAP • FPP • TPS 1 • TPS 2 • Crankshaft Sensor • Camshaft Sensor While disconnecting each sensor one at a time did you loose continuity?
6 7
• Replace Sensor Is the replacement complete? • Remove all test equipment except the DST. • Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-531 check for any stored codes. Does the engine operate normally with no stored codes?
-233-
DTC 532-External 5 V Ref Higher Than Expected
LT GRN/RED 50
+5 Volts
ECM
Conditions for Setting the DTC z External 5V reference z Check Condition-Cranking with battery voltage greater than 8 volts or engine running z Fault Condition-5V reference voltage higher than 5.4 volts z MIL-On during active fault and for 2 seconds after active fault z Adaptive-Disabled during active fault z Closed Loop-Enabled
Circuit Description The External 5 Volt supply powers some of the sensors and other components in the system. The accuracy of the 5 Volt supply is very important to the accuracy of the sensors and therefore control by the ECM. The ECM to determine if they are overloaded, shorted, or otherwise out of specification monitors the 5 Volt supply. This fault will set if the 5 Volt reference is above 5.4 volts.
-234-
DTC 532 External 5V Reference Higher Than Expected Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine running • DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display DTC 532?
Go to Step (3)
3
• Check all ECM ground connections Refer to Engine electrical power and ground distribution. Are the ground connections Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • • •
Key OFF Disconnect ECM connector Key ON Using DVOM check for Voltage between ECM harness wire LT GRN/R pin 50 and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Replace ECM Is the replacement complete?
Go to Step (6)
-
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-532 check for any stored codes. Does the vehicle engine normally with no stored codes?
-235-
Intermittent problem Go to Intermittent section
DTC 555-RTI 2 Loss
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-236-
DTC 555 RTI 2 Loss Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 555 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-555 check for any stored codes. Does the engine operate normally with no stored codes?
-237-
Intermittent problem Go to Intermittent section
DTC 556-RTI 3 Loss
ECM
Microprocessor Microprocessor
RAM RAM
Conditions for Setting the DTC
z z z z z z z
Engine Control Module Check Condition- Key on Fault Condition- Internal microprocessor error MIL- On until code is cleared by technician Adaptive- Disabled for the remainder of the key-on cycle Closed Loop- Enabled Power Derate (level 2 until fault is cleared manually)
Circuit Description The ECM runs checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared.
-238-
DTC 556 RTI 3 Loss Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key On, Engine Running • DST (Diagnostic Scan Tool) connected in • System Data Mode • Clear system fault code Does DTC 555 reset with the engine idling?
Go to Step (3)
3
•
Check all ECM power and ground circuits. Refer to power and ground distribution in engine electrical section. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
-
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-556 check for any stored codes. Does the engine operate normally with no stored codes?
-239-
Intermittent problem Go to Intermittent section
DTC 611-FPP High Voltage
FPP A C B
5 volts
LT GRN/RED
50
DK BLUE
38
Signal
BLK/LT GREEN
49
Sensor Ground
ECM
Conditions for Setting the DTC Foot Pedal Position Check Condition-Key On Fault Condition-FPP1 sensor voltage exceeds 4.8 MIL-On during active fault Adaptive-Enabled Closed Loop-Enabled Power Derate (level 1) and Low Rev Limit (1300 rpm) enforced Forced Idle (650) rpm
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. Less depression of pedal results in lower voltage, and greater depression results in higher voltage. This fault will set if voltage is over 4.8 volts at any operating condition while the key is on. If the voltage exceeds 4.8, then FPP is considered to be out of specifications. At this point the ECM does not have a valid signal, and must therefore enforce the low rev limit and Power Derate (level 1). When these are enforced the maximum throttle position is 50%. The Low Rev Limit is enforced for the remainder of the key-on cycle. Rev limit is still enforced if the active fault is no longer present; the MIL will be on for the remainder of the key-on cycle. This is a reminder that the Low Rev Limit is still enforced.
-240-
DTC 611 FPP Voltage High Step 1
Action Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP voltage of 4.8 volts or greater with the foot pedal in the idle position? • Slowly increase FPP while observing FPP voltage Does DST FPP voltage ever exceed 4.8 volts?
Go to Step (8)
4
• • •
5
• •
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6)
6
• •
7
•
8
• Key OFF • Disconnect FPP sensor from wire harness • Key ON Does DSC display FPP voltage less than 0.2 volts? • Disconnect ECM wire harness connector C001 • Using a DVOM check for voltage between the ECM FPP signal pin 38 and engine ground Do you have voltage between them?
3
9
Key OFF Disconnect FPP sensor connector Inspect connector and wire terminals for damage, corrosion or contamination Any problems found? Disconnect ECM connector C001 Check continuity between FPP sensor connector ground pin B and ECM connector FPP sensor ground pin 49 Do have continuity between them?
Key ON Using a DVOM check for voltage at ECM wire harness connector FPP signal pin 38 and ECM sensor ground terminal pin 49 Do you have voltage between them?
Using a DVOM check for voltage at ECM wire harness connector between ECM FPP signal pin 38 and engine ground Do you have voltage between them?
-241-
Value(s) -
Yes Go to Step (2)
Go to step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
No Go to OBD System Check Section Go to Step (3)
Intermittent problem Go to Intermittent section Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (7)
Intermittent problem Go to Intermittent section
Go to Step (9)
Go to Step (10)
10 11
12
13 14
15
• Replace ECM Is the replacement complete? • Probe FPP sensor connector ground circuit pin B with a test light connected to battery voltage Does the test light come on? • Key OFF • Disconnect ECM wire harness connector • Inspect the ECM wire harness connector terminals for damage, corrosion or contamination Did you find a problem? • Replace FPP sensor Is the replacement complete? • Key OFF • Disconnect ECM connector • Check continuity between FPP sensor connector ground pin B and ECM connector FPP sensor ground pin 49 Do have continuity between them? • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-611 check for any stored codes. Does the engine operate normally with no stored codes?
-242-
Go to Step (15)
-
Go to Step (12)
Go to Step (14)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (15)
Go to step (13)
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to OBD System Check
System OK
-
-243-
DTC 612-FPP Low Voltage
FPP A C B
5 volts
LT GRN/RED
50
DK BLUE
38
Signal
BLK/LT GREEN
49
Sensor Ground
ECM
Conditions for Setting the DTC
Foot Pedal Position Check Condition-Key On Fault Condition-FPP sensor voltage less than 0.2 MIL-On during active Adaptive-Enabled Closed Loop-Enabled Power Derate (level 1) and Low Rev Limit enforced (1300) rpm Forced Idle (650) rpm
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. Less depression of pedal results in lower voltage, and greater depression results in higher voltage. This fault will set if voltage is less than 0.2 volts at any operating condition while the key is on. If the voltage is less than 0.2, then FPP is considered to be out of specifications. At this point the ECM does not have a valid signal, and must therefore enforce the low rev limit and Power Derate (level-1). When these are enforced the maximum throttle position is 50%. The low rev limit is enforced for the remainder of the key-on cycle. If the active fault is no longer present, the MIL light will be on for the remainder of the key-on cycle. This is a reminder that the Low Rev Limit is still enforced.
-244-
DTC 612 FPP Voltage Low Step 1
Action Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP voltage of 0.2 volts or less with the foot pedal in the idle position? • Slowly depress FP while observing FPP voltage Does DST FPP voltage ever drop below 0.2 volts?
Go to Step (7)
4
• • •
5
• •
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6)
6
• Replace FPP Sensor Is the replacement complete? • Key OFF • Disconnect FPP Sensor from wire harness • Jumper 5 volt reference circuit pin A and FPP signal circuit pin C together • Key ON Does DST display FPP voltage of 4.8 volts or greater?
Go to Step (18)
8
•
9
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (10)
3
7
Value(s) -
Go to step (4)
Key OFF Disconnect FPP sensor connector Inspect connector and wire terminals for damage, corrosion or contamination Any problems found? Key ON Using A DVOM check for voltage at the FPP sensor connector between 5 volt reference pin A and FPP sensor ground pin B Do you have voltage between them?
Check FPP connector wire terminals for damage, corrosion or contamination? Any problems found?
Probe FPP connector signal circuit pin C with a test light connected to battery voltage Does the DST display FPP voltage of 4.8 volts or greater?
-245-
Yes Go to Step (2)
5.0 Volts
Go to Step (8)
No Go to OBD System Check Section Go to Step (3)
Intermittent problem Go to Intermittent section Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (9)
Go to Step (6)
Go to Step (14)
10
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between FPP sensor connector 5 volt reference pin A and ECM connector 5 volt reference pin 50 Do you have continuity between them?
Go to Step (11)
11
•
12
•
13
•
14
• • •
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (15)
15
•
16
•
17
• Replace ECM Is the replacement complete?
Using A DVOM check for continuity between ECM 5 volt reference pin 50 and engine ground Do you have continuity between them?
Using a DVOM check for continuity between ECM connector 5 volt reference pin 50 and ECM sensor ground pin 49 Do you have continuity between them?
Inspect FPP and ECM connector terminal terminals for damage, corrosion or contamination Any problems found?
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between FPP connector signal pin C and ECM connector FPP signal pin 38 Do you have continuity between them? Using a DVOM check for continuity between ECM connector FPP signal pin 38 and engine ground Do you have continuity?
Using a DVOM check for continuity between ECM FPP signal pin 38 and ECM connector FPP sensor ground pin 49 Do you have continuity between them?
-246-
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (18)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (12)
Go to Step (13)
Go to Step (17)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (16)
Go to Step (13)
-
18
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-612 check for any stored codes. Does the engine operate normally with no stored codes?
-247-
System OK
Go to OBD System Check
DTC 613-FPP Higher Than IVS Limit
ECM LT GRN/RED
F P P
DK BLU
BLK/LT GRB
I V S
50
+ 5 volts
38
FPP Signal
49
Sensor Ground + 5 volts
PPL/YEL
39
IVS Signal
Conditions for Setting the DTC • • • • • • • •
Foot Pedal Position/Idle Validation Switch Check Condition-Engine Cranking or Running MIL-On during active fault Fault Condition-IVS at idle and FPP voltage greater than 1.2 volts Adaptive-Enabled Closed Loop-Enabled Power Derate (level 1) and Low Rev Limit enforced (1300) rpm Forced Idle (650) rpm
Circuit Description The engine load command to the ECM is determined by operator depression of the electronic foot pedal. The ECM monitors the foot pedal position and controls the throttle to maintain the commanded power level. Because a problem with the foot pedal signal can result in a higher or lower power than intended by the operator, the pedal used with this control system incorporates a sensor with an idle validation switch. Checks and cross checks are constantly conducted by the ECM to determine the validity of the signals. The Idle Validation Switch (IVS) is a normally closed contact (idle) that opens the IVS circuit to the ECM when the pedal is depressed more than the idle position. This fault will set if the IVS is at idle (closed) and the FPP voltage is greater than 1.2 volts. During this fault, Power Derate (level 1) and the Low Rev Limit are enforced. When these are enforced the maximum throttle position is 50%. The Low Rev Limit and Power Derate are enforced for the remainder of the key-on cycle. If the active fault is no longer present, the MIL light will be on for the remainder of the key-on cycle. This is a reminder that the Power Derate and Low Rev Limits are still enforced
-248-
DTC 613 FPP Higher Than IVS Limit Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display IVS “idle” with the foot pedal fully depressed?
Go to Step (3)
Go to Step (7)
3
• Key OFF • Disconnect foot pedal from harness • Key ON Does DST display IVS “idle”?
Go to Step (4)
Go to Step (5)
4
• Replace foot pedal Is the replacement complete?
Go to Step (8)
-
5
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between IVS signal and engine ground Do you have continuity between them?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
• Replace ECM Is the replacement complete?
Go to Step (8)
-
7
•
8
• •
Depress foot pedal until DST reads FPP voltage between 1.1 and 1.3 volts Does DST display IVS “idle”
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-613 check for any stored codes. Does the engine operate normally with no stored codes?
-249-
1.1 to 1.3 volts
Go to Step (4)
System OK
Intermittent problem Go to Intermittent section Go OBD System Check
DTC 614-FPP Lower Than IVS Limit
ECM LT GRN/RED
F P P
DK/ BLU
BLK/LT GRN
I V S
50
+ 5 volts
38
FPP Signal
49
Sensor Ground + 5 volts
PPL/YEL
39
IVS Signal
Conditions for Setting the DTC • • • • • • • •
Foot Pedal Position/Idle Validation Switch Check Condition-Engine Cranking or Running MIL-On during active fault Fault Condition-IVS at idle and FPP voltage greater than 1.2 volts Adaptive-Enabled Closed Loop-Enabled Power Derate (level 1) and Low Rev Limit enforced (1300) rpm Forced Idle (650) rpm
Circuit Description The engine load command to the ECM is determined by operator depression of the electronic foot pedal. The ECM monitors the foot pedal position and controls the throttle to maintain the commanded power level. Because a problem with the foot pedal signal can result in a higher or lower power than intended by the operator, the pedal used with this control system incorporates a sensor with an idle validation switch. Checks and cross checks are constantly conducted by the ECM to determine the validity of the signals. The Idle Validation Switch (IVS) is a normally closed contact (idle) that opens the IVS circuit to the ECM when the pedal is depressed more than the idle position. This fault will set if the IVS is off-idle (open) and the FPP voltage is less than 0.6 volts. During this fault, Power Derate (level 1) and the Low Rev Limit are enforced. When these are enforced the maximum throttle position is 50%. These are enforced for the remainder of the key-on cycle. If the active fault is no longer present, the MIL light will be on for the remainder of the key-on cycle. This is a reminder that the Power Derate and Low Rev Limits are still enforced.
-250-
DTC 614 FPP Lower Than IVS Limit Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display IVS “OFF IDLE” with the foot pedal in the idle position?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Key OFF Jumper IVS signal and IVS ground together at wire harness connector • Key ON Does DST display IVS “ON”
Go to step (4)
Go to Step (5)
4
• Replace Foot Pedal Is the replacement complete?
Go to Step (7)
-
5
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between IVS signal and engine ground Do you have continuity?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
• Replace ECM Is the replacement complete?
Go to Step (7)
-
7
• •
System OK
Go OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-614 check for any stored codes. Does the engine operate normally with no stored codes?
-251-
DTC 631-TPS 1 Signal Voltage High
TPS 1 A
LT GRN/RED
50
PPL/LT BLUE
C
53
Signal Sensor Ground
BLK/LT GRN
B
5 volts
49
ECM
Conditions for Setting the DTC Throttle Position Sensor #1 Check Condition-Cranking or Running Fault Condition-TPS sensor voltage exceeds 4.8 MIL-On during active fault Power Derate 1 Low rev limit 1300 rpm Forced idle 650 rpm
Circuit Description The Electronic Throttle has two counter acting Throttle Position Sensors. Two sensors are used for improved safety and redundancy. The Throttle Position sensor uses a variable resistor to determine signal voltage based on throttle plate position, and is connected to the throttle shaft. Less opening results in lower voltage, and greater opening in higher voltage. The TPS value is used by the ECM to determine if the throttle is opening as commanded. This fault will set if voltage is above 4.8 volts at any operating condition while the engine is cranking or running. Power derate 1 will be enforced limiting the throttle to 50% maximum. Low rev limit and forced idle will also be enforced during this fault.
-252-
DTC 631 TPS 1 Signal Voltage High Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF DST (Diagnostic Scan Tool) connected Does the DST display TPS 1 voltage of 4.8 volts or greater with the throttle closed
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever exceed 4.8 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• Key OFF • Disconnect TPS 1 electrical connector • Key ON Does DST display TPS 1 voltage less than 0.2 volts?
Go to Step (7)
Go to Step (5)
5
• • • •
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
Key OFF Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage between TPS 1 signal at the ECM connector pin 53 and engine ground
Do you have voltage? 6
• Replace ECM Is the replacement complete?
Go to Step (11)
-
7
•
Back probe sensor ground circuit at the ECM side of the wire harness pin 49 with a test light connected to battery voltage Does the test light come on?
Go to Step (8)
Go to Step (10)
8
•
Inspect the TPS 1 electrical connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (9)
9
• Replace TPS 1sensor Is the replacement complete?
Go to Step (11)
-
10
• • •
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM connector Using a DVOM check for continuity between the TPS 1 connector sensor ground pin B and ECM connector TPS 1 sensor ground pin 49 Do have continuity between them?
-253-
11
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-631 check for any stored codes. Does the engine operate normally with no stored codes?
-254-
System OK
Go to OBD System Check
-255-
DTC 632-TPS 1 Signal Voltage Low
TPS 1 A
LT GRN/RED
50
PPL/LT BLUE
C
53
Signal Sensor Ground
BLK/LT GRN
B
5 volts
49
ECM
Conditions for Setting the DTC Throttle Position Sensor #1 Check Condition-Cranking or Running Fault Condition-TPS sensor voltage less than 0.2 MIL-On during active fault Power Derate 1 Low rev limit 1300 rpm Forced idle 650 rpm
Circuit Description The Electronic Throttle has two counter acting Throttle Position Sensors. Two sensors are used for improved safety and redundancy. The Throttle Position sensor uses a variable resistor to determine signal voltage based on throttle plate position, and is located within the throttle. Less opening results in lower voltage, and greater opening in higher voltage. The TPS value is used by the ECM to determine if the throttle is opening as commanded. This fault will set if voltage is less than 0.2 volts at any operating condition while the engine is cranking or running. Power derate 1 will be enforced limiting the throttle to 50% maximum and low rev limit and forced idle will also be enforced during this fault.
-256-
DTC 632 TPS 1 Signal Voltage Low Step 1
Action Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 1 voltage of 0.2 volts or less with the throttle closed • Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever fall below 0.2 volts?
Go to Step (4)
• • •
Go to Step (7)
3
4
5
6 7
8 9
Key OFF Disconnect the TPS 1 electrical connector Jumper the 5 volt reference circuit pin A and TPS 1 signal circuit pin C together at the throttle connector • Key ON Does DST display TPS 1voltage of 4.0 volts or greater? • Key OFF • Disconnect ECM wire harness connector Using a DVOM check continuity between TPS 1 connector signal pin C and ECM connector TPS 1 signal pin 53 Do have continuity between them? • Replace ECM Is the replacement complete? • Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
• Replace the TPS 1 Is the replacement complete? • Remove all test equipment except the DST. • Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-632 check for any stored codes. Does the engine operate normally with no stored codes?
-257-
Value(s) -
Yes Go to Step (2)
Go to Step (4)
Go to Step (6 )
Go to Step (9)
No Go to OBD System Check Section Go to Step (3)
Intermittent problem Go to Intermittent section Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. -
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (9)
Go to Step (8)
System OK
Go to OBD System Check
-
DTC 633-TPS 2 Signal Voltage High
PNK/WHT 4
24
DBW +
Motor
1
TPS1
6
TAN/ORN
PPL/LT BLU
25
53
BLK/LT GRN 2
TPS2
49
LT BLU/DK BLU 5
3
54
LTGRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC Throttle Position Sensor #2 Check Condition-Cranking or Running Fault Condition-TPS 2 sensor exceeds 4.8 volts MIL-On during active fault Power Derate 1 Low rev limit 1300 rpm Forced idle 650 rpm
Circuit Description The Electronic Throttle has two counter acting Throttle position Sensors. Two sensors are used for improved safety and redundancy. The Throttle Position sensor (TPS2) uses a variable resistor to determine signal voltage based on throttle plate position, and is located within the throttle. Less opening results in higher voltage and greater opening in lower voltage. The TPS value is used by the ECM to determine if the throttle is opening as commanded. This fault will set if voltage is above 4.8 volts at any operating condition while the engine is cranking or running. Power derate 1 will be enforced limiting the throttle to 50% maximum. Low rev limit and forced idle will also be enforced during this fault.
-258-
DTC 633 TPS 2 Signal Voltage High Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 2 voltage of 4.8 volts or greater with the throttle closed
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever exceed 4.8 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• Key OFF • Disconnect electronic throttle connector • Key ON Does DST display TPS 2 voltage less than 0.2 volts?
Go to Step (7)
Go to Step (5)
5
• • • •
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between electronic throttle connector TPS 2 signal pin 5 and engine ground
Do you have voltage? 6
• Replace ECM Is the replacement complete?
Go to Step (11)
-
7
•
Back probe sensor ground circuit at the ECM side of the wire harness pin 49 with a test light connected to battery voltage Does the test light come on?
Go to Step (8)
Go to Step (10)
8
•
Inspect the electronic throttle wire harness connector and terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (9)
9
• Replace electronic throttle Is the replacement complete?
Go to Step (11)
10
• • •
Go to Step (6)
Key OFF Disconnect ECM connector Using a DVOM check for continuity between throttle connector sensor ground pin 2 and ECM connector sensor ground pin 49 Do have continuity between them?
-259-
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
11
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-633 check for any stored codes. Does the engine operate normally with no stored codes?
-260-
System OK
Go to OBD System Check
-261-
DTC 634-TPS 2 Signal Voltage Low
PNK/WHT 4
24
DBW +
Motor
1
TPS1
6
TAN/ORN
PPL/LT BLU
25
53
BLK/LT GRN 2
TPS2
49
LT BLU/DK BLU 5
3
54
LTGRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC Throttle Position Sensor #2 Check Condition-Cranking or Running Fault Condition-TPS 2 sensor voltage less than 0.2 MIL-On during active fault Power Derate 1 Low rev limit 1300 rpm Forced idle 650 rpm
Circuit Description The Electronic Throttle has two counter acting Throttle Position sensors. Two sensors are used for improved safety and redundancy. The Throttle Position Sensor (TPS2) uses a variable resistor to determine signal voltage based on throttle plate position, and is located within the throttle. Less opening results in higher voltage and greater opening in lower voltage. The TPS value is used by the ECM to determine if the throttle is opening as commanded. This fault will set if voltage is below 0.2 volts at any operating condition while the engine is cranking or running. Power derate 1 will be enforced limiting the throttle to 50% maximum. Low rev limit and forced idle will also be enforced during this fault.
-262-
DTC 634 TPS 2 Signal Voltage Low Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 2 voltage of 0.2 volts or less with the throttle closed
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever fall below 0.2 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• • •
Key OFF Disconnect electronic throttle connector Jumper the 5 volt reference circuit and TPS 2 signal circuit together at the throttle connector • Key ON Does DST display TPS 2 voltage of 4.0 volts or greater?
Go to Step (7)
Go to Step (5)
5
• Key OFF • Disconnect ECM wire harness connector Using a DVOM check continuity between TPS 2 connector signal and ECM connector TPS 2 signal terminals Do have continuity between them?
Go to Step (6 )
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
• Replace ECM Is the replacement complete?
Go to Step (9)
-
7
•
Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
• Replace throttle Is the replacement complete?
Go to Step (9)
-263-
Go to Step (8)
-
9
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-634 check for any stored codes. Does the engine operate normally with no stored codes?
-264-
System OK
Go to OBD System Check
-265-
DTC 635-TPS1 Higher Than TPS 2 PNK/WHT 4
24
DBW +
Motor
1
TPS1
6
TAN/ORN
PPL/LT BLU
25
53
BLK/LT GRN 2
TPS2
49
LT BLU/DK BLU 5
3
54
LTGRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC Throttle Position Sensor 1 & 2 Check Condition-Key On Fault Condition-TPS1 higher than TPS2 MIL-On for remainder of key on cycle Power Derate 1 Low rev limit 1300 rpm Forced idle 650 rpm
Circuit Description There are 2 Throttle Position Sensors located within the throttle which use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read low voltage when closed and TPS2 will read high voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if TPS1 is 20% (or more) higher than TPS2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. Power derate 1 will be enforced limiting the throttle to 50% maximum. Low rev limit and forced idle will also be enforced during this fault.
-266-
DTC 635 TPS 1 Higher Than TPS 2 Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • • •
Key OFF Disconnect wiring harness connector to throttle Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 and TPS 2 less than 0.1 volts?
Go to Step (5)
Go to Step (4)
4
• • • •
Key OFF Disconnect ECM wiring harness connector Key ON Using a DVOM check for voltage between TPS 1 or TPS 2 (the one that is over 0.1 volts) and engine ground Do you have voltage?
Repair the TPS 1 or TPS 2 circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (13)
5
•
Jumper TPS 1 and TPS 2 signal to the 5 volt reference at the throttle connector Does DST display TPS 1 and TPS 2 voltage over 4.95 volts
Go to Step (6)
Go to Step (8)
6
•
Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• Replace Throttle Is the replacement complete?
Go to Step (14)
-
8
• •
Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM wire harness connector from ECM • Using a DVOM check for continuity between throttle connector TPS 1 signal and ECM connector TPS 1 signal terminal Do you have continuity between them?
-267-
9
•
Using a DVOM check for continuity between throttle connector TPS 2 signal and ECM connector TPS 2 signal terminal Do you have continuity between them?
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
10
•
Using a DVOM check for continuity between throttle connector TPS 1 signal and engine ground Do you have continuity?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (11)
11
•
Using a DVOM check for continuity between throttle connector TPS 2 signal and engine ground Do you have continuity?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (12)
12
•
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
Go to Step (13)
13
• Replace ECM Is the replacement complete?
Go to Step (14)
-
14
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-635 check for any stored codes. Does the engine operate normally with no stored codes?
-268-
System OK
Go to OBD System Check
-269-
DTC 636-TPS1 Lower Than TPS2
PNK/WHT 4
24
DBW +
Motor
1
TPS1
6
TAN/ORN
PPL/LT BLU
25
53
BLK/LT GRN 2
TPS2
49
LT BLU/DK BLU 5
3
54
LTGRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC Throttle Position Sensor 1 & 2 Check Condition-Key On Fault Condition-TPS1 lower than TPS2 MIL-On for remainder of key on cycle Power Derate 1 Low rev limit 1300 rpm Forced idle 650 rpm
Circuit description There are 2 Throttle Position Sensors located within the throttle which use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read low voltage when closed and TPS2 will read high voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if TPS1 is 20% (or more) lower than TPS2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. Power derate 1 will be enforced limiting the throttle to 50% maximum. Low rev limit and forced idle will also be enforced during this fault.
-270-
DTC 636 TPS 1 Lower Than TPS 2 Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • • •
Key OFF Disconnect wiring harness connector to throttle Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 and TPS 2 less than 0.1 volts?
Go to Step (5)
Go to Step (4)
4
• • • •
Key OFF Disconnect ECM wiring harness connector Key ON Using a DVOM check for voltage between TPS 1 or TPS 2 (the one that is over 0.1 volts) and engine ground Do you have voltage?
Repair the TPS 1 or TPS 2 circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (13)
5
•
Jumper TPS 1 and TPS 2 signal to the 5 volt reference at the throttle connector Does DST display TPS 1 and TPS 2 voltage over 4.95 volts
Go to Step (6)
Go to Step (8)
6
•
Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• Replace Throttle Is the replacement complete?
Go to Step (14)
-
8
• •
Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM wire harness connector from ECM • Using a DVOM check for continuity between throttle connector TPS 1 signal and ECM connector TPS 1 signal terminal Do you have continuity between them?
-271-
9
•
Using a DVOM check for continuity between throttle connector TPS 2 signal and ECM connector TPS 2 signal terminal Do you have continuity between them?
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
10
•
Using a DVOM check for continuity between throttle connector TPS 1 signal and engine ground Do you have continuity?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (11)
11
•
Using a DVOM check for continuity between throttle connector TPS 2 signal and engine ground Do you have continuity?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (12)
12
•
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
Go to Step (13)
13
• Replace ECM Is the replacement complete?
Go to Step (14)
-
14
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-636 check for any stored codes. Does the engine operate normally with no stored codes?
-272-
System OK
Go to OBD System Check
-273-
DTC 637- Unable to Reach Higher TPS PNK/WHT 4
24
DBW +
Motor
TAN/ORN 1
TPS1
25 PPL/LT BLU
6
53
BLK/LT GRN 2
TPS2
49
LT BLU/DK BLU 5
3
54
LT GRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC Throttle Position Sensor Check Condition-Cranking or Running Fault Condition-Throttle command is 20% more than throttle position MIL-On during active fault Engine Shut Down
Circuit Description There are 2 Throttle Position Sensors located within the throttle which use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read low voltage when closed and TPS2 will read high voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if the throttle command is 20% or more than the actual throttle position. During this active fault the MIL light will turn on and the engine will shut down.
-274-
DTC 637 Throttle Unable to Open Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive By Wire) test mode • Depress Foot Pedal until theThrottle Command is 63%-68% Is the TPS voltage less than 2.0 volts?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • •
Key OFF Disconnect wire harness connector from throttle Probe TPS 1 signal circuit with test light connected to battery voltage • Key ON Is TPS voltage 4.0 volts or greater?
Go to Step (4)
Go to Step (8)
4
• Check throttle bore for foreign object Did you find a problem?
Go to Step (5)
Go to step (6)
5
• Remove the foreign object Has the object been removed?
Go to Step (11)
-
6
•
Check throttle connector terminals for damage corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• Replace throttle Is the replacement complete?
Go to Step (11)
-
8
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between throttle connector TPS 1 signal terminal and ECM TPS 1 signal terminal Do you have continuity between them?
Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
•
Using a DVOM check for continuity between throttle connector TPS 1 signal and engine ground Do you have continuity between them?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (10)
10
• Replace ECM Is the replacement complete?
Go to step (11)
-
-275-
11
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-637 check for any stored codes. Does the engine operate normally with no stored codes?
-276-
System OK
Go to OBD System Check
-277-
DTC 638-Throttle Unable To Close
PNK/WHT 4
24
DBW +
Motor
TAN/ORN 1
TPS1
25 PPL/LT BLU
6
53
BLK/LT GRN 2
TPS2
49
LT BLU/DK BLU 5
3
54
LT GRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC Throttle Position Sensor Check Condition-Cranking or Running Fault Condition-Throttle position is 20% greater than throttle command MIL-On during active fault Engine Shut Down
Circuit Description There are 2 Throttle Position Sensors located within the throttle which use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read low voltage when closed and TPS2 will read high voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if the throttle command is 20% less than the actual throttle position. During this active fault the MIL light will turn on and the engine will shut down.
-278-
DTC 638 Throttle Unable to Close Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive By Wire) test mode • Depress Foot Pedal until theThrottle Command is between 63%-68% Is the TPS 1 voltage greater than 2.0 volts?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • •
Key OFF Disconnect wire harness connector from throttle Probe TPS 1 signal circuit with test light connected to battery voltage • Key ON Does DST display TPS 1 voltage less than 0.2 volts
Go to Step (6)
Go to Step (4)
4
• • • •
Key OFF Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage between throttle connector signal terminal and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Replace ECM Is the replacement complete?
Go to Step (13)
-
6
•
Back probe sensor ground circuit at ECM connector with test light connected to battery voltage Does the test light come on?
Go to Step (9)
Go to Step (7)
7
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between throttle connector signal ground and ECM signal ground circuit terminals Do you have continuity between them?
Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
• •
Go to Step (13)
-
9
• Check throttle for foreign object in bore Did you find a foreign object in the bore?
Go to Step (10)
Go to Step (11)
10
• Remove foreign object Is the removal complete?
Go to Step (13)
-
11
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (12)
Replace ECM Is the replacement complete?
Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find the problem?
-279-
12
• Replace throttle Is the replacement complete?
13
• •
Go to Step (13)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-638 check for any stored codes. Does the engine operate normally with no stored codes?
-280-
System OK
Go to OBD System Check
-281-
DTC 651-Max Govern Speed Override
PNK/WHT 4
24
DBW +
Motor
TAN/ORN 1
25 PPL/LT BLU
TPS1
6
53
BLK/LT GRN 2
49
LT BLU/DK BLU
TPS2
5
3
54
LT GRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC
z z z z z z
Max Govern Speed Override Check Condition- Engine Running Fault Condition- Engine RPM greater than 3800 for 2 seconds continuously MIL- On during active fault Adaptive- Enabled Closed Loop- Enabled
Circuit description This fault will set anytime the engine RPM exceeds 3800 for 2 seconds or more continuously. This speed overrides any higher max governor speeds programmed by the user. This is to help prevent engine or equipment damage. The MIL will be on during this active fault.
-282-
DTC 651 Max Govern Speed Override Step
Action
Value(s)
Yes
No
-
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST in Active Fault Mode Are any other DTC codes present with DTC 651?
Go to Step (3)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired?
Go to step (4)
4
•
Check the Service Part Number on the ECM to ensure correct calibration is in use Is the Service Part Number Correct?
Go to Step (6)
5
• Replace ECM with correct Service Part Number Is the replacement complete?
Go to Step (9)
6
• Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK?
Go to Step (8)
7
•
Correct mechanical operation of the throttle. Refer to Engine & Component R&R Section 1E Has the mechanical operation of the throttle been corrected?
Go to step (9)
8
•
Go to Step (9)
Go to OBD System Check Section
9
• • •
System OK
Go to OBD System Check
Check engine for large manifold vacuum leaks. Refer to Fuel Systems Section 1B Symptom Diagnostics Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-651 check for any stored codes. Does the engine operate normally with no stored codes?
-283-
Go to Step (4)
-
Go to Step 5
Go to Step (7) -
DTC 652-Fuel Rev Limit
PNK/WHT 4
24
DBW +
Motor
TAN/ORN 1
25 PPL/LT BLU
TPS1
6
53
BLK/LT GRN 2
49
LT BLU/DK BLU
TPS2
5
3
54
LT GRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC z z z z z z
Fuel Rev Limit Check Condition- Engine Running Fault Condition- Engine RPM greater than 4000 for 2 seconds continuously MIL- On during active fault Adaptive- Enabled Closed Loop- Enabled
Circuit Description This fault will set anytime engine RPM exceeds 4000 for 2 seconds or more continuously. When these conditions are met, the ECM shuts off the fuel injectors. This is to help prevent engine or equipment damage. The MIL will be on during this active fault.
-284-
DTC 652 Fuel Rev Limit Step
Action
Value(s)
Yes
No
-
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST in Active Fault Mode Are any other DTC codes present with DTC 651?
Go to Step (3)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired?
Go to step (4)
4
•
Check the Service Part Number on the ECM to ensure correct calibration is in use Is the Service Part Number Correct?
Go to Step (6)
5
• Replace ECM with correct Service Part Number Is the replacement complete?
Go to Step (9)
6
• Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK?
Go to Step (8)
7
•
Correct mechanical operation of the throttle. Refer to Engine & Component R&R Section 1E Has the mechanical operation of the throttle been corrected?
Go to step (9)
8
•
Go to Step (9)
Go to OBD System Check Section
9
• • •
System OK
Go to OBD System Check
Check engine for large manifold vacuum leaks. Refer to Fuel Systems Section 1B Symptom Diagnostics Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-652 check for any stored codes. Does the engine operate normally with no stored codes?
-285-
Go to Step (4)
-
Go to Step 5
Go to Step (7) -
DTC 653-Spark Rev Limit
PNK/WHT 4
24
DBW +
Motor
TAN/ORN 1
25 PPL/LT BLU
TPS1
6
53
BLK/LT GRN 2
49
LT BLU/DK BLU
TPS2
5
3
54
LT GRN/RED
50
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 VOLTS
ECM
Conditions for Setting the DTC z z z z z z
Spark Rev Limit Check Condition- Engine running Fault Condition- Engine RPM greater than 4100 for 2 seconds continuously MIL- On during active fault Adaptive- Enabled Closed Loop- Enabled
Circuit description This fault will set anytime the engine RPM exceeds 4100 for 2 seconds or more continuously. When these conditions are met, the ECM will shut off spark to the engine. This is to help prevent engine or equipment damage. The MIL will be on during this active fault.
-286-
DTC 653 Spark Rev Limit Step
Action
Value(s)
Yes
No
-
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST in Active Fault Mode Are any other DTC codes present with DTC 651?
Go to Step (3)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired?
Go to step (4)
4
•
Check the Service Part Number on the ECM to ensure correct calibration is in use Is the Service Part Number Correct?
Go to Step (6)
5
• Replace ECM with correct Service Part Number Is the replacement complete?
Go to Step (9)
6
• Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK?
Go to Step (8)
7
•
Correct mechanical operation of the throttle. Refer to Engine & Component R&R Section 1E Has the mechanical operation of the throttle been corrected?
Go to step (9)
8
•
Go to Step (9)
Go to OBD System Check Section
9
• • •
System OK
Go to OBD System Check
Check engine for large manifold vacuum leaks. Refer to Fuel Systems Section 1B Symptom Diagnostics Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-653 check for any stored codes. Does the engine operate normally with no stored codes?
-287-
Go to Step (4)
-
Go to Step 5
Go to Step (7) -
DTC 721-Transmission Over Temperature
ECM + 5 volts CO20
C
DK BLU/YEL
36
Transmission Temperature Voltage
To Transmission Temperature Switch/Relay Circuit
Conditions for Setting the DTC Check Condition-Engine running Transmission Temperature High Fault Condition- closed circuit/voltage low MIL-On during active fault Power Derate 20% Engine Shut Down Circuit Description The transmission temperature switch is used to communicate a high temperature condition to the ECM. Transmission damage can occur if the transmission is operated at high temperature. The ECM uses an analog voltage input with an internal 5 volt reference. If the transmission temperature circuit is grounded, the input voltage will be near zero. If it is open the input will be near 5 volts. The temperature switch is normally open and should close at 122 C and remain closed until the temperature drops to 115 C. The fault will set if the switch becomes closed with the engine running for longer than 10 seconds. Power derate will be enforced to a maximum throttle position of 20%.
Diagnostic Aids Before performing any electrical diagnostics be sure to check the transmission fliud levels and cooling systems for proper operation. Also verify that the truck is being operated to the manufactures specifications in regards to load, speed and environmental conditions. Failure to follow this recommendation may result in a false DTC diagnosis.
-288-
DTC 721- Transmission Over Temperature Step Action 1 Did you perform the On Board (OBD) System Check?
2
Did you perform the Diagnostic Aids check for DTC 721?
• • •
3
•
4
Yes Go to Step (2)
Go to step (3)
Key Off Disconnect ECM connector C001 Disconnect transmission temperature switch connector CO20 Using a high impedance DVOM check for continuity between ECM pin 36 and engine ground
Do you have continuity? • Verify transmission relay lamp circuit is in proper working order and not shorted to ground. Is the transmission relay lamp circuit ok?
5
• Replace transmission temperature switch Is the replacement complete?
6
• • • • •
7
Value(s) -
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC 721 previously set. • Observe the MIL • Observe engine performance and drive ability • After operating the engine within the test parameters of DTC-721 check for any stored codes. Does the engine operate normally without setting DTC 721? • Replace the ECM Is the replacement complete?
-289-
Repair the shorted circuit to ground as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
No Go to OBD System Check Section Perform the Diagnostic Aids check for DTC 721 Go to Step (4)
Go to Step (6)
Repair the circuit as required. See chassis electrical system section. -
System OK
Go to Step (7)
Go to Step (8)
-
8
• • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC 721 previously set. • Observe the MIL • Observe engine performance and drive ability • After operating the engine within the test parameters of DTC-721 check for any stored codes. Does the engine operate normally with no stored codes?
-290-
System OK
Go to OBD System Check
SECTION 1E1
FUEL SYSTEM Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 Low Pressure Lock-Off (LPL) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 Pressure Trim Valve (PTV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 Low Pressure Regulator (LPR) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 Fuel Trim Valve (FTV) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295 Temperature Manifold Absolute Pressure (TMAP) . . . . . . . . . . . . . . . . . . . . . . . .295 Electronic Throttle Control Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . .296 Mixer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 FTV Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Coolant Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Vapor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 Balance Line Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 PTV Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 FTV Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . .299 Three Way Catalytic Converter Muffler Replacement . . . . . . . . . . . . . . . . . . . . . .299 Gasoline Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline MPFI Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Gasoline Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 Electronic Throttle Control Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . .300 Fuel Rail Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 Temperature Manifold Absolute Pressure Replacement . . . . . . . . . . . . . . . . . . .302 Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . .302
-291-
LPG REPAIR INSTRUCTIONS
INLET
Propane Fuel System Pressure Relief !
OUTLET
Figure 1 Fuel Filter
WARNING
The propane fuel system operates at pressures up to 21.5 BAR (312 psi). To minimize the risk of fire and personal injury, relieve the propane fuel system pressure (where applicable) before servicing the propane fuel system components.
Propane Fuel Filter Replacement (Figure 1) Removal Procedure 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
To relieve propane fuel system pressure: 1.
Close the manual shut-off valve (MSV) on the propane fuel tank.
2.
Disconnect the negative battery cable.
2.
Start and run the vehicle until the engine stalls.
3.
3.
Turn the ignition switch OFF.
Slow loosen the fuel inlet fitting to the filter and remove the line.
4.
Remove the outlet fitting from the filter
5.
Remove the filter and discard.
!
WARNING
Installation Procedure
Residual vapor pressure will be present in the fuel system. Ensure the work area is well ventilated before disconnecting any fuel line.
NOTE
Propane Fuel System Leak Test !
Be sure to install the filter in the correct direction of the flow. Do Not use Teflon tape on the pipe fittings use only a liquid pipe sealant
WARNING
Never use an open flame of any type to check for propane fuel system leaks. Always inspect the propane fuel system for leaks after performing service. Check for leaks at the fittings of the serviced or replaced component. Use a commercially available liquid leak detector or an electronic leak detector. When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector.
6.
Install the filter to the proper location and secure.
7.
Install the outlet fuel line and tighten to specification.
Tighten 27 N•m (20 ft lbs) 8.
Reconnect the negative battery cable
9.
Open manual shut-off valve.
10.
-292-
Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test.
Electric Lockoff to LPR Adapter Electric Lockoff
PTV Low Pressure Regulator
TMAP LPR Mounting Bracket
Electronic Throttle Control
FTV Mixer to Throttle Adapter
Mixer
Throttle Body to Manifold Adapter Manifold Gasket Adapter Seal
Figure 2 LPG Fuel System Installation Procedure
Low Pressure Lock-off (LPL) Replacement
NOTE
(Figure 2)
Do not use Teflon tape on any fuel fitting. Use a liquid pipe thread sealant when installing fittings.
Removal Procedure 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 2.
Disconnect the negative battery cable.
3.
Disconnect the LPL electrical connector.
4.
Disconnect the LPG fuel inlet line from the LPL inlet fitting.
5.
Unscrew the LPL from the LPR inlet fitting.
-293-
1.
Apply pipe thread sealant to the LPR inlet fitting.
2.
Install the LPL to the LPR. Tighten the LPL finger tight plus 1 to 2 turns and place the LPL in the correct position.
3.
Install the fuel inlet line.
4.
Tighten the fuel line fitting to the LPL
Tighten
Low Pressure Regulator (LPR) Replacement
27 N•m (20 ft lbs) 5.
Connect the LPL electrical connector.
6.
Connect the negative battery cable.
7.
Open the tank manual shut off valve.
8.
Start the vehicle and leak check the propane fuel system at each serviced fitting.
(Figure 2) Removal Procedure 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
Pressure Trim Valve (PTV) Replacement (Figure 2)
2.
Disconnect the negative battery cable.
3.
Clamp the coolant hoses to the LPR or drain the radiator.
4.
Remove the LPL. Refer to Low Pressure Lockoff Replacement.
5.
Remove the PTV Refer to Pressure Trim Valve Replacement.
6.
Disconnect the supply and return coolant lines from the LPR.
7.
Remove the retaining pin from the water inlet and outlet fittings and retain.
8.
Remove the coolant inlet and outlet fitting retaining pins and retain.
Removal Procedure 1. Disconnect the PTV electrical connection. 2.
Remove the vacuum hose from the PTV.
3.
Remove and retain the two (2) retaining bolts and plate.
4. Remove the PTV.
9. Remove the inlet fitting.
Installation Procedure
NOTE Apply a small amount of O-ring lubricant to the PTV O-ring before installation
10.
Remove the outlet fitting and retain.
11.
Disconnect the FTV supply line.
12.
Remove the two LPR mounting bolts and retain
13.
Lift LPR assembly and remove the two (2) LPR mounting bolts and retain.
14.
Loosen the fuel vapor hose clamp at the LPR fuel outlet fitting.
6.
Install the PTV using the two mounting bolts and retaining plate.
15.
Disconnect the fuel vapor hose from the LPR outlet fitting and remove the LPR.
7.
Tighten retaining bolts.
16.
Remove the retaining pin from the vapor outlet fitting and retain.
17.
Remove and retain the vapor outlet fitting from the LPR.
18.
Remove the LPR.
Tighten 9 N•m (80 lb-in) 8.
Connect the PTV vacuum line.
9. Connect the PTV electrical connector. 10.
Start the vehicle.
11.
Connect the diagnostic service tool and verify the engine is operating in closed loop and no MIL light is present.
Installation Procedure
NOTE Do not use Teflon tape on any fuel fitting. Use a liquid pipe thread sealant when installing fittings. Lubricate the O-ring of the PTV before installing into the LPR. -294-
Lubricate the O-rings on each of the fitting.
Installation Procedure
1. Install the inlet water fitting and secure with retaining pin. 2.
Install the outlet water fitting and secure with retaining pin.
3.
Install vapor outlet fitting and secure with retaining pin.
4.
Insert the vapor hose to the fuel outlet fitting and place clamp.
5.
Install the FTV supply line and secure
6.
Secure the LPR to the mounting bracket using the two (2) retaining bolts and tighten to specification.
NOTE Apply a small amount of O-ring lubricant to the PTV O-ring before installation 5.
Install FTV to throttle body.
6.
Install the two bolts.
7. Tighten retaining bolts .
Tighten 9 N•m (80 lb-in)
Tighten
8.
14 N•m (10 ft lbs)
Connect Fuel supply hose.
9. Connect electrical connection.
7.
Install the water inlet and outlet lines to the fittings and place clamps.
8.
Install the water inlet and outlet lines to the fittings and place clamps.
9.
Install LPL. Refer to Low Pressure Lock-off Replacement.
Temperature Manifold Absolute Pressure (TMAP)
Install the PTV. Refer to Pressure Trim Valve Replacement.
(Figure 2)
10. 11.
10.
Start the vehicle.
Tighten fuel line fitting.
Removal Procedure
Tighten 27 N•m (20 ft lbs)
1. Disconnect the TMAP electrical connector.
12.
Replace the drained coolant .
2.
Remove the one (1) retaining bolt.
13.
Start the vehicle and leak check the propane fuel system at each serviced fitting.
3.
Remove the TMAP.
Installation Procedure
Fuel Trim Valve (FTV) Solenoid
NOTE
Replacement (Figure 2)
Apply a small amount of O-ring lubricant to the PTV O-ring before installation.
Removal Procedure 1. Disconnect the FTV electrical connection.
4. Install the TMAP.
2.
Remove the fuel supply hose from the FTV.
5.
3.
Remove the two (2) retaining bolts and retain.
Tighten
4.
Remove the FTV.
7 N•m (62 lb-in) 6.
-295-
Install and tighten the one (1) retaining bolt.
Start the vehicle.
Tighten
Electronic Throttle Control Assembly Replacement
12 N•m (106 lb-in) 19.
(Figure 3)
Install the two (2) bolts and nuts from the FTV support bracket and retain.
Tighten 12 N•m (106 lb-in)
Removal Procedure
20.
Connect the fuel vapor hose and secure clamp.
Remove the air intake duct.
21.
Connect the balance line to the LPR.
Disconnect the electronic throttle control device electrical connector.
22. Connect the PTV vacuum line.
1.
Disconnect the negative battery cable.
2. 3.
23.
Connect both TPS electrical connectors.
24.
Connect the electronic throttle control electrical connector.
25.
Connect the FTV electrical connector.
7. Disconnect the balance line to the LPR.
26.
Connect the air inlet duct.
8.
Release mixer fuel inlet hose clamp and remove hose from mixer inlet.
27.
Start engine.
28.
9.
Remove the two (2) bolts and nuts from the FTV support bracket and retain.
Install the diagnostic tool and check for DTC codes and no MIL light.
4. Disconnect the FTV electrical connector. 5.
Disconnect the FTV supply line.
6.
Disconnect the PTV vacuum line.
10.
Remove the four (4) manifold adapter retaining bolts to electronic throttle control and retain bolts.
11.
Separate the mixer assembly from the electronic throttle control.
(Figure 2)
12.
Remove and discard the adapter O-ring and the mixer assembly sealing O-ring.
Removal Procedure
13.
Remove throttle body assembly.
Mixer Replacement
Installation Procedure
NOTE Lightly Lubricate both the O-rings of the throttle control device to adapter Cover throttle body adapter opening to prevent debris from entering engine until reassembly
1.
Disconnect the negative battery cable.
2.
Remove the air intake duct.
3.
Remove the throttle body assembly Refer to Electronic Throttle Control Assembly Replacement.
4.
Remove the four (4) screws from the FTV adapter to the mixer and retain.
5.
Remove and discard the FTV adapter to the mixer O-ring.
Installation Procedure
14.
Install O-ring to the top of the electronic throttle control assembly.
15.
Install the O-ring to the manifold adapter.
16.
Insert electronic throttle control assembly into the bottom of the mixer assembly.
Lightly lubricate the O-ring of the mixer to throttle body assembly O-ring before installing.
17.
Install the electronic throttle control to the manifold adapter and secure.
Cover throttle body adapter opening to prevent debris from entering engine until reassembly.
18.
Tighten the four screws to specification.
NOTE
-296-
6. 7.
Tighten
Install FTV adapter to the mixer O-ring onto the adapter.
9 N•m (80 lb-in)
Install the mixer to the FTV adapter assembly and secure with the 4 retaining screw.
Tighten
10.
Install FTV adapter to the mixer O-ring onto the adapter.
11.
Install the mixer to the FTV adapter assembly and secure with the 4 retaining screw.
9 N•m (80 lb-in) 8. 9.
Tighten
Install throttle body Refer to Electronic Throttle Control Device Replacement.
9 N•m (80 lb-in)
Connect the air inlet duct.
10.
Start engine.
11.
Install the diagnostic tool and check for DTC codes and no MIL light.
12.
Install Throttle body Refer to Electronic Throttle Control Device Replacement.
13.
Connect the air inlet duct.
14.
Start engine.
15.
Install the diagnostic tool and check for DTC codes and no MIL light.
FTV Adapter Replacement Coolant Hose Replacement (Figure 2) Removal Procedure Removal Procedure
1.
Drain coolant.
2.
Using a hose clamp pliers disconnect both hose clamps on each hose.
3.
Remove the coolant inlet hose form each fitting.
1.
Disconnect the negative battery cable.
2.
Remove the air intake duct.
3.
Remove the throttle body assembly Refer to Electronic Throttle Control Assembly Replacement.
4.
Remove the four (4) screws from the FTV adapter to the mixer and retain.
5.
Remove and discard the FTV adapter to the mixer O-ring.
NOTE
6.
Remove the two (2) FTV retaining bolts and retain the bolts and the FTV.
Coolant hose are specifically designed, DO NOT use hose material or length other than the OEM specified parts
4. Remove the coolant outlet hose.
Installation Procedure
Installation Procedure
DO NOT mix the inlet or outlet hoses when reinstalling
NOTE Lightly Lubricate the O-ring of the Mixer to throttle body assembly O-ring before installing . Cover Throttle body adapter opening to prevent debris from entering engine until reassembly.
1.
Install hose clamps and set back on each hose.
2.
Reinstall the coolant inlet hose to each fitting.
3.
Reinstall the coolant outlet hose to each fitting.
4. Reset clamps.
9. Install the FTV to the adapter using the two (2) retaining bolts and secure.
-297-
5.
Refill with coolant.
6.
Start engine and check for coolant leaks.
9.
Vapor Hose Replacement Removal Procedure 1.
Using a hose clamp pliers disconnect both hose clamps .
2.
Remove the vapor hose form each fitting.
Vapor supply hose is specifically designed, DO NOT use hose material or length other than the OEM specified parts
4.
Reinstall the vapor hose to each fitting.
5.
Reset clamps.
6.
Start engine and check for leaks.
Reinstall the small hose section and set clamps.
11.
Start engine and check for leaks.
Removal Procedure
NOTE
Install hose clamps and set back on each hose.
10.
PTV Hose Replacement
Installation Procedure
3.
1.
Using a hose clamp pliers disconnect the clamps on the hose fitting at the mixer.
2.
Using a small screw driver push locking clip back on PTV connection.
3.
Remove the hose and discard.
Installation Procedure
NOTE PTV hoses are specifically designed, DO NOT use hose material or length other than the OEM specified parts
Balance Line Hose Replacement Removal Procedure
4.
Install hose clamps and set back on the mixer hose end.
5.
Reinstall hose at the PTV and push lock in place.
6.
Reinstall hose at the mixer and set clamp.
1. Remove the clamp to the fitting at the mixer. 2.
Remove small hose to check valve.
3.
Remove and retain check valve.
4. Remove the one (1) hose routing retaining bolt and retain. 5.
Install Check valve and set clamp (Directional part arrow pointing to mixer).
7. Start engine and check for leaks.
Remove clamp at the LPR connection.
FTV Hose Replacement
Installation Procedure
Removal Procedure
NOTE Balance line hoses are specifically designed, DO NOT use hose material or length other than the OEM specified parts.
1.
Using a small screw driver push locking clips back on FTV connection at FTV and LPR.
2.
Remove the hose and discard.
Installation Procedure
DO NOT mix the hoses when reinstalling. Install check valve in correct direction (Arrow on check valve pointing toward mixer). 7.
Install hose clamps and set back on each hose.
8.
Reinstall the LPR hose end to the LPR fitting and set clamp.
NOTE FTV hoses are specifically designed, DO NOT use hose material or length other than the OEM specified parts
-298-
4.Install O-2 sensor
Engine Control Module Replacement
Tighten 41 N•m (30 lb-ft) 5.
Start engine.
1. Disconnect Negative battery cable.
6.
Check for any DTC codes and clear.
2.
Remove controller from mounting bracket.
7.
3.
Push connector lock back to unlock connector.
Verify engine is in closed loop and no MIL lights are present.
Removal Procedure
4. Unplug controller and remove.
Three Way Catalytic Converter Muffler Replacement
Installation Procedure
Removal Procedure
NOTE
1. Remove the TWC muffler using the OEM end product processes
Controller is calibrated for each engine verify you have the correct controller 5.
Installation Procedure
Plug connector into controller.
NOTE
6. Push lock into place. 7.
Mount controller into mounting bracket.
8.
Reconnect the battery cable.
The Three Way Catalytic converter is specifically designed to meet the emission control of the certified engine. Use only the OEM specified parts
9. Install Diagnostic service tool. 10.
Start engine.
11.
Check for any DTC codes and clear.
12.
Verify engine is in closed loop and no MIL lights are present.
Heated Exhaust Gas Oxygen Sensor Replacement
2.
Install the TWC muffler using the OEM end product processes.
3.
Start engine.
4. Check for any DTC codes and clear 5.
Verify engine is in closed loop and no MIL lights are present.
Removal Procedure
GASOLINE REPAIR INSTRUCTIONS
1. Disconnect Negative battery cable. 2.
Disconnect the O-2 sensor electrical connector.
3.
Using a O-2 Sensor socket remove the O-2 Sensor and discard.
Gasoline MPFI Fuel System Pressure Relief
Installation Procedure !
WARNING
NOTE The fuel system operates at pressures up to 414 kPa (60 psi). To minimize the risk of fire and personal injury, relieve the Gasoline fuel system pressure (where applicable) before servicing the propane fuel system components.
Before installing the O-2 sensor, lubricate threads with anti-seize compound GM P/N 5613695 or equivalent. Avoid getting compound on the sensor tip. -299-
To relieve Gasoline fuel system pressure: 1.
Disconnect the electrical connector at the fuel pump.
2.
Start and run the vehicle until the engine stalls.
3.
Turn the ignition switch OFF.
Electronic Throttle Control Assembly Replacement (Figure 3)
4. Remove the Cap on the gasoline pressure test port. 5.
Removal Procedure
Wrap a shop towel around the fitting and using a small screw driver depress valve and insure there is no pressure left in the system.
!
Disconnect the negative battery cable.
2.
Remove the air intake duct.
3.
Disconnect the electronic throttle control electrical connection.
WARNING
4. Remove the four (4) manifold adapter to electronic throttle control assembly bolts and retain bolts.
Residual vapor pressure will be present in the fuel system. Ensure the work area is well ventilated before disconnecting any fuel line.
Gasoline Fuel System Leak Test !
1.
5.
Remove the O-ring gasket, discard O-ring.
6.
Remove the throttle body assembly.
Installation Procedure
WARNING
NOTE
Never use an open flame of any type to check for propane fuel system leaks.
Lightly Lubricate the both the O-rings of the throttle control device to TBI assembly.
Always inspect the gasoline fuel system for leaks after performing service. Check for leaks at the fittings of the serviced or replaced component.
Cover Throttle body adapter opening to prevent debris from entering engine until reassembly. 7. Install the O-ring onto the manifold adapter. 8.
Install the electronic throttle control assembly and secure with the four (4) bolts. Tighten 12 N•m (106 lb-in)
9. Connect both electronic throttle control assembly electrical connections.
Figure 3 Electronic Throttle Body -300-
10.
Connect the air inlet duct.
11.
Connect the negative battery cable.
12.
Start engine.
13.
Install diagnostic tool and check for DTC codes or MIL lights.
and press down to set the rails.
Pressure Test Port 11.
Install the six (6) injector retaining clips.
12.
Secure the fuel rail to the manifold with the four (4) retaining bolts. Tighten 12 N•m (106 lb-in)
Pressure Regulator
Fuel Rail Assy
Figure 4 Fuel Rail Assembly
Fuel Rail Replacement (Figure 4) Removal Procedure
13.
Connect the vacuum line to the pressure regulator.
14.
Connect the fuel return line.
15.
Connect the fuel supply line.
16.
Install the electronic throttle control assembly Refer to Electronic Throttle Control Assembly Replacement.
17.
Install the air duct.
18.
Connect the negative battery cable.
19.
Start engine.
20.
Install diagnostic tool and check for DTC codes or MIL lights.
1.
Disconnect the negative battery cable.
2.
Disconnect the air duct.
3.
Remove the electronic throttle control assembly Refer to Electronic Throttle Control Assembly Replacement.
4.
Disconnect the fuel supply line to the rail assembly.
1.
Disconnect the negative battery cable.
5.
Disconnect the fuel return line to the rail assembly.
2.
Relieve the fuel system pressure. Refer to Gasoline Fuel System Pressure Relief.
6.
Disconnect the vacuum line to the Pressure regulator.
3.
Remove the fuel rail assembly Refer to Fuel Rail Replacement.
7.
Remove the four (4) fuel rail retaining bolts to the manifold and retain.
8.
With a screw driver press back on the six (6) injector retaining clips and retain.
9.
Carefully lift the fuel rail off the injectors.
Injector Replacement Removal Procedure
4. Disconnect the six (6) injector electrical connections. 5.
Remove each injector.
Installation Procedure
Installation Procedure
NOTE Apply a small amount of O-ring lubricant to the injector O-rings before installation.
NOTE Lightly Lubricate the O-ring of the throttle body assembly and the inlet O-ring on each injector.
Lightly Lubricate the O-ring of the throttle body assembly and the inlet O-ring on each injector.
Cover Throttle body adapter opening and injectors to prevent debris from entering engine or the injectors until reassembly.
Cover Throttle body adapter opening and injectors to prevent debris from entering engine or the injectors until reassembly.
10.
6.
Carefully place the fuel rail over all the injector -301-
Install the injectors.
7.
Connect the injector electrical connectors.
8.
Reinstall the fuel rail assembly Refer to Fuel Rail Replacement.
9.
Start engine and check for leaks.
10.
Installation Procedure
NOTE
Install diagnostic service tool and verify engine is operating closed loop and no MIL light is present.
Controller is calibrated for each engine verify you have the correct controller. 5.
Temperature Manifold Absolute Pressure Replacement
6. Push lock into place. 7. Mount controller into mounting bracket. 8.
Removal Procedure 1. Disconnect the TMAP electrical connection. Remove the one (1) retaining bolt and retain.
3.
Remove the TMAP.
Reconnect the battery cable.
9. Install Diagnostic service tool.
(Figure 2) 2.
Plug connector into controller.
10.
Start engine.
11.
Check for any DTC codes and clear.
12.
Verify engine is in closed loop and no MIL lights are present.
Installation Procedure
Heated Exhaust Gas Oxygen Sensor Replacement
NOTE Apply a small amount of lubricant to the TMAP O-ring
Removal Procedure 1. Disconnect Negative battery cable.
4.
Install TMAP.
5.
Secure using the two (2) retaining bolt. Tighten 6 N•m (54 in lbs)
6.
Connect the TMAP electrical connector.
Disconnect the O-2 sensor electrical connector.
3.
Using a O-2 Sensor socket remove the O-2 Sensor and discard.
Installation Procedure
7. Start engine. 8.
2.
Install diagnostic service tool and check for DTC codes and MIL lights.
NOTE Before install the O-2 sensor lubricate threads with anti-seize compound GM P/N 5613695 or equivalent. Avoid getting compound on the sensor tip
Engine Control Module Replacement
4.
Removal Procedure
Tighten 41 N•m (30 lb-ft)
1. Disconnect Negative battery cable. 2.
Remove controller from mounting bracket.
3.
Push connector lock back to unlock connector.
Install O-2 sensor.
4. Unplug controller and remove.
-302-
5.
Start engine.
6.
Check for any DTC codes and clear.
7.
Verify engine is in closed loop and no MIL lights are present.
TECHNICAL PUBLICATIONS FEEDBACK
(Please Print)
Dealer Name: Address: City: Zip Code:
Submitted By: P.O. Box: State: Country:
The following discrepancy or omission has been discovered in:
❏ Operation & Maintenance Manual
❏ Option Bulletin
❏ Part List/Manual
❏ Special Instructions
❏ Service Manual
❏ Service Data Manual
❏ Electronic Manual
❏ Other
Publication #
Engine Model #
Truck model #
Issue date #
Truck serial #
Page #
(Please Print)
Explanation of discrepancy or omission:
(Please fax or mail completed form to): Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2121 W. Sam Houston Parkway N. Houston, Texas 77043-2305 Fax: 713-365-1616
Mitsubishi Caterpillar Forklift Europe B.V. Attn: Service Engineering P.O Box 30171 1303 AC, Almere, The Netherlands Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Service Engineering No. 2 Tuas Avenue 20 Singapore 638818 Republic of Singapore Fax: 65-861-9277
Cat Lift Trucks
Service Manual
GM 4.3L and G6 Fuel System Supplement
99789-84111
®
Lift Trucks
Service Manual GM 4.3L, G6 Gasoline Engine 003103-up
For use with the GC35K-GC70K; GP40-GP50; GP40K-GP50K Chassis Service Manuals.
99789-84120
FOREWORD This service manual covers the GM 4.3L Gasoline Engine installed in CAT® Lift Trucks and gives detailed maintenance and repair information. For your convenience the instructions are grouped by systems as a ready reference. The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what you will learn from this service manual. Read the respective sections of this manual carefully and familiarize yourself with all the components before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are for engines with serial numbers in effect at the time of printing. CAT Lift Trucks reserves the right to change specifications or design without notice and without incurring obligation. Whenever a question arises regarding this engine, or this manual, consult your Cat lift truck dealer for the latest available information. For items pertaining to the chassis, refer to the Chassis Service Manual. This service manual covers the fuel system for units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
Notes, Cautions, and Warnings NOTES, CAUTIONS, and WARNINGS are used in this manual to emphasize important and critical instructions. They are used for the following conditions:
NOTE
To highlight an essential operating procedure or condition.
! CAUTION
!
Operating procedures or practices that will result in damage to or destruction of the engine if not strictly observed.
WARNING
Operating procedures or practices that will result in serious injury or loss of life if not correctly followed.
-I-
How to Read This Manual Scope of Explanation This book describes the service procedures for the engine removed from a vehicle. For procedures concerning the removal of the engine from the vehicle and on-vehicle inspection and servicing, refer to the appropriate service manuals separately prepared for the individual models. Maintenance and Servicing Procedures (1) A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts. (2) The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures; the symbol N indicates a non- reusable part; the tightening torque is provided wher e applicable.
• Removal Steps: The part designation number corresponds to the number in the illustration to indicate removal steps. • Installation Steps: Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. • Disassembly Steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps. • Reassembly Steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps.
Classification of Major Maintenance/Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail.
A
Indicates there are essential points for removal or disassembly.
B
Indicates there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and application of sealants and adhesives is provided, by using symbols, in the diagram of component parts, or on the page following the component parts page, and explained.
Grease (multi-purpose grease unless there is a brand or type specified) Sealant or adhesive Brake fluid, automatic transmission fluid or air conditioner compressor oil Engine oil or gear oil
Inspecting Only the inspections to be performed by using special tools or measuring instruments are covered. General service procedures not covered in this manual, such as visual inspections and cleaning of parts should always be performed during actual service operations.
-II-
Removal and Installation
➧A ➧
Removal steps 1. Plug 2. Nut 3. Bolt 4. Pan 5. Gasket 6. Bolt 7. Pin 8. Pump 9. Retainer 10. Shaft 11. Bolt 12. Pin 13. Cover 14. Screen
Unit: kgf-m (lb-ft) [N-m] *kgf-m (lb-in.) [N-m] 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Plug Valve Spring Filter Fitting Valve Bolt Adapter - Oil Filter Gasket Connector Gasket
23
N
22
N
25 20 19
24 T = 2.08 (15) [20]
Denotes nonreusable part.
21
18
10
9 Lubricate all internal parts with engine oil during
7
8 T = 9.14 (66) [90]
6 17
14
16 15
13
INSTALLATION OR REMOVAL SERVICE POINTS
➧A ➧ Install the oil pump screen.
12 T = 1.22 (106) [12]
• If removed, replace the oil pump screen. The oil pump screen must have a good press fit into the oil pump body. • Mount the oil pump in a soft jawed vise. • Apply sealer to the end of the pipe. • Use the (J 21882) and a soft-faced hammer to tap the oil pump screen into the pump body. The screen must align parallel with the bottom of the oil pan when it is installed.
11 5
N
Denotes tightening torque.
4 1
2 3
T = 2.49 (18) [25]
T = 2.49 (18) [25]
J 21882
Operating procedures, cautions, etc., on removal, installation, disassembly and reassembly are described.
This alphabetical letter corresponds to a part that is indentified in the drawing on the first page of each section. The letter appears during an explanation of removal, installation, disassembly or reassembly steps.
-III-
T = 2.49 (18) [25]
!
WARNING
!
The OPERATION & MAINTENANCE MANUAL outlines the proper and safe lubrication and maintenance for the truck, as recommended by Cat Lift Trucks.
WARNING
Do not operate this truck unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper truck operation is dangerous and could result in injury or death.
Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance. Improperly performed lubrication or maintenance procedures are dangerous and could result in injury or death.
5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, use ladders, scaffolds, or work platforms to perform safe repair operations. 6. To reduce the risk of back injury, use hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To reduce the risk of burns, be alert for hot parts on trucks which have just been stopped and have hot fluids in lines, tubes and compartments. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure before completely removing the last two bolts or nuts. 9. Be careful when removing filler caps, breather and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot. 10. Always use tools that are in good condition and understand how to correctly use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts. 12. If possible, make all repairs with the truck parked on a level, hard surface. Block the truck so it does not roll while working on or under it. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on the truck. Hang “Do Not Operate” tag in the Operator’s Compartment.
Because the service mechanic may be unfamiliar with many of the systems on this truck it is important to use caution when performing service work. Knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the truck components, the service mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions, cautions and notices that should always be observed. 1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the part or system. 2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welder's gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on truck. 3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly. 4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.
-IV-
!
WARNING
14. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operations. Do not reinstall damaged wiring. Reinstall the wiring so it will not be damaged in operation by contacting sharp corners, or by rubbing against an object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices, including guards and shields, are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. 17. When the mast needs to be in the raised position during maintenance and repairs, always support the mast and carriage to keep the carriage or attachments raised. 18. Loose or damaged fuel, lubricant and hydraulic lines, or tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones that are bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible upon close inspection of the hose. This oil can penetrate the skin and cause serious injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields must be correctly installed if they protect against oil spray onto hot exhaust components in the event of a line, tube, or seal failure. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly. Be alert for possible pressure when disconnecting any device from a system that uses pressure. 21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
!
WARNING
22. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. If dust containing asbestos is present, there are several common sense guidelines that should be followed. a. Never use compressed air for cleaning. b. Avoid brushing or grinding asbestos containing materials. c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. d. Use exhaust ventilation on permanent machining jobs. e Wear an approved respirator if there is no other way to control the dust. f. Comply with applicable rules and regulations for the work place. g. Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air.
-V-
Precautions
• • • •
Precautions for Disassembly and Assembly This section contains basic safety precautions and outlines basic recommended procedures, some of which require special tools, devices or work methods. However, the safety precautions contained herein are not for all service work. It is the responsibility of service personnel to know that specific requirements, precautions and work hazards exist and to discuss these with a foreman or supervisor.
Replacing Engine Gaskets Gasket Reuse and Applying Sealant • Do not reuse any gasket unless specified. • Gaskets that can be reused will be identified in the service procedure. • Do not apply sealant to any gasket or sealing surface unless specified in the service procedure. Separating Components • Use a rubber mallet in order to separate the components. • Bump the part sideways in order to loosen the components. • Bumping of the component should be done at bends or reinforced areas of the component to prevent distortion of the components. Cleaning Gasket Surfaces • Use care to avoid gouging or scraping the sealing surfaces. • Use a plastic or wood scraper in order to remove all the sealant from the components. • Do not use any other method or technique to remove the sealant or the gasket material from a part. • Do not use abrasive pads, sand paper or power tools to clean the gasket surfaces. • These methods of cleaning can cause damage to the component sealing surfaces. • Abrasive pads also produce a fine grit that the oil filter cannot remove from the engine oil. This fine grit is abrasive and can cause internal engine damage.
Disassembly 1. Always use tools that are in good condition. Understand how to use them before performing any service work. 2. Use an overhaul stand or a work bench, if necessary. Also, use bins to keep engine parts in order of removal. 3. Lay down the disassembled and cleaned parts in the order in which they were removed to save time for assembly. 4. Pay attention to marks on assemblies, components and parts for their positions or directions. If necessary, add marks to aid in assembly. 5. During removal or cleaning, carefully check each part for any sign of faulty condition. Signs of wear or abnormalities that caused the engine to work abnormally are more easily and accurately spotted during removal or cleaning. 6. Get help when lifting or carrying a part that is too heavy or awkward for one person to handle. If necessary, use a jack or a hoist.
Separating Parts Important: Many internal engine components will develop specific wear patterns on their friction surfaces. When disassembling the engine, internal components MUST be separated, marked and organized in a way to ensure reinstallation to the original location and position. Mark or identify the following components: • Piston and the piston pin • Piston to the specific cylinder bore • Piston rings to the specific cylinder bore • Connecting rod to the crankshaft journal • Connecting rod to connecting rod cap • Crankshaft bearings and connecting rod bearings • Engine camshaft and valve lifters • Valve lifters, valve rocker arms and valve rocker arm supports
Valve to valve guide Valve spring to cylinder head location Engine block bearing cap location and direction Oil pump drive and driven gears
Service Prior to Assembly • Dirt will cause premature wear of the rebuilt engine. Clean all the component. • Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer’s specification must be repaired or replaced. • When the components are re-installed into an engine, return the components to the original location, position and direction. • During assembly, lubricate all the moving parts with clean engine oil (unless otherwise specified). The engine oil will provide the initial lubrication when the engine is first started.
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Tools and Equipment
Assembling Components • Assemble components using only the sealant (or equivalent) that is specified in the service procedure. • Sealing surfaces must be clean and free of debris or oil. • Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly. • Components requiring lubrication will be identified in the service procedure. • Apply only the amount of sealant specified in the service procedure to a component. • Do not allow the sealant to enter into any blind threaded holes, as the sealant may prevent the fastener from clamping properly or cause component damage when tightened. • Tighten fasteners to the proper specifications. DO NOT overtighten the fasteners.
Special tools are listed and illustrated throughout this manual. The tools (or equivalents) are specially designed to quickly and safely accomplish the operations for which the tools are intended. The use of special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners. To properly service the engine assembly, the following items should be readily available: • Approved eye protection and safety gloves • A clean, well-lit, work area • A suitable parts cleaning tank • A compressed air supply • Trays or storage containers to keep parts and fasteners organized • An adequate set of hand tools • Approved engine repair stand • An approved engine lifting device that will adequately support the weight of the components
Assembly Cleanliness and Care This engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. Care and cleanliness are important when any internal engine parts are serviced. During assembly, a liberal coating of engine oil should be applied to friction areas to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of truck surfaces and friction areas are part of the repair procedure. This is considered standard shop practice, even if not specifically stated. When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surface as when removed. 1. Wash all parts, except for oil seals, O-rings, rubber sheets, etc., with cleaning solvent and dry them with air pressure. 2. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 3. Use only good-quality lubricants. Be sure to apply a coat of oil, grease or sealant to parts as specified. 4. Be sure to use a torque wrench to tighten parts for which torques are specified. 5. Replace gaskets and packings with new ones.
-VII-
General Precautions Removal and Disassembly Confirm the location of the faulty part and find the probable cause of the trouble. Then decide whether removal or disassembly is required. If so, carry out the removal or disassembly according to the steps shown in this service manual. To prevent erroneous installation and to facilitate installation work, punch or draw alignment marks in places where neither function nor appearance is affected. Make a distinction between the items removed from one assembly and those removed from another assembly, especially when disassembling a unit having a large number of component parts or when disassembling two or more similar parts. Always do the following: 1. Keep the removed parts in order. 2. Make a distinction between the parts to be replaced and the parts to be reused. 3. When replacing bolts and nuts, use only ones of the specified size. Special Tools When specified, be sure to use the special tools for the specific service work. Using other tools may cause damage to parts and/or injury to workers. Non-reusable Parts Whenever any of the following parts are removed, be sure to replace them with new ones. 1. Oil seals 2. Gaskets (except rocker cover gasket) 3. Packings 4. O-rings 5. Lock washers 6. Split pins Recommended Replacement Parts 1. For replacement parts, use only genuine Cat parts. 2. Use of the available sets and kits of service parts is recommended. 3. To unify parts, or for other reasons, service parts are subject to change. When replacing parts in the engine, carefully check for possible modifications by referring to the updated parts catalog for the specific engine. Genuine Cat Parts
-VIII-
Handling of Electrical System Shocks are harmful to sensors and relays. Never drop or throw them.
When disconnecting a connector, do not pull the harness. Hold the halves of the connector to separate them from each other.
When disconnecting a lock type connector, push the lock lever(s) in the direction(s) shown by the arrow(s).
When connecting a lock type connector, push the plug into the socket until it clicks.
-IX-
Handling of Rubber Hoses and Tubes Take care not to spill gasoline or oil on rubber hoses or tubes, otherwise the rubber is likely to deteriorate.
Greasing During assembly or installation, coat the designated surfaces with the specified grease or oil.
Cooperation When two or more persons work together, each worker should pay attention to the safety of the other(s).
-X-
TABLE OF CONTENTS Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I How to Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI Precautions for Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
Determining When to Overhaul the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine Specifications - Gas and LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Major Nuts and Bolts Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealers, Adhesives, and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of RTV and Anaerobic Sealer (Gasket Eliminator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 13 14 16
Base Engine Misfire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Train Diagnosis (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 17 18 19
Valve Train Diagnosis (Noise Diagnosis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Oil Consumption Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low or No Oil Pressure Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing the Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 22 22 23 25
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Intake Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Intake Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Oil Level Indicator and Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold and Heat Shields Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold and Heat Shields Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Level Indicator and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 34 34 35 35
Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Valve Rocker Arm Cover Removal (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Rocker Arm Cover Removal (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Rocker Arm and Push Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Lifter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal and Valve Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Reaming/Valve and Seat Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal and Valve Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Rocker Arm and Push Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Rocker Arm Cover Left Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Rocker Arm Cover Right Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-XI-
38 38 39 41 42 43 45 46 48 49 50 51 53 54 55
TABLE OF CONTENTS Oil Pan, Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Oil Oil Oil Oil Oil Oil Oil Oil
Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Adapter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Adapter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58 59 60 60 62 63 64 65
Front Cover, Timing Chain, and Crankshaft Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Engine Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Front Cover Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain and Sprockets Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Balancer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Balancer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain and Sprockets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Front Cover Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Front Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68 68 68 70 71 72 73 73
Balancer and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Balance Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Bearings Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balance Shaft and Bearing Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balance Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78 80 80 82 83 84 85 86
Crankshaft, Flywheel, Rear Seal, and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Engine Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Crankshaft Rear Oil Seal and Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Crankshaft and Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Crankshaft and Bearings Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Service Prior to Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Crankshaft and Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Bearing Clearance Measuring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Micrometer Method for Crankshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Crankshaft Rear Oil Seal and Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Engine Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Engine Block Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Boring and Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reboring the Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 110 111 112 113
Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Piston, Connecting Rod, and Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rod and Bearings Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Connecting Rod and Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118 119 119 122 123 124
Gasoline Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Carburetor Assembly (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Assembly (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Horn Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-XII-
129 131 132 132
TABLE OF CONTENTS Carburetor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Horn Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137 138 140 144 147 148
Electrical Throttle and Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU Input/Output Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
149 150 151 152 152
GM 4.3L, G6 Engine ECU Error Code Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Ignition System and Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Ignition System - Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Distributor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Distributor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Distributor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Coil Installation and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Ignition Sensing Coil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Distributor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Alternator and V-Belt (Units built before 01/01/2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Accessory Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Starter Motor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Fuel System - Gasoline (Units built before 01/01/2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Fuel Pump and Fuel Hose (Units built before 01/01/2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Fuel Pump Disassembly and Reassembly (Units built before 01/01/2004) . . . . . . . . . . . . . . . . . . . . 177 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Main Point of Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Fuel System - LP (Units built before 01/01/2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Vacuum Fuel Lockoff Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Model J Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Pressure Regulator / Converter Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 On-Truck Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Regulator / Converter Disassembly, Inspection, Cleaning, and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Regulator / Converter Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Pressure / Converter Regulator Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Regulator/Lockout - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Impco CA 100 Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 LPG Carburetor Adjustment Procedure-co/exhaust Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Governor Speed Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Accelerator Cable Adjustment - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
-XIII-
Determining When to Overhaul the Engine
Engine Set-Up and Testing After overhaul, the engine must be tested before it is installed in the truck. If a suitable test stand is not available, the following procedures can be used after the engine is installed in the truck.
Deciding when to overhaul the engine is determined by considering the following factors:
1. Fill the crankcase with the proper quantity and grade of engine oil.
A drop in compression pressure as well as an increase in lube oil consumption and excessive blowby.
Notice: DO NOT use cooling system seal tabs (or similar compounds) unless otherwise instructed. The use of cooling system seal tabs (or similar compounds) may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly.
Lack of power, increase in fuel consumption, drop in lube oil pressure, hard starting and abnormal sound are also engine troubles. These troubles, however, are not always the result of low compression pressure and give no valid reason for overhauling the engine.
2. Fill the cooling system with the proper quantity and grade of coolant. 3. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding. 4. Start the engine and listen for unusual noises. 5. Check the truck oil pressure gauge or light and confirm that the engine has acceptable oil pressure. If necessary, install an oil pressure gauge and measure the engine oil pressure. 6. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature. 7. Listen for improperly adjusted or sticking valves, sticking valve lifters or other unusual noises. 8. Inspect for oil and/or coolant leaks while the engine is operating. 9. Verify that the distributor is properly positioned. 10. Perform a final inspection for the proper engine oil and coolant levels.
The engine develops troubles of widely different varieties when its compression pressure drops. Following are the list of typical troubles caused by this compression pressure fault. 1. 2. 3. 4.
Lack of power Increase in fuel consumption Increase in lube oil consumption Excessive blowby through breather due to worn cylinders, pistons, etc. 5. Excessive blowby due to poor seating of worn inlet and exhaust valves 6. Hard starting 7. Abnormal sound In most cases, these troubles occur concurrently. Some of them are directly caused by low compression pressure, but others are not. Among the troubles listed above, 1, 2, and 6 could be caused by low compression pressure. The most valid reason for overhauling the engine is (4). To determine when to overhaul the engine, it is reasonable to take this trouble into consideration in conjunction with the other troubles.
-1-
Engine Replacement
7. Support engine using appropriate sling and hoist. Use existing lifting eyes. 8. Disconnect the fuel line and fuel line clamp. 9. Remove the starter. Refer to Engine Electrical. 10. Disconnect the torque convertor bolts from the flywheel. 11. Support the transmission with a jack. 12. Remove the transmission to engine bolts. 13. Remove the front engine mount bolts. 14. Remove the distributor. 15. Use the engine lifting device to remove the engine from the truck.
Removal Procedure
NOTE If the engine is damaged internally and a new engine assembly is installed in the truck, ensure that all foreign material is flushed out of the cooling system. It is also necessary to flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage. 1. Disconnect battery. 2. Raise the truck and support with stands. 3. Drain fluids. a. Remove the oil pan drain plug, and allow oil to drain. b. Remove the oil filter. c. Remove both coolant drain plugs and allow coolant to drain. 4. Remove the engine hood and overhead guard. 5. Disconnect the exhaust pipe from the exhaust manifolds. 6. Disconnect the following items: • The wiring harnesses • The throttle cable • The fuel lines
Installation Procedure
NOTE If the engine is damaged internally and a new engine assembly is installed in the truck, ensure that all foreign material is flushed out of the cooling system. It is also necessary to flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage. 1. Use the engine lifting device to lower the engine into place. 2. Install the engine into the truck. 3. Install the front engine mounts. 4. Install the distributor. 5. Install the following items: • The wiring harnesses • The vacuum lines • The throttle cable • The fuel lines 6. Install torque convertor to flywheel bolts. 7. Install the transmission to engine bolts. 8. Install the oil filter. 9. Install the pump drive shaft. 10. Install the starter. Refer to Engine Electrical. 11. Connect the fuel line and fuel line clamp. 12. Connect the exhaust pipe to the exhaust manifolds. 13. Lower the truck. 14. Fill the crankcase with oil. 15. Fill radiator with coolant. 16. Connect battery. 17. Install engine hood and overhead guard.
-2-
Description and Operation
Piston and Connecting Rod Assemblies The cast aluminum pistons use two compression rings and one oil control assembly. The piston is a low friction, lightweight design with a flat top and barrel shaped skirt. The piston pins are offset 0.9 mm (0.0354 in) toward the major thrust side (right side) to reduce piston slap as the connecting rod travels from one side of the piston to the other side after a stroke. The piston pins have a floating fit in the piston and are retained by a press fit in the connecting rod. The connecting rods are forged steel. The connecting rods are machined with the rod cap installed for proper clearances and alignments.
Engine Component Description Balance Shaft The cast iron balance shaft is mounted in the crankcase above and in-line with the camshaft. A camshaft gear drives the gear attached to the balance shaft. The front end of the balance shaft is supported by a ball-type bearing. The rear end of the balance shaft uses a sleeve-type bearing. Camshaft The steel camshaft is supported by four bearings pressed into the engine block. The camshaft timing chain sprocket mounted to the front of the camshaft is driven by the crankshaft sprocket through a camshaft timing chain.
Valve Train Motion is transmitted from the camshaft through the hydraulic roller valve lifters and the tubular valve pushrods to the roller type valve rocker arms. The roller type valve rocker arm pivots on a needle type bearing in order to open the valve. The valve rocker arms for each bank of cylinders are mounted to a one piece valve rocker arm support. Each valve rocker arm is retained on the valve rocker arm support and the cylinder head by a bolt. The hydraulic valve lifters keep all the parts of the valve train in constant contact. Each hydraulic valve lifter acts as an automatic adjuster and maintains zero lash in the valve train. This eliminates the need for periodic valve adjustment.
Crankshaft The cast nodular iron crankshaft is supported by four crankshaft bearings. The number four crankshaft bearing at the rear of the engine is the end thrust bearing. The crankshaft bearings are retained by bearing caps that are machined with the engine block for proper alignment and clearances. The crankshaft position sensor reluctor ring has three lugs used for crankshaft timing and is constructed of powdered metal. The crankshaft position sensor reluctor ring has a slight interference fit onto the crankshaft and an internal keyway for correct positioning.
Drive Belt System Description The drive belt system consists of the following components: • The drive belt • The drive belt tensioner • The drive belt idler pulley • The crankshaft balancer pulley • The accessory drive component mounting brackets • The accessory drive components — The power steering pump, if belt driven — The generator — The engine cooling fan, if belt driven — The water pump, if belt driven — The vacuum pump, if belt driven
Cylinder Heads The cast iron cylinder heads have one intake and one exhaust valve for each cylinder. A spark plug is located between the valves in the side of the cylinder head. The valve guides and seats are integral to the cylinder head. The 4.3L, G6 heavy duty applications have pressed in exhaust valve seats. The valve rocker arms are positioned on the valve rocker arm supports and retained by a bolt. Engine Block The cast iron engine block has six cylinders arranged in a V shape with three cylinders in each bank. Starting at the front side of the engine block, the cylinders in the left bank are numbered 1-3-5 and cylinders in the right bank are numbered 2-4-6 (when viewed from the rear). The firing order of the cylinders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets. Exhaust Manifolds The cast iron exhaust manifolds direct exhaust gases from the combustion chambers to the exhaust system. Intake Manifold The intake manifold is cast aluminum.
-3-
The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the truck is not equipped with the accessory.
Torque Values and / or Fastener Tightening Strategies • Cylinder head bolts, the crankshaft bearing cap bolts, the connecting rod bolts and balance shaft bolt apply a torque angle strategy. In an on-truck situation where a torque angle meter may not fit into the truck packaging, a three step tightening process may be followed using a torque wrench. • Certain fasteners should not be reused. Bolts, studs or other fasteners that must be replaced will be called out in the specific service procedures. Changed Engine Specifications Engine mechanical specifications remain the same as the 1999 products. New Sealants and / or Adhesives No new sealants or adhesives have been added. Disassembly and Assembly Procedure Revisions • Valve rocker arm and pushrod • Timing chain and sprockets • Discard all used gaskets, seals or O-ring seals unless otherwise indicated. Gaskets, seals or O-ring seals that can be reused will be identified in the specific service procedure.
New Product Information The purpose of New Product Information is to highlight or indicate important product changes from the previous model year. Changes may include one or more of the following items: • A component comparison from the previous year • Fastener changes • Torque values and/or fastener tightening strategies • Changed engine specifications • New sealants and/or adhesives • Disassembly and assembly procedure revisions • Engine mechanical diagnostic procedure revisions • New special tools required Component Comparison • Eliminated the oil filter adapter assembly • Revised the water pump seal • Revised the engine coolant thermostat • New roller type timing chain and sprockets • New roller pivot type valve rocker arm assemblies using a one piece valve rocker arm support to replace the ball pivot type valve rocker arm system • Cylinder heads revised using dry holes for the valve rocker arm bolts
Engine Mechanical Diagnostic Procedure Revisions • Valve Train diagnostic information is now provided in table form. Potential or probable causes are supplied for each specific concern. • Engine Noise diagnostic information is now provided in table form. Potential or probable causes are supplied for each specific concern. New Special Tools Required No special tools are required.
-4-
Engine Identification • The Truck Identification Number (VIN) Derivative is located on the left side rear of the engine block (1) or on the right side rear (2) and typically is a nine digit number stamped or laser etched onto the engine at the truck assembly plant. — The first digit identifies the division. — The second digit identifies the model year. — The third digit identifies the assembly plant. — The fourth through ninth digits are the last six digits of the Truck Identification Number (VIN).
569359
• Engines built at the Tonawanda engine plant have the engine identification number located at the right front top of the engine block. — The first digit (1) is the source code. — The second and third digits (2) are the month of the build. — The forth and fifth digits (3) are the date of the build. — The sixth, seventh and eighth digits (4) are the broadcast code.
195338
• Engines built at the Romulus engine plant have the engine identification number located at the right front top of the engine block. — The first digit (1) is the source code. — The second and third digits (2) are the month of the build. — The forth digit (3) is the hour of the build. — The fifth and sixth digits (4) are the date of the build. — The seventh, eighth and ninth digits (5) are the broadcast code.
195339
-5-
Specifications Engine Specifications - Gas and LP-Gas
Application
Specification METRIC
ENGLISH
Engine Engine Model
GM 4.3L, G6
Manufacturer
General Motors
Type
Gasoline / LPG
Cooling System
Water Cooled
No. of Cylinders - Arrangement
6 - 90° V
No. of Stroke
4
Type of Combustion Chamber
Semi - Spherical
Valve Arrangement
Overhead
Type of Cylinder Liner
Integral
Cylinder Bore x Stroke, mm (in) Displacement, cc (cu in)
101.6x88.39
4.00x3.48
4293
262
Compression Ratio
9.2:1
Rated Output, PS/rpm
94 / 2450
Rated Torque, kgf -m/rpm
31.0
1200
Min. rpm
750 ± 50
Max. rpm
2650-2700
Dimensions (LxWxH), mm (in)
710x620x740 (28x24.5x29)
Weight, kg (lbs)
26
572
Installation Position
Rear
Ignition
Spark
Firing Order
1-6-5-4-3-2
Initial Ignition Timing BTDC deg
0° Gasoline, 8° L.P.G.
Rotation (View From Pulley)
CW
Voltage for Electric System
12 V
-6-
Specifications Engine Specifications - Gas and LP-Gas, continued
Application
Specification METRIC
Ignition System Ignition Coil -
Distributor
-
HEI or EST Type
Mold
Manufacturer
AC Delco
Type
Pointless
Manufacturer
AC Delco
Type of Spark Advance Control Spark Plug -
Internal Solid State Circuit
Model
AC R44LTS
Manufacturer
AC Delco
Size, mm (in)
14
0.55
Gap, mm (in)
.889
.035
Fuel System
GAS / LP
Carburetor/ Mixer-Type
IFZ / CA100
Manufacturer Governor -
AISAN Kogyo Co. / IMPCO
Type
Electronic / Pneumatic
Manufacturer Fuel Pump -
ENGLISH
Mitsubishi Heavy Industries / AISAN Kogyo Co.
Type
Electromagnetic
Manufacturer
Jidosha Kiki
Engine Lubrication System Type
Pressure Feed
Oil Pump
Gear Pump
Oil Filter
Paper Element
Oil Cooler
Oil to Water Type
Refill Capacity, Liter (Quart) Oil Pan
4.0 (4.2)
Oil Filter and Cooler
0.7 (0.8)
Total
4.7 (5.0)
-7-
Specifications Engine Specifications - Gas and LP-Gas, continued Application
Specification
Cooling System Type Complete Engine Refill Capacity, Liter (Quarts) Water Pump Thermostat Type/ Opening Temp° F Alternator Type Manufacturer Rated Output, V - A Regulator Starter Type Manufacturer Voltage - Output, V - kW
Forced Circulation 18.2 (4.84) Centrifugal Type, V - Belt Driven Wax Type / 180 3 - Phase AC MANDO 12 - 50 Built in IC Type Electromagnetic Delco Remy 12 V - 0.75
Engine Mechanical Specifications
-8-
Engine Mechanical Specifications,
continued
-9-
Engine Mechanical Specifications,
continued
-10-
Major Nuts and Bolts Tightening Torque
Torque Item
Remarks kgf-m N-m
Balance Shaft Retainer Plate Bolts Balance Shaft Driven Gear Bolt (First Pass) Balance Shaft Driven Gear Bolt (Final Pass) Belt Idler Pulley Bolt Camshaft Retainer Bolt Camshaft Sprocket Bolt Connecting Rod Nut (First Pass) Connecting Rod Nut (Final Pass) Crankshaft Balancer Bolt Crankshaft Bearing Cap (Preferred Method) Crankshaft Pulley Bolt First Pass Final Pass Crankshaft Position Sensor Bolt Crankshaft Rear Oil Seal Housing Nut and Bolt Crankshaft Rear Oil Seal Housing Stud Cylinder Head Bolts (First Pass in Sequence) Cylinder Head Bolts (Long Bolts Final Pass in Sequence) Cylinder Head Bolts (Medium Bolts Final Pass in Sequence) Cylinder Head Bolts (Short Bolts Final Pass in Sequence) Cylinder Head Core Hole Plug Distributor Cap Bolt Distributor Clamp Bolt Drive Belt Tensioner Bolt EGR Valve Bolt (First Pass) EGR Valve Bolt (Final Pass) EGR Valve Inlet Pipe Clamp Bolt EGR Valve Inlet Pipe Nut at Exhaust Manifold EGR Valve Inlet Pipe Nut at Intake Manifold Engine Block Coolant Drain Plug Engine Block Left Rear Oil Gallery Plug Engine Block Oil Gallery Plugs (Left Side, Right Rear) Engine Coolant Heater Bolt/Screw Engine Coolant Temperature (ECT) Sensor Engine Flywheel Bolt Engine Front Cover Bolt Engine Front Lift Bracket Bolt Engine Mount Bracket Bolt to Engine Engine Mount Bracket Nut to Engine Mount Bracket Bolt-Through-bolt Engine Oil Pressure Gauge Sensor Exhaust Manifold Bolts and Stud (First Pass) Exhaust Manifold Bolts and Stud (Final Pass) Front Lift Bracket Stud
NOTE
1.22 2.08 5.09 1.22 2.49 2.77 9.67 5.91 2.08 .81 1.22 .61 3.05
2.08 .24 2.49 5.09 .71 3.05 2.49 3.05 2.49 2.08 3.05 2.08 0.20 2.08 10.25 1.22 1.52 5.11 6.93 3.05 1.52 3.05 3.59
lb•in
12 — 20 15 35 degrees 50 37 12 — 25 18 27 20 70 degrees 95 70
106 —
58 43 20 15 73 degrees 9 — 12 — 6 — 30 22 75 degrees 65 degrees 55 degrees 20 15 2 — 25 18 50 37 7 — 30 22 25 18 30 22 25 18 20 15 30 22 20 15 2 — 20 15 100 74 12 — 15 11 54 40 68 50 30 22 15 11 30 22 35 26
—
Important: Unless otherwise noted all torques are dry.
-11-
lb•ft
— 106 — — —
80 106 53 —
— 21 — — 62 — — — — — — — 18 — — 106 — — — — — — —
Major Nuts and Bolts Tightening Torque,
continued
Torque Item
Remarks kgf-m N-m
Ignition Coil Stud Intake Manifold Bolt (First Pass) Intake Manifold Bolt (Second Pass) Intake Manifold Bolt (Final Pass) Knock Sensor Oil Fill Tube Lower Support Bolt and Stud Oil Fill Tube Nut Oil Fill Tube to Oil Fill Tube Lower Support Bolt Oil Filter Adapter Bolts Oil Filter Fitting Oil Level Indicator Tube Bolt Oil Level Indicator Tube to Oil Fill Tube Lower Support Bolt Oil Pan Baffle Bolt Oil Pan Bolts (Tighten in Sequence) Oil Pan Nuts (Tighten in Sequence) Oil Pan Drain Plug Oil Pan Skid Plate Bolt Oil Pressure Fittings (Plus Necessary Alignment) Oil Pressure Sensor and Switch Oil Pump Bolt-to-Rear Crankshaft Bearing Cap Oil Pump Cover Bolts Spark Plug Wire Support Bolt Spark Plugs (New Cylinder Head) Spark Plugs (All Subsequent Installations) Valve Lifter Guide Retainer Bolt Valve Lifter Push Rod Guide Bolt Valve Rocker Arm Ball Stud Valve Rocker Arm Bolt Valve Rocker Arm Cover Bolts Valve Rocker Arm Nut Water Outlet Stud Water Pump Bolts Water Pump Pulley Bolts
NOTE
1.22 .31 1.22 1.52 2.49 2.49 1.22 0.50 2.08 5.60 1.22 0.50 1.22 2.49 2.49 2.49 2.08 1.52 3.05 9.14 1.22 1.22 3.05 1.52 1.66 1.66 4.85 3.05 1.22 2.49 2.49 4.56 2.49
12 3 12 15 25 25 12 5 20 55 12 5 12 25 25 25 20 15 30 90 12 12 30 15 16 16 47 30 12 25 25 45 25
Important: Unless otherwise noted all torques are dry.
-12-
lb•ft — — — 11 18 18 — — 15 41 — — — 18 18 18 15 11 22 66 — — 22 11 12 12 35 22 — 18 18 33 18
lb•in 106 27 106 — — — 106 44 — — 106 44 106 — — — — — — — 106 106 — — — — — — 106 — — — —
Sealers, Adhesives and Lubricants Application Balancer Shaft Driven Gear Bolt Camshaft Retainer Bolt Crankshaft Balancer Keyway Cylinder Head Bolt Engine Block to Crankshaft Rear Oil Seal Housing Junction at the Oil Pan Sealing Surfaces Engine Block to Engine Front Cover Junction at the Oil Pan Sealing Surfaces Engine Block at the Lower Intake Manifold Sealing Surfaces Engine Block Coolant Drain Hole Plug Engine Block Oil Gallery Plug Engine Coolant Temperature (ECT) Gauge Sensor Engine Oil Engine Oil Pressure Sensor Engine Oil Pressure Sensor Fitting Engine Oil Supplement Exhaust Manifold Bolt/ Stud Expansion Cup Plug (Balance Shaft Rear Bearing Hole) Expansion Cup Plug (Camshaft Rear Bearing Hole) Lower Intake Manifold Bolt Oil Level Indicator Tube Oil Pump Screen Tube Valve Rocker Arm Stud Valve Train Component Prelube Water Pump Bolt
Type of Material Threadlock Threadlock Adhesive Sealant Adhesive
GM Part Number 12345382 12345382 12346141 12346004 12346141
MCFA Part Number A000006061 A000006061 A000000165 2I4256 A000000165
Adhesive
12346141
A000000165
Adhesive
12346141
A000000165
Sealant Sealant Sealant SAE 5W30 Oil Sealant Sealant Lubricant Threadlock Sealant Sealant Threadlock Sealant Sealant Threadlock Lubricant Sealant
12346004 12346004 12346004 12345610 5QT 12346004 12346004 1052367 12345382 12346004 12346004 12345382 12346004 12346004 12345493 12345501 12346004
2I4263 2I4263 2I4263 2I4263 2I4263 A000006061 2I4263 2I4263 A000006061 2I4263 2I4263 2I4256 2I4263
Form-In-Place Gasket (FIPG) The engine has several places where the form-in-place gasket (FIPG) is in use. To ensure the gasket is fully sealed, use the following precautions when applying the FIPG: 1. It is absolutely necessary to apply the sealant in the right amount, evenly and without a break. 2. Bead size, continuity, and location are crucial to a good seal. Too thin a bead causes leakage. Too thick a bead can be squeezed out of location and cause blockage or narrowing in the fluid feed line.
NOTE
Since the FIPG used in the engine hardens as it reacts with moisture in the air, it is normally used in the metallic flange area.
Disassembly The parts assembled with the FIPG can be easily disassembled. Break the seal by striking it with a mallet or by inserting a flat, thin gasket scraper and hammering it through the joint. Use caution to prevent damage to the joined parts.
Surface Preparation Use a gasket scraper or wire brush to thoroughly remove all surface oil and dirt from all gasket application surfaces. Completely remove any old FIPG still remaining in the bolt holes. All application surfaces must be flat.
Form-In-Place Gasket Application Apply the FIPG in a smooth, continuous bead without any breaks. Also cover the bolt hole circumference with an even, continuous bead. Wipe away any excess and mount the parts while the FIPG is still wet (15 minutes or less). Check the mounted parts and wipe away any excess sealant.
-13-
Use of RTV and Anaerobic Sealer
• Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.
Sealant Types Important: The correct sealant and amount of sealant must be used in the proper location to prevent oil leaks, coolant leaks or the loosening of the fasteners. DO NOT interchange the sealants. Use only the sealant (or equivalent) as specified in the service procedure. The following 2 major types of sealant are commonly used in engines: • Aerobic sealant [Room Temperature Vulcanizing (RTV)] • Anaerobic sealant, which include the following: — Gasket eliminator — Pipe — Threadlock
Anaerobic Type Gasket Eliminator Sealant Anaerobic type gasket eliminator sealant cures in the absence of air. This type of sealant is used where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no sealant or gasket is readily;y noticeable, then the 2 parts were probably assembled using an anaerobic type gasket eliminator sealant. Use the following information when using gasket eliminator sealant: • Always follow all the safety recommendations and directions that are on the gasket eliminator sealant container. • Apply a continuous bead of gasket eliminator sealant to one flange. The surfaces to be sealed must be clean and dry. Important: Do not allow the gasket eliminator sealant to enter any blind threaded holes, as the gasket eliminator sealant may prevent the fasteners from clamping properly, seating properly or cause damage when the fastener is tightened. Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket eliminator sealant on the sealing surface. Important: Gasket eliminator sealed joint fasteners that are partially torqued and the gasket eliminator sealant allowed to cure more than 5 minutes, may result in incorrect shimming and sealing of the joint. • Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners. • After properly tightening the fasteners, remove the excess gasket eliminator sealant from the outside of the joint.
Aerobic Type Room Temperature Vulcanizing (RTV) Sealant Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type of sealant is used where 2 components (such as the intake manifold and the engine block) are assembled together. Use the following information when using RTV sealant: • Do not use RTV sealant in areas where extreme temperatures are expected. These areas include: — The exhaust manifold — The head gasket — Any other surface where a different type of sealant is specified in the service procedure • Always follow all the safety recommendations and the directions that are on the RTV sealant container. • Use a plastic or wood scraper in order to remove all the RTV sealant from the components. Important: Do not allow the RTV sealant to enter any blind threaded holes, as it may prevent the fasteners from clamping properly or cause damage when the fastener is tightened. The surfaces to be sealed must be clean and dry. • Use a RTV sealant bead size as specified in the service procedure. • Apply the RTV sealant bead to the inside of any bolt hole areas. • Assemble the components while the RTV sealant is still wet to the touch (within 3 minutes). Do not wait for the RTV sealant to skin over.
Anaerobic Type Threadlock Sealant Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for threadlocking and sealing of bolts, fittings, nuts and studs. This type of sealant cures only when confined between 2 close fitting metal surfaces. Use the following information when using threadlock sealant: • Always follow all safety recommendations and directions that are on the threadlock sealant container. • The threaded surfaces must be clean and dry. • Apply the threadlock sealant as specified on the threadlock sealant container.
-14-
Important: Fasteners that are partially torqued and then the threadlock sealant allowed to cure more than five minutes, may result in incorrect clamp load of assembled components. Tighten the fasteners in sequence (if specified) and to the proper torque specification. DO NOT overtighten the fasteners. Anaerobic Type Pipe Sealant Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type of sealant is used where 2 parts are assembled together and require a leak proof joint. Use the following information when using pipe sealant: • Do not use pipe sealant in areas where extreme temperatures are expected. These areas include: — The exhaust manifold — The head gasket — Surfaces where a different sealant is specified • Always follow all the safety recommendations and the directions that are on the pipe sealant container. • The surfaces to be sealed must be clean and dry. • Use a pipe sealant bead of the size or quantity as specified in the service procedure. Important: Do not allow the pipe sealant to enter any blind threaded holes, as the pipe sealant may prevent the fasteners from clamping properly or cause component damage when the fastener is tightened. • Apply the pipe sealant bead to the inside of any bolt hole areas. • Apply a continuous bead of pipe sealant to 1 sealing surface. • Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO NOT overtighten the fasteners.
-15-
Diagnostic Information and Procedures Base Engine Misfire Diagnosis The following diagnosis information covers common problems and possible causes. When the proper diagnosis is made, the problem should be corrected by adjustment, repair or part replacement, as required. Refer to the appropriate section of the manual for these procedures. This diagnostic table will assist in engine misfire diagnosis due to a mechanical problem such as a faulty camshaft or leaking headgasket. It is assumed that the base engine timing is correct and the acceptable fuel is being used. The Gasoline engine is equipped with an ECU Diagnostics tester. See Engine Diagnostics Tester section.
-16-
Diagnostic Information and Procedures,
continued
Engine Compression Test
• Piston Rings Leaking- Compression low on first stroke. Tends to build up on the subsequent strokes but does not reach normal. Improves considerably with addition of oil. • Valves Leaking- Compression low on first stroke. Does not tend to build up on the subsequent strokes. Does not improve much with addition of oil. Use approximately three squirts of oil from a plunger type oiler. • If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the two cylinders. 5. Install the removed parts. 6. Connect the disconnected components.
1. Engine should be at room temperature. a. Disconnect the Battery terminal and the terminal connector from the distributor. b. Remove the spark plugs. c. Block the throttle body plate wide open. d. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes (four puffs). 3. The lowest reading cylinder should not be less than 70% of the highest cylinder. No cylinder reading should be less than 689 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kpa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kpa (105 psi). 1035x70%=725 (150x70%=105). 4. If some cylinders have low compression, inject approximately 15 ml (one tablespoon) of engine oil into the combustion chamber through the spark plug hole. • Normal - Compression on each cylinder builds up quickly and evenly to specified compression.
-17-
Engine Noise Diagnosis
-18-
Valve Train Diagnosis
Diagnostic Table
-19-
Diagnostic Table, continued
-20-
Valve Train Diagnosis,
continued
-21-
Oil Leak Diagnosis
-22-
Oil Leak Diagnosis, continued
-23-
Drive Belt Tensioner Diagnosis
-24-
Engine Lubrication
44610
Full pressure lubrication, through a full-flow oil filter, is supplied by a gear-type oil pump. Oil is drawn up through the oil pump screen and passes through the pump to the oil filter. The oil filter is a full-flow paper element unit with an anti-drain back valve. An oil filter bypass valve is used to ensure adequate oil supply in the event the filter becomes plugged or develops excessive pressure drop. Filtered oil flows into the main gallery and then to the camshaft,
balance shaft, rear bearing, and crankshaft bearings. The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the valve lifters through the hollow valve pushrods to the valve rocker arms. Oil drains back to the crankcase through the oil drain holes in the cylinder head. The camshaft timing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oil splash.
-25-
-26-
Lower Engine View 1
Legend (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Oil Level Indicator Tube Bolt Oil Level Indicator Oil Level Indicator Tube Engine Oil Pressure Sensor Fitting Balance Shaft Bearing (Rear) Knock Sensor Expansion Cup (Balance Shaft Rear Bearing Hole) Engine Block Rear Oil Gallery Plug Expansion Cup Plug (Camshaft Rear Bearing Hole) Engine Block Dowel Straight Pin (Transmission Locator) Left Side Oil Gallery Plug Oil Filter Adapter Gasket Oil Filter Adapter Seal (O-ring) Oil Filter Adapter (Typical) Oil Filter Adapter Bolt Oil Filter Oil Filter Fitting Oil Filter Adapter Bolt Oil Filter Bypass Valve Engine Coolant Drain Hole Plug Engine Block Core Hole Plug Dowel Pin (Cylinder Head Locator) Water Pump Gasket
-27-
(25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48)
Water Pump Water Pump Bolt Front Oil Gallery Plug Camshaft Bearings Engine Camshaft Camshaft Retainer Camshaft Retainer Bolt Balance Shaft Drive Gear Camshaft Sprocket Camshaft Timing Chain Camshaft Sprocket Bolt Balance Shaft Gear Bolt Balance Shaft Driven Gear Balance Shaft Retainer Bolt Balance Shaft Retainer Balance Shaft Piston Ring Set Piston Piston Pin Connecting Rod Bolt Connecting Rod Connecting Rod Bearings Connecting Rod Cap Hex Nut
-28-
Intake Manifold Removal and Installation
Torque Specifications First pass: .31 kgf•m (27 lb•in) [3 N•m] Second pass: 1.22 kgf•m (106 lb•in) [12 N•m] Third pass: 1.52 kgf•m (11 lb•ft) [15 N•m]
N
Removal steps
➧B➧ ➧A ➧
1. 2. 3. 4. 5.
N
Cover - Thermostat Gasket Thermostat Manifold Gasket
-29-
Intake Manifold Removal
9. Remove the intake manifold.
NOTE Important: Make sure the ends of the fuel system lines are properly sealed. Do not allow dirt or debris to enter the fuel system. 1. Drain the engine coolant. 2. Remove the distributor clamp and bolt. 3. Remove the distributor.
31510
10. Remove and discard the intake manifold
Intake Manifold Clean and Inspect 1. Clean the intake manifold in cleaning solvent. 2. Dry the intake manifold with compressed air. 3. Inspect the intake manifold for the following: • Damage to the gasket sealing surfaces (1), (2) • Restricted exhaust gas recirculation system passages • Restricted cooling system passages (3) • Cracks or damage
34403
4. 5. 6. 7. 8.
Remove Remove Remove Remove Remove
the air inlet duct. the throttle linkage. the ignition coil. PCV valve and vacuum hoses. the intake manifold bolts.
NOTE Important: The intake manifold may be removed as an assembly. Do not remove the intake manifold components unless component service is required.
480570
-30-
➧A
3. Apply a 5 mm (0.197 in.) bead of sealant MCF P/N A000000165 (GM P/N 12346141) or equivalent to the front and rear top of the engine block intake mounting surface. a. Extend the sealant bead 13 mm (0.50 in.) onto the intake manifold gasket. Front and rear of the engine block.
Intake Manifold Installation
NOTE Important: Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly. 1. Apply a 4.0 mm (0.157 in.) patch of adhesive patch of sealant P/N A000000165 (GM 12346141) or equivalent to the cylinder head side of the lower intake manifold gasket at each end front top of the engine block.
NOTE Important: The intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch. 2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins to properly seat the intake manifold gasket on the cylinder head.
b. Install the intake manifold on to engine block. c. Apply threadlock (GM P/N 12345382) or equivalent to the threads of the intake manifold bolts. 4. Install the intake manifold bolts in sequence and torque in the 3 step method.
NOTE Note: Care must be used to apply the correct amount of sealant onto the gaskets. Applying excessive amounts of sealant may prohibit the intake gaskets from sealing properly.
31510
-31-
NOTE Important: Proper manifold fastener tightening sequence and torque are critical. Always follow the tightening sequence and torque the intake manifold bolts using the three (3) step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. 5. Tighten the manifold bolts as shown below. 1st pass .31 Kgf•cm (27 lbf.in) [3 N•m] Tightening torque 2nd pass for intake 1.22 Kgf•cm (106 lbf.in) [12 N•m] manifold Final pass 1.52 Kgf•cm (11 lbf.ft) [15 N•m]
-32-
Exhaust Manifold Removal and Installation
Torque Specifications: First pass: 1.52 kgf•m (11 lb•ft) [15 N•m] Final pass: 3.05 kgf•m (22 lb•ft) [30 N•m]
1
New
2 6 4 5
Removal steps
➧A➧ ➧B ➧
1. 2. 3. 4. 5. 6.
Gauge - Oil Tube - Level Gage Shield - Exhaust Shield - Spark Plug Shield - Spark Plug Manifolds - Exhaust
-33-
3
Oil Level Indicator and Tube Removal
Exhaust Manifold Clean and Inspect
1. Remove oil level indicator from the tube. 2. Remove the oil level indicator tube bolt from the right cylinder head. 3. Remove the oil level indicator tube from the engine block.
! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the exhaust manifolds in cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the exhaust manifolds for the following: • Damage to the gasket sealing surfaces (1) • Damage to the exhaust gas recirculation (EGR) pipe fitting (2) (left manifold) • Damage to the threaded holes (3) • Restrictions within exhaust passages • Broken or damaged exhaust manifold heat shields (4) (if applicable) • Broken or damaged exhaust manifold
11472
➧ B ➧ Exhaust Manifold and Heat Shields Removal 1. Remove the studs and bolts from the exhaust manifold and heat shields. 2. Remove the exhaust manifold and heat shields. 4. Measure the alignment or surface flatness of the exhaust manifold flanges using a straight edge and a feeler gauge. Refer to Engine Mechanical Specifications. If the surface flatness is not within the specifications, the exhaust manifold is warped and must be replaced.
3. Remove and discard the exhaust manifold gaskets.
-34-
Exhaust Manifold and Heat Shields Installation
➧ B ➧ Oil Level Indicator and Tube Installation
1. Install NEW exhaust manifold gaskets.
1. Clean and inspect the tube and indicator for damage or serviceability. 2. Apply a sealer MCF P/N 2I4256 (GM P/N 12346004) or equivalent around the oil level indicator tube 13 mm (0.5 in.) below the bead.
328540
2. Install the exhaust manifold. 3. Install the spark plug heat shields. 4. Use Locktite (G/M P/N 12345382) or equivalent to the threads of the exhaust manifold bolts and stud. 5. Install the exhaust manifold bolts and stud and torque to the specified torque. Tightening torque 1st pass exhaust manifold bolts
1.52 Kgf•m (11 lb•ft) [15 N•m]
Tightening torque final pass exhaust manifold bolts
3.05Kgf•m (22 lb•ft) [30 N•m]
188009
3. Install the oil level indicator tube into the engine block. Rotate the tube into position. 4. Install the oil level indicator tube bolt to the cylinder head.
Tightening torque oil level indicator 1.22 Kgf•m (106 lb•in) [12 N•m] tube bolt 5. Install the oil level indicator into the tube.
188045
6. Install the spark plug wires to the spark plug wire retainers. 7. Install the spark plug wires onto the spark
-35-
-36-
Cylinder Head and Valves Removal and Installation
Removal steps 1. Rocker Arm Cover 2. Bolts ➧ A ➧ 3. Cylinder Head Assy ➧ B ➧ 4. Gasket 5. Nut 6. Rocker Arm 7. Rocker Arm Support 8. Key 9. Cap 10. Spring 11. Seal 12. Valves
1
Torque Specifications For Cylinder Head Bolts: All bolts first pass in sequence 3.05 kgf•m (22 lb•ft) [30N•m] Long Bolts final pass in sequence 75 degrees Medium Bolts final pass in sequence 65 degrees Short Bolts final pass in sequence 55 degrees
T=2.49 kgf•m (18 lb•ft) [25 N•m]
8 5
3
2
ng
9
Lo
10
Sh
or
t
M
ed
iu
m
6
11
3
12
N
T=4.16 kgf•m (30 lb•ft) [40 N•m]
-37-
Valve Rocker Arm Cover Removal (Left)
7. Remove the valve rocker arm cover gasket. 8. Discard the valve rocker arm cover gasket.
1. Disconnect the negative battery cable. 2. Remove the ignition coil. 3. Disconnect the spark plug wires from the spark plugs. 4. Remove the PCV valve and tube. 5. Remove the rocker arm cover bolts. Discard the grommets from the rocker arm valve cover and replace with new grommets.
328573
Valve Rocker Arm Cover Removal (Right) 1. Disconnect the negative battery cable. 2. Disconnect the spark plug wires from the spark plugs. 3. Remove the crankcase vent tube. 4. Remove the starter relay. 5. Remove the oil level indicator tube. 6. Remove the valve rocker arm cover bolts. 7. Remove the valve rocker arm cover bolt grommets. Discard the valve rocker arm bolt grommets and replace with new grommets.
328566
6. Remove the valve rocker arm cover.
4042
328568
-38-
8. Remove the valve rocker arm cover.
3. Inspect the valve rocker arm cover for the following: • Damage to the PCV valve grommet (1) • Damage to the bolt holes (2) A damaged valve rocker arm cover may interfere with the valve rocker arms. • Damage to the exterior of the valve rocker arm cover (3) • Gouges or damage to the sealing surface (4) • Damage to the oil fill tube grommet (5) • Restrictions to the ventilation system passages
480524
9. Remove the valve rocker arm cover gasket. 10. Discard the valve rocker arm cover gasket.
334508
Valve Rocker Arm and Push Rod Removal Note: Mark, sort and organize all the components for assembly. 1. Remove the rocker arm cover. • For the right side of the truck, refer to Valve Rocker Arm Cover Replacement (Left). • For the left side of the truck, refer to Valve Rocker Arm Cover Replacement (Right). 2. Remove the following components from the cylinder head and place in a part’s rack so they can be reinstalled to their original location. • The valve rocker arm nuts (former style) • The valve rocker arm balls (former style) • The valve rocker arms
328573
Valve Rocker Arm Cover Clean and Inspect
! CAUTION Safety glasses must be worn or eye injury may occur. 1. Clean the valve rocker arm cover in cleaning solvent. 2. Dry the valve rocker arm cover with compressed air.
-39-
5. Place the following parts in a rack so they can be reinstalled in their original locations: • The valve pushrods • The valve rocker arms
(Former Style)
4045
2a. Remove the valve rocker arms (new style). (New Style)
4047
Valve Rocker Arm and Push Rods Clean and Inspect Important: Parts that are to be reused must be marked, sorted and organized for assembly. 1. Mark, sort and organize the components for assembly.
480526
3. Remove the valve rocker arm stud (former style).
! CAUTION
(Former Style)
Refer to Safety Glasses Caution in Cautions and Notices. 2. Clean the components with cleaning solvent. 3. Dry the components with compressed air. 4. Inspect the valve rocker arm components for the following: • Valve rocker arm valve push rod socket contact surface (1). The contact surface must be smooth with no scoring or excessive wear. • Valve rocker arm pivot for binding or damage (2) • Valve rocker arm valve stem contact surface (3) • Valve rocker arm bolt threads for damage (4)
4081
3a. Remove the valve rocker arm supports (new style)
(New Style)
480527
4. Remove the valve pushrods.
-40-
Important: Place the components in a rack so that the components can be reinstalled to their original location. 2. Remove the valve lifters.
4578
NOTE Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits. Use the J 3049 or the J 9290-01 to remove these valve lifters. 3. Use the J 3049 pliers to remove the valve lifters.
Valve Lifter Removal Tools Required • J 3049 Valve Lifter Remover (Plier Type) • J 9290-01 Valve Lifter Remover (Slide Hammer Type) Important: Place the components in a rack so that the components can be reinstalled to their original location. 1. Remove the bolts and the valve lifter push rod guide.
31350
4. If the valve lifters cannot be removed with the J3049, use the J 9290-01 to remove the valve lifters.
4577
-41-
Valve Stem Oil Seal and Valve Spring Removal Tools • • •
Required J 23590 Spark Plug Adapter J 5892-D Valve Spring Compressor J 38606 Valve Spring Compressor
34571
5. Clean the components with cleaning solvent. 6. Dry the components with compressed air. 7. Inspect the valve lifter pushrod guides for excessive wear. 8. Inspect the valve lifter pushrod guides for cracks or damage. 9. Inspect the valve lifter for the following: • Broken or damaged clip (1) • Worn pushrod socket (2) • Scuffed or worn lifter body (3) If the valve lifter shows scuffing or wear, inspect the engine clock valve lifter bores for wear. • Worn roller (4) • Loose or damaged pin (5) • Plugged oil hole (6)
4041
1. 2. 3. 4. 5.
Remove the valve rocker arm cover. Remove the valve rocker arms. Remove the spark plugs. Install the J 23590. Apply compressed air to hold the valves in
4048
6. Install the valve rocker arm nut. 7. Use the J 5892-D valve springs compressor.
178485
1964
-42-
3. Remove the following components from the left cylinder head: • The electrical connector at the coolant temperature sensor • Spark plugs
8. Use the J 38606 if clearance does not permit use of J 5892-D.
J 38606
31730
9. 10. 11. 12. 13.
Remove the valve keys. Carefully release the valve spring tension. Remove the J 5892-D or J 38606. Remove the cap, rotator, and spring. Remove the valve seal.
31868
4. Remove the alternator and bracket from the right cylinder head. 5. Remove valve rocker arm cover.
Cylinder Head Removal 1. Remove the intake manifold.
4041
2. Remove the exhaust manifold.
-43-
8. Remove and discard the cylinder head gasket.
6. Remove the cylinder head bolts.
5131
4047
NOTE
9. Remove the dowel pins (cylinder head locator) (if required).
After removal, place the cylinder head on two wood blocks to prevent damage. 7. Remove cylinder head.
330548
5130
-44-
Cylinder Head Disassembly and Assembly Disassembly Tools Required • J 8062 Valve Spring Compressor
! CAUTION Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.
31715
(1) Key (2) Cap
(3) Seal (4) Spring
(5) Valve (6) Valve
Assembly Tools Required • J 8062 Valve Spring Compressor • J 42073 Valve Stem Oil Seal Installer 1. Clean the valve spring seat area. 2. Install the valve into the proper port.
! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Use J 8062 to compress the valve springs.
NOTE J 8062
Important: In order for tool J 42073 to work properly, the valve is installed into the cylinder head. 3. Lubricate guide and valve stem oil seals (3) with clean engine oil.
NOTE Important: Install the valve stem oil seal (3) onto the valve stem (5 or 6). Push the seal down until the seal contacts the valve guide (2). 4. Valve stem oil seal alignment onto the valve guide is critical.
34468
2. 3. 4. 5. 6.
Remove the valve stem keys (1). Remove the cap (2) from the valve (5 or 6). Remove the valve spring (4). Remove the valve stem oil seal (3). Remove the valve (5 or 6). Place the valves in a rack in the proper sequence so you can install them in the same order.
36371
-45-
5. Place the J 42073 over the valve stem and oil seal. Lightly tap on the J 42073 until the tool bottoms out against the valve spring seat. 6. Install the valve spring (4).
J 8062
NOTE Important: A correctly installed seal should not bottom against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in.) gap (2) between the bottom edge of the seal (5) and the valve guide (4).
34468
Cylinder Head Clean and Inspect Tools Required • J8089 Carbon Removing Brush • J 9666 Valve Spring Tester • J 8001 Dial Indicator Set 1. Clean the valve stems and cylinder heads on a buffing wheel. 2. Clean the following components in cleaning solvent: • Valve stem keys • Valve spring cap • Valve spring • Cylinder head 3. Dry the components with compressed air. 4. Use the J 8089 to clean the carbon from the combustion chambers and the valve area. Be careful not to scuff the chamber.
36373
7. Install the cap (2) on the valve stem. 8. Use the valve spring compressor J 8062 to compress the valve spring. 9. Install the valve stem keys (1). • Use grease to hold the keys in place while disconnecting the valve spring compressor J 8062. • Make sure the keys seat properly in the upper groove of the valve stem. • Tap the end of the stem with a plastic-faced hammer to seat the keys if necessary. 10. Measure the valve spring installed height from the valve spring seat to the locating surface on the cap.
! CAUTION Safety glasses must be worn or eye injury may occur.
J 8089
-46-
9. Valve stems (1) with excessive valve guide (2) clearance must be repaired or the cylinder head replaced.
5. Inspect the cylinder head for the following: • Damage to the gasket surfaces • Damage to the threaded bolt holes • Burnt or eroded areas in the combustion chambers • Cracks in the exhaust ports and combustion chambers • External cracks in the water chambers • Restrictions in the intake or exhaust passages • Restrictions in the cooling system passages • Rusted, damaged or leaking core plugs 6. Measure the cylinder head for warpage with a straight edge and feeler gauge. • A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in) withing a 152.4 mm (6.0 in) area must be repaired or replaced. • A cylinder head exhaust manifold deck with warpage in excess of 0.05 mm (0.002 in) withing a 152.4 mm (6.0 in) area must be repaired or replaced. • A cylinder head intake manifold deck with warpage in excess of 0.10 mm (0.004 in) withing a 152.4 mm (6.0 in) area must be repaired or replaced. 7. Use the valve spring tester J 9666 to measure the valve spring. • Replace the intake valve spring if the spring tension is less than 360 N (81 lb) at 45.2 mm (1.78 in.). • Replace the exhaust valve spring if the spring tension is less than 425 N (96 lb) at 45.2 mm (1.78 in.).
156172
10. Measure the valve stem-to-bore clearance. Excessive valve stem-to-bore clearance may cause excessive oil consumption and may cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness. a. Clamp the dial indicator J 8001 on the exhaust port side of the cylinder head. b. Locate the indicator so the movement of the valve stem from side to side (crosswise to the cylinder head) will cause a direct movement of the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide. c. Drop the valve head about 1.6 mm (0.064 in.) off the valve seat. d. Use light pressure when moving the valve stem from side to side to obtain clearance reading.
J 9666
4960
8. Inspect the valve spring for squareness.
J 8001 40075
35214
-47-
Valve Guide Reaming / Valve and Seat Grinding
! CAUTION Safety glasses must be worn or eye injury may occur.
Tools Required • J 8001 Dial Indicator Set • J 5830-02 Valve Guide Reamer Set 1. Measure the valve stem-to-guide clearance. Refer to Cylinder Head Clean and Inspect.
NOTE Important: Exhaust valves with excessive valve stem-to-guide clearance must be replaced with the available service valve that has an 0.0774 mm (0.0305 in) oversize valve stem. The intake valves are NOT available with oversize valve stems. Replace the cylinder head if after using a NEW intake valve and in order to measure the valve stem-to-guide clearance, the valve stem-to-guide clearance is not within specifications. 3. Use the J 5830-3 in order to ream the exhaust valve guide in order to achieve the correct valve stem-to-guide clearance. 4. Always recondition the exhaust valve seat after reaming the exhaust valve guide bores and installing new exhaust valves.
J 8001
35214
2. Improper valve stem (1) to valve guide (2) clearance may cause excessive oil consumption.
480556
5. Inspect the valves for the following: • Burnt or damaged areas (1) • Undersize margain (2) • Bent stem (3) • Scoring or other damage to the stem (4) • Worn key groove (5) • Worn stem tip (6) 156172
-48-
• Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the valve head and the valve stem. Replace the valve if the valve stem is excessively worn or wrapped. Replace the valve if the edge margain (4) of the valve head is less than 0.79 mm (0.031 in) thick after grinding. • Several different types of equipment are available for reconditioning valves and valve seats. Follow the equipment manufacturer’s recommendations for equipment use to attain the proper results.
156174
6. Inspect the valve contact for the following: • Undersize margain (1) • Pitted surfaces (2) • Burnt or eroded areas (3) • Acceptable edge (margain) (4) Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired.
Cylinder Head Assemble Tools Required • J 8062 Valve Spring Compressor • J 42073 Valve Stem Seal Installer Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seal. The exhaust valve oil stem seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal, or the material may be red in color (2) with no paint stripe. The intake valve oil seal is black in color. 1. Assemble the valve into the proper valve guide. 2. Select the proper valve stem oil seal for the specific valve guide. 3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil.
156173
7. Reconditioning of the valves and valve seats: • The valves must seat perfectly for the engine to deliver optimum power and performance. • Cooling the valve heads is another important factor. Good contact between each valve and valve seat in the cylinder head is necessary to insure that the heat in the valve head is properly carried away. • Regardless of what type of equipment is used, it is essential that the valve guide bores are free from carbon or dirt in order to ensure the proper centering of the pilot in the valve guide. The valve seats should be concentric to within 0.05 mm (0.002 in) total indicator reading.
4. Assemble the valve stem oil seal onto the valve stem.
-49-
9. Use the valve spring compressor J 8062 in order to compress the valve springs. 10. Install the valve stem keys. 10.1 Use grease in order to hold the valve stem keys in place while disconnecting the valve spring compressor J 8062. 10.2 Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 10.3 Tap the end of the valve stem with a plastic-faced hammer in order to seat the valve stem keys, if necessary.
! CAUTION Safety glasses must be worn or eye injury may occur. 5. Install the valve stem oil seal onto the valve guide using the valve stem seal installer J 42073. Tap the valve stem oil seal onto the valve guide until the valve stem seal installer J 42073 bottoms against the valve spring seat. 6. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide.
J 8062
36373
Valve Lifter Installation
7. Install the valve spring (3). 8. Install the valve spring cap (2) onto the valve spring (3) and over the valve stem.
NOTE Parts that are to be reused must be marked, sorted and organized for assembly. If reusing the valve lifters, install the valve lifters in the original positions. 1. Apply engine oil to the valve lifter rollers. 2. Install the valve lifters. 3. Install the valve lifter pushrod guides.
480555
! CAUTION Compressed valve springs have high tensions against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.
Tightening torque for valve lifter pushrod guide bolts
-50-
1.66 Kgf•m (12 lb ft) [16 N•m]
5. Install the cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowell pins and the cylinder head gasket.
Cylinder Head Installation Tools Required • J 36660 Electronic Torque Meter 1. Clean the cylinder head gasket surfaces on the engine block. 2. Inspect the dowel pins (cylinder head locators) for proper installation. 3. Clean the cylinder head gasket surfaces on the cylinder head.
480536
6. Apply sealant P/N 2I4256, GM P/N 12346004 or equivalent to the threads of the cylinder head bolts. 7. Install the cylinder head bolts finger tight.
334303
NOTE Do not use any type of sealer on the cylinder head gasket (unless specified). 480533
4. Install the NEW cylinder head gasket in position over the dowel pins (cylinder head locators).
8. Tighten the cylinder head bolts in sequence and use the two step method.
Tightening torque for cylinder head bolts
First Pass 3.05 Kgf•m (22 lb ft) [30 N•m] Final Pass Long bolts 75 degrees Medium bolts 65 degrees Short bolts 55 degrees
9. Use the electronic torque meter J 36660 to tighten the cylinder head bolts in sequence on the final pass. • Tighten the long bolts (1,4,5,8 and 9) on the final pass in sequence to 75 degrees. • Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees. • Tighten the short bolts (2,3,6,7,10 and 11) on the final pass in sequence to 55 degrees.
334299
-51-
13. If reusing the engine coolant temperature gauge sensor (if applicable), apply sealant GM P/N 12346004 or equivalent to the threads of the engine coolant temperature gauge sensor. 14. Install the engine coolant temperature gauge sensor (if applicable). Tightening torque for coolant temperature gauge
2.07 Kgf•m (15 lb ft) [20 N•m]
5132
10. Install the spark plug wire support and bolts. Tightening torque for wire support and bolts
1.22 Kgf•m (106 lbf.in) [12 N•m]
15. If reusing the engine coolant temperature sensor (if applicable), apply sealant GM P/N 12346004 or equivalent to the threads of the engine coolant temperature sensor. 16. Install the engine coolant temperature sensor (if applicable).
328588
11. Measure the NEW spark plugs for the proper gap. Adjust the spark plug gap if necessary. Specification Spark plug gap to .889 mm (0.035 in). 12. Install the spark plugs. Tightening torque for spark plugs NEW
3.05 Kgf•m (22 lb ft) [30 N•m]
USED PLUGS
1.52 Kgf•m (11 lb ft) [15 N•m]
Tightening torque for coolant temperature sensor
328582
-52-
2.07 Kgf•m (15 lb ft) [20 N•m]
Valve Rocker Arm and Push Rod Installation
4. Install the valve rocker arm assemblies as follows: 4.1 Finger start the bolt at location (1) 4.2 Finger start the bolt at location (2) 4.3 Finger start the bolt at location (3) 4.4 Finger start the remaining valve rocker arm bolts.
Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. 1. Install the valve pushrods.
480529
NOTE 480580
Be sure that the arrow on the valve rocker arm support is in the up position.
5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2).
2. Install the valve rocker arm supports.
3. Apply prelube GM P/N 12345501 or equivalent to the following valve rocker arm contact surfaces: • Valve pushrod socket (1) • Roller pivot (2) • Valve stem tip (3)
334551
NOTE Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the valve rocker arm bolts. Tightening torque for valve rocker arm bolts
-53-
3.05 Kgf•m (22 lb ft) [30 N•m]
Valve Rocker Arm Cover Installation (Left)
4. Install the valve rocker arm cover bolts and torque to the specified torque.
Important: Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover grommets. 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover. 2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
Tightening torque for valve rocker arm bolts
3.05 Kgf•m (22 lbf.ft) [ 30 N•m]
4041
328573
5. Install PCV valve and tube. 6. Connect the spark plug wires to the spark plugs and route the wires so that they do not touch the engine or exhaust system. 7. Install the ignition coil. 8. Connect the negative battery cable.
3. Install the valve rocker arm cover onto the cylinder head.
480519
31868
-54-
Valve Rocker Arm Cover Installation (Right)
4. Install the valve rocker arm cover bolts and torque to the specified torque.
Important: Do not reuse the valve rocker arm cover gasket or the valve rocker arm cover bolt grommets. 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover. 2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
Tightening torque for valve rocker arm bolts
3.05 Kgf•m (22 lbf.ft) [ 30 N•m]
328573 328568
3. Install the valve rocker arm cover onto the cylinder head.
480524
-55-
-56-
Oil Pan, Pump and Filter Removal and Installation
N
N
Removal steps 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Plug Pan Gasket Bolt Pump Retainer Shaft Pin Pin Cover Screen Plug Valve Spring Filter Fitting Valve Adapter, Oil Filter Gasket Connector, Cooler Gasket
N
-57-
Oil Pan Removal
5. Remove oil filter adapter bolts. 6. Remove oil filter adapter gasket. 7. Remove oil filter adapter O-ring seal, if equipped.
1. Remove the water pump. 2. Remove crankshaft balancer.
4555
8. Remove the oil pan. 42882
3. Drain the engine oil. 4. Remove the following fasteners from the oil pan: • The bolts • The nuts
330568
9. Remove the oil pan gasket. 10. Discard the oil pan gasket and replace with NEW at reassembly.
NOTE Important: Discard old oil pan gasket. 330559
387757
-58-
Oil Pump Removal
Oil Pan Clean and Inspect
1. Remove the bolt that attaches the oil pump to the rear crankshaft bearing cap.
1. Remove the oil pan baffle bolts and the oil pan baffle.
4548
2. Remove the oil pump driveshaft and the 387763
! CAUTION Safety glasses must be worn or eye injury may occur. 2. Clean the oil pan and the oil pan baffle in cleaning solvent. 3. Dry the oil pan and the oil pan baffle with compressed air. 4. Inspect the oil pan for the following: • Gouges or damage to the oil pan sealing surfaces (1) • Damage to the threaded holes (2) • Damaged oil pan drain hole threads (3) • Damage to the oil pan baffle • Damage to the exterior of the oil pan A damaged oil pan may interfere with the proper position of the oil pump screen, or may not distribute oil properly in the oil pan sump area.
4549
3. Inspect the pins (oil pump locator) for damage, and replace the pins if required.
330578
4554
-59-
2. Remove the oil filter adapter and gasket.
5. Install the oil pan baffle and the bolts. Tightening torque for oil pan baffle bolts
1.22 Kgf•m (106 lb in) [12 N•m]
4555
3. Remove the seal.
387763
Oil Filter Adapter Removal 1. Remove the oil filter adapter bolts.
4556
Oil Pump Disassemble 1. Remove the oil pump drive shaft and oil pump driveshaft retainer.
4554
5274
-60-
2. If necessary, remove the oil pump screen. • The oil pump screen has a press fit into the pump cover. • Do not remove the screen from the pipe. The pipe and screen are serviced as a complete assembly
5. Remove the drive gear and the driven gear. 6. Matchmark the gear teeth for assembly.
5278
7. Remove the following items: a. The oil pump pressure relief valve spring straight pin. b. The oil pump pressure relief spring c. The oil pump pressure relief valve
5275
3. Remove the oil pump cover bolts.
30401
Oil Pump Clean and Inspect 1. Clean the oil pump components in cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the oil pump for the following conditions: • Scoring gears (2) for the following: • Damaged gears (2) for the following: ❍ Chipping ❍ Gailing ❍ Wear • Scoring, damage or casting imperfections to the body (3) • Damaged or scored gear shaft (4) • Damaged or scored gear shaft (5) • Damaged bolt hole threads • Worn oil pump driveshaft bore • Damaged or sticking oil pump pressure relief valve (minor imperfections may be removed with a fine oil stone) • Collapsed or broken oil pump relief valve spring
5276
4. Remove the pump cover.
5277
-61-
3. Coat the drive gear, the driven gear and the housing gear surfaces with clean engine oil. 4. Install the drive gear and the driven gear into the pump body. a. Align the matchmarks on the gears. b. Install the smooth side of the gear toward the pump cover.
186750
4. If the oil pump is to be reused, install a NEW oil pump pressure relief valve spring. 5. During oil pump installation, install a NEW oil pump driveshaft retainer. 5278
Oil Pump Assemble
5. Install the pump cover.
Tools Required • J 21882 Oil Pump Screen Installer.
NOTE Important: Replace the pressure relief valve spring when you reuse the oil pump. 1. Apply clean engine oil to the oil pump pressure relief valve, oil pump pressure relief valve spring and oil pump body. 2. Install the following items: a. The oil pump pressure relief valve b. The oil pump pressure relief valve spring c. The oil pump pressure relief valve spring straight pin
5277
6. Install the cover bolts. Tightening torque for cover bolts
1.22 Kgf•m (106 lb•in) [12N•m]
7. Inspect the pump for smoothness of operation by turning the oil pump driveshaft by hand.
30401
-62-
9. Install the oil pump drive shaft and the NEW oil pump drive shaft retainer.
5276 5274
8. Install the oil pump screen. a. If removed, replace the oil pump screen. The oil pump screen must have a good press fit into the oil pump body. b. Mount the oil pump in a soft jawed vise. c. Apply sealant MCF P/N 2I4256 GM P/N 12346004 or equivalent to the end of the oil pump screen pipe. d. Use the oil pump screen installer J 21882 and a soft-faced hammer to tap the oil pump screen into the pump body. The screen must align parallel with the bottom of the oil pan when it is installed.
Oil Filter Adapter Installation 1. Install the seal.
4556
2. Install the oil filter adapter and gasket.
J 21882
5280
NOTE Install a NEW oil pump driveshaft retainer during assembly. 4555
-63-
3. Install the oil filter adapter bolts.
4554
330576
4. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten to the specified torque.
Oil Pump Installation 1. Inspect for properly installed pins (oil pump locator).
Tightening torque for 9.14 Kgf•m (66 lb ft) [90 N•m] Oil pump bolts
330572
330578
Important: DO NOT reuse the oil pump driveshaft retainer. During assembly, install a NEW oil pump driveshaft retainer. 2. Install the oil pump. 3. Position the oil pump onto the pins.
-64-
Oil Pan Installation
Important: Always install a NEW oil pan gasket. The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. 3. Install the NEW oil pan gasket into the groove in the oil pan.
1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of PERMATEX® Gasket Maker P/N A000000165 GM P/N 12346141 or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces.
317310 387757
2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of PERMATEX® Gasket Maker P/N A000000165, GM P/N 12346141 or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces.
Important: The oil pan alignment must always be flush or forward no more than 0.3 mm (0.011 in) from the rear face of the engine block. 4. Install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing. 5. Slide the oil pan back against a suitable straight edge.
317313
330568
-65-
6. Install the oil pan bolts and nuts, but do not tighten. 7. Measure the pan-to-transmission housing clearance using a feeler gauge and a straight edge. Use a feeler gauge to check the clearance between the oil pan-to-transmission housing measurement points. If the clearance exceeds 0.3 mm (0.011 in) at any of the 3 oil pan-totransmission housing measurement points (1), then repeat the step until the oil pan-totransmission housing clearance is within the specification. The oil pan must always be forward of the rear face of the engine block.
10. Install a NEW oil pan drain plug seal (O-ring) onto the oil pan drain plug. 11. Install the oil pan drain plug into the oil pan. Tightening torque for oil pan drain plug
2.49 Kgf•m (18 lb•ft) [25N•m]
188048
12. Install the NEW engine oil level sensor (if applicable). 38496
Tightening torque for oil level sensor
Notice: If the clearance is more than 0.3 mm (0.011 in), powertrain durability may be reduced. 8. Tighten the oil pan bolts and nuts in sequence (1-12). 9. Measure the clearance between the 3 oil panto-transmission housing measurement points in order to ensure proper alignment. Tightening torque for oil pan nuts and bolts
2.49 Kgf•m (18 lb•ft) [25N•m]
38481
-66-
13.2 kgf•m (115 lb in) [13N•m]
Front Cover, Timing Chain, and Crankshaft Balancer Removal and Installation
8 7 3 4
6
9 5 2
Removal steps 1. 2. 3. 4. 5. 6. 7. 8. 9.
1
-67-
Cover Seal Bolt Sprocket Chain Drive Gear Bolt Gear Sprocket
Engine Front Cover Removal
Engine Front Cover Oil Seal Removal
1. 2. 3. 4.
1. Disconnect the negative battery cable. 2. Remove the crankshaft balancer. 3. Remove the crankshaft front seal.
Remove Remove Remove Remove
the the the the
crankshaft balancer. water pump. crankshaft position sensor bolt. crankshaft position sensor.
Timing Chain and Sprockets Removal Tools Required • J 23523-F Crankshaft Balancer Remover and Installer • J 5825-A Crankshaft Sprocket Puller
NOTE Check the camshaft timing chain free play. Replace the camshaft timing chain if it can be moved back and forth in excess of 16 mm (0.625 in.). 1. Remove the engine front cover. 2. Check the camshaft timing chain free play. 2.1. Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2). 2.2. Measure the free play on the slack side (3) of the camshaft timing chain. If the camshaft timing chain can be moved side to side in excess of 11 mm (0.43 in), replacement of the camshaft timing chain and the sprockets is recommended during assembly.
5. Remove the crankshaft position sensor seal (O-ring). 6. Discard the crankshaft position sensor seal (O-ring).
7. Remove the engine front cover bolts. 8. Remove the engine front cover. 9. Discard the engine front cover.
NOTE Do not reuse the engine front cover. Always install a new engine front cover.
480542
-68-
3. Remove the crankshaft position sensor reluctor ring.
6. Remove the crankshaft sprocket using the crankshaft sprocket puller J 5825-A. J 5825 - A
480541
7. Remove the camshaft balancer key. 4. Remove the camshaft sprocket bolts.
387761
Timing Chain and Sprockets Clean and Inspect
480544
5. Remove the camshaft sprocket and the camshaft timing chain.
! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the components with cleaning solvent. 2. Dry the components with compressed air. 3. Inspect the camshaft timing chain for binding or wear.
480546
! CAUTION Safety Glasses must be worn or eye injury may occur.
-69-
4. Inspect the camshaft sprocket and the crankshaft sprocket for the following: • Broken teeth (1) • Damaged teeth (2) • Chipped teeth (3) • Worn teeth • Uneven wear on the edge of the teeth • Worn valleys between the sprocket teeth • Crankshaft sprocket keyway for wear
3. Use the balancer remover and installer J23523-F in order to remove the crankshaft balancer. a. Install the balancer remover and installer J23523-F plate and bolts onto the crankshaft balancer and tighten.
Tightening torque for Balancer bolts
2.49 Kgf•m (18 lb ft) [25 N•m]
b. Install the balancer remover and installer J23523-F forcing screw into the plate. c. Rotate the balancer remover and installer J23523-F forcing screw clockwise in order to remove the crankshaft balancer. 4. Remove the balancer remover and installer J23523-F from the crankshaft balancer.
J 23523-F
Crankshaft Balancer Removal Tools Required • J 23523-F Balancer Remover and Installer 1. Remove the crankshaft balancer bolt and washer.
4059
Important: If replacing the crankshaft balancer, NEW weights must be installed into the NEW crankshaft balancer, in the same location as the old weights in the old balancer. 5. Note the position and length of any crankshaft balancer front groove pins, if applicable.
173172
2. Remove the bolts and the crankshaft pulley.
334258 188055
-70-
b. Install the J 23523-F screw into the end for the crankshaft. c. Install the J 23523-F bearing, the washer and the nut onto the J 23523-F screw. d. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring. 6. Remove the J 23523-F.
Crankshaft Balancer Installation Tools Required • J 23523-F Crankshaft Balancer Remover and Installer 1. Look to ensure that the front groove pin (crankshaft balancer) is installed in the proper location (if applicable).
J 23523–F
334258 4065
Important: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. 2. Apply a small amount of adhesive A000000165, GM P/N 12346141 or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint. 3. Align the keyway of the crankshaft balancer with the crankshaft balancer key. 4. Install the crankshaft balancer onto the end of the crankshaft.
7. Install the crankshaft pulley and bolts. Tightening torque for Crankshaft pulley bolts 5.94 Kgf•m (43 lb ft) [58 N•m]
8. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine.
1
2 342203
9. Install the crankshaft balancer washer and the bolt, tighten to the specified torque. Tightening torque for Crankshaft Balancer bolt 188059
5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. a. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer and tighten to the specified torque. Tightening torque for 2.49 Kgf•m (18 lb ft) [25 N•m] Balancer bolts
-71-
9.67 Kgf•m (70 lb•ft) [95N•m]
Timing Chain and Sprockets Installation
4. Rotate the crankshaft until the crankshaft sprocket is at the 12 o’clock position. Important: Install the crankshaft sprocket with the alignment mark at the 6 o’clock position. 5. Install the crankshaft sprocket and the camshaft timing chain.
Tools Required • J 5590 Crankshaft Sprocket Installer 1. Install the key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.
387766
2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. 3. Use the crankshaft sprocket installer J 5590 to install the crankshaft sprocket.
480546
6. Look to ensure that the crankshaft sprocket is aligned at the 12 o’clock position and the camshaft sprocket is aligned at the 6 o’clock position.
J 5590 480574
480575
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Engine Front Cover Oil Seal Installation
Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole).
Tools Required • J 35468 Crankshaft Seal Installer and Centering Tool 1. Install the crankshaft front seal. 2. Install the crankshaft balancer.
7. Install the camshaft sprocket bolts. Tightening torque for camshaft sprocket bolts
Engine Front Cover Installation
2.49 Kgf•m (18 lb•ft) [25N•m]
NOTE Once the composite engine front cover is removed DO NOT reinstall the engine front cover. Always install a new engine front cover.
Tightening torque for front cover bolts
1.22 Kgf•m (106 lb•in) [12 N•m]
1. Install the NEW engine front cover. 2. Install the front cover bolts.
480544
8. Install the crankshaft position sensor reluctor ring. a. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. b. Use the crankshaft sprocket installer J 5590 to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket.
4068
J 5590
480574
-73-
Water Pump Removal
Important: Do not reuse the original crankshaft position sensor seal (o-ring). When installing the crankshaft position sensor, be sure the crankshaft position sensor is fully seated and held stationary in the engine front cover crankshaft position sensor bore. A crankshaft position sensor that is not completely seated will cock in the engine front cover and may result in erratic engine operation.
Tools Required • J 41240 Fan Clutch Remover and Installer 1. Remove the bolts and the fan and water pump pulley using the J 41240.
3. Lubricate the NEW crankshaft position sensor seal (o-ring) with clean engine oil. 4. Install the NEW crankshaft position sensor seal (o-ring) onto the crankshaft position sensor.
2. Remove the clamps and water pump inlet hose.
5. Install the crankshaft position sensor until fully seated into the engine front cover. 6. Install the crankshaft position sensor bolt. Tightening torque for crankshaft position bolt
.82 Kgf•m (71 lb ft) [8 N•m]
3. 4. 5. 6.
-74-
Remove the water pump bolts. Remove the water pump. Remove the water pump gaskets. Discard the water pump gaskets.
Water Pump Clean and Inspect
Water Pump Installation Tools Required • J 41240 Fan Clutch Remover and Installer 1. If reusing the fasteners, apply sealant GM P/N 12346004 or equivalent to the threads of the water pump bolts. 2. Install the water pump and the NEW water pump gaskets. 3. Install the water pump bolts.
! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Remove all the old gasket material from the water pump sealing surfaces. 2. Clean all the dirt and any debris from the water pump. 3. Inspect the water pump for the following: • Leakage or damage to the housing cover or gasket (1) • Excessive scratches or grouping to the gasket sealing surfaces (2) • Leakage from the water pump vent hole (3) A stain around the vent hole is acceptable. If leakage occurred (dripping) with the engine operating and the cooling system pressurized, then replace the water pump. • Damaged bolt hole threads (4) • Excessive side-to-side movement of the water pump shaft (5) • Leakage around the water inlet pipe (6) • Leakage around the heater hose pipe (7) • Restrictions within the internal coolant passages
Tightening torque for water pump bolts
4.56 Kgf•m (33 lb ft) [45 N•m]
Important: After final assembly, the water pump inlet hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose. 4. Install the water pump inlet hose and the water pump inlet hose clamps.
-75-
5. Install the fan and water pump pulley and bolts using the J 41240. Tightening torque for water pump pulley bolts
2.497 Kgf•m (18 lb ft) [25 N•m]
-76-
Balancer and Camshaft Removal and Installation
1
2
3 12 13 9 11 7 10
5 4
6 Removal steps 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
8
-77-
Rod Guide Lifter Camshaft Gear Gear Kit Retainer Retainer Camshaft Balancer Bearing Kit - Camshaft Bearing Bearing Plug
Balance Shaft Removal
NOTE
Tools Required • J 23523-F Crankshaft Balancer Remover and Installer • J 38834 Balancer Shaft Bearing Service Kit 1. Remove the balance shaft drive gear. Inspect the sprockets for chipped teeth and wear. Worn sprockets will wear a new chain.
Important: The balance shaft drive and driven gears are serviced as a set. The set includes the balance shaft driven gear bolt.
5135
2. Remove the bolt and the balance shaft driven gear. Inspect the balance shaft drive and driven gears for nicks and burrs. a. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. b. Remove the balance shaft bolt. c. Remove the wrench from the balance shaft 3. Remove the balance shaft driven gear from the balance shaft.
9847
5136
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c. Install the J 38834-1 into the J 26941. d. Slide the J 37734-2 and into the balance shaft bore of the engine block. e. Install the J 38834 bearing, washer and nut onto the J 38834-1. f. Using a wrench, secure the J 38834-1 and then rotate the J 37734 nut clockwise until the balance shaft rear bearing is removed from the engine block. g. Remove the J 26941 from the balance shaft rear bearing. 7. Discard the balance shaft rear bearing.
4. Remove the bolts and the balance shaft retainer.
J 38834-1 5137
NOTE Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the front bearing from the balance shaft. 5. Use a soft-faced hammer to remove the balance shaft from the engine block. J 38834-2
J 26941
5139
5139
6. Use the balancer shaft bearing service kit J 38834 and the crankshaft balancer remover and installer J 26941 in order to remove the balance shaft rear bearing. a. Install the crankshaft balancer remover and installer J 26941 legs behind the balance shaft rear bearing and secure. b. Install the balancer shaft bearing service kit J 38834 with the short threaded end through the balance shaft bore in the front of the engine block.
-79-
Camshaft Removal
Camshaft Bearing Removal
Tools Required • J23523-F Crankshaft Balancer Remover/Installer 1. Remove the camshaft retainer bolts and retainer.
Tools Required • J 33049 Camshaft Bearing Replacer
NOTE Important: A loose camshaft bearing may be caused by an enlarged, out-of-round or damaged engine block camshaft bearing bore.
NOTE Important: Always remove the camshaft inner bearings #2 and #3 first. The camshaft outer bearings #1 and #4 serve as a guide for the camshaft bearing replacer J 33049. 1. Select the cone (1), the handle (10), the expanding driver (4-8), the washer (2 or 3) and the expander assembly (15) from the J 33049 2. Assemble the J 33049.
5146
Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 2. Remove the camshaft. a. Install the three 6/16 x 4.0 inch bolts in the camshaft front bolt holes. b. Carefully rotate and pull the camshaft out of the bearings.
66100
5147
-80-
4. Remove the camshaft bearing replacer J 33049 from the engine block. 5. Remove the camshaft outer bearing #1 and #4. a. Insert the J 33049 into the camshaft outer bearing #1. b. Tighten the J 33049 expander assembly nut until snug. c. Drive the camshaft outer bearing #1 from the camshaft outer bearing bore #1. d. Loosen the J 33049 expander assembly nut. e. Remove the camshaft outer bearing #1 from the J 33049 expander assembly. f. Remove the J 33049 from the engine block. g. Insert the J 33049 expander assembly into the camshaft outer bearing #4. h. Tighten the J 33049 expander assembly nut until snug. i. Drive the camshaft outer bearing #4 from the camshaft inner bearing #4. j. Loosen the J 33049 expander assembly nut. k. Remove the camshaft outer bearing #4 from the J 33049 expander assembly. 6. Remove the camshaft bearing replacer J 33049 from the engine block. 7. Discard the camshaft bearings.
3. Remove the camshaft inner bearings #2 and #3. a. Insert the camshaft bearing replacer J 33049 through the front of the engine block and into the camshaft inner bearing #2. b. Tighten the J 3304) expander assembly nut until snug. c. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049. d. Drive the camshaft inner bearing #2 from the camshaft inner bearing bore #2. e. Loosen the J 33049 expander assembly nut. f. Remove the camshaft inner bearing #2 from the J 33049 expander assembly. g. Insert the J 33049 expander assembly into the camshaft inner bearing #3. h. Tighten the J 33049 expander assembly nut until snug. i. Push the J 33049 guide cone into the camshaft front bearing in order to align the J 33049. j. Drive the camshaft inner bearing #3 from the camshaft inner bearing bore #3. k. Loosen the J 33049 expander assembly nut. l. Remove the camshaft inner bearing #3 from the J 33049 expander assembly.
J 33049
J 33049
4985
63219
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Camshaft and Bearings Clean and Inspect
7. Measure the engine camshaft journals with a micrometer. If the camshaft journals are more than 0.025 mm (0.0010 in) out-of-round, then replace the engine camshaft.
Tools Required • J 7872 Magnetic Base Indicator Set 1. Clean the engine camshaft in cleaning solvent. 2. Dry the engine camshaft with compressed air. 3. Inspect the camshaft retainer plate for damage. If the camshaft retainer plate is damaged, replace as necessary. 4. Inspect the camshaft bearings for correct fit into the engine block camshaft bearings bores. The camshaft bearings have an interference fit to the engine block camshaft bearing bores and must not be loose in the engine block camshaft bearing bores.
188014
8. Measure for a bent engine camshaft or excessive engine camshaft run out using the magnetic base indicator J7872. • Mount the engine camshaft in a suitable stand between centers. • Use the magnetic base indicator J7872 to check the intermediate engine camshaft journals. 9. Measure the engine camshaft lobe lift using the magnetic base indicator J7872. • Place the engine camshaft on the V-blocks. • Use the magnetic base indicator J7872 to measure the engine camshaft lobe lift. 10. Replace the engine camshaft if the engine camshaft lobe lift is not within specifications. Refer to General Specifications.
334499
NOTE Important: If any camshaft bearing is excessively worn or scored, replace all the camshaft bearings. 5. Inspect the camshaft bearings for excessive wear or scoring. 6. Inspect the engine camshaft for the following: • Worn, scored or damaged bearing journals (1) • Worn engine camshaft lobes (2) • Damaged bolt hole threads (3) • Damaged camshaft sprocket locator pin (4)
188095
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Camshaft Bearing Installation
NOTE
Tools Required • J 33049 Camshaft Bearing Service Kit
Important: The camshaft bearings vary in size. When ordering the new camshaft bearings, be sure to order the correct camshaft bearings for the application to be serviced. Always install the camshaft outer bearings #1 and #4 first. The camshaft outer bearings serve as a guide for the camshaft bearing service kit J 33049 and help center the camshaft inner bearings during the installation process.
NOTE Important: When installing the camshaft bearings, always make sure that the camshaft bearing lubrication hole is located above the 3 o’clock position (1) or the 9 o’clock position (2). The proper positioning of the camshaft bearing lubrication hole is in order to ensure the best lubrication of the engine camshaft journals.
3. Install the NEW camshaft outer bearings #4 and #1. a. Install the NEW camshaft outer bearing #4 onto the J33049 expander assembly. b. Tighten the J 33049 expander assembly nut until snug. c. Align the lubrication hole of the camshaft outer bearing #4 above the 3 o’clock position or the 9 o’clock position of the camshaft outer bearing bore #4 at the rear of the engine block. d. Drive the camshaft outer bearing #4 into the camshaft outer bearing bore #4 at the rear of the engine block. e. Loosen the J 33049 expander assembly nut. f. Remove the camshaft outer bearing #4 from the J 33049 expander assembly. g. Install the NEW camshaft outer bearing #1 onto the J33049 expander assembly. h. Tighten the J 33049 expander assembly nut until snug. i. Align the lubrication hole of the camshaft outer bearing #1 above the 3 o’clock position or the 9 o’clock position of the camshaft outer bearing bore #1 at the front of the engine block. j. Drive the camshaft outer bearing #1 into the camshaft outer bearing bore #1 at the front of the engine block. k. Loosen the J 33049 expander assembly nut. l. Carefully slide the J 33049 into the engine block until the J 33049 expander assembly is positioned between the camshaft inner bearing bores.
594647
1. Select the handle (10), the expanding driver (4-8), the washer (2 or 3) and the expander assembly (15) from the camshaft bearing service kit J 33049. 2. Assemble the camshaft bearing service kit J 33049.
66100
-83-
g. Install the NEW camshaft inner bearing #2 onto the J33049 expander assembly. h. Tighten the J 33049 expander assembly nut until snug. i. Align the lubrication hole of the camshaft inner bearing #2 above the 3 o’clock position or the 9 o’clock position of the camshaft inner bearing bore #2 of the engine block. j. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049. k. Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2 of the engine block. l. Loosen the J 33049 expander assembly nut. 5. Carefully remove the J 33049 from the engine block. 6. Install a new camshaft rear bearing hole plug. Coat the outside diameter of the plug with MCF P/N 2I4256 (GM P/N 12346004) sealant or equivalent. a. Install the plug flush to 0.80 mm (1/32 in.) b. Install the plug while RTV is still wet.
J 33049 63219
J 33049
Camshaft Installation 1. Apply clean engine oil or equivalent, to the following components: • The engine camshaft lobes • The camshaft bearing journals • The camshaft bearings 2. Install three 5/16-18 x 4.0 in. bolts into the engine camshaft front bolt holes.
4985
4. Install the NEW camshaft inner bearings #3 and #2. a. Install the NEW camshaft inner bearing #3 onto the J33049 expander assembly. b. Align the lubrication hole of the camshaft inner bearing #3 above the 3 o’clock position or the 9 o’clock position of the camshaft inner bearing bore #3 of the engine block. c. Push the J 33049 guide cone into the camshaft front bearing bore #1 in order to align the J 33049. d. Drive the camshaft inner bearing #3 into the camshaft inner bearing bore #3 of the engine block. e. Loosen the J 33049 expander assembly nut. f. Carefully slide the J 33049 until the J33049 expander assembly is positioned between the camshaft inner bearing bore #2 and the camshaft outer bearing bore #1.
NOTE Important: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft
5147
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Balance Shaft Clean and Inspect
3. Use the bolts as a handle in order to install the engine camshaft. 4. Remove the 3 bolts from the front of the engine camshaft. 5. If reusing the fasteners, apply thread lock GM P/N 12345382 or equivalent to the threads of the camshaft retainer bolts. 6. Install the camshaft retainer and bolts.
Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft.
188106
1. Clean the following components in cleaning solvent. • The balance shaft (1) • The balance shaft retainer (2) • The balance shaft rear bearing • The balance shaft driven gear (4) • The balance shaft drive gear 2. Dry the following components with compressed air. • The balance shaft (1) • The balance shaft retainer (2) • The balance shaft rear bearing • The balance shaft driven gear (4) • The balance shaft drive gear 3. Inspect the balance shaft bearings for the following: • Front ball bearing for damage or wear • Front ball bearing for smoothness of operation • Rear sleeve bearing for wear, scoring or other damage. 4. Inspect the balance shaft (1) for the following: • Wear or scoring on the rear bearing journal • Damaged bolt hole threads • Damage to the balance shaft driven gear locator pin 5. Inspect the balance shaft retainer (2) for wear or damage 6. Inspect the balance shaft retainer bolts (3) for damaged threads. 7. Inspect the driven gear (4) for the following: • Excessive wear or damage • Nicks, burns or scoring
188030
Tightening torque for Camshaft 1.22Kgf•m (106 lb•in) [12N•m] Retainer bolts
-85-
8. Inspect the driven gear bolt (5) for damaged threads. 9. Inspect the balance shaft drive gear for the following: • Excessive wear or damage • Nicks, burns or scoring
2. Remove the J 38834.
J 38834-1 J 38834-3
J 38834-2 340085
Balance Shaft Installation
9848
Tools Required • J 36996 Balance Shaft Installer. • J 8092 Universal Driver Handle. • J 36660 Torque / Angle Meter. Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft. 1. Apply clean engine oil or equivalent to the balance shaft front bearing. 2. Use the balance shaft installer J 36996 and the universal drive handle J 8092 in order to install the balance shaft.
Balance Shaft Bearing and/or Bushing Installation Tools Required • J 38834 Balance Shaft Service Kit 1. Use the J 38834 in order to install the balance shaft rear bearing. a. Install the J 38834-3 onto the short threaded end of the J 38834-1. b. Install the J 38834 nut, the washer and the bearing on the long threaded end of the J 38834-1. c. Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. d. Install the J 38834-2 on the inside of the balance shaft front bearing bore. e. Lubricate the NEW balance shaft rear bearing with clean engine oil. f. Install the balance shaft rear bearing onto the J 38834-2. g. Align the balance shaft rear bearing for installation. h. Using a wrench, secure the J 38834- into place. i. Rotate the J 38834 until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore.
J 8092
J 36996 5141
-86-
3. Install the balance shaft retainer and bolts.
7. Remove the wrench from the balance shaft. 8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case.
Tightening Torque for Balance 1.22Kgf•m (106 lb•in) [12N•m] Shaft bolts
188031 5136
4. Install the balance shaft driven onto the balance shaft. 5. If reusing the fastener, apply thread lock MCF P/N 2I4264, GM P/N 12345382 or equivalent to the threads of the balance shaft driven gear bolt. 6. Install the balance shaft driven gear bolt. a. Use a wrench to secure the balance shaft. b. Place the wrench onto the balance shaft near to the balance shaft front bearing. c. Install the balance shaft driven gear bolt. Tightening Torque for Balance Shaft Driven gear bolt First Pass
2.08 Kgf•m (15 lb ft) [20N•m]
Tightening Torque for Balance Shaft Driven gear bolt Final Pass
35°
9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time.
9847
-87-
10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o’clock position.
12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o’clock position.
9848 9849
11. Remove the balance shaft drive gear. 13. Position the balance shaft drive gear onto the engine camshaft. 14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.
9847
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Crankshaft, Flywheel, Rear Seal, and Bearings Removal and Installation
Removal Steps 1. Bolt 2. Bushing - Flywheel 3. Flywheel Assy 4. Housing 5. Seal 6. Gasket 7. Hub 8. Bolt 9. Balancer 10. Crankshaft Bearing Cap 11. Lower Bearing Kit 12. Crankshaft 13. Upper Bearing Kit
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Crankshaft Rear Oil Seal and Housing Removal
Engine Flywheel Removal 1. Remove the flywheel bolts. 2. Remove the flywheel.
1. Remove the crankshaft rear oil seal housing nuts and bolts. 2. Remove the crankshaft rear oil seal housing, seal, and gasket.
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Engine Flywheel Clean and Inspect 1. Clean the engine flywheel in cleaning solvent. 2. Dry the engine flywheel with compressed air. 3. Inspect the engine flywheel for the following: • Stress cracks around the engine flywheel-totorque converter bolt hole locations (1) • Missing balance weights • Stress cracks around the engine flywheel-tocrankshaft bolt hole locations (2) or (3)
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3. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a screw driver into the notches provided in the rear seal retainer and pry out the seal. 4. Discard the crankshaft oil seal.
NOTE Important: Do not attempt to repair the welded areas (if present) that retain the ring gear to the engine flywheel plate. Always install a NEW engine flywheel. • Welded areas that retain the ring gear onto the engine flywheel for cracking (4) (if present) • Damaged ring gear teeth (5)
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5. Remove the crankshaft bearings from the crankshaft bearing caps
Crankshaft and Bearings Removal 1. Mark or Identify the crankshaft bearing cap locations, direction and positions for assembly. 2. Remove the crankshaft bearing cap bolts. 3. Remove the crankshaft bearing caps.
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6. Remove the crankshaft bearings from the engine block. 334329
4. Remove the crankshaft.
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Crankshaft and Bearings Clean and Inspect Tools Required • J 7872 Magnetic Base Dial Indicator • J 36660 Electronic Torque Angle Meter
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! CAUTION Safety glasses must be worn or eye injury may occur.
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Important: Use care when handling the crankshaft. Avoid damage to the crankshaft bearing surfaces. 1. Clean the crankshaft in cleaning solvent. Remove all sludge or restrictions from the oil passages. 2. Dry the crankshaft with compressed air.
5. Inspect the crankshaft for the following: • Crankshaft journals (1) should be smooth with no evidence of scoring or damage. • Deep grooves (2) • Scratches or uneven wear (3) • Pitted surfaces (4) • Wear or damage to the thrust journal surfaces • Scoring or damage to the rear seal surface • Restrictions to the oil passages • Damage to the threaded bolt holes
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3. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth, do not scratch the crankshaft bearing surface. 4. Dry the crankshaft bearings with compressed air.
6. Inspect the crankshaft balancer key (1), the keyway (2) and the threaded hole (3) for damage. Repair or replace the crankshaft as necessary.
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7. Measure the crankpins for out-of-round and taper. Refer General Specifications.
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8. Use a suitable support to support the crankshaft on the front and rear journals. 9. Use the magnetic dial indicator J 7872 to measure the crankshaft journal run out. The crankshaft run out should not exceed 0.025 mm (0.0010 in).
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11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue. 35210
10. Measure the crankshaft end play. Important: In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearings and the crankshaft bearing caps, the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened to specifications. • Firmly thrust the crankshaft first rearward, then forward. This will align the crankshaft rear bearings and the crankshaft thrust surfaces. • With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance. Refer to General Specifications. • If the correct end play cannot be obtained, verify that the correct size crankshaft bearing has been installed. Refer to General Specifications. • Inspect the crankshaft for binding. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, then loosen the crankshaft bearing cap bolts, one bearing cap at a time, until the tight crankshaft bearing is located.
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12. Inspect the crankshaft bearings for excessive scoring or discoloration. 13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material.
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14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings. • If the lower half of the crankshaft bearing is worn or damaged, both the upper and lower halves of the crankshaft bearing should be replaced. • Generally, if the lower half of the crankshaft bearing is suitable for use, the upper half of the crankshaft bearing should also be suitable for use.
Burrs on the crankshaft bearing cap, foreign matter between the crankshaft bearing and the engine block or crankshaft bearing cap or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing.
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Service Prior to Assembly
5. Install the crankshaft bearings into the crankshaft bearing caps. 6. Apply clean engine oil to the crankshaft bearings.
Dirt will cause premature wear of the rebuilt engine. During assembly, lubricate all moving parts lightly with engine oil or engine assembly lubricant (unless otherwise specified.) This will provide initial lubrication when the engine is started.
Crankshaft and Bearings Installation Tools Required • J 36660 Electronic Torque Angle Meter 1. Install the crankshaft bearings into the engine block. 2. Apply clean engine oil to the crankshaft bearings.
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7. Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. 8. Install the crankshaft bearing cap bolts until snug.
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3. Apply clean engine oil to the crankshaft bearing journals. 4. Install the crankshaft.
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9. Thrust the crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps. 334336
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10. Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings. 11. Tighten the crankshaft bearing cap bolts. a. Tighten the crankshaft bearing cap bolts to 2.08 Kgf•m (15 lb•ft) [20N•m] on the first pass. b. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the electronic torque angle meter J 36660. Tightening torque for Crankshaft Bearing Cap Bolts
• In order to determine the correct replacement
1st pass 2.08 Kgf•m (15 lb•ft) [20N•m] Final pass 73 degrees
•
12. Measure the crankshaft end play. a. Firmly thrust the crankshaft rearward, and then forward. This will align the crankshaft rear bearing thrust surfaces. b. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft rear bearing thrust surface to measure the clearance.
•
Specification Crankshaft end play 0.05-0.20 mm (0.002-0.008 in) 13. Rotate the crankshaft in order to check for binding. A bent crankshaft or lack of proper crankshaft bearing clearance may cause binding. 14. If the crankshaft does not turn freely, loosen the crankshaft bearing cap bolts on 1 crankshaft bearing cap at a time in order to determine the location of the binding. A lack of proper crankshaft bearing clearance may be caused by the following: • Burrs on the crankshaft bearing cap • Foreign material between the crankshaft bearing and the engine block • Foreign material between the crankshaft bearing and the crankshaft bearing cap • Damaged crankshaft bearing • Improper size crankshaft bearing
•
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Micrometer Method for Crankshaft Bearings 1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements. 2. Determine the taper and the out-of-round of the crankshaft journal. Refer to General Specifications. 3. Install the crankshaft bearings into the engine block or connecting rod assembly.
Measure Crankshaft Bearing Clearances • The crankshaft bearings are of the precision
•
crankshaft bearing size, the crankshaft bearing clearance must be measured accurately. Either the micrometer or plastic gauge method may be used; however, the micrometer method gives more reliable results and is preferred. When checking connecting rod bearing clearances, the plastic gauge method will result in unreliable measurements. The use of J 43690 is preferred. Normally the crankshaft bearing journals wear evenly and are not out-of-round. However, if a crankshaft bearing is being fitted to an outof-round crankshaft bearing journal, be sure to fit to the maximum diameter of the crankshaft bearing journal. If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal will result in rapid crankshaft bearing failure. If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications, replace the crankshaft bearings. Always replace both the upper and lower crankshaft bearings as a set. A standard or oversize crankshaft bearing combination may result in the proper clearance. If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings, it may be necessary to repair or replace the crankshaft.
insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required. The service crankshaft bearings are available in the standard size and an undersize. The selective fitting of the crankshaft bearings are necessary in production in order to obtain close tolerances. For this reason, in one journal bore you may use one-half of a standard crankshaft bearing with one-half of a undersize crankshaft bearing.
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4. Install the bearing cap bolts and tighten to specifications.
10. If the crankshaft bearing clearances exceeds specifications, install new crankshaft bearings as follows: a. Measure the crankshaft bearing inside diameter (ID) at the top and the bottom using an inside micrometer. b. Compare the crankshaft bearing clearance to the specifications. Refer to General Specifications. 11. Replace or repair the crankshaft if the proper clearances cannot be obtained.
Micrometer Method for Connecting Rod Bearings Important: Do not shim, scrape or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface. 1. Measure the crankpin diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements. 2. Determine the taper and the out-of-round. Refer to General Specifications. 3. Install the connecting rod bearings into the connecting rod cap and the connecting rod. 4. Install the connecting rod caps and the nuts and tighten to the specified torque by a two step method. Torque all nuts to the specified torque on the first pass. Tighten the nuts on the final pass an additional 70 degrees using the electronic torque angle meter J-36660.
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5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. 6. Install the crankshaft bearing cap bolts and tighten to the specified torque using a two step method. Tightening torque for Crankshaft Bearing Cap bolts First Pass
2.08 Kgf•m (15 lb ft) [20 N•m]
Tightening torque for Crankshaft Bearing Cap bolts Final Pass
Additional 73°
7. 8.
9.
Tightening torque for Connecting 2.77 Kgf•m Rod Cap Nuts First Pass (20 lb ft) [27 N•m]
Measure the bearing inside diameter (ID) at two points 90 degrees apart. In order to determine the crankshaft bearing clearance, subtract the average journal diameter from the average bearing inside diameter. Compare the crankshaft bearing clearance to the specifications. Refer to General Specifications.
Tightening torque for Connecting Rod Cap Nuts Final Pass
Additional 70°
5. Measure the connecting rod bearing inside diameter (ID) at the top and the bottom using an inside micrometer. 6. Compare the connecting rod bearing clearance to the specifications. Refer to General Specifications. 7. If the connecting rod bearing clearance is within specifications, the connecting rod bearing is satisfactory. • Replace the connecting rod bearing if the clearance is not within specifications. • Always replace both the upper and the lower connecting rod bearings as an assembly. 8. A standard or undersize connecting rod bearing combination may result in the proper clearance.
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If the proper connecting rod bearing clearance cannot be achieved using the standard or the undersize connecting rod bearings, it will be necessary to replace or repair the crankshaft.
Measuring Connecting Rod Bearing Clearances J43690 Method
5. Install the foot (1) and bolt (2) to the pivot arm assembly (3). Tighten the bolt until snug.
1. Remove the oil pan and other necessary components to gain access to the connecting rods. Remove the oil pump, screen and deflector (when applicable). 2. Rotate the crankshaft until the crankshaft journal/connecting rod to be measured is in the 10 o’clock position. Important: The crankshaft must be secure with no movement or rotation in order to obtain an accurate reading. Remove an intermediate bearing cap (as required) in order to secure the crankshaft and allow measurement of connecting rod bearing clearances. 3. Remove the bearing cap bolts (1), cap (2) and bearing half. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Insert a piece of paper card stock onto the crankshaft journal. Install the bearing half, bearing cap and bolts. Refer to Fastener Tightening Specifications.
6. Install the screw (1 or 3) to the pivot arm assembly (2).
7. Install the pivot arm assembly (1) onto the connecting rod.
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8. Position the foot of the pivot arm assembly over the large end of the connecting rod bolt. 9. Position the screw (1) onto the small end of the connecting rod bolt and tighten securely.
11. Align the center of the base (1) with the screw (3) of the pivot arm assembly. Tighten the bolt (2) until snug.
12. Align the link (1) of the pivot arm assembly on a plane (3) equal to that of the connecting rod beam (2).
10. Install the base (1) and bolt (2) to the oil pan rail.
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13. With the link of the pivot arm assembly aligned to the beam of the connecting rod, position the pivot arm to the base and insert the pin (1).
Important: The clamp of the swivel base and the shaft of the indicator should be free of oil or other debris. A loose or improperly clamped indicator may indicate incorrect readings. 16. Install the indicator (2) to the swivel base (1). Tighten the clamp of the baser until snug.
14. Install the handle (1) to the pivot arm assembly. 17.
15. Select the adapter (2) (as required) and install to the swivel base (1). Tighten until snug.
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Install the swivel base (1) to the oil pan rail of the engine block. Tighten until snug.
18. Adjust the swivel base as required and position the indicator tip slightly above the connecting rod cap. Lock the swivel base in position by rotating the locking lever (1). Do not allow the tip of the indicator to contact the connecting rod at this time.
21. Lightly actuate the handle of the pivot arm assembly (multiple items in both directions) to ensure the oil film is removed from the journal.
19. The tip of the indicator should be positioned above and NOT in contact with the cap end of the connecting rod.
22.
Load the handle in the forward position and zero the dial indicator. Load the handle multiple times in both directions and record the reading.
Important: During this procedure, card stock may enter the crankshaft journal oil galleries. Be sure to remove all card stock from the bearing journal and oil galleries prior to reassembly. 23. 24.
20. Rotate the fine adjustment knobs on the dial indicator end of the swivel base to position the tip of the indicator in contact with the connecting rod.
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Remove the bearing cap bolts, cap and paper stock. Replace the bearing halves as required to obtain the proper bearing clearance.
Plastic Gauge Method for Crankshaft Bearings
4. Install the crankshaft bearings into the crankshaft bearing caps.
1. Install the crankshaft bearings into the engine block.
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5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block. 6. Install the crankshaft bearing cap bolts and tighten in a two step method. First pass tighten to the specified torque and the final pass tighten an additional 73 degrees using the electronic torque angle meter J 36660.
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2. Install the crankshaft.
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3. Install the gauging plastic the full width of the journal.
Tightening Torque for Crankshaft Bearing Cap Bolts First Pass
2.08 Kgf•m (15 lb ft) [20 N•m]
Tightening Torque for Crankshaft Bearing Cap Bolts Final Pass
Additional 73°
7. Remove the crankshaft bearing cap bolts. 8. Remove the crankshaft bearing caps. The gauging plastic may adhere to either the crankshaft bearing journal or the crankshaft bearing surface.
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9. Without removing the gauging plastic, measure the compressed width at the widest point using the graduated scale on the edge of the gauging plastic envelope. If the flattened gauging plastic tapers toward the middle or the ends, there may be a difference in clearance indicating taper, low spot or other irregularity of the crankshaft bearing or the crankshaft bearing journal. • Normally the crankshaft bearing journals wear evenly and are not out-of-round. However, if a crankshaft bearing is being fitted to an outof-round 0.0254 mm (0.0010 in) (maximum) crankshaft bearing journal, be sure to fit to the maximum diameter of the crankshaft bearing journal. If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal is excessively outof-round, the interference between the crankshaft bearing and the crankshaft bearing journal will result in rapid crankshaft bearing failure. • If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications, replace the crankshaft bearing.
Connecting Rod Side Clearance Measuring Procedure
Always replace both the upper and lower crankshaft bearings as a unit. • A standard or undersize crankshaft bearing combination may result in the proper clearance. If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings, it may be necessary to repair or replace the crankshaft. Important: Do not shim, scrape or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.
Crankshaft Balancer Clean and Inspect
1. Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance. Refer to General Specifications. 2. Connecting rod side clearances may also be measured with a dial indicator set.
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! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the crankshaft balancer in cleaning solvent. 2. Dry the crankshaft balancer with compressed air. 3. Inspect the crankshaft balancer for the following: • Loose or improperly installed front groove pin (1) (crankshaft balancer) A properly installed front groove pin should be installed until flush or below flush with the face of the crankshaft balancer. Important: A crankshaft front oil sealing surface with excessive scoring, grooves, rust or other damage must be replaced. • Worn, grooved or damaged crankshaft front oil sealing surface (2) Minor imperfections on the crankshaft balancer crankshaft front oil seal surface may be removed with a polishing compound or fine grade emery cloth. • Worn, chunking or deteriorated rubber (3) between the hub and the outer ring • Worn or damaged keyway (4) • Worn or damaged bolt hole threads (5)
10. Remove the flattened gauging plastic. 11. Measure the remaining crankshaft bearing journals.
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Important: Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing. 2. Install the NEW crankshaft rear oil seal housing gasket.
Crankshaft Rear Oil Seal and Housing Installation Tools Required • J 35621-B Rear Main Seal Installer Notice: Refer to Fastener Notices in Cautions and Notices. 1. Install the crankshaft rear oil seal housing retainer stud.
Tightening torque for crankshaft rear oil seal housing retainer stud
3. Install the crankshaft rear oil seal housing onto the crankshaft rear oil seal housing retainer stud. 4. Install the crankshaft rear oil seal housing nut and bolts. Tightening torque for crankshaft rear oil seal housing nut and bolts
1.22 Kgf•m (53 lb ft) [6 N•m]
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1.22 Kgf•m (106 lb ft) [12 N•m]
5. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing. 6. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange. 7. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin. 8. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface. 9. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. Minor imperfections may be removed with a fine grade emery cloth. Important: DO NOT allow oil or any other lubricants to contact the seal lip of the crankshaft rear oil seal.
14. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. a. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. b. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the crankshaft rear oil seal. 15. Remove the J 35621-B from the crankshaft. 16. Wipe off any excess engine oil with a clean rag.
Engine Flywheel Clean and Inspect
! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Clean the engine flywheel(1) or (2) in cleaning solvent. 2. Dry the engine flywheel with compressed air.
10. Remove the sleeve from the crankshaft rear oil seal. 11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal. 12. Install the crankshaft rear oil seal onto the J 35621-B. 13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail.
3. Inspect the engine flywheel (automatic transmission) (if equipped) for the following: • Stress cracks around the engine flywheelto-torque converter bolt hole locations (1) • Missing balance weights • Stress cracks around the engine flywheelto-crankshaft bolt hole locations (2) or (3)
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Important: Do not attempt to repair the welded areas (if present) that retain the ring gear to the engine flywheel plate. Always install a NEW engine flywheel. • Welded areas that retain the ring gear onto the engine flywheel for cracking (4) (if present). • Damaged ring gear teeth (5)
5. Inspect the engine flywheel (manual transmission) (if equipped) for the following: • Pitted friction surface (1) • Scoring or grooves (2) • Damaged ring gear teeth (4) • Loose or improperly positioned ring gear The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the engine flywheel.
4. Inspect the engine flywheel (manual transmission) (if equipped) for loose or improperly installed flywheel weights (if applicable). A properly installed flywheel weight should be installed until flush or below flush with the face of the engine flywheel.
Engine Flywheel Installation 1. Install the engine flywheel to crankshaft. 2. Align the locator hole to the pin. 3. Install the engine flywheel bolts. Tightening torque for engine 10.25 Kgf•m (74 lb•ft) [100 N•m] flywheel bolts
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Clutch Pilot Bearing Installation
! CAUTION Refer to Safety Glasses Caution in Cautions and Notices. 1. Install the NEW clutch pilot bearing using a suitable clutch pilot bearing installation tool. 2. Measure to ensure the proper installation depth is obtained.
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Cylinder Block Cleaning and Inspection
Disassembly steps 1. Engine support (R.H.) 2. Engine support (L.H.) 3. Cylinder block
7EN0035
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Engine Block Plug Removal
3. Remove the engine oil pressure sensor fitting.
Tools Required • J 41712 Oil Pressure Switch Socket 1. Remove the knock sensor from the engine block.
188020
4. Remove the dowel straight pins (transmission locator) (if required).
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2. Remove the engine oil pressure gauge sensor using the oil pressure switch socket J41712.
334350
5. Remove the engine block left side oil gallery plug. 6. Remove the engine block left rear oil gallery plug. 7. Remove the engine block right rear oil gallery plug. J 41712
188018
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8. Remove the expansion cup plug (camshaft rear bearing hole) and discard.
10. Remove the spring type S pin (crankshaft rear oil seal housing locator) (if required).
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11. Remove the front oil gallery plugs or balls from the front of the engine block and discard. 12. Insert a 3/8 x 26 in. rod into the rear oil gallery holes in order to drive out the front oil gallery plugs or balls.
334364
9. Remove the expansion cup plug (balance shaft rear bearing hole) and discard.
5270
13. Remove the engine block core hole plugs. a. Use a suitable tool in order to drive the engine block core hole plugs into the coolant jacket. b. Use a suitable tool in order to pull the engine block core hole plugs from the coolant jacket. c. Discard the engine block core hole plugs. 334366
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14. Remove the oil filter bypass valve and discard.
1. Clean all the remaining sealing or gasket material from the sealing surfaces. 2. Clean the engine block with cleaning solvent. 3. Flush the engine block with clean water or steam. 4. Clean the cylinder bores. 5. Clean the oil galleries and the oil passages. 6. Clean the scale and the deposits from the coolant passages. Notice: Clean all debris, dirt and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to the components. 7. Clean the engine block cylinder head bolt holes. 8. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil. 9. Inspect the following areas: • Coolant jackets (1) for cracks • Cylinder bores (2) for scratches or gouging • Valve lifter bores (3) for excessive scoring or wear • Threaded holes (4) for damage • Crankshaft bearing webs (5) for cracks • Crankshaft bearing caps (6) and the crankshaft bearing bores (7) for damage ■ The crankshaft bearing bores should be round and uniform when measuring the inside diameter (ID). ■ The surface where the crankshaft bearings contact the crankshaft bearing bore should be smooth. ■ If a crankshaft bearing cap is damaged and requires replacement, replace the crankshaft bearing cap first, then rebore the engine block crankshaft bearing bores and check for proper alignment. Finally, check the crankshaft for the proper clearances. • Engine block core hole plug bores (8) for damage • Engine block (9) for cracks or damage • Engine mount bosses (10) for damage 10. Measure the cylinder bores for taper and out-ofround. a. Depress the plunger on the cylinder bore guage J 8087 7 mm (0.275 in) or until the J 8087 enters the cylinder bore. b. Center the cylinder bore guage J 8087 in the cylinder bore and turn the indicator dial to 0. c. Move the cylinder bore guage J 8087 up and down the cylinder bore to determine the cylinder bore taper. Refer to General Specifications. d. Turn the J8087 to different points around the cylinder bore to determine the cylinder bore out-of-round condition. Refer to Engine Mechanical Specifications.
188026
Engine Block Clean and Inspect Tools Required • J 8087 Cylinder Bore Gauge
! CAUTION Safety Glasses must be worn or eye injury may occur.
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Cylinder Boring and Honing Honing Procedure 1. When honing the cylinder bores, follow the manufacturer’s recommendations for equipment use, cleaning and lubrication. • Use only clean sharp stones of the proper grade for the amount of material to be removed. • Dull, dirty stones cut unevenly and generate excessive heat. • DO NOT hone to a final grade with a coarse or medium- grade stone. • Leave sufficient metal so that all the stone marks will be remove with the fine grade stones. • Perform the final honing with a fine-grade stone and hone the cylinder bore in a crosshatch pattern at 45-65 degrees to obtain the proper clearance.
J 8087
NOTE Caution: Do not grind the mating surfaces of the cylinder block and cylinder head beyond 0.2 mm (0.008 in.) of total grinding limit.
186747
2. During the honing operation, thoroughly check the cylinder bore. • Repeatedly check the cylinder bore fit with the selected piston. • All measurements of the piston or cylinder bore should be made with the components at normal room temperature. 3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. 4. Repeatedly check the measurement at the top, the middle and the bottom of the cylinder bore. • The finish marks should be clean but not sharp. • The finish marks should be free from imbedded particles or torn or folded material. 5. By measuring the selected piston at the sizing point and then by adding the average of the clearance specification, the final cylinder bore honing dimension required can be determined.
7EN266
11. Check the Cylinder head mounting surface for flatness, using a precision straight edge and feeler gauge. • Set the straight edge on the sealing surface to be inspected. • Put the feeler gauge at various locations; check the gap between the straight edge and the sealing surface. • If the gap is greater than 0.05 mm (0.002 in.) within 152 mm (6 in.) at any sealing location, the block must be replaced. • If the gap is found to be less than 0.05 mm (0.002 in.) at any sealing location and a cause for leakage is suspected, then the minor irregularities may be carefully machined from the block. 12. Check the Oil pan, timing cover and intake manifold mounting surfaces for nicks. Minor irregularities may be cleaned up with a flat file.
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6. When finished, the reconditioned cylinder bores should have less than or meet the specified outof-round and taper requirements. 7. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. • Scrub the cylinder bores with a stiff bristle brush. • Rinse the cylinder bores thoroughly with clean hot water. • Dry the cylinder bores with a clean rag. • Do not allow any abrasive material to remain in the cylinder bores. ■ Abrasive material may cause premature wear of the new piston rings and the cylinder bores. ■ Abrasive material will contaminate the engine oil and may cause premature wear of the bearings. 8. Perform final measurements of the piston and the cylinder bore. 9. Permanently mark the top of the piston for the specified cylinder to which it has been fitted. 10. Apply clean engine oil to each cylinder bore in order to prevent rusting.
3. From the piston O.D. measurement, calculate the valve of the cylinder bore to which every cylinder is to be rebored. Rebore diameter = Piston O.D. + 0.02 mm (8 x 10-4 in.) to 0.04 mm (1.6 x 10-3 in.) (Cylinder-to-piston clearance) - 0.02 mm (8 x 10-4 in.) (honing allowance) 4. Rebore all cylinders to the calculated diameter.
NOTE Reboring should be made in the order of the cylinders numbers to prevent warping due to excessive temperature. 5. With a hone, a. Recondition the cylinders that have less than 0.025 mm (0.0010 in.) wear or taper. b. Bore and hone the cylinders that have more than 0.025 mm (0.0010 in.) of wear or taper to the smallest oversize piston that will permit complete resurfacing of all the cylinders. 6. Hone the cylinders to the finished size (piston O.D. + piston-to-cylinder clearance). • During the honing operations occasionally: – Clean the cylinder bore. – Measure the cylinder bore for a proper piston fit.
Reboring the Cylinders
NOTE
Boring Procedure
Important: Handle the pistons with care. Do not force the pistons through the cylinders until you hone the cylinder to the correct size. The piston can be distorted through careless handling.
! CAUTION Safety Glasses must be worn or eye injury may occur. 1. Before starting the honing or reboring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline.
1. To determine the size of the oversize piston to be used in all cylinders, choose the cylinder that requires the largest amount of reboring and use its size as the basis for all piston sizes. 2. Two kinds of oversize pistons are available; 0.50 mm (0.02 in.) O.S. and 1.00 mm (0.039 in.) O.S. Those oversizes are based on the piston skirt O.D. measured along the datum line as shown in the figure. For all cylinders, select oversize pistons with the same diameter.
188016
7EN268
-112-
2. File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar. 3. Follow the instructions furnished by the manufacturer regarding the use of the boring equipment. 4. When reboring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction. 5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly. 6. When making the final cut with the boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for finish honing. This gives the required position to the cylinder clearance specifications. (Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons, the piston rings and the cylinder bores). 7. Check each cylinder for proper cylinder-to-piston clearance.
2. Apply sealant MCF P/N 2I4256 GM P/N 12346004 or equivalent to the outside diameter of the new front engine oil gallery plugs. 3. Install the new front engine block oil gallery plugs. A properly installed front engine oil gallery plug must be installed slightly below flush with the front face of the engine block.
5270
4. Apply threadlock GM P/N 12345382 or equivalent to the outside diameter of the NEW engine block core hole plugs. 5. Install the NEW engine block core hole plugs. Properly installed engine block core hole plug must be installed flush with the bottom of the chamfer (1) of the engine block core hole.
Engine Block Plug Installation Installation Procedure Tools Required • J 41712 Oil Pressure Switch Socket
! CAUTION Wear safety glasses in order to avoid eye damage. 1. Install a new oil filter bypass valve. a. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. b. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart.
6. Install the spring type S pin (crankshaft rear oil seal housing locator) (if required).
188023
-113-
11. Apply sealant MCF P/N 2I4256 GM P/N 12346004 or equivalent to the threads of the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil gallery plug. Tightening torque for left and right side rear oil gallery plugs Tightening torque for left rear oil gallery plug
2.08 Kgf•m (15 lb•ft) [20N•m]
3.05 Kgf•m (22 lb•ft) [30 N•m]
334546
7. Apply sealant MCF P/N 2I4256/GM P/N 12346004 or equivalent to the outside diameter of the new expansion cup plug (balance rear bearing hole). 8. Install the new expansion cup plug (balance shaft rear bearing hole).
182841
12. Install the dowel straight pins (transmission locator) (if required).
334540
9.
Apply sealant MCF P/N 2I4256/GM P/N 12346004 or equivalent to the outside diameter of the new expansion cup plug (camshaft rear bearing hole). 10. Install the new expansion cup plug (camshaft rear bearing hole). 334548
-114-
13. Install the left side dowel pins (cylinder head locator) (if required).
16. Install the engine block coolant drain hole plug. Tightening torque for engine block coolant drain hole plug
2.08 Kgf•m (15 lb•ft) [20N•m]
188052 334303
17. Apply sealant MCF P/N 2I4256/GM P/N 12346004 or equivalent to the threads of the engine oil pressure sensor fitting.
14. Install the right side dowel pins (cylinder head locator) (if required).
NOTE Important: Do not loosen the engine oil pressure fitting after the initial torque has been obtained.
Tightening torque for engine oil pressure sensor fitting
334314
15. Apply sealant MCF P/N 2I4256/GM P/N 12346004 or equivalent to the threads of the engine block coolant drain hole plug.
-115-
1.52 Kgf•m (11 lb•ft) [15 N•m]
18. Install the engine oil pressure sensor fitting.
23. Install the knock sensor.
NOTE
Tightening torque for 2.08 Kgf•m (15 lbf•ft) [20 N•m] knock sensor
Important: Do not rotate the engine oil pressure fitting clockwise more than 359 degrees after the initial torque has been obtained. 19. Rotate the engine oil pressure sensor fitting clockwise to the proper position (1) 50 degrees from the centerline.
10793
20. Apply sealant MCF P/N 2I4256/GM P/N 12346004 or equivalent to the threads of the engine oil pressure gauge sensor. 21. Install the engine oil pressure gauge sensor using the oil pressure switch socket J 41712. 22. Apply sealant MCF P/N 2I4256/GM P/N 12346004 or equivalent to the threads of the knock sensor. Tightening torque for engine oil pressure gauge sensor
3.05 Kgf•m (22 lb•ft) [30 N•m]
J 41712
188018
-116-
Piston and Connecting Rod Removal and Installation
Removal steps 1. 2. 3. 4. 5. 6. 7. 8. 9.
Nut Rod Cap Bearing Bearing Piston and Connecting Rod Assy Pin Rod - Connecting Piston Ring Kit
-117-
Piston, Connecting Rod, and Bearing Removal
NOTE Important: Place matchmarks or numbers on the connecting rods and the connecting rod caps. Assemble the connecting rod caps to the matching connecting rods. 2. Remove the connecting rod nuts. 3. Remove the connecting rod cap. 4. Remove the connecting rod bearings. • Keep the bearings with the original connecting rod and connecting rod cap. • Wipe the oil from the bearings. • Wipe the oil from the crankpins.
Tools Required • J 24270 Cylinder Bore Ridge Reamer • J 5239 Guide Set 1. Use the cylinder boer ridge reamer J 24270 to remove the cylinder ring ridge. a. Turn the crankshaft until the piston is at the bottom of the stroke. b. Place a cloth on top of the piston. c. Use a ridge reamer to remove cylinder ring ridge. d. Turn the crankshaft so the piston is at the top of the stroke. e. Remove the cloth. f. Remove the cutting debris.
480549
11497
5. Use the guide set J 5239 to protect the crankshaft vournals and to remove the connecting rod and the piston out of the top of the engine block.
31373
-118-
Piston and Connecting Rod Disassemble
4. Mark, separate and organize the parts for assembly.
Tools Required • J 24086 Piston Pin Remover/Installer
NOTE Important: Mark the piston for installation to the proper cylinder. 1. Remove the piston rings from the pistons.
34671
Piston, Connecting Rod and Bearings Clean and Inspect Important: Measurement of all components should be taken with the components at room temperature. Do not use a wire brush in order to clean any part of the piston.
! CAUTION
4967
2. Press the piston pin from the connecting rod using the piston pin remover/installer J 24086-C. 3. The piston pin has an interference fit into the connecting rod, and is full floating in the piston.
Safety Glasses must be worn or eye injury may occur. 1. Clean the piston and connecting rod in solvent. 2. Dry the components with compressed air.
J 24086-C
4965
34671
-119-
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
6. Inspect the piston pin for scoring, wear or other damage. 7. Measure the piston ring-to-piston ring groove side clearance. a. Insert the edge of the piston ring into the piston ring groove. b. Roll the piston ring completely around the piston. ■ If binding is caused by a distorted piston ring groove, MINOR imperfections may be removed with a fine file. ■ If binding is caused by a distorted piston ring, replace the piston ring.
4977
4. Clean the piston oil lubrication holes and slots. 5. Inspect the piston for the following: • Eroded areas (1) on the top of the piston • Scuffed or damaged skirt (2) • Damage to the pin bore (3) • Cracks in the piston ring lands, the piston skirt or the pin bosses • Piston ring grooves for nicks, burrs or other warpage which may cause the piston ring to bind
4969
8. Measure the piston ring side clearance with a feeler gauge. 9. If the side clearance is too small, try another piston ring set. 10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly. 11. To determine the proper piston ring side clearance, refer to General Specifications.
156168
22934
-120-
12. To determine piston pin-to-bore clearance, use a micrometer and measure the piston pin.
188016
16. Inspect the connecting rod for an out-of-round bearing bore. Refer to General Specifications. 4976
13. To determine piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore. 14. To determine the piston pin-to-bore clearance, subtract the piston pin diameter from the piston pin bore diameter. Refer to General Specifications.
156167
17. Inspect the connecting rod for twisting. 18. Inspect the connecting rod for damage to the bearing cap and bolt threads.
4975
15. Measure the piston with a micrometer at a right angle to the piston pin bore, measure the piston at 11 mm (0.433 in) from the bottom of the skirt. Refer to General Specifications. If the piston is not within specifications, replace the piston and pin as an assembly.
156169
-121-
19. Measure the piston compression ring end gap. Important: Fit each compression ring to the cylinder in which it will be used. 20. Place the compression ring into the cylinder bore. a. Push the compression ring into the cylinder bore to approximately 6.5 mm (0.25 in) above the ring travel. The ring must be square to the cylinder wall. b. Use a feeler gauge in order to measure the end gap. c. Select another size ring set if the end gap exceeds specifications. Refer to General Specifications.
2. Measure the cylinder bore guage J 8087 with a micrometer and record the reading.
J 8087
4974
3. With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 in) from the bottom of the skirt. 4. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-tobore clearance. Refer to General Specifications. 5. If the proper clearance cannot be obtained, then select another piston and measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing or boring. 6. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder.
Piston Selection Tools Required • J 8087 Cylinder Bore Gauge Important: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores should not have excessive wear or taper. A used piston and piston pin set may be reinstalled if, after cleaning and inspection, the piston and piston pin are within specifications. 1. Use the cylinder bore guage J 8087 to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore and 90 degrees to the crankshaft centerline.
J 8087
188016
4972
-122-
Piston, Connecting Rod and Bearing Installation
Important: The mark on top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and connecting rod cap should face the front of the engine block on the left bank, and to the rear of the engine block on the right bank. 4. Install the piston and connecting rod assembly, and the piston ring compressor J 8037 into the proper cylinder bore.
Tools Required •J 5239 Guide Set •J 8037 Piston Ring Compressor •J 36660 Torque Angle Meter 1. Coat the following components with clean engine oil: • The piston • The piston rings • The cylinder bore • The bearing surfaces 2. Install the guide set J 5239 onto the connecting rod bolts.
J 5239
J 8037 492144
5. Use the piston ring compressor J 8037 and the guide set J 5239 to lightly tap the top of the piston with a wooden hammer handle. a. Hold the piston ring compressor J 8037 firmly against the engine block until all of the piston rings enter
387765
3. Install the piston ring compressor J 8037 onto the piston and compress the piston rings.
J 8037
J 8037
480573
5159
-123-
b. Use the guide set J 5239 to guide the connecting rod onto the crankshaft journal. 6. Remove the piston ring compressor J 5239.
8. After the piston and connecting rod assemblies have been installed, then lightly tap each connecting rod assembly (parallel to the crankpin) in order to insure that the connecting rods have side clearance.
J 5239
5163
9. Use a feeler gauge or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.16-0.44 mm (0.006-0.017 in.).
31373
7. Install the connecting rod cap, bearings and nuts. Tightening torque 1st pass for rod cap nuts 2.77 Kgf•m (20 lbf•ft) [27 N•m]
Piston and Connecting Rod Assemble Tools Required • J 24086-C Piston Pin Remover/ Installer
• On the final pass, use the electronic torque angle meter J 36660 to tighten the nuts an additional 70 degrees. Tightening torque for rod cap nuts
! CAUTION Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personnel injury.
Final pass Additional 70°
NOTE Important: Applying excessive heat to the connecting rod may damage or distort the rod. Rod temperature SHOULD NOT exceed 315°C (600°F). At this temperature, the end of the connecting rod will turn a straw color upon visual inspection.
NOTE Important: After the MCF-1083 (J 24086-C) installer hub bottoms on the support assembly, DO NOT exceed 35,000 kPa (5,000 psi) or the tool may be damaged.
480545
-124-
2. Install the piston rings onto the piston. a. Install the oil control piston ring spacer. b. Install the lower oil control piston ring. c. Install the upper oil control piston ring. d. Install the lower compression piston ring. The mark on the side of the piston ring should face the top of the piston. e. Install the upper compression piston ring. The mark on the side of the piston ring should face the top of the piston.
NOTE Important: When assembling the piston and connecting rod, the mark on the top of the piston must point to the front of the engine block. The left bank connecting rods should have the flange face toward the front of the engine block. The right bank connecting rods should have the flange face toward the rear of the engine block. The piston pin has an interference fit into the connecting rod and is full floating in the piston. 1. Install the piston pin and connecting rod assembly. a. Lubricate the piston holes in both the piston and the connecting rod assembly with clean engine oil. b. Use a torch and apply MILD heat to the piston pin end of the connecting rod. c. Press the piston pin into the piston and connecting rod assembly using the piston pin remover/installer J 24086-C. d. Inspect for proper installation of the piston and piston pin. The piston must move freely on the piston pin with no binding or interference.
490763
J 24086-C
3. Space the compression piston ring end gaps 120 degrees apart. 4. Space the oil control piston ring end gaps a minimum of 90 degrees apart.
4965
NOTE Important: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.
-125-
-126-
Gasoline Carburetor Removal and Installation
1. 2. 3. 4. 5. 6. 7. 8.
Carburetor Fuel Inlet Intake Air Connector Accelerator Cable Carburetor Connector Gasket Adapter Gasket
-127-
Carburetor Assembly Removal Procedure 1. Remove Intake Air Connector. 2. Disconnect Accelerator Cable from Carburetor. 3. Disconnect Carburetor Connector.
NOTE Important: Mark and organize all hoses for assembly. 4. Disconnect the Following Hoses: • Fuel inlet hose • Emmision control hoses • Vacuum Lines 5. Remove the four carburetor mounting nuts. 6. Lift out the carburetor. 7. Cover the inlet hole of the intake manifold with a cloth.
PO5026
PO5024
PO5034
-128-
Carburetor Assembly (Upper) Removal and Installation 7 1 15 2 27
28 29 34 6 4 36
33 32 30
35
31 5
38 37
40
39
16
26 24
22
Disassembly steps Stud bolt Nipple union Pivot bolt Acceleration pump arm FICB link Air Horn Wire clamp Pivot pin Wire Float Plunger Spring Needle valve Acceleration pump plunger Plunger boot Air horn gasket Needle valve seat Gasket Screw Retainer
18
23
25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
3
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Power piston Spring Primary upper slow jet Screw Coil housing Gasket Screw Cover Spring E-ring Stopper Spring Collar Diaphragm Solenoid Valve Gasket Screw Choke lever Screw Thermostat housing
-129-
21 20
17 14
19 13
10
12 11 9 8
-130-
Carburetor Assembly (Lower) Removal and Installation
1 19
13
4
7 6
5
18 14 3
2
5
20
15 17
16 12
Disassembly steps 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Discharge weight Spring Check ball Plunger spring Retainer Check ball Primary slow jet Plug Spring Ball Plug Ball 23 Power valve Passage plugs Gaskets Primary main jet Gasket Passage ring Screw Primary small venturi Gasket Snap ring Screw Fast idle cam breaker (FICB) Fast idle cam Passage screw Bolt Carburetor Body Carburetor flange Insulator
8
11
21
24
28
27
25 30 22
29 26
-131-
9 10
Carburetor Disassembly
3. Disconnect Fast Idle Cam Breaker (FICB) Link.
Hint: The following instructions are organized to allow work on only one component group at a time. This will help avoid confusion between similar looking parts from different subassemblies that are on the workbench at the same time. 1. To facilitate reassembly, arrange parts in order. 2. Be careful not to mix up or lose balls, clips or springs.
Air Horn Disassembly
PO5033
1. Remove Carburetor Stud Bolt and Nipple Union.
4. Remove Air Horn Assembly. a. Remove the seven screws and following parts: • Number plate (1) • Wire clamps (2) • Switch harness clamp (3) • Coil housing and solenoid valve harness clamp (4) b. Lift off the air horn assembly together with the air horn gasket.
PO4859
2. Remove Acceleration Pump Arm. a. Remove the snap ring from the pump connecting link. b. Remove the pivot bolt. c. Disconnect the pump arm from the pump plunger. d. Disconnect the pump connecting link from the throttle lever and remove the pump arm and pump connecting link.
PO5522
5. Remove Float and Needle Valve. Remove the float pivot pin, float and needle valve subassembly.
PO5109 PO5035
-132-
6. Remove Acceleration Pump Plunger. a. Remove the pump plunger and boot. b. Remove air horn gasket.
9. Remove Primary Upper Slow Jet.
PO5082
10. Disconnect Wires from Carburetor Connector. a. Pry up the locking lugs with a screwdriver and pull out the terminal. 11. Remove Coil Housing. a. Remove the three screws, retainer, coil housing and gasket.
PO4976
7. Remove Needle Valve Seat. a. Remove the needle valve seat and gasket.
PO5083
8. Remove Power Piston. a. Remove the screw, retainer, power piston and spring.
PO4723
12. Remove Choke Breaker (CB). a. Remove the three screws, cover and spring.
PO4721
PO4722
-133-
b. Remove the E-ring, stopper, spring collar and diaphragm.
b. Remove the two screws and thermostat housing.
PO4853
PO4725
15. Remove Fast Idle Cam Breaker (FICB) Link. a. Remove the screw and FICB link.
13. Remove Fuel Cut Off Solenoid Valve. a. Remove the solenoid valve and gasket.
PO4977
PO4724
14. Remove Thermostat Housing. a. Remove the screw and choke lever.
Carburetor Body Disassembly 1. Remove Check Balls for Acceleration Pump. a. Remove the pump discharge weight, spring and large ball. b. Remove the plunger spring.
PO4727
PO4719
-134-
c. Using tweezers, remove the ball retainer. d. Remove the small ball.
4. Remove Power Valve.
PO4890 PO5036
5. Remove Primary Main Jets. a. Remove the two passage plugs and gaskets.
2. Remove Slow Jets. a. Remove the primary slow jet.
PO4718 PO4926
b. Remove the primary main jets and gaskets.
3. Remove Check Balls for Auxiliary Acceleration Pump (AAP). a. Remove the plug, spring and ball (a). b. Remove the plug and ball (b).
PO4949
PO4944
-135-
6. Remove Small Venturies. a. Remove the passage ring.
8. Remove Fast Idle Cam.
PO4714
9. Separate Carburetor Body and Flange. a. Remove the passage screw and spring washer.
PO4858
b. Remove the two screws, primary small venturi and gasket.
PO5019
PO5509
7. Remove Fast Idle Cam Breaker (FICB). a. Remove the snap ring. b. Remove the two screws. c. Disconnect the link, and remove the FICB.
b. Remove the two bolts. c. Separate the body and flange. d. Remove the insulator.
PO4733
PO4712
-136-
General Cleaning Procedure
2. Inspect Power Piston. a. Check that the power piston moves smoothly.
1. Clean Disassembled Parts Before Inspection. a. With a soft brush, wash and clean the cast parts in carburetor cleaner. b. Clean the carbon around the throttle valve. c. Thoroughly wash the other parts in carburetor cleaner. d. Blow all dirt and other foreign material from the jets, fuel passages and restrictions in the body.
PO4893
3. Inspect Power Valve. a. Check for faulty opening and closing action.
PO4975
Carburetor Inspection 1. Inspect Float and Needle Valve. a. Inspect the pivot pin (1) for scratches and excessive wear. b. Inspect the float (2) for broken lips and wear in the pivot pin holes. c. Inspect the spring (3) for breaks and deformation. d. Inspect the needle valve (4) and plunger (5) for wear or damage. e. Inspect the strainer (6) for rust and breaks.
PO4740
4. Inspect Fuel Cut Off Solenoid Valve. a. Connect the connector terminals to the battery terminals. b. You should feel a “click” from the solenoid valve when the battery power is connected and disconnected. If the solenoid valve is not operating properly, replace it.
PO4739
PO4741
-137-
5. Inspect Choke Heater (Coil Housing). a. Using an ohmmeter, measure the resistance between the terminals.
2. Install Fast Idle Cam.
Resistance (Cold): 17.3 - 18.7 Ω at 20°C (68°F) If a problem is found, replace the choke heater.
PO4714
3. Install Fast Idle Cam Breaker (FICB). a. Connect the link, and install the FICB with the two screws. b. Secure the link with the snap ring.
PO4742
Carburetor Assembly Hint: Use new gaskets and O-rings throughout. 1. Assemble Carburetor Body and Flange. a. Assemble the flange and body together with a new insulator. b. Install the two bolts.
PO4733
4. Install Small Venturies. a. Install a new gasket and the primary venturi with the two screws.
PO4712
c. Install the passage screw together with the spring washer.
PO4946
PO5509
-138-
b. Install the passage ring.
6. Install Power Valve.
PO4890
PO4858
7. Install Primary Slow Jet.
5. Install Primary Main Jets. a. Install the primary main jets with new
PO4873 PO4871
8. Install Check Balls for Acceleration. a. Install the plunger small ball. b. Using tweezers, install the ball retainer.
b. Install the primary passage plugs with new gaskets.
PO4718
PO5036
-139-
c. Install the plunger spring (c). d. Install the pump discharge large ball, spring and weight (d).
b. Install the choke lever with the screw.
PO4727
3. Install Fuel Cut Off Solenoid Valve. a. Install a new O-ring to the solenoid valve. b. Install the solenoid valve together with a new gasket.
PO4891
Air Horn Assembly 1. Install Fast Idle Cam Breaker (FICB) Link. Install the FICB link with the screw.
PO4724
4. Install Choke Breaker (CB). a. Install the diaphragm into the thermostat case, and install the collar, spring and stopper with the E-ring. b. Insert the shaft of the diaphragm into the hole of the thermostat case.
PO4977
2. Install Thermostat Housing. a. Install the thermostat housing with the two screws.
PO4853
PO4725
-140-
c. Install the following parts with the three screws: • Spring
b. Pull on the wire to check that it is securely locked.
PO4738
7. Install Primary Upper Slow Jet. PO5425
5. Install Coil Housing. a. Install the gasket to the thermostat case. b. Align the bi-metal spring with the wire spring and install the coil housing, aligning the choke lever as shown in the illustration.
PO5082
8. Install Power Piston. a. Install the spring and power piston with the retainer and screw. PO5060
c. Align the scale center line of the thermostat case with the coil housing line, and install the plate with the three screws. d. Check the choke valve action. 6. Connect Wires to Connector. a. Push in the terminal until it is securely locked in the connecting lug.
PO4919
PO4730
-141-
9. Install Needle Valve Seat. a. Install the valve seat together with a new gasket.
c. Allow the float to hang down by its own weight. Measure the clearance between the float tip and air horn. Float level (Raised position): 7.0 mm (0.276 in.). Hint: This measurement should be made without a gasket on the air horn.
PO5083
10. Adjust Float Level. a. Insert the needle valve, spring and plunger into the needle valve seat. Hint: After adjusting the float level, install the clip onto the needle valve.
PO4889
d. Adjust by bending the portion of the float lip marked A.
PO4857 PO4735
b. Install the float with the pivot pin.
e. Lift up the float. Measure the clearance between the needle valve plunger and float tip. Float level (lowered position): 0.9 - 1.1 mm (0.035 - 0.043 in.)
PO4860
PO4736
-142-
f. Adjust by bending the position of the float lip marked B. g. After adjusting the float level, remove the float, plunger, spring and needle valve.
13. Install Needle Valve and Float. a. Hook the needle valve clip to the lip portion of the float.
PO4973
PO4737
b. Install the float and secure it with the pivot
h. Assemble the clip onto the needle valve.
PO4720 PO5035
11. Install New Air Horn Gasket. a. Place the air horn gasket on the air horn. 12. Install Acceleration Pump Plunger. a. Install a new boot and the pump plunger.
14. Install Air Horn Assembly. a. Install the wire clamp in position.
PO5037
PO4976
-143-
b. Place the air horn in the carburetor body. c. Install the following parts with the seven screws: • Number plate (1) • Wire clamps (2) • Switch harness clamp (3) • Coil housing and solenoid valve harness clamp (4)
17. Install Nipple Union. a. Install a new gasket and nipple union. 18. Check for Smooth Operation of Each Part.
PO4974
Carburetor Adjustment 1. Check and Adjust Throttle Valve Opening. a. Check the full opening angle of the primary throttle valve. Standard angle: 90° from horizontal
PO5522
15. Connect Fast Idle Cam Breaker (FICB) Link.
PO5033 PO5032
16. Install Acceleration Pump Arm. a. Connect the pump connecting link to the throttle lever. b. Connect the pump arm to the pump plunger. c. Install the pump arm with the pivot bolt. d. Secure the link with the snap ring.
b. Adjust by bending the primary throttle stop lever.
PO5113 PO5109
-144-
2. Set Automatic Choke. a. Set the coil housing line so that it is aligned with the center line of the thermostat housing. Hint: The choke valve becomes fully closed when the atmospheric temperature reaches 30°C (86°F).
b. Check the primary throttle valve angle. Standard angle: 23.3° - 25.3° from horizontal
PO5074
c. Adjust by turning the fast idle adjusting screw. PO5039
b. Depending on truck operating conditions, turn the coil housing and adjust the engine starting mixture. If too rich ........ Turn clockwise. If too lean ....... Turn counterclockwise.
PO5077
4. Check and Adjust Unloader. a. With the primary throttle valve fully opened, check the choke valve angle. Standard angle: 35° - 39° from horizontal
PO5088
3. Check and Adjust Fast Idle Setting. a. Position the fast idle lever onto the 1st step as shown.
PO5068
PO4909
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b. Adjust by bending the unloader lever.
b. Apply vacuum to the FICB and release it. c. Check that the choke linkage moves, and that the fast idle cam is released to the 3rd step.
PO5078
5. Check and Adjust Fast Idle Cam Breaker (FICB). a. Set the fast idle cam: • While holding the throttle slightly open, push the choke valve closed, and hold it closed as you release the throttle valve.
PO5511
d. Adjust by bending the FICB lever.
PO5090
6. Check and Adjust Choke Breaker (CB). a. Set the fast idle cam. b. Apply vacuum to the CB. c. Check the choke valve angle. Standard angle: 43.5° - 44.5° from horizontal
PO5028
• Check that the fast idle lever is set in the 1st step of the fast idle cam as shown.
PO4913
PO5067
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d. Adjust by turning the CB adjusting screw.
c. Adjust turning the idle speed adjusting screw.
PO5485
PO5087
7. Check and Adjust Acceleration Pump. a. Apply vacuum to fast idle cam breaker (FICB). b. Rotate the throttle shaft and check the length of the stroke. Standard stroke: 10.9 mm (0.429 in.). c. Adjust the pump stroke by bending the connecting link.
9. Preset Idle Mixture Adjusting Screw. If the idle mixture adjusting screw has been removed, fully screw it in and then unscrew it the following amount: Standard: Return 2 3/4 turns from fully closed position.
NOTE Use care not to screw it in too tightly and damage the screw tip.
PO5021
8. Preset Idle Speed Adjusting Screw. a. Apply vacuum to fast idle cam breaker (FICB). b. Check the primary throttle valve angle. Standard angle: 16° from horizontal
PO5086
10. Check for smooth operation of each part. 11. Install carburetor stud bolt.
Operational Adjustments 1. 2. 3. 4. 5.
Start engine. Allow engine to reach operating temperature. Install tachometer. Idle speed adjustment. Idle mixture adjustment.
Adjust by using the following tools: 1. Tachometer 2. Exhaust Gas Analyzer 3. Vacuum Gauge PO5075
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Carburetor Installation
3. Connect Carburetor Connector. 4. Connect and Adjust Accelerator Cable. a. Loosen the locknut of the Adjusting Nut at carburetor and rotate the Adjusting Nut until all slack from the accelerator cable is removed. Do not set cable so tight as to pull the accelerator pedal. b. Adjustment of the accelerator pedal is required to obtain correct low idle setting. This requires the installation of the floor plate and the engine cover open in order to view the movement of the mechanical throttle body bell crank. c. Adjust the throttle cable tension at the throttle position sensor to 0-2 mm of free play at accelerator pedal before the throttle position sensor starts to move. The clevis at both ends of the cable should not be slack. d. Loosen the locking nut on the accelerator pedal stop bolt to allow adjustment of the accelerator pedal stop bolt. e. Depress the accelerator pedal while viewing the throttle body bell crank. The bell crank will rotate as the accelerator pedal is depressed. f. Set the stop bolt height so the bell crank moves the full range of motion within 0-1 mm from stop plate at carburetor. Tighten the locknut to secure the accelerator stop bolt once adjustment is obtained. g. Start the engine but do not make adjustment until the engine is at operating temperature and the vacuum switch has opened to pull the choke to the off position. h. Slowly depress and release the Accelerator Pedal a few times. Check that there is no slack in the cable when the stepping motor lever is not in motion. The cable will be loose while choke is ON and the cable will be tight when the choke is OFF. Readjust as necessary. i. Install Intake Air Connector. j. Adjust Idle Speed (750 + - 50) and Idle Mixture. k. High RPM cannot be adjusted. It is controlled by the ECU. l. Adjust Choke. m. Check torque converter stall speed per chassis service manual.
1. Install Carburetor. a. Place the insulator and new gaskets on the intake manifold.
PO5025
b. Place the carburetor on the insulator. c. Install the four carburetor mounting nuts. Tightening torque for carburetor mounting nuts
130 Kgf•m (9 lb•ft) [13 N•m]
PO5034
2. Connect the Following Hoses. a. Emission control hoses. b. Fuel inlet hose. c. Outer vent control hose. d. Vacuum lines.
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Electrical Throttle and Governor Control System System Operation Description This controller activates gasoline engine carburetor with a stepping motor to vary air-fuel ratio for controlling engine rpm. Engine rpm is controlled by varying the position of the accelerator pedal. It has a built-in fault detection circuit to provide a fail-safe processing function. Characteristics Low idle: 750 ± 50 rpm High idle: 2650 rpm Speed regulation (rated load): +/- 50% (at 2650 rpm) Instantaneous maximum speed: 2800 rpm Governor: All-speed type Fail-safe processing function This controller detects any of the following faults to perform necessary fail-safe processing and causes the check lamp to indicate error codes in a flickering manner, thereby alerting the operator of a malfunction. A fault code is stored in the memory even after the power has been turned OFF and, when the diagnostic switch is turned ON, it is displayed. 1. 2. 3. 4. 5. 6. 7. 8.
Engine Over Speed Accelerator sensor fault Idle switch fault Throttle CLOSE position detection switch fault Throttle OPEN position detection switch fault Stepping motor fault Rotary pulse fault Alternator fault
The motor output shall perform PWM of approximately 60% to prevent the motor from overheating.
-149-
ECU Input/Output Interfaces The following table shows the input/output specifications of this controller.
Connector No. Signal
Connection
Input/Output
Specification
A1
AP
Motor A phase (blown)
Output
Motor output
A2
BP
Motor B phase (red)
Output
Motor output
A3
OUT1
Check lamp
Output
Open collector output
A4
OUT2
Output
Open collector output
A5
IN1
Throttle CLOSE position detection switch
Input
Contactor input (connected to GND)
A6
AI1
Accelerator sensor signal
Input
Analog input
A7
AI2
Alternator voltage signal
Input
Analog input
A8
P12V
Controller power source
B1
AN
Motor ~ A phase (amber)
Output
Motor output
B2
BN
Motor ~ B phase (yellow)
Output
Motor output
B3
RYNO
Relay output
Output
Non-voltage contactor output
B4
OUT3
Output
Open collector output
B5
IN2
Throttle OPEN position detection switch
Input
Contactor input (connected to GND)
B6
IN3
Idle switch
Input
Contactor input (connected to GND)
B7
GND
Accelerator sensor ground
0V
B8
VCC
Accelerator sensor power source
5V
C1
P12V
Motor common (white)
C2
GND
Throttle position detection switch (R)
C3
RYC
Relay output (R)
C4
REF HI
C5
GND
C6
Power from battery (12V)
Output
12V 0V
Output
Non-voltage contactor output
Pulse input
Input
Pulse input interface
Pulse input (R)
Input
Pulse input interface
IN4
Diagnostic switch
Input
Contactor input (connect to GND)
C7
IN5
Test program switch
Input
Contactor input (connect to GND)
C8
GND
Controller GND
0V
-150-
ECU Schematic
-151-
Method of Operation
Speed Control
Initial Setting Turning the power ON allows the controller to activate the motor in the direction of decreasing the fuel. Under this condition, the throttle CLOSE position detection switch turns ON and, after the motor has been activated in the direction of increasing the fuel, the throttle OPEN position detection switch turns ON. By these actions, the starting point of the stepping motor is settled. Now, the controller is on standby at the starting position (opens 45 degrees from the throttle CLOSE position). Since the starter function is now inhibited, the starter inhibit relay within the controller is turned OFF. With the controller on standby, the motor can be activated by depressing the accelerator pedal. Once the accelerator pedal is depressed, the throttle position corresponding to the stroke of the accelerator pedal is maintained until engine start-up is detected.
Low Idle Speed When the accelerator sensor is in low idle region, the controller allows the engine to run at 750 rpm. The target of steady-state speed regulation is +/50 rpm. High Idle Speed When the accelerator sensor is in full open position, the controller allows the engine to run at 2650 rpm. The engine speed is so controlled that it does not exceed 2800 rpm even if the accelerator pedal is suddenly operated or if the engine is brought into no-load condition. The engine is considered to be overrunning if its speed exceeds 3000 rpm. In such a case, the current to the governor drive motor is cut off to bring the throttle to the full close position. Normal Speed Region The engine runs at the controlled speed determined on the basis of the “accelerator position characteristic” curve. (This is all-speed characteristic.)
The controlled engine speed with a rated load is 2650 ± 50 rpm. Stopping As the starter switch key is turned to OFF position, the controller power source is turned OFF at the same time, the ignition pulse dies away and the fuel cut-off solenoid is operated to shut down the engine. If the power source is turned ON while the engine is in the process of being shut down, the initial setting outlined above is omitted. In such a case, the engine speed is reduced to low idle level, and the position of the throttle CLOSE position detection switch is detected. The control function is continued on the basis of this switch position.
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ECU Diagnostics Tester Procedure Tools required • ECU Diagnostics Tester (91868-02300) and your Lift Truck Service Manual. • Inductive Tachometer • Digital Volt/Ohmmeter How to read error code flashes, when an error occurs 1. Turn the engine off. 2. Connect the Diagnostic Tester harness to the engine harness connector located near the distributor. 3. Move the toggle switch on the ECU diagnostic tester to OFF position. 4. Turn the truck key switch to the ON position (the light on the tester will flash continuously at 1 second intervals). 5. Flip the toggle switch on the tester to ON position - Error codes will flash at 3 second intervals. If there are no errors, the light will continue to flash at 1 second intervals. 6. From the error code, determine the reason and result for the error from the following table. 7. Turn the key switch OFF and remove the diagnostic tool. How to clear the error history from the ECU Part numbers 16A94-01000, 16A94-11000, 16A94-31000 1. Repeat Steps 1 and 2 above. 2. Move the toggle switch on the tester to ON position. 3. Turn the truck key switch to ON position (the light on tester will flash continuously at 1 second intervals). 4. Turn the key switch OFF and remove the diagnostic tool. How to clear the error history from ECU Part number 16A94-41000 1. Install diagnostic tool. 2. Turn the diagnostic tool switch to ON position. 3. Press the throttle pedal down 50% or more and while holding the throttle pedal down, turn the ignition switch to ON position. The fault codes are now cleared.
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GM 4.3L, G6 Gasoline Engine ECU Error Code Description (ECU Part Numbers 16A94-01000, 16A94-11000, 16A94-31000) Error Code
Condition
Cause
Effects on Operation
1
Engine Over Speed
Engine rpm at 3000 for more than 0.30 seconds
2
Input signal from accelerator sensor is out of specification
Input voltage signal from accelerator sensor Close throttle valve fully, shut power exceeded 97% of maximum input signal source of starter, back to normal voltage from accelerator sensor did not operation after restarting exceed 10% of maximum when idle position sensing switch on the accelerator sensor is off
3
Idle position sensing Idle position sensing switch on accelerator switch on accelerator sensor stayed at on when input voltage sensor is not correct signal from accelerator sensor exceeds 50% of maximum
4
Throttle close position sensing switch on carburetor is not correct
During calibration the ECU did not receive Close throttle valve fully, shut power on-signal from throttle close position sensing source to starter, back to normal switch even if stepping motor was moved operation after restarting correctly
5
Throttle open position sensing switch on carburetor is not correct
During calibration the ECU did not receive Can be operated normally except on-signal from throttle open position sensing limiting engine speed to 1500 rpm, back to normal operation after restarting switch even if stepping motor was moved correctly (98 degrees)
6
Stepping motor is not ECU received unexpected on-signal from correct throttle open or close position sensing on carburetor
7
Revolution pulse signal ECU did not receive revolution pulse signal Close throttle valve fully, back to from distributor is not from distributor for more than specified period normal operation after restarting correct while voltage of alternator L terminal was within normal operating range, before engine reaches operating speed: 1 second, after engine reaches operating speed: 0.1 seconds
8
Alternator problem
Can be operated normally except limiting engine speed to 1500 rpm, back to normal operation after restarting
Close throttle valve fully, back to normal operation after restarting
Voltage of alternator L terminal remained Close throttle valve fully, back to lower than normal operating range over 30 normal operation after restarting seconds when ECU receives revolution pulse signal from distributor
Engine Initialize To reset error history
Close throttle valve fully back to normal operation after restarting
Every 30 engine starts Turn key switch on with check box switch on
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GM 4.3L, G6 Gasoline Engine ECU Error Code Description (ECU Part Number 16A94-41000) Error Code
Condition
1
Engine Over Speed
2
Accelerator sensor is out of specification
3
4
Cause Engine at 3000 rpm for more than 0.30 seconds
Input voltage signal from accelerator sensor exceeded 4.61 volts for more than 1.0 sec., input signal voltage from accelerator sensor did not exceed 10% of maximum for more than 1.0 sec., when the idle position sensing switch is on the accelerator sensor Idle position sensing Idle position sensing switch on accelerator switch on accelerator sensor stayed at on for more than 1.0 sec., sensor is not correct while input voltage signal from accelerator sensor exceeded 50% of maximum Throttle close position During calibration the ECU did not receive sensing switch on on-signal from throttle close position sensing carburetor is not switch, even if stepping motor was moved correct correctly.
5
Throttle open position sensing switch on carburetor is not correct
6
Stepping motor is not ECU received unexpected on-signal from correct throttle open or close position sensing switches on carburetor for more than 1 sec. Revolution pulse signal ECU did not receive revolution pulse signal from distributor is not from distributor for more than 0.2 seconds correct
7
Carburetor Stepping motor Initializes To reset error history
During calibration the ECU did not receive on-signal from throttle open position sensing switch even if stepping motor was moved correctly (98 degrees).
Effects on Operation Close throttle valve fully, back to normal operation when engine goes down to under 2000 rpms Close throttle valve fully, shut power source of starter, back to normal operation after restarting
Close throttle valve fully, back to normal operation after restarting
Close throttle valve by 5% of maximum stroke and shut power source of stepping motor, back to normal operation after restarting Operates normally except limiting engine stepping motor stroke to 90 degrees, back to normal operation after resetting error history Close throttle valve fully, back to normal operation after restarting
Close throttle valve fully, back to normal operation when ECU receives a revolution pulse signal for more than 0.2 sec. After every 5 engine starts or after the error codes have been cleared from the ECU. (Carburetor will cycle from Full Open to Full Close to set throttle stroke) Install diagnostic tool 91868-02300. Turn the diagnostic tool switch to the ON position. Press throttle pedal down 50% or more and while holding the throttle pedal down turn the ignition switch to the ON position. The fault codes are now cleared.
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Ignition System and Distributor Removal and Installation
➧ A ➧ ➧A ➧ ➧ A ➧ ➧A ➧ ➧ ➧ ➧B➧ ➧C➧ ➧D➧
Removal steps 1. Spark Plug Wires 2. Ignition Coil Wire 3. Coil 4. Distributor 5. Gasket 6. Spark Plugs
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Ignition System - Distributor Removal and Installation
1
13
6 7
2
14 15
8
16
9 3 10
Removal steps 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
11
Screw Distributor Cap Rotor Shaft Assembly Retainer Shield Sensing Coil Pole, Stationary Screw (4) EST Module Pin Housing Tab Washer Washer Gear Roll Pin
4
12 5
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➧ ➧C Distributor Removal
Distributor Disassembly 1. Remove the rotor from the shaft by lifting straight from the end of the shaft. 2. Put an alignment mark on the shaft and gear for correct installation. Use a small punch to remove the roll pin as shown. Do not damage the shaft or gear.
NOTE Position the engine to TDC (top dead center) #1 compression stroke before removing the distributor. This will be a good reference point when reinstalling the distributor in the engine.
! CAUTION Before starting removal steps of coil or distributor, disconnect the negative battery cable. 1. Remove all wires from the distributor, spark plug, coil and harness wires. 2. Remove the two screws on the distributor cap and remove the cap. 3. Place a mark on the distributor housing where the rotor is pointing. Put a corresponding mark on the distributor housing and on the engine. This will be a known starting point for reassembly. 4. Remove the bolt and clamp that hold the distributor in the engine and remove the distributor.
ESTDISO1
3. Remove the gear, washer, and tab washer. 4. Remove the shaft with the pole piece and plate from the housing.
! CAUTION When the distributor is disassembled, the retainer must be replaced. NEVER use an old retainer. 5. Remove the retainer from the housing using a screwdriver. Remove the shield. 6. Remove the sensing coil connector from the module. Lift the locking tab with a screwdriver. Remove the sensing coil. 7. Remove the two screws that fasten the EST module to the plate. Remove the EST module.
Distributor Assembly
NOTE A small amount of silicon grease is supplied with each replacement module. If more silicon grease is needed, use the 5P8937 Heat Sink Compound.
34403
5. Remove the distributor gasket and replace with a NEW one at reassembly.
1. Completely cover the bottom of the EST module with a thin layer of 5P8937 Heat Sink Compound or an equivalent compound for heat transfer.
-159-
➧B➧ Coil Installation and Testing
5. Install the coil wire on the distributor and the coil. 6. Make sure all wires fit tightly around the distributor cap and spark plugs. Install each wire in the supporting clips and make sure all wires are kept clear of the exhaust manifold and heat shields.
1. Ignition coil testing, open and short circuits, and coil can be tested on or off the engine. 2. Make sure all test points are clean from paint, dirt, grease and oil before testing. Disconnect all wires from the coil before testing.
COIL01
➧B
➧
IGNITSY2
3. Ignition coil testing. a) Connect a volt/ohmmeter as shown in step 1. Set the meter on ohms scale. If the meter indication is infinity or open circuit, the coil is good. b) Connect the meter as shown in step 2. Set the meter on the ohms scale. If the meter indication is < (less than) 1 ohm, the coil is good. c) Connect the meter as shown in step 3. Set the meter on the ohms scale, 20k. If the meter indication shows infinity or open circuit the coil should be replaced. 4. Install the coil to the mounting bracket and connect the distributor wire, coil wire and engine wiring harness.
Coil Removal
! CAUTION Before starting removal steps of coil or distributor, disconnect the negative battery cable. 1. Remove coil mounting bolts and coil from the bracket. 2. Remove all wires connected to the coil. 3. Check coil for damage or broken connectors.
Ignition Sensing Coil Test
NOTE The following procedure will check the resistance of the sensing coil for the ignition module inside the distributor. The distributor can be left on the engine or removed for this test. 1. Connect an ohmmeter to either sensing coil connection and the housing as shown in step 1. If the reading is not infinity or open, replace the sensing coil.
-160-
2. Connect an ohmmeter to both connectors of the sensing coil as shown in step 2. Move the connectors at the sensing coil and at the connector to find any open circuits that are not constant. The ohmmeter will correctly indicate 500 to 1500 ohms. If the indication is not constant or is not within the resistance range, replace the sensing coil.
1. Remove the distributor cap from the distributor.
301393
2. Install a NEW distributor gasket onto the distributor.
IGNITSY4
Distributor Installation Important: The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at Top Dead Center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke.
3. Align the indent hole on the driven gear with the paint mark. 4. Ensure that the distributor rotor segment points to the cap hold area.
492137
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5. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft. Rotate the oil pump driveshaft with a screwdriver if necessary. 6. Align the flat (1) in the distributor housing toward the front of the engine.
8. Once the distributor is fully seated, align the distributor rotor segment with the number 6 pointer (1) that is cast into the distributor base. If the distributor rotor segment does not come with a few degrees of the number 6 pointer (1), the gear mesh between the distributor and camshaft may be off a tooth or more. Repeat the procedure again in order to achieve proper alignment.
523746
7. Install the distributor and distributor clamp. Tighten the bolt enough to hold the distributor in position, but do not tighten completely. a. Align the rotor with the mark on the distributor housing made during removal. b. Align the mark on the distributor housing and the engine made during removal.
334555
9. Install the distributor clamp bolt and tighten to the specified torque. Tightening Torque for Distributor Clamp Bolt
2.49 Kgf•m (18 lb ft) [25 N•m]
10. If the distributor cap is not being replaced, inspect the cap for carbon build up, cracks or small holes. Replace the distributor cap if it is damaged. Install the distributor cap and NEW distributor cap bolts, tighten to the specified torque. Tightening Torque for Distributor Cap Bolts
310298
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.24 Kgf•m (21 lb in) [2.4 N•m]
connector on the side of the distributor. Next connect the alligator clip lead from the tool to the positive (+) side of the 12 volt battery with the engine running. This will cause the engine to slow down and default the distributor to basic timing. Read the timing off the balancer pulley with the timing light. If timing is showing something other than what is shown in the engine specifications (gas or LP) section it must be adjusted. Loosen the distributor and rotate it until the correct reading is obtained. Retighten the distributor, hold down clamp, and recheck timing again.
11. Install the coil lead wire and engine harness connector to the distributor.
! CAUTION Do not shut engine off with the 12 volt lead connected to the battery or restart the engine with the timing shunt connected. Connecting the timing shunt to 12 volt + battery with the engine not running can cause damage to the ECU or the EST module.
12. Reconnect the negative battery cable.
Ignition Timing
NOTE Before trying to start the engine, make sure the distributor is installed correctly, and all high voltage wires are connected and installed correctly on the coil and distributor. 1. The ignition timing setting is different for gasoline and LPG models and there is also a year break. Units built before 2004 are set at 0° BTDC for Gasoline units or 8° BTDC for LPG units. Year 2004 and up the timing is set at 0° BTDC and the computer takes care of the timing.
IGNITSY7
➧D➧ Spark Plug Inspection Check each spark plug for the following faults. If necessary, replace the spark plug: 1. Damage to insulator. 2. Wear to electrodes. 3. Deposit of carbon. To remove carbon deposit, use a plug cleaner or wire brush. At the same time, clean the insulator tip (glass). 4. Damage to gasket. 5. Burnt insulator gasket (glass). Black carbon coating on the insulator tip is caused by too rich a fuel mixture, excessively insufficient intake air, or misfires due to excessively large plug gap. Whitish coating on the insulator tip is caused by too thin a fuel mixture, advanced ignition timing, or loose spark plug. 6. Check the plug gap. If necessary, adjust it to specification. .889mm, .035 in. gap. 7. Do not over tighten spark plugs when replacing or inspecting them. See Torque section for values.
IGNITSY6
2. Connect an inductive type timing light on No. 1 spark plug wire. 3. Start the engine. The engine does not start rotating the distributor clockwise or counterclockwise until the engine starts. If engine still will not start, go back to the EST Distributor Installation section. Once the engine is running smoothly let it idle until the engine reaches normal operational temperature. 4. With engine running at an idle and warm, unplug the 4-wire connector on the distributor (gas only) and connect the timing shunt tool to the 4-pin
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Alternator and V-Belt (Units built before 01/01/2004) Removal and Installation
1
T= 2.49 Kgf•m (18 lb •ft) [25 N•m]
3
4
2 T= 4.16Kgf•m(30 lb •ft) [41 N•m]
5
Removal Steps 1. Bolt 2. Bolt 3. Alternator
6
4. Belt T= 5.94Kgf•m (43 lb•ft) [58 N•m]
5. Pulley 6. Pulley
T= 2.49Kgf•m (18 lb•ft) [25 N•m]
-165-
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Alternator Removal and Installation
6 5
9
8 3 2 4 1 7 14
11 13 12
10
16 15
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Removal steps 1. Nut 2. Pulley 3. Rotor Assy 4. Bearing Retainer 5. Bearing 6. Front Bracket 7. Spacer 8. Fan 9. Stator Assy 10. Condenser Assy 11. Regulator 12. Brush 13. Spring 14. Slinger 15. Rectifier Assy 16. Rear Bracket
Accessory Drive Belt Replacement
Installation Procedure 1. Route the belts over all the pulleys including the alternator. 2. Rotate alternator to tension belts and tighten mounting bolts.
Removal Procedure 1. Loosen alternator mounting bolts. 2. Rotate alternator to reduce belt tension and remove drive belt.
43858
43856
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Starter Motor Removal and Installation
6
5 4
Removal Steps
3
2 1
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1. 2. 3. 4. 5. 6.
Bolt Spring Washer Starter Motor Cord Starter Harness Starter Relay
Starter Motor Testing
Troubleshooting
Electrically the motor consists of the brush assembly and the armature. The solenoid contains pull-in and hold-in windings, and the motor external wiring is the same as field-coil motors. No periodic maintenance or lubrication is required.
Cranking Circuit Before removing any unit in a cranking circuit for repair, the following checks should be made. Battery: Ensure that the battery is fully charged, and that it passes the load test. The starting motor cannot operate properly if the battery is discharged or defective. Wiring: Inspect the wiring for damage. Inspect all connections to the cranking motor, solenoid, ignition switch or any other control switch, and battery, including all ground connections. To eliminate any excessive resistance, disconnect and wire brush all wiring connectors in the cranking circuit. This will ensure optimum performance from the wiring. Cables, when properly attached at the battery side terminals, are sealed and normally required no periodic maintenance attention. Switches: Inspect all switches to determine their condition. With switches closed, use a voltmeter to check the circuit for continuity. Replace defective switches and wiring as required. Motor: If the battery, wiring and switches are in satisfactory condition, and the engine is known to be functioning properly, remove the motor and follow the test procedures outlined below. Regardless of the construction, never operate the cranking motor more than 30 seconds at a time without pausing to allow it to cool for at least two minutes. Overheating caused by excessive cranking will seriously damage the cranking motor.
In the basic circuit, the solenoid windings are energized when the switch is closed. The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear and the solenoid main contacts to close, and cranking takes place. When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should be opened immediately when the engine starts.
Cranking Motor Tests With the cranking motor removed from the engine, the pinion should be checked for freedom of operation by turning it on the screw shaft. The armature should be checked for freedom of rotation by prying the pinion with a screwdriver. Tight bearings or a bent armature shaft will cause the armature not to turn freely. If the armature does not turn freely the motor should be replaced.
-170-
Check Pinion Clearance 1. With motor lead disconnected from solenoid, connect 12 volt battery to solenoid “S” terminal and drive housing. 2. Momentarily flash a jumper lead from solenoid “M” terminal to drive housing. Pinion will shift into crank position.
3. Push pinion back to take up any movement, and check clearance between pinion and retainer with a feeler gauge. The clearance should be 0.010 and 0.160 in. 4. Clearance is necessary to prevent wear on drive collar during cranking. Clearance is not adjustable. If not within limits, check for improper assembly or for worn parts.
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Fuel System - Gasoline (Units built before 01/01/2004) Removal and Installation
Removal steps 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
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Nut Washer - Spring Washer Seal - Oil Hose Bolt Horn - Air Bolt Pipe - Fuel Hose Hose Carburetor Gasket Nut Hose Hose Adapter Gasket - Adapter Cable Lever Bracket Motor - Step Bracket - Motor
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Fuel Pump and Fuel Hose (Units built before 01/01/2004) Removal and Installation
Precautions for Installation • Install the fuel pump filter side bottom. • Put in the fuel hose securely to the nipple or joint, clamp it, and make sure that no fuel leaks. • Fasten the fuel hose securely to prevent it from being damaged by vibrations and touching any rotating or hot part.
NOTE This manual only covers the fuel system supplied on units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
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Fuel Pump (Units built before 01/01/2004) Disassembly and Reassembly
Disassembly Steps 1. Pump cover 2. Magnet
N
3. Cover gasket
N
4. Filter
N
5. Filter gasket 6. Pump body
Main Point of Disassembly
! CAUTION The transistorized fuel pump is of the totally enclosed type, except the filter side. Ordinary service work should be restricted to inspection and cleaning of the filter; never disassemble the fuel pump unnecessarily. Do not tamper with the fuel inlet elbow. Only items (2) to (5) can be replaced independently. 1. Remove the pump cover with a 17 mm (0.67 in.) wrench. Then take out the filter. Never impact upon the pump body during removal.
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Inspection Checking and Cleaning the Filter Check the filter for clogging and dirtiness. If necessary, clean or replace the filter. Checking the Fuel Pump for Proper Function Turn the ignition switch to ON and listen for clicks. If no click is made, connect the fuel pump directly to a 12-volt power source and try listening for clicks. Replace if no sound is found. Checking Delivery Flow Check the pump delivery flow by using the method shown in the figure. Delivery flow of the pump is considered normal if 15-second delivery is 225 cm3.
Main Point of Reassembly Filter 1. Before installing the filter, check that the pump body side plunger valve is not clogged with dust. 2. Be sure to install a NEW filter gasket. 3. Fit the cleaned magnet to the cover without fail and install the cover securely. During trial run, check the cover and piping. For fuel leaks, use a soap/water solution or leak detector solution on all fittings while engine is running.
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Fuel System - LP (Units built before 01/01/2004) Removal and Installation
2
1
N3 5 4 6
N 7 10 20
8
13
11
N 12
14
9
Removal steps 1. Nut 2. Carburetor Assy
N
3. Gasket 4. Spacer 5. Hose 6. Governor - Air
N
7. Gasket 8. Hose 9. Hose 10. Nut 11. Adapter
N
12. Gasket - Adapter 13. Actuator - Vacuum 14. Unit, Idle - Up
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Maintenance Checks
5. With the carburetor air-gas valve and cover removed, it is a simple matter to check the converter and fuel lock for leaks. The following checks should indicate each component is operating properly. • Turn fuel on at the tank and check carburetor open gas jet for leakage. If the fuel lock and the converter are operating properly, no fuel will leak through. • Press the primer button on the front of the converter to open the gas regulator valve. A small amount of gas should pass through the jet as the system is emptied back to the fuel lock. If the fuel lock is operating properly, the gas flow will soon cease as soon as the fuel downstream of the fuel lock is exhausted. • Next remove the vacuum hose to the VFF30 fuel lock from the fitting at the source of vacuum. With the primer button depressed, apply vacuum to the fuel lock vacuum hose. Fuel should flow immediately and stop flowing when suction is relieved. 6. With consistent starting and idling, the vaporizer/ regulator need not be disassembled. If inconsistent, remove the regulator front cover and diaphragm assembly to check for oil and dirt deposits. If granules of foreign matter are embedded in the Viton rubber of the secondary valve, the valve and seat may be washed clean; however, it may be wise to replace the Viton valve for a perfect seal. These granules almost invariably enter the vaporizer in solution in the liquid propane and drop out as the fuel is vaporized, similar to salt water through a filter with deposits of salt left after evaporation of the water. It is seldom a sign of insufficient filtration. Foreign matter and scale from the tank generally deposit in the filter when a new tank is installed. Welding scale and rust are frequently present in new tanks, and occasionally residual water from the hydrostatic pressure testing is still in the tank.
At scheduled preventative maintenance increments: 1. Check coolant hoses for deterioration. Hardened hoses may crack or be subject to rupture, particularly if thermostats hotter than 160-170 degrees F are used, or if hoses are located adjacent to an exhaust manifold. Also check all vacuum hoses. 2. The fuel vapor hose is located between the vaporizer / regulator and the carburetor. Remove the hose and check for undue deterioration. Particularly check the vapor outlet fitting from the regulator for tightness. 3. Use a soap/water solution or leak detector solution on all fittings while engine is running. 4. If starting and idling have been consistently satisfactory, it should be unnecessary to disassemble the carburetor air valve from the bowl. If inconsistent, remove the air valve cover, spring and air valve with the diaphragm. Check the gas-metering valve and gas jet for accumulation of foreign deposits or greasy substance, and clean both with a brush and kerosene or equivalent solvent as needed. Check the air valve diaphragm for integrity and flexibility. Hold the diaphragm up against a strong light to check for small tears or pinholes. Normal life of the diaphragm and seat is 2,000 hours, barring excessive backfiring or similar abnormalities. When reinstalling the air-gas valve assembly in the bowl, mixer models CA100, CA125 and CA225 require reinstallation of the gas-metering valve in position with two gas valve slots opposing the gas inlet flow. This is for ideal air-fuel distribution.
NOTE This manual only covers the fuel system supplied on units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
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Vacuum Fuel Lockoff Filter (Units built before 01/01/2004)
Theory of Operations • Impco vacuum fuel locks are normally closed. • They use air valve vacuum from the air fuel mixer to open the fuel lock. • If the engine stops or is turned off, engine vacuum dissipates and the fuel lockoff closes automatically. This is a desirable safety feature. • When the engine is cranking or running, air valve vacuum is transmitted from the mixer to the lockoff through a 3/16 in. vacuum hose. • The vacuum acts upon a diaphragm assembly. Atmospheric pressure forces it inward against the valve operating lever. • As the valve operating lever is depressed it moves the valve operating pin. • As the valve operating pin moves it lifts the valve off of its seat. • This allows propane to flow through the lockoffs 10 micron filter and on to the pressure regulator. Vacuum Fuel Lock Service Procedures • The Impco VFF30 vacuum fuel filter lockoff is fully field serviceable. • A repair kit is available which includes all the wear parts necessary to rebuild the unit. Each part is also available individually.
• To test a unit for external leakage, apply an approved leak test solution to the entire outer surface and watch for leaks. • To test a unit for internal leakage remove the vacuum hose from the port marked VAC. • Apply an approved leak test agent to your finger tip and lightly place finger over port marked VAC. • Position your finger so that any LPG leaking internally and escaping out of the vacuum port will create small bubbles around your fingertip. • If bubbles are found, the pin and o-ring need replacing. Vacuum Fuel Lock Installation Tips • Lockoffs with filter elements should be positioned so that the filter can be changed as easily as possible. • Vacuum lockoffs should be positioned so that the atmospheric vent is not restricted. • Vacuum lockoffs should be positioned so that debris will not enter the atmospheric vent. • Vacuum lockoffs should be connected to air valve vacuum, not manifold vacuum.
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Model J, K and Cobra Converter / Regulator (Units built before 01/01/2004)
LPG Pressure Regulator / Converter Service Procedures
Theory of Operation This converter is a water-heated, two-stage vaporizer. Fuel enters the converter at tank pressure as a liquid and its pressure is reduced to 0.1 to 0.15 kgf/cm2 (1.4 to 2.1 psi) [10 to 15 kPa] within the primary or vaporizing chamber -- it is converted from liquid to a gas. Heat for vaporization is supplied form the engine cooling system.
• lmpco pressure regulators have proven to be very reliable and require very little maintenance due to the robustness of their design and the small number of moving parts. Only periodic disassembly for the purpose of inspection and cleaning is required. The time interval between inspections varies with the quality of the fuel being used. A quick pressure test is all that is required to verify proper regulator operation. Repair kits are available, if required. These kits contain complete instructions and all wear parts necessary to rebuild an Impco pressure regulator.
Gas then passes through the secondary valve which is controlled by the secondary diaphragm and flows into the secondary chamber where it is drawn off through the gas outlet to the carburetor.
NOTE This manual only covers the fuel system supplied on units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
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On-Truck Pressure Test
Regulator / Converter Bench Test
1. Shut off fuel supply at fuel storage container and run engine out of fuel. 2. Remove the primary test port plug. 3. Connect a 0-5 psi gauge to the primary test port. 4. Remove secondary test port plug. 5. Install a 0-10 inch wc (water column) gauge. 6. Slowly open fuel storage container valve. 7. Start engine. 8. Note gauge pressure readings. 9. Primary pressure should be approximately 1.5 psi. 10. Secondary pressure on regulators with a blue spring should be negative 1.5 w c. 11. Secondary pressure on regulators with an orange spring should be negative 0.5 w c. 12. Press throttle several times then allow engine to idle. 13. Gauge readings will fluctuate and then should return to normal as engine idles and pressures stabilize. 14. If pressure readings differ from those stated above, the regulator should be disassembled and inspected as outlined below in "Regulator Disassembly, Inspection, Cleaning and Assembly".
1. 2. 3. 4. 5. 6. 7.
Remove the primary test port plug. Connect a 0-5 psi gauge to the primary test port. Connect compressed air to the fuel inlet. Pressurize the regulator. Note reading on pressure gauge. Gauge reading should be approximately 1.5 psi. There should be no air escaping from the regulator outlet. 8. If air is escaping from the regulator outlet check the secondary diaphragm, secondary valve and seat. 9. Slowly push primer button several times and release. 10. Gauge will fluctuate but should return to approximately 1.5 psi.
Pressure Regulator / Converter Installation Tips 1. Mount regulator below top of radiator. Air in the cooling system will seek the highest point. The regulator must not be the highest point. Air trapped in the regulator may cause it to freeze. 2. Mount regulator with fuel outlet pointing down. This allows for any heavy ends, such as butyl oil, that may be present in the fuel, to drain from the regulator. If any heavy ends are allowed to accumulate in the regulator they may interfere with the movement of the diaphragms. 3. Mount regulator to a solid surface. Fuel lines and coolant lines must not be used to support regulator. 4. Mount regulator as close as practical to the air fuel mixer. Since the regulator requires a negative pressure signal from the air fuel mixer to operate, mounting them close together will ensure short cranking time when starting the engine.
Regulator / Converter Disassembly, Inspection, Cleaning, and Assembly 1. Shut off fuel supply at fuel storage container and run engine out of fuel. 2. Disconnect fuel inlet and outlet lines. 3. Drain cooling system. 4. Remove regulator. 5. Disassemble regulator. 6. Clean primary and secondary valves with soap and warm water and inspect for wear. Replace if required. 7. Clean primary and secondary diaphragms with soap and warm water and inspect for wear. 8. Inspect primary diaphragm lever for straightness. Replace if required. 9. Always replace the coolant chamber gasket. 10. Clean regulator castings with parts cleaning solvent and inspect. It is very rare for the castings to require replacement. 11. Reassemble regulator. 12. Use an anti-seize compound on screws. 13. Use an approved pipe sealant on fittings. 14. Bench test regulator.
Regulator/Lockout - Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Turn off engine. Run engine to clear LP system. Drain coolant. Remove battery. Disconnect LP line at lockout. Remove LP regulator/lockout assembly. Remove water hoses from regulator. Remove low pressure hose from regulator. Remove vacuum hose from lockout. Remove bracket from regulator/lockout. Separate lockout from regulator.
Impco CA 100 Air Fuel Mixer
Air Valve Mixer Theory Of Operation The air-gas valve mixer is mounted in the intake air stream above the throttle plates and is designed to create a slight pressure drop (negative pressure) as air is drawn through it in to the engine. This negative pressure signal is communicated to the upperside of the diaphragm through passages in the air-gas valve assembly (the air-gas valve assembly is mounted in the center of and supported by the diaphragm).
Atmospheric pressure above the diaphragm forces it down against the secondary metering spring and opens the secondary valve allowing fuel to flow to the air-gas valve mixer. The tapered shape of the gas-metering valve is designed to maintain the correct air/fuel ratio over the entire operating range of the engine.
Atmospheric pressure acting on the underside of the diaphragm forces it upward against the metering spring. The metering spring is calibrated to generate about negative 6-inches of water column at idle and up to about negative 14-inches of water column at wide open throttle. The amount of negative pressure generated is a direct result of throttle position and the amount of air flowing through the mixer. As the diaphragm rises it lifts the tapered gas metering valve off of its seat and exposes the fuel outlet to the negative pressure generated within the mixer. This allows the negative pressure signal to travel to the secondary chamber of the pressure regulator and act upon the underside of the secondary diaphragm.
This manual only covers the fuel system supplied on units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
NOTE
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Model CA100 Carburetor Repair Kit (Units built before 01/01/2004) Installation Instructions
1. 2. 3. 4. *5. *6. *7. *8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Screw Cover Spring, Air Valve Screw Plate, backup Diaphragm Ring, Air Valve Air Valve Mixer Body Fitting Screw, idle Spring, idle screw Plug Gasket Spacer Adaptor Air Valve Assembly
* Components included in the Repair Kit 205403
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Model CA100 Carburetor Repair Kit Installation 1. Remove the air valve cover and retaining screws.
3. Press the air valve down until it bottoms into the body.
205406 205407
4. Reassemble the air valve cover and install retaining screws.
2. Lift out and replace the air valve assembly in the mixer body.
205405
205407
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LPG Carburetor Adjustment Procedure CO/Exhaust Analyzer 1. Check engine coolant and transmission oil is at full levels, and inching pedal is properly adjusted. 2. Turn idle mixture adjustment screw all the way “in” clockwise, then turn it “out” 1-1/2 rotations. 3. Allow the engine and transmission temperature to warm up to operating temperature. Transmission temperature gauge should be just over first break line or higher.
NOTE There is a 5-10 second delay between making a power valve adjustment and picking up the effect on the analyzer. A slight change in power valve setting will produce a significant change in CO level.
NOTE Turning the power valve clockwise produces a rich mixture and higher CO levels. Turning it counterclockwise will produce a lean mixture and lower CO levels.
NOTE For console box without trans temperature gauge, warm truck up until engine coolant gauge is at block line or slightly above.
10. Remove gas collection hose.
4. Adjust low idle to 750 ± 50 rpm using low idle adjustment screw. Then check engine timing and adjust as required to specification (8°BTDC). 5. Insert gas collection hose of emission analyzer into tail pipe of truck approximately 250mm (10 in.) Do not insert during warm up. 6. Check idle adjustment with truck at low (750 ± 50 rpm) and in neutral, adjust the Idle Mixture Adjustment Screw until the co-emission level is to a maximum CO% of 0.8%.
Governor Speed Adjustment Procedure 1. Set transmission in neutral position. 2. Press the accelerator pedal all the way to full open throttle. High RPM is 2650. 3. Turn spring adjustment nut (A) clockwise to increase rpm. Turn nut counter clockwise to decrease rpm. 4. When turning nut, hold the adjusting screw (A1). The adjusting screw is only used to adjust hunting.
NOTE Turning the screw “in” will make the fuel mixture rich, higher CO level, and turning it “out” will make it lean, lower CO level. 7. Adjust the idle screw located on the idle up vacuum device so that it contacts the plunger. 8. Check high idle RPM to make sure it is not beyond 2650. If it is adjust the governor. 9. Power adjustment -- make sure truck is adequately secured, hold at converter stall full throttle (no more than 10 seconds at a time), and adjust power valve until the CO emission level is a maximum of 1.0%.
Adjustment for Eliminating Hunting: 1. Set transmission in neutral position. 2. Press the accelerator pedal all the way. 3. Gradually turn the adjusting screw (B) clockwise until the engine no longer hunts.
! CAUTION Do not attempt to depress the inching pedal. Do not continue “stall speed” run for more than 10 seconds. A failure to follow this precaution would result in destruction of the torque converter.
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Accelerator Cable Adjustment — LPG
NOTE Adjustment of the Accelerator Cable and the Accelerator Pedal Stop Bolt is required to obtain correct engine RPM. 1. The Floor Plate must be installed and the engine cover open to view the movement of the throttle cable linkage. 2. With the engine stopped, pre adjust the tension to 2-4 mm of free play at accelerator pedal before throttle linkage begins to move. Throttle linkage and cable must be able to follow Idle Up Actuator rod when engine is running to obtain correct low Idle setting. 3. Loosen the locking nut on the accelerator pedal stop bolt to allow adjustment of the accelerator stop bolt. 4. Depress the accelerator pedal while viewing the throttle cable linkage. The linkage will move the full range of motion from the stops as the accelerator pedal is depressed. 5. Set the stop bolt height so the throttle linkage moves the full range of motion within 0-1 mm from the stop plates at carburetor. Tighten the locknut to secure the accelerator stop bolt once adjustment is obtained. 6. With the engine running and at operating temperature make final tension adjustment of 0-2 mm free play at accelerator pedal before throttle linkage begins to move. Readjust as necessary. 7. Adjust Idle Speed and Idle Mixture. Low idle 750 + - 50 rpm, High rpm 2650 – 2700 rpm. 8. Check torque converter stall speed per chassis service manual.
NOTE This manual only covers the fuel system supplied on units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
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Special Tools and Equipment
J 3049 - A Valve Lifter Remover
J 5892 - D Valve Spring Compressor
J 5239 Connecting Rod Bolt Guide Set
J 7872 Magnetic Base Dial Indicator
J 5590 Installer
J 8001 Dial Indicator Set
J 5825 - A Crankshaft Gear Remover
J 8037 Ring Compressor
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J 8062 Valve Spring Compressor
J 9666 Valve Spring Tester
J 8087 Cylinder Bore Gauge
J 21882 Oil Suction Pipe Installer
J 8089 Carbon Removing Brush
J 23523 - F Balancer Remover and Installer
J 8092 Universal Driver Handle
J 24086 - C Piston Pin Remover/Installer
J 8520 Cam Lobe Lift Indicator
J 5830-02 Valve Guide Reamer Set
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J 24270 Cylinder Bore Ridge Reamer
J 35621 - B Rear Main Seal Installer
J 26941 Bushing/Bearing Remover
J 36660 Electronic Torque Angle Meter
J 33049 Camshaft Bearing Service Kit
J 36996 Balance Shaft Installer
J 35468 Cover Aligner/Seal Installer
J 38606 Valve Spring Compressor
90425-09120 Pulley Puller
J 38834 Balance Shaft Service Kit
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J 41712 Oil Pressure Switch Socket
Timing Shunt
J 42073 Valve Stem Seal Installer
91868-02300 ECU Diagnostic Tester
91H20-09220 Seal Cutter
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Service Manual GM 4.3L, G6 Engine LPG Fuel System Supplement GC35K AT87A-10231-up GC40K AT87A-10231-up GC40K-STR AT87A-10231-up GC45K-SWB AT87A-10231-up GC45K AT88A-10231-up AT88A-10231-up GC55K GC55K-STR AT88A-10231-up AT89A-10231-up GC60K GC70K AT89A-10231-up GC70K-STR AT89A-10231-up
For use with the GM 4.3L, G6 Engine and GC35K-GC70K Chassis Service Manuals
99789-84122
TABLE OF CONTENTS 1 — GENERAL INFORMATION GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 HOW TO IDENTIFY THE ENGINE YEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 SERVICING YOUR EMISSIONS CERTIFIED ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 FUEL QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 FUEL SYSTEM CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 WARNINGS, CAUTIONS AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 PROPER USE OF THIS SERVICE MANUAL, TOOLS AND EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
2 — MAINTENANCE SERPENTINE BELT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ENGINE ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ENGINE CRANKCASE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 FUEL SYSTEM INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ELECTRONIC PRESSURE REGULATOR (EPR) MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 2-6 AIR FUEL MIXER/THROTTLE CONTROL DEVICE MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . 2-7 EXHAUST SYSTEM AND CATALYTIC CONVERTER INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . 2-8
3 — LPG FUEL SYSTEM DESCRIPTION AND OPERATION OF THE FUEL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4 — LPG SYSTEM DIAGNOSIS FUEL SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 DIAGNOSTIC AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5 — LPG SYMPTOM DIAGNOSTICS LPG SYMPTOM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 INTERMITTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 NO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 HARD START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CUTS OUT, MISSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 HESITATION, SAG, STUMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 BACKFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LACK OF POWER, SLUGGISHNESS, OR SPONGINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 POOR FUEL ECONOMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 SURGES/CHUGGLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS RESULTS OF INCORRECT OPERATION . . . 5-15
6 — DIAGNOSTIC SCAN TOOL CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 DST INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 INSTALLING THE USB ADAPTER DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 INSTALLING THE USB ADAPTER DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 PASSWORD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 PASSWORD DIALOG BOX FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 CONNECTING THE PC TO THE SPECTRUM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 DST SERVICE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 SPARK KILL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 INJECTOR KILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 DBW TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 EXTERNAL POWER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
i
TABLE OF CONTENTS PLOT/LOG MENU FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 DST PLOT INTERFACE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 SNAPSHOT HOT KEY FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 DST LOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 REPROGRAMMING THE ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 SPECTRUM DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 DLC COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 BLINK CODE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 INTERMITTENT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
7 — ENGINE WIRING SCHEMATIC CHASSIS SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ENGINE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 ELECTRICAL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 ECM POWER, POWER RELAY CONTROLS & ECM GROUND CIRCUITS PAGE ECM-1. . . . . . . . . . . . . . . . . . . . . 7-7 ECM ENGINE / FUEL SENSOR CIRCUITS (1) PAGE ECM-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 ECM ENGINE / FUEL SENSOR CIRCUITS (2) PAGE ECM-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ECM ACTUATOR CIRCUITS PAGE ECM-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 ECM INTERFACE CONNECTOR CIRCUITS PAGE ECM-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 ECM EPR AND DIAGNOSTIC CONNECTOR CIRCUITS PAGE ECM-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
8 — ENGINE WIRE HARNESS REPAIR ON-VEHICLE SERVICE WIRE HARNESS REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 CONNECTORS AND TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 MICRO-PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 METRI-PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 WEATHER-PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9 — DIAGNOSTIC TROUBLE CODES (DTCs) OBD SYSTEM CHECK/MIL (MALFUNCTION INDICATOR LAMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 IGNITION CONTROL SYSTEM DIAGNOSTIC CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 DTC-16 — NEVER CRANK SYNCED AT START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 DTC-107 — MAP LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 DTC-108 — MAP HIGH PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 DTC-111 — IAT HIGHER THAN EXPECTED 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 DTC-112 — IAT LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20 DTC-113 — IAT HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 DTC-117 — ECT/CHT LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 DTC-118 — ECT/CHT HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30 DTC-121 — TPS 1 LOWER THAN TPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 DTC-122 — TPS 1 SIGNAL VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38 DTC-123 — TPS 1 SIGNAL VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42 DTC-127 — IAT HIGHER THAN EXPECTED 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45 DTC-129 — BP LOW PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46 DTC-134 — EGO 1 PRE CAT OPEN/LAZY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50 DTC-154 — EGO 2 POST CAT OPEN/LAZY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54 DTC-187 — FT VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58 DTC-188 — FT VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60 DTC-219 — MAX GOVERN SPEED OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64 DTC-221 — TPS 1 HIGHER THAN TPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66 DTC-222 — TPS 2 SIGNAL VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70 DTC-223 — TPS 2 SIGNAL VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74 DTC-336 — CRANK SYNC NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-78 DTC-337 — CRANK LOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82 DTC-341 — CAMSHAFT SYNC NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86 DTC-342 — CAMSHAFT SENSOR LOSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90 DTC-359 — FUEL RUN-OUT LONGER THAN EXPECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
ii
TABLE OF CONTENTS DTC-524 — OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96 DTC-562 — SYSTEM VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100 DTC-563 — SYSTEM VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-102 DTC-601 — FLASH CHECKSUM INVALID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-104 DTC-604 — RAM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-106 DTC-606 — COP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-108 DTC-642 — EXTERNAL 5 VOLT REFERENCE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110 DTC-643 — EXTERNAL 5 VOLT REFERENCE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-114 DTC-650 — MIL CONTROL OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-116 DTC-652 — EXTERNAL 5 VOLT 2 REFERENCE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-120 DTC-653 — EXTERNAL 5 VOLT 2 REFERENCE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-124 DTC-685 — RELAY COIL OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-126 DTC-686 — RELAY CONTROL GROUND SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-130 DTC-687 — RELAY COIL SHORT TO POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-132 DTC-1111 — FUEL REV LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136 DTC-1112 — SPARK REV LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-138 DTC-1121 — FPP 1 AND 2 REDUNDANCY LOST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-140 DTC-1151 — CLOSED LOOP MULTIPLIER HIGH LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-142 DTC-1152 — CLOSED LOOP MULTIPLIER LOW LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-146 DTC-1161 — ADAPTIVE LEARN HIGH LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-148 DTC-1162 — ADAPTIVE LEARN LOW LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-152 DTC-1171 — EPR PRESSURE HIGHER THAN EXPECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-154 DTC-1172 — EPR PRESSURE LOWER THAN EXPECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-156 DTC-1173 — EPR COMMUNICATION LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-158 DTC-1174 — EPR SUPPLY VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-162 DTC-1175 — EPR SUPPLY VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-164 DTC-1176 — EPR INTERNAL ACTUATOR FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-168 DTC-1177 — EPR INTERNAL CIRCUITRY FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-170 DTC-1178 — EPR INTERNAL COMMUNICATION ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-172 DTC-1511 — AUX ANALOG PU1 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-174 DTC-1512 — AUX ANALOG PU1 LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-178 DTC-1521 — CHT HIGHER THAN EXPECTED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-182 DTC-1522 — CHT HIGHER THAN EXPECTED 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-184 DTC-1612 — RTI 1 LOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-186 DTC-1613 — RTI 2 LOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-188 DTC-1614 — RTI 3 LOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-190 DTC-1615 — A/D LOSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-192 DTC-1616 — INVALID INTERRUPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-194 DTC-1626 — CAN TX FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-196 DTC-1627 — CAN RX FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-200 DTC-1628 — CAN ADDRESS CONFLICT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-204 DTC-1645 — MIL CONTROL GROUND SHORT TO POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-206 DTC-2111 — UNABLE TO REACH LOWER TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-210 DTC-2112 — UNABLE TO REACH HIGHER TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-214 DTC-2121 — FPP 1 LOWER THAN FPP 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-218 DTC-2122 — FPP 1 HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-222 DTC-2123 — FPP 1 LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-226 DTC-2126 — FPP 1 HIGHER THAN FPP 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-230 DTC-2127 — FPP 2 LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-234 DTC-2128 — FPP 2 HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-238 DTC-2229 — BP HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-242 DTC-2300 — PRIMARY LOOP OPEN/LOW SIDE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-244 DTC-2301 — PRIMARY COIL SHORTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-248
10 — SERVICING THE FUEL SYSTEM ENGINE CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 ENGINE WIRE HARNESS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 FUEL TEMPERATURE (FT) SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
iii
TABLE OF CONTENTS OIL PRESSURE SENDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 TEMPERATURE MANIFOLD PRESSURE SENSOR (TMAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 FT150 FUEL MIXER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 VACUUM LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 HEATED EXHAUST GAS OXYGEN SENSOR (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 FUEL MIXER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 ELECTRONIC PRESSURE REGULATOR (EPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 ELECTRONIC PRESSURE REGULATOR (EPR)—SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 MIXER TO THROTTLE BODY O-RING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 MIXER TO THROTTLE PLASTIC THROTTLE BODY SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 THROTTLE BODY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 THROTTLE BODY-ADAPTER O-RING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 REPLACEMENT OF ADAPTER-INTAKE MANIFOLD GASKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 FUEL VAPOR HOSE—(EPR) TO FUEL MIXER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 SHUT-OFF VALVE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 EPR MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 ECM MOUNTING BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 LPG FUEL SYSTEM PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 LPG FUEL CONTROL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 PROPANE FUEL SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 RESTRICTED EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 EPR COOLANT HOSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
11 — LPG PARTS DIAGRAM MIXER AND THROTTLE BODY ASSEMBLY (NEW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 MIXER AND THROTTLE BODY ASSEMBLY (FORMER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 EPR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 REGULATOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 HOSE ASSEMBLIES COOLANT/VACUUM/FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 ENGINE CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
12 — APPENDIX ALTITUDE VS. BAROMETRIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 IGNITION SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 EXTENDED ECT TEMPERATURE VS. RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
iv
1 — GENERAL INFORMATION BTU British Thermal Unit. A measurement of the amount of heat required to raise the temperature of 1lb. of water 1 degree F.
GENERAL INFORMATION
GLOSSARY Air Valve Vacuum (AVV) The vacuum signal taken from below the air valve assembly and above the throttle butterfly valve.
Butane An odorless, colorless gas, C4H10 found in natural gas and petroleum. One of the five LP gases.
ADP Adaptive Digital Processor.
CAFE Corporate Average Fuel Economy.
Air/Fuel Ratio The amount or balance of air and fuel in the air fuel mixture that enters the engine.
CARB California Air Resources Board.
Analog Voltmeter A meter that uses a mechanical needle to point to a value on a scale of numbers. It is usually of the low impedance type and used to measure voltage and resistance.
Carbon Monoxide (CO) A chemical compound of a highly toxic gas that is both odorless and colorless. Carburetor An apparatus for supplying an internal-combustion engine a mixture of vaporized fuel and air.
Aromatics Pertaining to or containing the six-carbon ring characteristic of the benzene series. Found in many petroleum distillates.
Cathode Ray Tube A vacuum tube in which cathode rays usually in the form of a slender beam are projected on a fluorescent screen and produce a luminous spot.
Backfire Combustion of the air/fuel mixture in the intake or exhaust manifolds. A backfire can occur if the intake or exhaust valves are open when there is a mis-timed ignition spark.
Circuit A path of conductors through which electricity flows.
Benzene An aromatic (C6H6). Sometimes blended with gasoline to improve anti-knock value. Benzene is toxic and suspected of causing cancer.
Closed Loop Operation Applies to systems utilizing an oxygen sensor. In this mode of operation, the system uses oxygen sensor information to determine air/fuel ratio. Adjustments are made accordingly and checked by comparing the new oxygen sensor to previous signals. No stored information is used.
Bi-Fueled A vehicle equipped to run on two fuels. Blow-By Gases formed by the combustion of fuel and air, which ordinarily should exert pressure only against the piston crown and first compression ring. When rings do not seal, these gases escape or “blow by” the side of the piston into the crankcase.
CNG Compressed Natural Gas. CKP Crankshaft Position Sensor
1-1
1 — GENERAL INFORMATION CMP Camshaft Position Sensor
Diaphragm Port The external port located at the fuel inlet assembly and connected to the vacuum chamber above the air valve diaphragm.
Conductor A material, normally metallic, that permits easy passage of electricity.
DLC Data Link Connector.
Contaminants Impurities or foreign material present in fuel.
DVOM Digital Volt/Ohm Meter. A meter that uses a numerical display in place of a gauge and is usually of the high impedance type.
Control Module One of several informal names for a solid state microcomputer which monitors engine conditions and controls certain engine functions; i.e. air/fuel ratio, injection and ignition time, etc. The formal name and the one used throughout this manual is ECM, or Engine Control Module.
DTC Diagnostic Trouble Code DST Diagnostic Scan Tool.
Converter A LPG fuel system component containing varying stages of fuel pressure regulation combined with a vaporizer.
DVOM Digital volt/ohmmeter. ECT Engine Coolant Temperature.
Cryogen A refrigerant used to obtain very low temperatures.
ECM Electronic Control Module
Current The volume or flow of electrons through a conductor. Measured in amperes or amps.
ECOM A DLC cable supporting CAN and serial communication with a Spectrum II or III ECM.
DBW Drive By Wire
EFI Electronic Fuel Injection. A fuel injection system, which uses a microcomputer (ECM) to determine and control the amount of fuel, required by, and injected into, a particular engine.
Dedicated Fuel System A motor fuel system designed to operate on only one fuel type. Diaphragm A thin, flexible membrane that separates two chambers. When the pressure in one chamber is lower than in the other chamber, the diaphragm will move toward the side with the low pressure.
EGO Exhaust Gas Oxygen, used to describe a sensor. Also known as “HEGO” (Heat Exhaust Gas Oxygen) sensor, “O2” or “Oxygen sensor. EGR Exhaust Gas Recirculation.
1-2
1 — GENERAL INFORMATION EPA Environmental Protection Agency
Fuel Lock A solenoid-controlled valve located in the fuel line to stop the flow when the engine stops or the ignition switch is off.
A regulating agency of the Federal government which, among other duties, establishes and enforces automotive emissions standards.
Gasohol 10 percent ethanol, 90 percent gasoline. Often referred to as E-10.
Ethanol Grain alcohol (C2H5OH), generally produced by fermenting starch or sugar.
Gasoline A motor vehicle fuel that is a complex blend of hydrocarbons and additives. Typical octane level is 89.
Evaporative Emissions Controls An automotive emission control system designed to reduce hydrocarbon emissions by trapping evaporated fuel vapors from the fuel system.
GCP Spectrum III (90-pin) ECM.
Excess Flow Valve A check valve that is caused to close by the fuel when the flow exceeds a predetermined rate.
Greenhouse Effect A scientific theory suggesting that carbon dioxide from the burning of fossil fuels is causing the atmosphere to trap heat and cause global warming.
FTV Fuel Trim Valve.
HC Hydrocarbon. An organic chemical compound.
FFV Flexible Fuel Vehicle.
HD 10 A fuel of not less than 80% liquid volume propane and not more than 10% liquid volume propylene.
Firing Line The portion of an oscilloscope pattern that represents the total amount of voltage being expended through the secondary circuit.
HD 5 A fuel of not less than 90% liquid volume propane and not more than 5% liquid volume propylene.
FMVSS Federal Motor Vehicle Safety Standards. FPP Foot Pedal Position Sensor
HDV Heavy Duty Vehicle.
Fuel Injector a spring loaded, electromagnetic valve which delivers fuel into the intake manifold, in response to an electrical input from the control module.
Heavy Ends A term used to describe the build up of wax-like impurities that fall out of LPG when vaporized.
1-3
1 — GENERAL INFORMATION HEGO Heated Exhaust Gas Oxygen, used to describe a sensor. Also known as “EGO” (Exhaust Gas Oxygen sensor), “O2” or “Oxygen sensor.
Insulation A nonconductive material used to cover wires in electrical circuits to prevent the leakage of electricity and to protect the wire from corrosion.
Hg Chemical symbol for the element mercury. Used in reference to a measure of vacuum (inches of Hg).
Intercept An electrical term for a type of splice where the original circuit is interrupted and redirected through another circuit.
Hydrocarbon A chemical compound made up of hydrogen and carbon (HC). Gasoline and almost all other fuels are hydrocarbons.
ITK IMPCO Test Kit Knock Sound produced when an engine’s air/fuel mixture is ignited by something other than the spark plug, such as a hot spot in the combustion chamber. Also caused by a fuel with an octane rating that is too low and/or incorrect ignition timing. Also called detonation or ping.
Hydrostatic Relief Valve A pressure relief device installed in the liquid propane hose on a propane fuel system. IAT Intake Air Temperature
Lambda Sensor A feedback device, usually located in the exhaust manifold, which detects the amount of oxygen present in exhaust gases in relation to the surrounding atmosphere.
Ideal Mixture The air/fuel ratio at which the best compromise of engine performance to exhaust emissions is obtained. Typically 14.7:1.
LDV Light Duty Vehicle.
Ignition Reserve The difference between available voltage and the required voltage. ILEV Inherently Low Emission Vehicle.
Lean Mixture An air to fuel ratio above the stoichiometric ratio; too much air.
IMPCO Imperial Machine Products Company.
LEV Low Emission Vehicle.
IMPCO Technologies, Inc. A manufacturer of both LPG and Gasoline fuel systems.
Limp-in or Limp Home A mode where the ECM or a component has failed, but the vehicle remains operational although the engine may operate minimally. This term may also describe the drivability characteristics of a failed computer system.
Impedance A form of opposition of AC current flow (resistance) measured in ohms.
1-4
1 — GENERAL INFORMATION MTBE Methyl Tertiary Butyl Ether. Oxygenate add to gasoline to reduce harmful emissions and to improve the octane rating.
Liquid Petroleum Gas (LPG) A fuel commonly known as propane consisting mostly of propane (C3H8), derived from the liquid components of natural gas stripped out before the gas enters the pipeline, and the lightest hydrocarbons produced during petroleum refining. Octane level of LPG is 107.
Multi-fuel System A motor fuel system designed to operate on two different fuels, such as LPG and gasoline.
LPG Liquefied Petroleum Gas.
Natural Gas A gas formed naturally from buried organic material, composed of a mixture of hydrocarbons, with methane (CH4) being the dominant component.
M85 A blend of gasoline and methanol consisting of 85% methanol and 15% gasoline.
NGV Natural Gas Vehicle.
Measurements of Pressure 1 PSI=2.06 Hg (mercury) = 27.72” H2O (water column). At sea level atmospheric pressure is 29.92” Hg.
NOX See Oxides of Nitrogen.
Methanol Known as wood alcohol (CH3OH), a light, volatile, flammable alcohol commonly made from natural gas.
Octane Rating The measurement of the antiknock value of a motor fuel.
MIL Malfunction Indicator Lamp.
OEM Original Equipment Manufacturer, the vehicle manufacturer.
Misfire Failure of the air/fuel mixture to ignite during the power stroke.
Open-Loop An operational mode during which control module memory information is used to determine air/fuel ratio, injection timing, etc., as opposed to actual oxygen sensor input.
Mixer Fuel introduction device that does not include a throttle plate.
Orifice A port or passage with a calibrated opening designed to control or limit the amount of flow through it.
MFI Multiport Fuel Injection. A fuel injection system that uses one injector per cylinder mounted on the engine to spray fuel near the intake valve area of combustion chamber.
Oscilloscope An instrument that converts voltage and frequency readings into traces on a-cathode ray tube (also see Cathode Ray Tube).
MSV Manual Shut-Off Valve. Refers to the manually operated valve on the LPG tank.
1-5
1 — GENERAL INFORMATION Oxides of Nitrogen Chemical compounds of nitrogen bonded to various amounts of oxygen (NOX). A chief smog forming-agent.
Pressure Regulator A device to control the pressure of fuel delivered to the fuel injector(s). Primary Circuit The low-voltage or input side of the ignition coil.
Oxygen Sensor An automotive fuel system that produces a signal in accordance with the oxygen content of the exhaust gas. (See Lambda Sensor).
Propane An odorless and colorless gas, C3H8, found in natural gas and petroleum.
Oxygenate Oxygenates (such as MTBE, ethanol and methanol) added to gasoline to increase the oxygen content and therefore reduce exhaust emissions.
Psia Pounds per square inch absolute. PTV Pressure Trim Valve
Ozone A radical oxygen module (O3) that is found in the upper atmosphere and filters out ultraviolet radiation from the sun. Ground level ozone is formed by NOX, during the formation of photochemical smog.
Reactivity Refers to the tendency of an HC in the presence of NOX and sunlight to cause a smog-forming reaction. The lighter the HC, the lower reactivity tends to be.
Particulates Microscopic pieces of solid or liquid substances such as lead and carbon that are discharged into the atmosphere by internal combustion engines.
Regulator An assembly used to reduce and control the pressure of a liquid or vapor. Resistance The opposition to the flow of current in an electrical circuit. Measured in ohms.
Positive Crankcase Ventilation (PCV) An automotive emission control system designed to reduce hydrocarbon emissions by routing crankcase fumes into the intake manifold rather than to the atmosphere.
Rest Pressure Fuel pressure maintained within the system after engine shutdown.
Power Derate A mode of reduced engine power output for the purposes of protecting engine components during a failure or malfunction.
Rich Mixture An air to fuel ratio below the stoichiometric ratio; too much fuel. SAE Society of Automotive Engineers.
Pressure Differential The differential between atmospheric pressure and intake manifold (referred to as vacuum) pressure.
Secondary Circuit The high-voltage output side of the ignition coil.
1-6
1 — GENERAL INFORMATION SEFI or SFI Sequential Electronic Fuel Injection or Sequential Fuel Injection.
TLEV Transitional Low Emission Vehicle. TMAP Combined Air Inlet and Manifold Pressure Sensor.
Sensors Devices that provide the control module with engine information as needed to properly control engine function.
Toluene A liquid aromatic hydrocarbon C7H8.
Spark Line The portion of an oscilloscope pattern that represents the time during which the air/fuel mixture is being burned in the combustion chamber.
TPS Throttle Position Sensor. ULEV Ultra Low Emission Vehicle.
Splice An electrical term for the joining of two or more conductors at a single point.
USB Universal Serial Bus. A plug or interface supplied on most personal computers.
Stoichiometric Ratio An ideal fuel/air ratio for combustion in which all of the fuel and most of the oxygen will be burned.
Vaporization A process in which liquid changes states into gas.
Sulfur Oxides Chemical compounds where sulfur is bonded to oxygen produced by the combustion of gasoline or any other fuel that contains sulfur. As sulfur oxides combine with water in the atmosphere to form sulfuric acid.
Venturi Air Valve Vacuum (VAVV) An amplified air valve vacuum signal coming from the venturi area of the mixer, directly exposed to airflow before the addition of vaporized LPG.
System Pressure The fuel pressure maintained in the system during normal engine operation.
Volt/Ohmmeter (VOM) A combination meter used to measure voltage and resistance in an electrical circuit. Available in both analog and digital types. May be referred to as AVOM and DVOM.
Tap An electrical term for a type of splice where the original circuit is not interrupted.
Voltage The electrical pressure that causes current to flow in a circuit. Measured in volts.
TBI Throttle Body Injection. Any of several injection systems that have the fuel injector(s) mounted in a centrally located throttle body.
Voltage Drop A lowering of the voltage in a circuit when resistance or electrical load is added.
Throttle Body Controls engine RPM by adjusting the engine manifold vacuum to the mixer. Consists of a housing shaft, throttle liner and buttery valve. 1-7
1 — GENERAL INFORMATION Voltmeter A meter that uses a needle to point to a value on a scale of numbers usually of the low impedance type; used to measure voltage and resistance. VSS Vehicle Speed Sensor Xylene C6H4 (CH3)2. Any of three toxic, flammable, and oily isomeric aromatic hydrocarbons that are dimethyl homologues of benzene and usually obtained from petroleum or natural gas distillates. ZEV Zero Emission Vehicle.
1-8
1 — GENERAL INFORMATION
INTRODUCTION
SERVICING YOUR EMISSIONS CERTIFIED ENGINE
This service manual supplement has been developed to provide the service technician with the basic understanding of the IMPCO certified fuel and emission systems for the 4.3L GM engine. This manual should be used in conjunction with the base engine manual and the OEM service manual when diagnosing fuel or electrical problems.
Any maintenance and repair should be performed by trained and experienced service technicians. Proper tools and equipment should be used to prevent injury to the servicing technician and damage to the vehicle or components. Service repairs should always be performed in a safe environment and the technician should always wear protective clothing to prevent injury. For parts or labor to be reimbursed under the IMPCO Technologies Inc. emission warranty, only work performed by IMPCO or OEM trained technicians using only IMPCO specified parts will qualify for reimbursement.
HOW TO IDENTIFY THE ENGINE YEAR The 4.3L engine blocks have been stamped with a serial number and two digits identifying the model year (not to be confused with the actual date of production). The number can be found on a machined surface on the back of the engine block, just below the rear engine hanger. The last two digits represent the model year.
For parts or labor not reimbursed under warranty, a repair shop or person of the owner’s choosing may maintain, replace, or repair emission-control devices and systems. It is highly recommended that any replacement parts used for maintenance or for the repair of emission control systems be new OEM replacement parts. The use of other than genuine IMPCO replacement parts may impair the effectiveness of emission control systems, therefore, the owner should assure that such parts are warranted by their manufacturer to be equivalent to genuine IMPCO OEM parts in performance and durability.
FUEL QUALITY IMPCO-certified LPG engines and fuel systems are designed to operate on HD-5 or HD-10 specification LPG fuel. Fuel other than HD-5 or HD-10 specification may cause harm to the engines emission control system. IMPCO may deny emissions related warranty claims on this basis.
The location of the engine block date stamp is shown above. The “08” represents 2008 model year production.
1-9
1 — GENERAL INFORMATION
FUEL SYSTEM CAUTIONS
!
WARNINGS, CAUTIONS AND NOTES This manual contains several different Warnings, Cautions, and Notes that must be observed to prevent personal injury and or damage to the vehicle, the fuel system or personal property.
CAUTION
Do not smoke, carry lighted tobacco or use a lighted flame of any type when working on or near any fuel related component. Highly flammable air-fuel mixtures may be present and can be ignited causing personal injury.
A “WARNING” is an advisement that by performing a process or procedure listed in this manual improperly may result in serious bodily injury, death and/or serious damage to the vehicle or property damage. Typical Warning Label:
!
CAUTION
!
Do not allow propane to contact the skin. Propane is stored in the fuel tank as a liquid. When propane contacts the atmosphere, it immediately expands into a gas, resulting in a refrigeration effect that can cause severe burns to the skin.
!
Failure to heed instructions could result in death, injury, or property damage. A “CAUTION” label or statement is used when it has been determine that by performing a process or procedure defined in the manual improperly a less severe result may occur. It could however, result in serious bodily injury, and or serious damage to the vehicle or property damage.
CAUTION
Do not allow propane to accumulate in areas below ground level such as in a service pit or underground ventilation systems. Propane is heavier than air and can displace oxygen, creating a dangerous condition
!
WARNING
!
CAUTION
Less severe than WARNING but has the potential to cause injury or damage. Also used to notify of situations that could lead to eventual failure, injury or damage.
CAUTION
This caution label may also appear in area of this manual which applies to service and repair procedures which could render the fuel and emissions control system non-compliant. In addition it may also be used to indicate a failure to observe which may influence the terms of the warranty.
Do not make repairs to the LPG fuel system if you are not familiar with or trained to service LPG fuel system. Contact the dealer who sold you the vehicle to locate a repair facility with trained technicians to repair your fuel system
An “IMPORTANT” statement generally denotes a situation which requires strict adherence to
1-10
1 — GENERAL INFORMATION the assembly, tightening, or service procedure. Failure to observe this procedure could result in an unsafe condition or improper performance of the vehicle or a component.
IMPORTANT
It is important to remember that there may be a combination of Metric and Imperial fasteners used in the installation of the IMPCO fuel system. Check to insure proper fit when using a socket or wrench on any fastener to prevent damage to the component being removed or injury from “slipping off” the fastener.
A “NOTE” statement applies to a specific item or procedure which is to be followed during the servicing of the vehicle or its components.
PROPER USE OF THIS SERVICE MANUAL, TOOLS AND EQUIPMENT To reduce the potential for injury to the technician or others and to reduce damage to the vehicle during service repairs the technician should observe the following steps: •
The service procedures defined in this manual, when followed, have been found to be a safe and efficient process to repair the fuel system. In some cases special tools may be required to perform the necessary procedures to safely remove and replace a failed component.
•
The installed IMPCO fuel system has been certified with the Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) and complies with the regulation in effect at the time of certification. When servicing the fuel and emission control system you should follow all the recommended service and repair procedures to insure the fuel and emissions system is operating as designed and certified. Purposely or knowingly defeating or disabling any part or the fuel and emission system may be in violation of the anti-tampering provision of the EPA’s Clean Air Act.
•
Tools identified in this manual with a prefix of a “J” or “BT” can be procured through SPX in Warren, Michigan.
•
Tools identified in this manual with a prefix of “ITK” can be acquired through OEM Parts Distribution.
IMPORTANT
The IMPCO fuels system utilizes fuel lines and hoses with swivel connections that attach to fixed mating connectors. You should always use a wrench of the proper size on both the swivel and fixed fitting to prevent turning of the fixed fitting. Turning of the fixed fitting may cause a “twisting” or “kinking” of the hose and may result in a restriction of the fuel line or a leak.
!
WARNING
Always leak check any fuel system connection after servicing! Use an electronic leak detector and/or a liquid leak detection solution. Failure to leak check could result in serious bodily injury, death, or serious property damage.
1-11
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 1-12
2 — MAINTENANCE MAINTENANCE
The maintenance of an engine and related components are critical to its operating performance and lifespan. Lift truck engines operate in environments that often include hot and cold temperatures and extreme dust. The recommended maintenance schedule is listed in this section, however, environmental operating conditions and additional installed equipment may require more frequent inspection and servicing. The owner and/or service agent should review the operating conditions of the equipment to determine the inspection and maintenance intervals.
!
!
Alcohol or Methanol based anti-freeze or plain water are not recommended for use in the cooling system at anytime.
SERPENTINE BELT SYSTEM Serpentine belts utilize a spring-loaded tensioner to keep the belt properly adjusted. Serpentine belts should be checked according to the maintenance schedule in this section.
WARNING
When performing maintenance on the engine, turn the ignition OFF and disconnect the battery negative cable to avoid injury or damage to the engine.
IMPORTANT
The use of “belt dressing” or “anti-slipping agents” on belts is not recommended.
The engine installed in this equipment uses a serpentine drive belt configuration incorporated to drive the water pump, alternator and additional pumps or devices. It is important to note that the drive belt is an integral part of the cooling and charging system and should be inspected according to the maintenance schedule in this section. When inspecting the belts check for: •
Cracks
•
Chunking of the belt
•
Splits
•
Material hanging loose from the belt
•
Glazing, hardening
WARNING
COOLING SYSTEM It is important that the cooling system of the engine be maintained properly to ensure proper performance and longevity.
!
WARNING
Do not remove the cooling system pressure cap (radiator cap) when the engine is hot. Allow the engine to cool and then remove the cap slowly to allow pressure to vent. Hot coolant under pressure may discharge violently.
If any of these conditions exist the belt should be replaced with the recommended OEM replacement belt.
Note that the LPG vaporizer is connected to the cooling system and the fuel system maybe adversely affected by low coolant levels and restricted or plugged radiator cores. Therefore, the cooling system must be maintained accord-
2-1
2 — MAINTENANCE
ENGINE ELECTRICAL SYSTEM MAINTENANCE
ing to the recommend maintenance schedule in this section and also include: •
The regular removal of dust, dirt and debris from the radiator core and fan shroud.
•
Inspection of coolant hoses and components for leaks, especially at the radiator hose connections. Tighten hose clamps if necessary.
•
Check radiator hoses for swelling, separation, hardening, cracks or any type of deterioration. If any of these conditions exist the hose should be replaced with a recommended OEM replacement part.
•
The engine’s electrical system incorporates computers to control various related components. The electrical system connections and ground circuits require good connections. Follow the recommended maintenance schedule in this section to maintain optimum performance. When inspecting the electrical system check the following:
Inspect the radiator cap to ensure proper sealing.
•
Check Positive and Negative cables for corrosion, rubbing, chafing, burning and to ensure tight connections at both ends.
•
Check battery for cracks or damage to the case and replace if necessary.
•
Inspect engine wire harness for rubbing, chafing, pinching, burning, and cracks or breaks in the wiring.
•
Verify that engine harness connectors are correctly locked by pushing in and then pulling the connector halves outward.
•
Inspect ignition coil wire for hardening, cracking, arcing, chafing, burning, separation, split boot covers.
•
Check spark plug wires for hardening, cracking, chafing, arcing or burning, separation, and split boot covers.
•
Replace spark plugs at the required intervals per the recommended maintenance schedule.
•
Verify that all electrical components are securely mounted to the engine or chassis.
•
Verify that any additional electrical services installed by the owner are properly installed in the system.
•
Verify that the MIL, charging, and oil pressure lights illuminate momentarily during the start of the engine.
COOLANT Check coolant level in coolant recovery tank and add coolant as required. Add 50/50 mixture of ethylene glycol antifreeze and water or coolant per engine manufacturer’s instructions. Do not add plain water. Replace coolant per the recommended schedule.
IMPORTANT
The manufacturers of the engine and fuel system do not recommend the use of “stop leak” additives to repair leaks in the cooling system. If leaks are present the radiator should be removed and repaired or replaced.
2-2
2 — MAINTENANCE
ENGINE CRANKCASE OIL
SYNTHETIC OILS Synthetic oils have been available for use in industrial engines for a relatively long period of time and may offer advantages in cold and hot temperatures. However, it is not known if synthetic oils provide operational or economic benefits over conventional petroleum-based oils in industrial engines. Use of synthetic oils does not permit the extension of oil change intervals.
OIL RECOMMENDATION Select an engine oil that will best match the prevailing daytime temperature:
CHECKING/FILLING ENGINE OIL LEVEL
IMPORTANT
Care must be taken when checking engine oil level. Oil level must be maintained between the “ADD” mark and the “FULL” mark on the dipstick. To ensure that you are not getting a false reading, make sure the following steps are taken before checking the oil level. 1. Stop engine. 2. Allow approximately five minutes for the oil to drain back into the oil pan.
IMPORTANT
Oils recommended by the engine manufacturer already contain a balanced additive treatment. Oils containing “solid” additives, non-detergent oils, or low quality oils are not recommended by the engine manufacturer. The supplemental additives added to the engine oil are not necessary and may be harmful. The engine and fuel system supplier do not review, approve or recommend such products.
3. Remove the dipstick. Wipe with a clean cloth or paper towel and reinstall. Push the dipstick all the way into the dipstick tube. 4. Remove the dipstick and note the amount of oil on the dipstick. The oil level must be between the “FULL” and “ADD” marks.
Figure 2 Engine Oil Dipstick (Typical)
2-3
2 — MAINTENANCE 5. If the oil level is below the “ADD” mark reinstall the dipstick into the dipstick tube and proceed to Step 6.
IMPORTANT
Engine oil will be hot. Use protective gloves to prevent burns. Engine oil contains chemicals which may be harmful to your health. Avoid skin contact.
6. Remove the oil filler cap from the valve cover. 7. Add the required amount of oil to bring the level up to, but not over, the “FULL” mark on the dipstick Reinstall the oil filler cap to the valve rocker arm cover and wipe any excess oil clean.
3. Remove drain plug and allow the oil to drain. 4. Remove and discard oil filter and its sealing ring.
CHANGING THE ENGINE OIL
5. Coat sealing ring on the new filter with clean engine oil, wipe the sealing surface on the filter mounting surface to remove any dust, dirt or debris. Tighten filter securely (follow filter manufacturers instructions). Do not over tighten.
IMPORTANT
When changing the oil, always change the oil filter.
6. Check sealing ring on drain plug for any damage, replace if necessary, wipe plug with clean rag, wipe pan sealing surface with clean rag and re-install plug into the pan. Tighten to specification.
1. Start the engine and run until it reaches normal operating temperature.
7. Fill crankcase with oil.
!
CAUTION
8. Start engine and check for oil leaks.
An overfilled crankcase (oil level being too high) can cause an oil leak, a fluctuation or drop in oil pressure. When overfilled, the engine crankshafts splash and agitate the oil, causing it to aerate or foam.
9. Dispose of oil and filter in a safe manner.
FUEL SYSTEM INSPECTION AND MAINTENANCE PROPANE FUEL SYSTEM The Propane fuel system installed on this industrial engine has been designed to meet the emission standard applicable for the 2007 model year. To ensure compliance to these standards, follow the recommended maintenance schedule contained in this section.
IMPORTANT
Change oil when engine is warm and the old oil flows more freely. 2. Stop engine
INSPECTION AND MAINTENANCE OF THE FUEL STORAGE CYLINDER The fuel storage cylinder should be inspected daily or at the beginning of each operational shift for any leaks, external damage, adequate
2-4
2 — MAINTENANCE fuel supply and to ensure the manual service valve is open. Fuel storage cylinders should always be securely mounted, inspect the securing straps or retaining devices for damage ensure that all locking devices are closed and locked. Check to ensure that the fuel storage cylinder is positioned with the locating pin in the tank collar on all horizontally mounted cylinders this will ensure the proper function of the cylinder relief valve.
REPLACING THE FUEL FILTER: 1. Move the equipment to a well ventilated area and verify that sparks, ignition and any heat sources are not present. 2. Start the engine. 3. Close the manual valve. 4. When the engine stalls when it runs out of fuel, turn the ignition key to the OFF position and disconnect the battery negative cable.
When refueling or exchanging the fuel cylinder, check the quick fill valve for thread damage. Also verify O-ring is in place and inspect for cracks, chunking or separation. If damage to the O-ring is found, replace prior to filling. Check the service line quick coupler for any thread damage.
IMPORTANT
A small amount of fuel may still be present in the fuel line. Use gloves and proper eye protection to prevent burns. If liquid fuel continues to flow from the connections when removed, make sure the manual valve is fully closed.
IMPORTANT
When refueling the fuel cylinder, wipe both the female and male connection with a clean rag prior to filling to prevent dust, dirt and debris from being introduced to the fuel cylinder.
5. Slowly loosen the inlet fitting and disconnect. 6. Slowly loosen the outlet fitting and disconnect. 7. Remove the filter housing form the equipment.
INSPECTION AND REPLACEMENT OF THE FUEL FILTER
8. Check for contamination.
The Propane system on this emission certified engine utilizes an in-line replaceable fuel filter element. This element should be replaced, at the intervals specified in the recommended maintenance schedule. When inspecting the fuel filter check the following:
9. Tap the opening of the filter on a clean cloth. 10. Check for debris. 11. Check canister for proper mounting direction.
Check for leaks at the inlet and outlet fittings, using a soapy solution or an electronic leak detector and repair if necessary.
12. Reinstall the filter housing to the equipment.
•
Check to make sure filter is securely mounted.
14. Open the manual valve.
•
Check filter housing for external damage or distortion. If damaged replace fuel filter.
•
13. Tighten the inlet and outlet fittings to specification.
2-5
2 — MAINTENANCE
IMPORTANT
The fuel cylinder manual valve contains an Excess Flow Check Valve. Open the manual valve slowly to prevent activating the Excess Flow Check Valve.
IMPORTANT
The Electronic Pressure Regulator (EPR) components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine. If the EPR fails to operate or develops a leak, it should be repaired or replaced with the OEM recommended replacement parts. When inspecting the regulator check for the following items:
•
Check for any fuel leaks in the regulator body.
•
Check the inlet and outlet fittings of the coolant supply lines for water leaks.
•
Check the coolant supply lines for hardening, cracking, chafing or splits. If any of these conditions exist replace coolant lines.
•
Check coolant supply hose clamp connections, ensure they are tight.
•
Check to ensure the EPR is securely mounted and the mounting bolts are tight.
•
Check EPR electrical connection to ensure the connector is seated and locked.
During the course of normal operation oil or “heavy ends” may build inside the secondary chamber of the Electronic Pressure Regulator (EPR). These oil and heavy ends may be a result of poor fuel quality, contamination of the fuel, or regional variation of the fuel make up. A significant build up of oil can affect the performance of the secondary diaphragm response. The Recommended Maintenance Schedule found in this section recommends that the oil be drained periodically. This is the minimum requirement to maintain the emission warranty. More frequent draining of the EPR is recommended for special situations where substandard fuel may be a problem. Cat Lift Trucks recommends the EPR be drained at every engine oil change if contaminated or substandard fuel is suspected or known to have been used or in use with the emission compliant fuel system. This is known as special maintenance, and failure to follow this recommendation may be used to deny a warranty claim.
ELECTRONIC PRESSURE REGULATOR (EPR) MAINTENANCE AND INSPECTION
Check for any fuel leaks at the inlet and outlet fittings.
Check EPR for external damage.
CHECKING/DRAINING OIL BUILD-UP IN THE LOW PRESSURE REGULATOR
15. Check for leaks at the inlet and outlet fittings, and the filter housing end connection using a soapy solution or an electronic leak detector, if leaks are detected make repairs.
•
•
IMPORTANT
Draining the regulator when the engine is warm will help the oils to flow freely from the regulator. To drain the EPR, follow the steps below: 1. Move the equipment to a well ventilated area and ensure no external ignition sources are present. 2. Start the engine. 3. With the engine running close the manual valve. 4. When the engine runs out of fuel turn OFF the key when the engine stops and disconnect the negative battery cable. 2-6
2 — MAINTENANCE
IMPORTANT
IMPORTANT
A small amount of fuel may still be present in the fuel line, use gloves to prevent burns, wear proper eye protection. If liquid fuels continues to flow from the connections when loosened check to make sure the manual valve is fully closed.
The fuel cylinder manual valve contains an “Excess Flow Check Valve” open the manual valve slowly to prevent activating the “Excess Flow Check Valve.”
5. Slowly loosen the inlet fitting and disconnect.
19. Check for leaks at the inlet and outlet fittings using a soapy solution or an electronic leak detector. If leaks are detected make repairs. Check coolant line connections to ensure no leaks are present.
6. Loosen the hose clamp at the outlet hose fitting and remove the hose.
20. Start engine recheck for leaks at the regulator.
7. Remove the Retaining Pin in the LPG Temperature Sensor and remove from the EPR
21. Dispose of any drained material in safe and proper manner.
8. Remove the three EPR mounting bolts. 9. Place a small receptacle in the engine compartment.
AIR FUEL MIXER/THROTTLE CONTROL DEVICE MAINTENANCE AND INSPECTION
10. Rotate the EPR to 90˚ so that the outlet fitting is pointing down into the receptacle and drain the EPR. 11. Inspect the secondary chamber for any large dried particles and remove.
IMPORTANT
12. Remove the receptacle and reinstall the EPR with the three retaining bolts and tighten to specifications.
The Air Fuel Mixer components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine. The mixer should not be disassembled or rebuilt. If the mixer fails to operate or develops a leak the mixer should be replaced with the OEM recommended replacement parts.
13. Reinstall the outlet fitting and secure with the previously removed Retaining pin. 14. Reconnect the electrical connector (push in until it clicks and securely locks), then pull on the connector to ensure it is locked. 15. Connect the vacuum line.
When inspecting the mixer check for the following items:
16. Reconnect the outlet hose and secure the hose clamp. 17. Reinstall the fuel inlet line and tighten connection to specification.
•
Leaks at the inlet fitting.
•
Fuel inlet hose for cracking, splitting or chaffing, replace if any of these condition exist.
•
Ensure the mixer is securely mounted.
18. Slowly open the manual service valve.
2-7
2 — MAINTENANCE •
Inspect air inlet hose connection and clamp. Also inspect inlet hose for cracking, splitting or chafing. Replace if any of these conditions exist.
•
Inspect Air cleaner element according to the Recommended Maintenance Schedule found in this section.
•
Check Fuel lines for cracking, splitting or chafing. Replace if any of these conditions exist.
•
•
IMPORTANT
The HEGO sensor is sensitive to silicone based products. Do not use silicone sprays or hoses which are assembled using silicone lubricants. Silicone contamination can cause severe damage to the HEGO. When inspecting the Exhaust system check the following:
Verify Throttle body return action to ensure throttle shaft is not sticking. Repair if necessary. Check for leaks at the throttle body and intake manifold.
EXHAUST SYSTEM AND CATALYTIC CONVERTER INSPECTION AND MAINTENANCE
•
Exhaust manifold at the cylinder head for leaks and that all retaining bolts and shields (if used) are in place.
•
Manifold to exhaust pipe fasteners to ensure they are tight and that there are no exhaust leaks repair if necessary.
•
HEGO electrical connector to ensure connector is seated and locked, check wires to ensure there is no cracking, splits chafing or “burn through.” Repair if necessary.
•
Exhaust pipe extension connector for leaks tighten if necessary
•
Visually inspect converter to ensure muffler is securely mounted and tail pipe is properly aimed.
•
Check for any leaks at the inlet and outlet of the converter.
IMPORTANT
The exhaust system on this emission certified engine contains a Heated Exhaust Gas Oxygen Sensor (HEGO) which provides feed back to the ECM on the amount of oxygen present in the exhaust stream after combustion. The measurement of oxygen in the exhaust stream is measured in voltage and sent to the ECM. The ECM then makes corrections to the fuel air ratio to ensure the proper fuel charge and optimum catalytic performance. Therefore, it is important that the exhaust connections remain secured and air tight.
2-8
2 — MAINTENANCE
LPG CERTIFIED ENGINE MAINTENANCE REQUIREMENTS Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter. Interval Hours Daily 1000 1500 2000 2500
3000
3500
4000
4500
5000
General Maintenance Section Visual check for fluid leaks
X
Check engine oil level
X
Check coolant level
X
Change engine oil and filter
Every 200 hours or 30 days of operation
Check LPG system for leaks
Prior to any service or maintenance activity
Inspect accessory drive belts for cracks, breaks, splits or glazing
X
X
X
X
Inspect electrical system wiring for cuts, abrasions or corrosion
X
X
Inspect all vacuum lines and fittings for cracks, breaks or hardening
X
X
X
Engine Coolant Section Clean debris from radiator core
Every 200 hours or 30 days of operation
Change coolant
Every 1200 hours or 6 months, whichever comes first
Inspect coolant hoses for cracks, swelling or deterioration
X
X
X
X
X
Inspect Battery case for leaks or damage
X
X
X
X
X
Inspect battery cables for damage corrosion or contamination
X
X
X
X
X
Check all electrical connector retainer locks
X
X
X
X
X
Engine Ignition System
Replace spark plugs
X
X
Replace distributor cap and rotor
X
X
Clean secondary ignition coil tower
X
Check spark plug wires for cuts abrasions or hardening
X
X
X
X
Replace spark plug wires
X
Fuel System Maintenance Inspect air cleaner
Every 200 hours, or every 100 hours in dusty environment
Replace filter element
Annually, or Bi-annually in dusty environments
Replace fuel filter
X
X
X
X
Inspect Shut-off Valve for leaks and closing
X
X
Check throttle linkage for sticking
X
X
Leak check fuel lines
X
X
Check air induction for leaks
X
X
Check manifold for vacuum leaks
X
X
X
X
Check injector & rails for leaks Inspect EPR for coolant leaks
X
Annually or every 2000 hours
Drain EPR oil build up
Every 2500 hrs
Engine Exhaust System Inspect exhaust manifold for leaks
X
X
Inspect exhaust piping for leaks
X
X
Check HEGO sensor connector and wires for burns, cuts or damage
X
X
Inspect catalyst for mechanical damage
X
X
This maintenance schedule represents the manufacturer’s recommended maintenance intervals to maintain proper engine/equipment function. Federal, State, or Local regulations may require additional or more frequent inspection or maintenance intervals than those specified above. Check with the authority having jurisdiction for details.
2-9
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 2-10
3 — LPG FUEL SYSTEM LPG FUEL SYSTEM
LPG FUEL SYSTEM OPERATION
3-1
3 — LPG FUEL SYSTEM
DESCRIPTION AND OPERATION OF THE FUEL SYSTEMS
safety feature called an excess flow check valve. This feature reduces the flow from the service valve in the event of a rupture of the fuel line or any down stream.
PROPANE FUEL SYSTEM The primary components of the propane fuel system are the fuel storage tank, electronic pressure regulator (EPR), fuel mixer module with throttle control device, electric Shut-Off Valve, engine control module (ECM), and a catalytic converter. The system operates at pressures which range from 355.60 mm (14.0 inches) of water column up to 21.5 BAR (312 psi).
Typical Propane Cylinder
LPG FUEL TANK
1. Liquid Outage Fill Check Valve
Propane is stored in the fuel tank as a liquid. The approximate pressure of the fuel in the tank is 16.5 bar (240 psi) when the tank is full at an ambient temperature of 27˚C (81˚F). The boiling point, (temperature at which the liquid fuel becomes vapor) is approximately -40˚C (-40˚F). When the fuel changes from liquid to vapor the fuel expands and creates pressure inside the tank. When the tank service valve is opened the pressure inside the tank forces the liquid fuel out though the pick up tube located near the bottom of the fuel cylinder.
2. Pressure Relief Valve 3. Liquid Outage valve w/quick disconnect coupling 4. Filler Valve 5. Fuel Gauge 6. Vapor Withdrawal Tube (when applicable) 7. 80% Limiter Tube 8. Fuel Level Float 9. Liquid Withdrawal Tube SERVICE LINE Propane flows from the fuel tank to the electric LPG Shut-Off Valve via the service line. The service line is connected to the tank utilizing a quick coupler. The other end of the service line is connected to a bulkhead connector mounted on the equipment sheet metal. This bulkhead connector allows for a safe means of passing through the equipment’s engine compartment sheet metal and into the engine compartment. If a bulkhead connector is used a pressure relief device is mounted in the service line or the connector itself to prevent over pressurization. The service line is made of high pressure hose with special material or possibly tubing which is compatible with the LPG fuel and should always be replaced with an OEM supplied part.
Because the propane is stored under pressure the tank is equipped with a safety valves which are normally set at 25.8 bar (375 psi) to prevent tank rupture due to over-pressurization of the cylinder. The service valve mounted in the end of the cylinder controls the flow of fuel from the tank. By turning the handle to its “open” position, fuel flows out of the tank and into the service line. The service valve is also equipped with a
3-2
3 — LPG FUEL SYSTEM
!
CAUTION
The bulkhead assembly should never be removed. Never run a service line through the sheet metal. FUEL FILTER Propane, fuel like all other motor fuels is subject to contamination from outside sources. Refueling of the equipment tank and removal of the tank from the equipment can inadvertently introduce dirt and other foreign matter into the fuel system. It is therefore necessary to filter the fuel prior to entering the fuel system components down stream of the tank. An inline fuel filter has been installed in the fuel system to remove the dirt and foreign matter from the fuel, which is replaceable as a unit only. Maintenance of the filter is critical to proper operation of the fuel system and should be replaced according to the maintenance schedule or more frequently under severe operating conditions.
LPG Shut-Off Valve
Voltage to the LPG Shut-Off Valve is controlled by the engine control module (ECM). ELECTRONIC PRESSURE REGULATOR (EPR) The EPR is a combination vaporizer and pressure regulating device. The EPR functions as a negative pressure two stage regulator that is normally closed with the ability to supply additional fuel by command from the ECM. When the engine is cranking or running, a partial vacuum is created in the fuel line that connects the regulator to the mixer. This partial vacuum opens the regulator permitting fuel to flow to the mixer. Propane fuel enters the primary port of the EPR and passes through the primary jet and into the primary/heat exchanger chamber and expands as it heats up, creating pressure inside the chamber. When the pressure increases above 10.34 kpa (3.5 psi), sufficient pressure is exerted on the primary diaphragm to cause the diaphragm plate to pivot and press against the primary valve pin, thus closing off the flow of fuel. When the engine is cranking, sufficient vacuum will be introduced into the secondary chamber from the mixer drawing the secondary diaphragm down onto the spring loaded lever and opening the secondary valve. An increase in vacuum in the secondary chamber increases the downward action on the secondary lever,
Inline Fuel Filter
LPG SHUT-OFF VALVE The LPG Shut-Off Valve is an integrated assembly consisting of a 12 volt solenoid and a normally closed valve. When energized, the solenoid opens the valve and allows the Propane fuel to flow through the device. The valve opens during cranking and engine run cycles.
3-3
3 — LPG FUEL SYSTEM causing it to open wider and permitting more fuel flow to the mixer.
inches) of water column at full throttle. The vacuum being created is referred to as Air Valve Vacuum (AVV). As the air valve vacuum reaches 101.6mm (4.0 inches) of water column, the air valve begins to lift against the air valve spring. The amount of AVV generated is a direct result of the throttle position. At low engine speed the air valve vacuum and the air valve position is low thus creating a small venturi for the fuel to flow. As the engine speed increases the AVV increases and the air valve is lifted higher thus creating a much larger venturi. This air valve vacuum is communicated from the mixer venturi to the LPR secondary chamber via the low pressure fuel supply hose. As the AVV increases in the secondary chamber the secondary diaphragm is drawn further down forcing the secondary valve lever to open wider.
Electronic Pressure Regulator
!
The mixer is equipped with a low speed mixture adjustment which is retained in a tamper proof housing. The mixer has been preset at the factory and should not require adjustment. In the even that the idle adjustment should need to be adjusted refer the Fuel System Repair section of this manual.
CAUTION
The EPR is an emission control device and should only be serviced by qualified technicians.
!
AIR FUEL MIXER The air valve mixer is an air-fuel metering device and is completely self-contained. The mixer is an air valve design, utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load. The mixer is mounted in the air stream ahead of the throttle control device.
CAUTION
The air/fuel mixer is an emission control device. Components inside the mixer are specifically calibrated to meet the engine’s emissions requirements and should never be disassembled or rebuilt. If the mixer fails to function correctly, replace with an OEM replacement part.
When the engine begins to crank it draws in air with the air valve covering the inlet, and negative pressure begins to build. This negative pressure signal is communicated to the top of the air valve chamber through 4 vacuum ports in the air valve assembly. A pressure/force imbalance begins to build across the air valve diaphragm between the air valve vacuum chamber and the atmospheric pressure below the diaphragm. The air valve vacuum spring is calibrated to generate from 101.6 mm (4.0 inches) of water column at start to as high as 355.60 mm (14.0
THROTTLE CONTROL DEVICE—DRIVE BY WIRE Drive By Wire Engine speed control is maintained by the amount of pressure applied to the foot pedal located in the engine compartment. In a Drive By Wire (DBW) application, there is no direct connection between the operator pedal and the throttle shaft. Speed and load control
3-4
3 — LPG FUEL SYSTEM are determined by the ECM. Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine. In a drive by wire application the Electronic Throttle Control device or throttle body assembly is connected to the intake manifold of the engine. The electronic throttle control device utilizes an electric motor connected to the throttle shaft. In addition, a Foot Pedal Position sensor (FPP) is located in the operator’s compartment. When the engine is running electrical signals are sent from the foot pedal position sensor to the engine ECM when the operator depresses or release the foot pedal. The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air/fuel charge to the engine. The electronic throttle control device incorporates two internal Throttle Position Sensors (TPS) which provide output signals to the ECM as to the location of the throttle shaft and blade. The TPS information is used by the ECM to correct for speed and load control as well as emission.
Three Way Catalytic Converter
ENGINE CONTROL MODULE To obtain maximum effect from the catalyst and accurate control of the air fuel ratio, the emission certified engine is equipped with an onboard computer or Engine Control Module (ECM). The ECM is a 32 bit controller which receives input data from sensors mounted to the engine and fuel system and then outputs various signals to control engine operation.
THREE WAY CATALYTIC CONVERTER The Catalytic Converter is a component of the emissions system which is designed and calibrated to meet the emission standards in effect for 2007.
Engine Control Module (ECM)
The exhaust gases pass through the honeycomb catalyst which is coated with a mixture of metals (such as platinum, palladium, and rhodium) to oxidize and reduce CO, HC and NOX emission gases.
One specific function of the controller is to maintain a closed loop fuel control which is accomplished by use of the Heated Exhaust Gas Oxygen sensor (HEGO) mounted in the exhaust system. The HEGO sensor sends a voltage signal to the controller which then outputs signals to the EPR to change the amount of fuel being delivered from the regulator or mixer to the engine. The controller also performs diagnostic functions on the fuel system and notifies the operator of engine malfunctions by turning on a
3-5
3 — LPG FUEL SYSTEM Malfunction Indicator Light (MIL) mounted in the dash. Malfunctions in the system are identified by a Diagnostic Trouble Code (DTC) number. In addition to notifying the operator of the malfunction in the system, the controller also stores the information about the malfunction in its memory. A technician can than utilize a computerized diagnostic scan tool to retrieve the stored diagnostic code and by using the diagnostic charts in this manual to determine the cause of the malfunction. In the event a technician does not have the computerized diagnostic tool, the MIL light can be used to identify the diagnostic code to activate the “blink” feature and count the number of blinks to determine the diagnostic code number to locate the fault in the system.
The Heat Exhaust Gas Oxygen (HEGO) Sensor
HEATED EXHAUST GAS OXYGEN SENSORS The Heated Exhaust Gas Oxygen (HEGO) Sensors are mounted in the exhaust system, one upstream and one downstream of the catalytic converter. The HEGO sensors are used to measure the amount of oxygen present in the exhaust stream to determine whether the fuel air ratio is to rich or to lean. It then communicates this measurement to the ECM. If the HEGO sensor signal indicates that the exhaust stream is too rich, the ECM will decrease or lean the fuel mixture during engine operation. If the mixture is too lean, the ECM will richen the mixture. If the ECM determines that a rich or lean condition is present for an extended period of time which cannot be corrected, the ECM will set a diagnostic code and turn on the MIL light in the dash.
HEGO1 (upstream or before the catalytic converter) and HEGO2 (downstream) voltage output.
!
CAUTION
The Heated Exhaust Gas Oxygen Sensor (HEGO) is an emissions control component. In the event of a failure, the HEGO should only be replaced with the recommended OEM replacement part. The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers or air or fuel hoses treated with a silicone based lubricant.
By monitoring output from the sensor upstream and the sensor downstream of the catalytic converter, the ECM can determine the performance of the converter.
3-6
3 — LPG FUEL SYSTEM TMAP SENSOR The Air Temperature/Manifold Absolute Pressure or TMAP sensor is a combination of two sensors: 1. A variable resistor used to monitor the difference in pressure between the intake manifold and outside or atmospheric pressure; The ECM monitors the resistance of the sensor to determine engine load (the vacuum drops when the engine is under load or at wide open throttle). When the engine is under load, the computer may alter the fuel mixture to improve performance and emissions. The intake air temperature is also monitored by the ECM, primarily to richen the fuel/air mixture during a cold start. 2. The intake air temperature and another sensor to determine the air intake temperature. The Intake Air Temperature or IAT sensor is a variable resistance thermistor located in the air intake passage which measures the temperature of the incoming air. The ECM uses the resistance value to monitor incoming air temperature and calculate the engine’s airflow requirement. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads a higher voltage, and lower when warm. COOLANT TEMPERATURE SENSOR The Engine Coolant Temperature sensor or ECT is a variable resistance thermistor that changes resistance as the engine's coolant temperature changes. The sensor's output is monitored by the ECM to determine a cold start condition and to regulate various fuel and emission control functions via a closed loop emission system. OIL PRESSURE SENDER The Engine Oil Pressure sensor is designed to ensure adequate lubrication throughout the engine. It provides a pressure value for the oil pressure gauge and is monitored by the ECM. If the pressure drops, an MIL will occur.
3-7
3 — LPG FUEL SYSTEM
LPG Closed Loop Schematic
3-8
4 — LPG SYSTEM DIAGNOSIS LPG SYSTEM DIAGNOSIS
LPG System Diagnosis
Electronic Pressure Regulator Assembly
FUEL SYSTEM DESCRIPTION
commonly referred to as air valve vacuum. Once in the mixer, the fuel is combined with air and is drawn into the engine for combustion.
The Engine Control Module (ECM) receives information from various engine sensors in order to control the operation of the Electronic Pressure Regulator (EPR) and Shut-Off Valve. The Shut-Off Valve solenoid prevents fuel flow unless the engine is cranking or running.
DIAGNOSTIC AIDS This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Before starting this procedure, complete the following tasks to verify that liquid fuel is being delivered to the EPR:
LPG is stored in the tank as a liquid and delivered under pressure of up to 21.5 BAR (312 psi). At Key On, the EPR receives a two (2) second prime pulse from the ECM, allowing time for the LPG to flow from the tank through the fuel filter and fuel lines to the EPR. Inside of the EPR, fuel is vaporized and reduced in pressure in two stages. The first stage reduces the tank pressure to approximately 20.68 kilopascals (3.0 psi). The second stage then reduces the pressure to approximately negative 38.1 mm (1.5” of water column) when vacuum from the engine draws in fuel. The fuel is then drawn in from the secondary chamber of the EPR by the vacuum generated by air owing through the Mixer. This vacuum is also generates lift for the mixer air valve and is
4-1
•
Inspect fuel tank to verify it has a sufficient amount of fuel.
•
Verify manual shut off valve on the LPG tank is fully opened.
•
Verify that the excess flow valve has not been activated.
•
Inspect fuel tank to ensure it is properly mounted and rotated to the correct position.
•
Inspect the hoses leading from the tank ensuring they are properly connected and do not have any kinks or damage.
4 — LPG SYSTEM DIAGNOSIS TOOLS REQUIRED: •
7/16” Open end wrench (for test port plugs)
•
Test port adapter
•
Straight Blade screw driver
•
Needle nose pliers
DST •
Diagnostic Scan Tool (DST)
PRESSURE GAUGES •
0-10” Water Column Gauge
•
0-10 PSI Gauge
TEST DESCRIPTION The numbers below refer to step numbers on the Diagnostic Table: 1. This step checks the base mechanical EPR output pressure by disabling all fuel control devices. 9. This step checks for proper air valve operation. 12. This determines if fuel is available from the fuel tank supply system.
4-2
4 — LPG SYSTEM DIAGNOSIS
Step
Action
Value(s)
Yes
No
1
Were you referred to this procedure by a DTC diagnostic chart?
Go to Step 3
Go to Step 2
2
Connect the Diagnostic Scan Tool (DST) to the ECM Data Link Connector (DLC) and check for any DTCs. Are any DTCs present in the ECM?
Go to the applicable DTC Table
Go to Step 3
Perform the following visual and physical preliminary checks: • Check all ECM system fuses and circuit breakers (refer to Engine Wiring Schematic). • Check the ECM grounds for being clean, tight and in their proper locations (refer to Engine Wiring Schematic). • Check the vacuum hoses for damage, splits, kinks and proper connections. • Check the fuel system for any type of leak or restriction from the supply tank to the mixer. • Check for air leaks at all mounting areas of the intake manifold sealing surfaces. • Check for proper installation of the mixer assembly. • Check for air leaks at the mixer assembly and all intake ducting between intake manifold and air cleaner. • Check air cleaner and all vehicle intake ducting for restrictions. • Check exhaust system for flow obstructions or leaks.
Correct the faulty condition and Go to Step 20
Go to Step 4
Go to Step 9
Go to Step 5
Correct the faulty condition and Go to Step 20
Go to Step 6
Check the ignition wires for the following conditions: • Cracking or hardening • Proper routing • Bare or shorted wires • Carbon tracking Check the wiring harness for the following conditions: • Proper connections • Pinches • Cuts or abrasions Were any faulty conditions found in the preliminary checks? 4
Does the vehicle start and run?
5
Check the fuel system for the following conditions: • Verify the LPG fuel tank is at least 1/4 full. • Verify the manual fuel shut-off valve is open and operating correctly. • Verify the high-flow valve has not tripped. • Verify the quick disconnect is fully engaged and there are no kinks or obstructions in the high pressure LPG supply hose. • Verify the LPG fuel filter is clean and unobstructed. Were any faulty conditions found in the fuel supply system?
4-3
4 — LPG SYSTEM DIAGNOSIS
Step 6
Action • • • •
Connect a calibrated 0-5” PSI pressure gauge to the primary pressure test port of the EPR. Make sure the manual shut-off valve is open and turn the ignition to ON. Crank the engine and observe the pressure gauge. Does the pressure gauge indicate the proper primary fuel pressure?
Value(s)
Yes
No
2.0 – 4.0 PSI
Go to Step 7
If NO pressure was indicated, Go to Step 14 If LOW or HIGH pressure was indicated, Go to Step 15
7
LPG is a gaseous fuel and requires higher secondary ignition voltages than gasoline fueled engines. Check the ignition system for proper ignition secondary voltage output with J 26792 or equivalent. Remove the spark plugs and check for the following: • Correct plug type for LPG application. • Wet electrodes (oil fouling) • Cracks • Wear • Improper gap • Burned electrodes • Heavy deposits Were any faulty conditions found in the ignition system check?
8
Perform a leak-down test on the engine. Are all cylinder leak-down test results within specification?
9
• • •
Turn OFF the manual fuel shut-off valve. Start the engine and let it run until it dies. Remove the LPG Temperature Sensor from the EPR (DO NOT disconnect the electrical connector). • Inspect the inside of the low-pressure fuel supply hose for heavy-end deposits. Are there any deposits built-up in the low-pressure fuel supply hose?
4-4
<10% leakage
Correct the faulty condition and Go to Step 20
Go to Step 8
Go to Step 12
Repair the engine as necessary and Go to Step 20
Go to Step 16
Go to Step 10
4 — LPG SYSTEM DIAGNOSIS
Step 10
Action
Value(s)
Yes
No
Insert the Secondary Pressure Test Adapter into the EPR port from which you removed the LPG Temp Sensor. • Connect a CALIBRATED 0-10” water column (WC) vacuum gauge or manometer to the secondary pressure test port of the EPR. • Connect the DST to the vehicle DLC connector and open the GCP Display software. • Turn the manual shut-off valve ON. Start the engine and allow it to reach operating temperature. Compare the gauge secondary pressure reading to the actual pressure on the DST Faults Screen.
+/- 0.75” WC
Go to Step 19
Go to Step 11
-1.0” to -2.0” WC
Go to Step 15
Go to Step 13
Go to Step 14
Go to Step 13
Go to Step 20
NA
Go to Step 17
Go to Step 18
Go to Step 20
NA
•
(Sample Only—Readings will vary) Is the gauge secondary pressure within the specified percentage of the actual pressure indicated on the DST Faults Screen? 11
With the engine still running: • Disconnect the EPR electrical connector. NOTE: This action will cause a DTC to be set turning ON the MIL. •
With the engine idling, observe the pressure reading on the secondary pressure test port gauge. Is the pressure reading within specifications? 12
•
Turn OFF the manual shut-off valve and let the engine run until it dies. • Turn the ignition OFF. • Remove the Air induction hose from the mixer. • Crank the engine and observe the air valve for movement while the engine is cranking. NOTE: At cranking speeds, the air valve movement will be minimal. Is there movement in the air valve when the engine is cranking?
13
Replace the mixer assembly (refer to Fuel Mixer Replacement). Is the action complete?
14
• • •
15
Repair or replace the EPR (refer to EPR Repair Instructions). Is the action complete?
If turned OFF, turn ON the manual shut-off valve. Disconnect the Lock-off valve electrical connector. Apply 12V to the lock-off valve terminals and observe the pressure gauge. Does the pressure gauge indicate pressure?
4-5
Above 1.0 PSI
4 — LPG SYSTEM DIAGNOSIS
Step
Action
16
Value(s)
Yes
No
Inspect the following for heavy-end deposits: • Electronic Pressure Regulator. Inspect, clean and/or repair as necessary (refer to EPR Repair Instructions). • Inspect the diaphragm through the Mixer air inlet for any deposits or contaminants. DO NOT disassemble the Mixer. The Mixer is calibrated and disassembly may alter its calibration and adversely affect engine performance and/or emissions. Are all actions complete?
Go to Step 20
NA
17
Replace the ECM. Is the action complete?
Go to Step 20
NA
18
Replace the Lock-off Valve. Is the action complete?
Go to Step 20
NA
19
System working correctly at this time. Vehicle may have intermittent electrical connection conditions. • Return vehicle to original condition (but leave the diagnostic equipment connected). • Start the engine and wiggle test the harness while observing the DST Faults Screen and the pressure gauge readings. Repair any conditions encountered. Is the action complete?
Go to Step 20
NA
20
•
Clear any active or historic DTCs (DST Service or Faults Screen). • Clear Adaptive from memory (DST Service Screen). • Return the vehicle to original condition. • Operate the vehicle under all load and driving conditions for at least 10 minutes. • Park the vehicle with the engine running and connect the DST to the vehicle's DLC connector. • Open the GCP software and switch to the Faults Screen. • Let the vehicle idle with no load for at least 30 seconds and observe the Adaptive 1 fuel correction. Did the Adaptive 1 fuel correction remain within the specified values?
-15% to +15%
Go to Step 21
Go to Step 24
21
With engine still idling, apply a load with the hydraulic system for at least 10 seconds and observe the Adaptive 1 value. Did the Adaptive 1 fuel correction remain within the specified values?
-15% to +15%
Go to Step 22
Go to Step 24
22
Raise the engine rpms to 75-90% of maximum full governed speed with no load for at least 10 seconds and observe the Adaptive 1 fuel correction. Did the Adaptive 1 fuel correction remain within the specified values?
-15% to +15%
Go to Step 23
Go to Step 24
23
•
-15% to +15%
Go to Step 29
Go to Step 24
With the engine still running at 75-90% of full governed speed, apply a moderate load with the hydraulic system. • Observe the Adaptive 1 fuel correction. Did the Adaptive 1 fuel correction remain within the specified values?
4-6
4 — LPG SYSTEM DIAGNOSIS
Step
Action
Value(s)
Yes
No
24
Was the Adaptive 1 fuel correction less than -15%?
Go to Step 26
Go to Step 25
25
13. Was the Adaptive 1 fuel correction more than +15%?
Go to Step 27
NA
26
Engine is running RICH (system is trying to compensate by decreasing the amount of fuel). Check the following for any condition which may cause the engine to run RICH: • Ignition system (See Step 7). • Air cleaner and intake system (including vehicle intake ducting) for airflow obstructions. • Exhaust system for flow obstructions.
Go to Step 28
NA
27
Engine is running LEAN (system is trying to compensate by increasing the amount of fuel). Check the following for any condition which may cause the engine to run LEAN: • Intake manifold for leaks. • All throttle body and mixer gaskets or o-rings for leaks. • All vacuum hoses and fittings for leaks. • Exhaust system for leaks. NOTE: Exhaust system leaks allow for excess O2 to dilute the HEGO sensors giving a false reading. Engine may exhibit signs of a rich running condition but the Adaptive 1 corrections will indicate an excessive positive fuel adjustment.
Go to Step 28
NA
• HEGO 1 for correct switching characteristics. Are all actions complete? 28
Repeat Step 20.
NA
NA
29
• • • • •
NA
NA
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability Does the engine operate normally with no stored codes? Remove all diagnostic equipment and return vehicle to original condition. Return vehicle to customer.
4-7
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 4-8
5 — LPG SYMPTOM DIAGNOSTICS LPG SYMPTOM DIAGNOSTICS
LPG SYMPTOM DIAGNOSTICS Checks
Action Before using this section, you should have performed On Board Diagnostic (OBD) Check and determined that:
Before Using This Section
1. The ECM and MIL are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check. These checks are very important as they can lead to prompt diagnosis and correction of a problem. 1. 2. 3. 4.
LPG Fuel System Check
Verify the customer complaint. Locate the correct symptom table. Check the items indicated under that symptom. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich. IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at that time. 5. Take a data snapshot using the DST under the condition that the symptom occurs to review at a later time. • • • • • • •
Visual and Physical Checks
Check all ECM system fuses and circuit breakers. Check the ECM ground for being clean, tight and in its proper location. Check the vacuum hoses for splits, kinks and proper connections. Check thoroughly for any type of leak or restriction. Check for air leaks at all the mounting areas of the intake manifold sealing surfaces. Check for proper installation of the mixer assembly. Check for air leaks at the mixer assembly.
Check the ignition wires for the following conditions: • Cracking • Hardening • Proper routing • Carbon tracking. • •
Check the wiring for the following items: proper connections, pinches or cuts. The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the DST readings do not indicate a problem, then proceed in a logical order, easiest to check or most likely to cause the problem.
5-1
5 — LPG SYMPTOM DIAGNOSTICS
INTERMITTENT Checks
Action
DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC). Preliminary Checks Faulty Electrical Connections or Wiring
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables with this condition may result in the replacement of good parts. Faulty electrical connections or wiring can cause most intermittent problems. Check the suspected circuit for the following conditions: •
• • • •
•
Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully seated in the connector (backed out). Terminals not properly formed or damaged. Wire terminals poorly connected. Terminal tension is insufficient. Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the connector terminals in the problem circuit in order to ensure the proper contact tension (except those noted as “Not Serviceable”). See section Wiring Schematics. Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test
If a visual and physical check does not locate the cause of the problem, operate the vehicle with the DST connected. When the problem occurs, an abnormal voltage or scan reading indicates a problem circuit.
Intermittent MIL Illumination
The following components can cause intermittent MIL and no DTC(s): • • • • • •
Loss of DTC Memory
A defective relay. Switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating. The improper installation of add on electrical devices, such as lights, 2-way radios, electric motors, etc. The ignition secondary voltage shorted to a ground. The MIL circuit or the Diagnostic Test Terminal intermittently shorted to ground. The MIL wire grounds.
To check for the loss of the DTC Memory: 1. Disconnect the TMAP sensor. 2. Idle the engine until the MIL illuminates. 3. The ECM should store a TMAP DTC which should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store and remain, the ECM is faulty.
5-2
5 — LPG SYMPTOM DIAGNOSTICS
NO START Checks
Action
DEFINITION: The engine cranks OK but does not start. Preliminary Checks ECM Checks
Sensor Checks Fuel System Checks
None Use the DST to: • Check for proper communication with both the ECM • Check all system fuses engine fuse holder. Refer to Engine Controls Schematics. • Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for each. • •
Important: A closed LPG manual fuel shut off valve will create a no start condition. • • • • •
Ignition System Checks
Check the TMAP sensor. Check the cam angle sensor for output (RPM).
Check for air intake system leakage between the mixer and the throttle body. Verify proper operation of the low pressure lock-off solenoids. Verify proper operation of the fuel control solenoids. Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis. Check for proper mixer air valve operation.
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. 1. Check for the proper ignition voltage output with J 26792 or the equivalent.
2. Verify that the spark plugs are correct for use with LPG. Check the spark plugs for the following conditions: • Wet plugs. • Cracks. • Wear. • Improper gap. • Burned electrodes. • Heavy deposits. • Check for bare or shorted ignition wires. • Check for loose ignition coil connections at the coil. Engine Mechanical Checks Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system. Check for the following: • Vacuum leaks. • Improper valve timing. • Low compression. • Improper valve clearance. • Worn rocker arms. • Broken or weak valve springs. • Worn camshaft lobes.
5-3
5 — LPG SYMPTOM DIAGNOSTICS
Checks
Action
Exhaust System Checks
Check the exhaust system for a possible restriction: • Inspect the exhaust system for damaged or collapsed pipes: • Inspect the muffler for signs of heat distress or for possible internal failure. • Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
5-4
5 — LPG SYMPTOM DIAGNOSTICS
HARD START Checks
Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks
•
Make sure the vehicle’s operator is using the correct starting procedure.
Sensor Checks
•
Check the Engine Coolant Temperature sensor with the DST. Compare the engine coolant temperature with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 10 degrees greater or less than the ambient air temperature on a cold engine, check for high resistance in the coolant sensor circuit. Check the cam angle sensor. Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor connections.
•
Fuel System Checks
Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition. •
Verify the excess flow valve is not tripped or that the manual shut-off valve is not closed.
Check mixer assembly for proper installation and leakage. • Verify proper operation of the low pressure lock-off solenoid. • Verify proper operation of the EPR. • Check for air intake system leakage between the mixer and the throttle body. Check the fuel system pressures. Refer to the Fuel System Diagnosis.
Ignition System Checks
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. • •
Check for the proper ignition voltage output with J 26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped.
Check the spark plugs for the following conditions: • Wet plugs. • Cracks. • Wear. • Burned electrodes. • Heavy deposits • Check for bare or shorted ignition wires. • Check for moisture in the distributor cap. • Check for loose ignition coil connections. Important: 1. If the engine starts but then immediately stalls, check the cam angle sensor. 2. Check for improper gap, debris or faulty connections.
5-5
5 — LPG SYMPTOM DIAGNOSTICS
Checks
Action
Engine Mechanical Checks Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system. • • • • • • • •
Check for the following: Vacuum leaks Improper valve timing Low compression Improper valve clearance. Worn rocker arms Broken or weak valve springs Worn camshaft lobes.
Check the intake and exhaust manifolds for casting flash. Exhaust System Checks
Check the exhaust system for a possible restriction: • Inspect the exhaust system for damaged or collapsed pipes. • Inspect the muffler for signs of heat distress or for possible internal failure. • Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
5-6
5 — LPG SYMPTOM DIAGNOSTICS
CUTS OUT, MISSES Checks
Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks Ignition System Checks
None 1. 2. 3. 4.
Start the engine. Check for proper ignition output voltage with spark tester J 26792. Check for a cylinder misfire. Verify that the spark plugs are the correct type and properly gapped.
Remove the spark plugs and check for the following conditions: • • • • •
Insulation cracks. Wear. Improper gap. Burned electrodes. Heavy deposits.
Visually/Physically inspect the secondary ignition for the following: • • •
Ignition wires for arcing and proper routing. Cross-ring. Ignition coils for cracks or carbon tracking
Engine Mechanical Checks Perform a cylinder compression check. Check the engine for the following: • • • • • • Fuel System Checks
Check the fuel system: • • •
Additional Check
Improper valve timing. Improper valve clearance. Worn rocker arms. Worn camshaft lobes. Broken or weak valve springs. Check the intake and exhaust manifold passages for casting flash.
Plugged fuel filter. Low fuel pressure, etc. Refer to LPG Fuel System Diagnosis. Check the condition of the wiring to the low pressure lock-off solenoid.
Check for Electromagnetic Interference (EMI), which may cause a misfire condition. Using the DST, monitor the engine RPM and note sudden increases in rpms displayed on the scan tool but with little change in the actual engine rpm. If this condition exists, EMI may be present. Check the routing of the secondary wires and the ground circuit.
5-7
5 — LPG SYMPTOM DIAGNOSTICS
HESITATION, SAG, STUMBLE Checks
Action
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks
None
Fuel System Checks
• •
• • • • Ignition System Checks
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly. •
Additional Check
Check the fuel pressure. Refer to LPG Fuel System Diagnosis. Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a faulty low pressure regulator or a restriction in the fuel system. Check the TMAP sensor response and accuracy. Check Shut-Off electrical connection. Check the mixer air valve for sticking or binding. Check the mixer assembly for proper installation and leakage. Check the EPR.
• •
Check for the proper ignition voltage output with J 26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped. Check for faulty spark plug wires. Check for fouled spark plugs.
• •
Check for manifold vacuum or air induction system leaks. Check the alternator output voltage.
5-8
5 — LPG SYMPTOM DIAGNOSTICS
BACKFIRE Checks
Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Checks Ignition System Checks
None Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire. • • • •
Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent. Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires. Check the connection at ignition coil. Check for deteriorated spark plug wire insulation.
Remove the plugs and inspect them for the following conditions: • Wet plugs. • Cracks. • Wear. • Improper gap. • Burned electrodes. • Heavy deposits. Engine Mechanical Check Important! The LPG Fuel system is more sensitive to intake manifold leakage than a gasoline fuel supply system. Check the engine for the following: • Improper valve timing. • Engine compression. • Manifold vacuum leaks. • Intake manifold gaskets. • Sticking or leaking valves. • Exhaust system leakage. • Check the intake and exhaust system for casting ash or other restrictions. Fuel System Checks
Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
5-9
5 — LPG SYMPTOM DIAGNOSTICS
LACK OF POWER, SLUGGISHNESS, OR SPONGINESS Checks
Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks
• •
• • • Fuel System Checks
• • • • • •
Sensor Checks
• •
Exhaust System Checks
Refer to the LPG Fuel system OBD System Check. Compare the customer’s vehicle with a similar unit to verify customer has an actual problem. Do not compare the power output of the vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics. Remove the air filter and check for dirt or restriction. Check the vehicle transmission. Refer to the OEM transmission diagnostics. Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent. Check for proper installation of the mixer assembly. Check all air inlet ducts for condition and proper installation. Check for fuel leaks between the EPR and the mixer. Verify that the LPG tank manual shut-off valve is fully open. Verify that liquid fuel (not vapor) is being delivered to the EPR. Check the Heated Exhaust Gas Oxygen Sensors (HEGO) for contamination and performance. Check for proper operation of the TMAP sensor. Check for proper operation of the TPS and FPP sensors.
Check the exhaust system for a possible restriction: • Inspect the exhaust system for damaged or collapsed pipes. • Inspect the muffler for signs of heat distress or for possible internal failure. • Check for possible plugged catalytic converter.
Engine Mechanical Check Check the engine for the following: • Engine compression. • Valve timing. • Improper or worn camshaft. • Refer to Engine Mechanical in the Service Manual. Additional Check
• •
Check the ECM grounds for being clean, tight, and in their proper locations. Check the alternator output voltage.
If all procedures have been completed and no malfunction has been found, review and inspect the following items: • Visually and physically, inspect all electrical connections within the suspected circuit and/or systems. • Check the DST data.
5-10
5 — LPG SYMPTOM DIAGNOSTICS
POOR FUEL ECONOMY Checks
Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by refueling records. Preliminary Checks
• • •
Check the air cleaner element (filter) for dirt or being plugged. Visually check the vacuum hoses for splits, kinks, and proper connections. Properly inflated tires.
Check the operators driving habits for the following: • Excessive idling or stop and go driving. • Carrying of very heavy loads. • Rapid acceleration. • Suggest to the owner to fill the fuel tank and to recheck the fuel economy and/or suggest that a different operator use the equipment and record the results. Fuel System Checks
• •
Check the EPR fuel pressure. Refer to LPG Fuel System Diagnosis. Check the fuel system for leakage.
Sensor Checks
•
Check the TMAP sensor.
Ignition System Checks
Verify that the spark plugs are the correct type and properly gapped. Remove the plugs and inspect them for the following conditions: • Wet plugs. • Cracks. • Wear. • Improper gap. • Burned electrodes. • Heavy deposits. Check the ignition wires for the following items: • Cracking. • Hardness. • Proper connections.
Cooling System Checks Additional Check
Check the engine thermostat to see if it is stuck open or for the wrong heat range. • • •
Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual. Check for dragging brakes.
5-11
5 — LPG SYMPTOM DIAGNOSTICS
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks
Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Preliminary Checks Sensor Checks
None Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance: • Check for silicone contamination from fuel or improperly used sealant. If contaminated, the sensor may have a white powdery coating result in a high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe driveability problem. Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks
• • • • • • • •
Ignition System Checks
• •
Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem. Check for a sticking mixer air valve. Verify proper operation of the EPR. Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual. Check the EPR fuel pressure. Refer to the LPG Fuel System Diagnosis. Check mixer assembly for proper installation and connection. Check for the proper ignition output voltage using the spark tester J26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped.
Remove the plugs and inspect them for the following conditions: • Wet plugs. • Cracks. • Wear. • Improper gap. • Burned electrodes. • Blistered insulators. • Heavy deposits. Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires. Additional Checks
Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system. • •
Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command. Check the ECM grounds for being clean, tight, and in their proper locations. Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality.
5-12
5 — LPG SYMPTOM DIAGNOSTICS
Checks
Action
Engine Mechanical Check Check the engine for: • Broken motor mounts. • Improper valve timing. • Low compression. • Improper valve clearance. • Worn rocker arms. • Broken or weak valve springs. • Worn camshaft lobes.
5-13
5 — LPG SYMPTOM DIAGNOSTICS
SURGES/CHUGGLES Checks
Action
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. Preliminary Checks Sensor Checks Fuel System Checks
None Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance. • • • • • •
Ignition System Checks
• •
Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem. Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis. Verify proper fuel control solenoid operation. Verify that the LPG manual shut-off valve is fully open. Check the in-line fuel filter for restrictions. Check for the proper ignition output voltage using the spark tester J26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped.
Remove the plugs and inspect them for the following conditions: • Wet plugs. • Cracks. • Wear. • Improper gap. • Burned electrodes. • Heavy deposits. Check the Crankshaft Position (CKP) sensor. Additional Check
• • • •
Check the ECM grounds for being clean, tight, and in their proper locations. Check the generator output voltage. Check the vacuum hoses for kinks or leaks. Check Transmission
5-14
5 — LPG SYMPTOM DIAGNOSTICS
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS RESULTS OF INCORRECT OPERATION
Functional check Any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy load, etc., is exhausted into the air cleaner and is drawn back into the engine.
A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following conditions: •
Rough or unstable idle
•
Stalling or low idle speed
•
Oil leaks
•
Oil in the air cleaner
•
Sludge in the engine
Proper operation of the crankcase ventilation system depends on a sealed engine. If irregular oil flow or dilution is noted and the crankcase ventilation system is functioning properly, check the engine for another possible cause. Correct any of these problems first. If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner element, or plugged hose. Replace any faulty items found. Use the following procedure:
A leaking PCV orifice or hose may cause the following problems: •
Rough Idle
•
Stalling
•
High idle speed
1. Remove the PCV hose (positive side) from the rocker arm cover. 2. Operate the engine at idle. 3. Place your thumb over the end of the hose in order to check for vacuum. If there is no vacuum at the hose end, check for plugged hoses damage or leakage to the manifold vacuum port. 4. Turn the engine OFF. 5. Inspect the PCV orifice in the valve cover for debris or blockage.
5-15
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 5-16
6 — DIAGNOSTIC SCAN TOOL
CONTENTS
DST INSTALLATION INSTRUCTIONS
•
Installation of the DST package to a personal computer (PC).
•
Software login and password functionality.
Before installing the DST software, please be sure your computer meets the minimum system requirements.
•
DST service pages.
•
Updating the ECM calibration using a MOT file.
•
DTC pages.
•
Electrical schematic.
DIAGNOSTIC SCAN TOOL
Supported operating systems are: Windows Vista Windows XP Windows 2000 Windows 98SE Minimum processor speed: Pentium II 450 MHz Pentium III 1.0 GHz for Windows Vista
Examples and snapshots used in this manual are based off of the initial DST tool release as of July, 2007. This tool is frequently updated and the illustrations may vary depending on the changes included in any updated DST display Interface. For example, the Electronic Pressure Regulator (EPR) may be referred to as the “megajector.” Terms, names and descriptions of parts and servicing procedures will be updated based on trade, brand, or common description to more accurately describe the part or service procedure.
Minimum RAM requirement: Windows Vista 512 MB Windows XP 256 MB Windows 2000 128 MB Windows ME/98SE 128 MB
6-1
*
At least one available RS232 serial or USB port.
*
USB adapter driver does not support Windows 98SE.
*
ECOM cable supports USB port only.
6 — DIAGNOSTIC SCAN TOOL Windows Vista Operating System
•
Open the DST_Series III folder
•
Open the Latest_GCP_Display folder 6-2
6 — DIAGNOSTIC SCAN TOOL
•
Double click on “setup.exe” (application file) to start the windows installer. If a previous version of the GCP software is installed, the uninstaller may remove the previous version and exit. You will be required to start the installer again to install the new version.
•
Click “Next” to continue 6-3
6 — DIAGNOSTIC SCAN TOOL
•
Click “Next” to continue
•
Click “Next” to continue 6-4
6 — DIAGNOSTIC SCAN TOOL
•
Click the “Finish” box to complete the installation.
•
Click “Yes” to restart your computer
6-5
6 — DIAGNOSTIC SCAN TOOL
•
Once installed, the software can be accessed from Start Menu→Programs→Impco GCP Display→ Impco GCP Display
6-6
6 — DIAGNOSTIC SCAN TOOL
INSTALLING THE USB ADAPTER DRIVER If your computer does not have an RS232 serial port you will need to install the USB adapter driver. You do not need to install this driver if you plan to use the ECOM DLC cable.
•
Open the DST_Series III folder
6-7
6 — DIAGNOSTIC SCAN TOOL •
Open the “USB Driver” folder
•
Double click on “setup.exe” (application file) and follow the on screen prompts.
Installing the ECOM DLC cable driver The ECOM USB cable is designed to replace both the serial DLC and the USB adapter cables. It also provides communication to the ECM on the CAN line for systems that are CAN enabled. It requires the installation of the ECOM driver and is compatible with the series II and series III DST software programs.
•
Open the DST_Series III folder 6-8
6 — DIAGNOSTIC SCAN TOOL
•
Double click on “setup.exe” (application file).
6-9
6 — DIAGNOSTIC SCAN TOOL •
Click “Next” to continue
•
Select install ECOM drivers only. Click “Next” and follow the on screen prompts.
•
See Password Login, page 6-17.
6-10
6 — DIAGNOSTIC SCAN TOOL Windows XP, 2000 and 98, SE Operating Systems
•
Open the DST folder
•
Open the Latest_GCP_Display folder
6-11
6 — DIAGNOSTIC SCAN TOOL
•
Double click on “setup.exe” (application file) to start the windows installer. If a previous version of the GCP software is installed, the uninstaller will remove the previous version and exit. You will be required to start the installer again to install the new version.
•
Click next to continue
6-12
6 — DIAGNOSTIC SCAN TOOL
•
Click next to continue
•
Click next to continue
6-13
6 — DIAGNOSTIC SCAN TOOL
•
Click the “Finish” box to complete the installation.
6-14
6 — DIAGNOSTIC SCAN TOOL •
Once installed, the software can be accessed from Start Menu Programs GCP Display GCP Display
INSTALLING THE USB ADAPTER DRIVER If your computer does not have an RS232 serial port, you will need to install the USB adapter driver. The installation of this driver is similar to the GCP display.
•
Open the DST folder
6-15
6 — DIAGNOSTIC SCAN TOOL
•
Open the “USB Driver” folder
•
Double click on “setup.exe” (application file) and follow the on screen prompts.
6-16
6 — DIAGNOSTIC SCAN TOOL
PASSWORD LOGIN Figure 1 shows the password dialog box, which is displayed when a software session begins. Login can be accomplished in two ways. 1. Enter an “All S/N Password” which is a password applicable to all ECMs of a given original equipment manufacture (OEM). 2. Enter a “Single S/N Password” and corresponding ECM serial number for a single ECM. A Single Serial Number password is unique to a specific ECM serial number and permits authorized service personnel to make changes or view information for a specific ECM. 3. In most instances the top “all” serial number boxes should be used for password entry. In this case, do not check the single serial number box. Each password is a 16-character alpha-numeric string specific to each Spectrum customer and determines which pages and variables are visible through the software. Passwords are assigned by the OEM support group and may change periodically. Check the “save password” box to automatically retain the password for future use.
Figure 1: Populated Password Dialog Box
6-17
6 — DIAGNOSTIC SCAN TOOL
PASSWORD DIALOG BOX FUNCTIONS •
Clear Password Button Erases the current password from the password field.
•
Paste Password Button Allows the user to copy a 16-character string from any word processor and paste the string in the password field.
•
Single Serial Number Access Checkbox Tells the software that the password is applicable for single serial number access.
•
Serial Number Field Only applicable when Single Serial Number Access Checkbox is checked. The entry field must be populated for the 6-digit serial number for which the Single Serial Number Access password applies (NOTE: Leading zeros included in the serial number are not required).
•
Save Password and S/N Checkbox Retains the password, and serial number (if applicable) for the next software session.
Should an invalid password be entered, the error prompt shown in figure (2) will be displayed and the software will not load. This prompt signifies the following: •
The All S/N password is invalid.
•
The Single S/N password is incorrect for the Single Serial Number entered.
•
An All S/N password is entered for Single Serial Number use.
•
The Single Serial Number password is valid, however, the Single Serial Number Access Checkbox is not checked.
Figure 2: Password Error Prompt
6-18
6 — DIAGNOSTIC SCAN TOOL If the Single S/N password entered is correct for the software but does not match the entered S/N of the targeted ECM, the prompt in Figure 3 will be displayed.
Figure 3: Incorrect Serial Number Message
Figure 4 shows the communication status if a valid software password is entered when attempting to connect to an ECM with a different key. In this instance the software will load but will not connect to the target (ECM).
Figure 4: Not Authorized to Connect Message
In the event you receive this error message call your OEM support group for more information.
6-19
6 — DIAGNOSTIC SCAN TOOL
CONNECTING THE PC TO THE SPECTRUM FUEL SYSTEM A laptop computer, with the diagnostic cable and software is the required tool for performing proper diagnostic testing of the Spectrum fuel system. It is also used to monitor sensor and actuator values and to read and clear Diagnostic Trouble codes. The DST software also performs several special tests. •
Connect the system diagnostic cable to the RS232 port on the back of the computer. If you do not have a RS232 port, use the USB to RS232 adapter supplied in the IMPCO ITK test kit. Be sure to install the USB driver to enable the USB adapter for use with your computer.
•
Connect the diagnostic cable to the DLC (diagnostic link connector) labeled in the electrical schematic. The DLC is located on the engine harness. The new 8 pin DLC requires the use of the 4 to 8 pin adapter included in the late model ITK test kits.
•
Turn the computer ON.
•
Start Windows.
•
From the start menu select Programs GCP Display GCP Display
•
Place the ignition key in the ON position.
Within several seconds the system Gauge screen should now appear and a green banner in the upper left hand will read “Connected.”
6-20
6 — DIAGNOSTIC SCAN TOOL
DST SERVICE PAGES
Gauge Page
Provides system data in large easy to read displays. Displays ECM configuration information for the ECM software, hardware, serial numbers and calibration dates.
6-21
6 — DIAGNOSTIC SCAN TOOL
Raw Volts Page
The raw volts page displays the sensor inputs and outputs in a raw voltage format. This page is most commonly used to check values in the diagnostic trouble shooting charts.
Service 1
6-22
6 — DIAGNOSTIC SCAN TOOL
Tests Page
Provides diagnostic information voltages and sensor outputs and includes diagnostic engine tools such as spark and injector kill controls. Please note that not all features are available for all applications. The disabled item menus are grayed out or rendered inoperative.
6-23
6 — DIAGNOSTIC SCAN TOOL
SPARK KILL
DBW TEST MODE
The spark kill mode allows the technician to disable the ignition on individual cylinders. If the Spark Kill diagnostic mode is selected with the engine running below 1000 RPM, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Spark System Test mode is selected with the engine running above 1000 RPM, the throttle will continue to operate normally. Disabling Ignition Outputs to disable the ignition system for an individual cylinder, use the mouse to highlight the “Spark Kill” button and select the desired coil. The spark output can be re-enabled by using the mouse to highlight the “Spark Kill” button and selecting “Normal.” If the engine is running below 1000 RPM, the spark output will stay disabled for 15 seconds and then re-set. If the engine is running above 1000 RPM, the spark output will stay disabled for 5 seconds and then re-set. This test mode has a timeout of 10 minutes. Record the RPM drop related to each spark output disabled. The spark outputs are arranged in the order which the engine fires, not by cylinder number.
The DBW (Drive by Wire) test mode allows the technician to control the throttle directly with the foot pedal or throttle input and is used during the diagnostic routines specified for FPP and TPS for Spectrum systems that use DBW control. FPP position displays the current position of the foot pedal as a percentage. FPP volts display the voltage which the ECM is reading from the FPP sensor. TPS Command displays the commanded throttle position expressed as a percentage, which is being sent to the throttle. TPS Position is the actual percent of throttle opening being sent to the ECM from the throttle. TPS volts display the actual TPS signal voltage the ECM is receiving from the throttle. To select this test mode the engine must be off and the key must be in the ON position.
EXTERNAL POWER TEST The external power test manually activates relays (relay power, fuel pump, and drive-by wire power) controlled by the ECM while the engine is in the “Stopped” or “Running” states. Reverts to normal operation if “Automatic” state is selected or ignition voltage is cycled from high to low.
INJECTOR KILL The Injector Kill mode is used to disable individual fuel injectors. If the Injector Kill mode is selected with the engine running below 1000 RPM, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Injector Kill mode is selected with the engine running above 1000 RPM, the throttle will continue to operate normally. To disable an injector, use the mouse to select the desired injector. The word “Normal” will change to the Injector you have selected. The injector driver can be re-enabled by selecting again. If the engine is running below 1000 RPM, the injector driver will stay disabled for 15 seconds and then re-set. If the engine is running above 1000 RPM, the injector driver will stay disabled for 5 seconds and then re-set. Record the change in RPM while each driver is disabled.
6-24
6 — DIAGNOSTIC SCAN TOOL
Faults Page
Stores DTC codes that may have occurred in the past (Historic Faults) or current set codes (Active Faults). Includes useful system voltages and sensor readings used while working with the fuel and emission trouble shooting charts. Shows power derate mode status. To erase a historic DTC code, double click on the code with the left mouse button. Then choose to “erase all codes” or only selected codes in the pop up box.
PLOT/LOG MENU FUNCTIONS The Plot/Log menu allows the user to graphically plot or numerically log variables that have been tagged for plotting/logging. To plot or log variables, a tag must be assigned to each variable of interest. A variable is tagged for plotting/logging through a single right-mouse click in the variable’s vicinity. Once a variable has been tagged for plotting/logging it is highlighted in green. Figure 5 shows an example of variables that have been tagged. A maximum of twenty (20) variables may be tagged for logging and a maximum of ten (10) variables may be tagged for plotting. The maximum achievable sample frequency/minimum period is dependent on the number of variables tagged.
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6 — DIAGNOSTIC SCAN TOOL
Figure 5: Tagged Variables for Plot/Log
Once the variables have been tagged as highlighted by the green color fill, select the “Plot/Log” function in the top menu bar as shown below in figure 6.
6-26
6 — DIAGNOSTIC SCAN TOOL
Figure 6
•
Select “Plot Tags” to open the snapshot window
Other functions available from the Plot/Log menu include: •
Clear Tags: Releases all plot/log variables.
•
Plot Tags (Ctrl + P, or P): Graphically plot all tagged variables.
•
Load Plot Setup: Loads and tags variables for plotting/logging that have been stored in a plot file (.plt).
•
Log Tags (Ctrl + L): Numerically log all variables that have been tagged for plotting/logging.
6-27
6 — DIAGNOSTIC SCAN TOOL Once the Plot Tags menu item has been selected, tagged variables are graphically plotted in a strip chart interface. An example of a plot is shown in Figure 7. Capabilities of the plotter are outlined in Table 1.
Start/Stop Button
Start or stop plotting of selected variables
Save Button
Save plotted data displayed in the plot to a comma-separated value file (CSV) on the PC hard drive. Format must not be altered if the Load function is to be used.
Snapshot Button
Convert the plot into a snapshot that may be panned, zoomed, scrolled, and saved
Close Button
Close the DST Plot interface
Load Setup Button
Load tags from a previously saved plot (.plt) file to allow for similar plots and logs to be generated
Load Plot Button
Load a previously saved plot from the PC into the DST Plot interface
Variable Selector Menu
Selects the active variable for axis scaling
Single Shot Acquisition Checkbox*
When checked, this does not allow the plot to scroll past the ‘Time Interval’ thereby preserving plotted data for post-processing.
Exclusive Serial Use Checkbox*
When checked, this allows exclusive serial communication for the plot variables. Other variables on the active page are not updated.
Min Y Value Field*
Specify the minimum Y-axis scaling for the active variable
Max Y Value Field*
Specify the maximum Y-axis scaling for the active variable
Sample Interval (ms) Field*
Define the sample period for recording and display Frequency (hz.) = 1000/ Sample Interval (ms)
Time Interval (s) Field*
Defines the total sample acquisition time for the plot.
*Accessible only when plotter is not running.
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Start plot
Variable selector
Figure 7 DST Plot
•
Click on the start button to start the DST plot function.
•
Click on the variable selector button to view selected sensors
6-29
6 — DIAGNOSTIC SCAN TOOL
Figure 8: DST Plot Snapshot
•
Click on the “Save” button to save the snapshot as a file. To replay the saved file, open the edis_saplot program from the windows start menu.
6-30
6 — DIAGNOSTIC SCAN TOOL
Start Menu Programs GCP Display edis_saplot
DST PLOT INTERFACE FUNCTIONS A graphic tool incorporated in the plotter is the snapshot function. This function allows data collected in a plot to be transferred into a second window for quick graphical post-processing. The snapshot allows the user to zoom in/out, pan left/right, and move cursors along the signal traces to measure the variable values in virtual real-time. An example of a snapshot is shown in Figure 8. Any CSV file in plot format (.plt) may be loaded into the snapshot. Table 2 outlines the available hot key functions of the snapshot screen.
6-31
6 — DIAGNOSTIC SCAN TOOL
SNAPSHOT HOT KEY FUNCTIONS Command
Function
<Single, left-click on trace>
Snap closest cursor to data
<Ctrl + Up/Down Arrows>
Move/pan plot along y axis
<Ctrl + Left/Right Arrows>
Move/pan plot along t axis
<Ctrl+Shift + Up/Down Arrows>
Zoom plot in and out in y axis
<Ctrl+Shift + Left/Right Arrows>
Zoom plot in and out in t axis
<Ctrl + Home>
Resize plot to default settings
<Ctrl + Page Up>
Zoom out by 10%
<Ctrl + Page Down>
Zoom in by 10%
<Page Up>
Toggle to previous cursor
<Page Down>
Toggle to next cursor
<Left/Right Arrow>
Follow selected data along trace
<Up/Down Arrow>
Follow selected data along trace
<Shift + Left/Right Arrow>
Move 10 points along trace
<Shift + Up/Down Arrow>
Move 10 points along trace
<Home>
Go to first visible point on current plot
<End>
Advance to last visible point on current plot
<Shift + Up/Down Arrow>
Toggle between traces/variables Table 1
6-32
6 — DIAGNOSTIC SCAN TOOL
DST LOGGER Another data capture function incorporated in the software is the DST logger. This tool serves as a PC data logger for any variable available in the ECM through the interface software. Figure 9 shows the interface display for configuring the DST Log. The interface allows the user to create the filename, set the sample rate for acquisition, set the time interval for sampling, and display the progress of acquisition. A maximum of twenty (20) variables may be tagged for the log. The amount of data stored is only limited by available PC RAM. The resulting text file may then be viewed by any standard Windows text editor/ reader program. To create a log file select the “Log Tags” in the drop down menu as shown in figure 6.
Figure 9: DST Log Interface
6-33
6 — DIAGNOSTIC SCAN TOOL
REPROGRAMMING THE ECM New software upgrades may become available for in field applications. Upgrading the ECM software is possible using the DST. Updates are released to service in MOT files (A MOT file has an extension .mot and is a binary S-record file that contains the full calibration and embedded software algorithms). The MOT file is the one file necessary to completely configure or update an existing ECM. The MOT may be supplied on a floppy disk, CD ROM or downloaded from the OEM service network. To update the ECM software follow the instructions below.
•
Turn the ignition key to the ON position.
•
Verify the DST is “connected” to the ECM.
•
From the “File” menu select “Reprogram target.”
6-34
6 — DIAGNOSTIC SCAN TOOL •
Navigate to the media where you have stored the MOT file. In the example above the MOT file was stored on the on the floppy (A) drive.
•
Highlight the correct .mot file using the left mouse button.
•
Click on “Load.”
•
Click “Yes” to continue.
•
Click the “Yes” box to continue with the update. Refrain from using other functions on the computer while the download takes place.
Do not disconnect the DLC, remove power or use the PC for any other function during this process. Any interruption during this reprogram process may render the ECM non programmable in the field.
6-35
6 — DIAGNOSTIC SCAN TOOL
The status bar shows the update process.
Message is displayed confirming the update was successful.
6-36
6 — DIAGNOSTIC SCAN TOOL
MALFUNCTION INDICATOR LAMP (MIL)
While a Diagnostic Trouble Code is current for a sensor, the ECM may assign a default “limp home” value and use that value in its control algorithms. All of the system diagnostic selftests run continuously during normal vehicle operation.
The Spectrum Fuel system has built-in diagnostics for system trouble shooting. The system has an overhead guard leg mounted malfunction indicator lamp (MIL) that provides indications of an emissions related problem. Most engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC) diagnostic trouble code and illuminate the MIL.
The Diagnostic Trouble Codes can be read by using either the MIL lamp or a laptop computer. Diagnostic Trouble Codes can be cleared from memory with a laptop computer, or by turning the ignition key to the OFF position and removing the ECM power fuse or battery cable for at least 15 seconds.
The MIL serves as notification to the operator of a problem related to the emission control system so the driver can arrange for service as soon as possible. It will also display DTC’s that have been stored due to a system malfunction.
If more than one DTC is detected, start the diagnostic repair with the lowest DTC number set. Diagnose each problem to correction unless directed to do otherwise by the diagnostic chart. The DTC’s are numbered in order of importance. Having DTC 112 and DTC122 both concerning the oxygen sensor, it is possible that by repairing DTC 112 first, the problem causing the DTC 122 may also be corrected.
The MIL should illuminate when the key is in the ON position and the engine is not running. This feature verifies that the lamp is in proper working order. If the MIL does not illuminate with the vehicle key ON/engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the MIL should turn off. If the lamp remains on while the engine is in the start or run mode a diagnostic trouble code may be set.
Diagnostic test charts contained in this manual refer to the DST to be connected and in the “System Data Mode.” This simply means that the DST is connected and communicating with the PC. In some instances the chart will call out a special test mode. An example of this would be instructions for the DST to be connected and in the DBW (drive by wire) mode. Always be sure to follow the special instructions to avoid a false diagnosis of fuel system components.
The MIL will be turned OFF after three (3) consecutive run cycles or by clearing the active code with the Diagnostic Scan Tool (DST).
SPECTRUM DIAGNOSTIC TROUBLE CODES (DTC) Diagnostic Trouble Codes are set when the Spectrum ECM (Electronic Control Module) runs a diagnostic self test and the test fails. When a DTC is set, the ECM will illuminate the MIL on the overhead guard leg and also save the DTC in memory. The ECM will continue to run the self test. If the system continues to fail the test, the lamp will stay illuminated and the DTC is stored as an active DTC. If the self test runs and passes, the DTC will be stored as historic DTC. All DTC’s are stored as historic faults until they are cleared. Most DTC’s will automatically clear from memory if the DTC does not reset within 50 to 100 consecutive engine run cycles.
DLC COMMUNICATION ERROR The ECM 5 volt reference circuit powers the Spectrum diagnostic link cable. In the event that the 5 volt reference signal is open or shorted to ground, you will not be able to connect to the system. If you are unable to connect, follow the quick checks listed below: Be sure you are using the correct password and latest software for the system you are connecting to.
6-37
6 — DIAGNOSTIC SCAN TOOL Check the ECM system power and ground circuits. Refer to DTC 562 for the power schematic. Also check for +12 volts switched power at ECM pin 45 with the ignition key ON. Check for power at the DLC connector for + 5 volts between pin 1 (BLK /LT GRN) and pin 2 (LT GRN RED) with the ignition key in the ON position. You may still be able to retrieve a code using the blink code function if none of the above recommendations prove useful. In the event of a 5 volt reference signal malfunction, DTC 642 or DTC 643 should set. If you find one of these codes using the blink code function, follow the DTC diagnostic chart recommendations for that specific DTC.
BLINK CODE FUNCTION Although the DST is considered a required tool to access the DTC codes, codes may be retrieved without a laptop computer using the blink code function. To enable this function follow the steps below: •
Jump pins 1 and 4 at the DLC connector.
•
Turn the ignition key to the on position
•
The system will now enter the self diagnostic blink code mode. Be ready with pen and paper to write down any codes that may be stored.
•
The ECM will flash the MIL indicator with a pause between represented numbers that represent DTC codes. The sequence starts with code 1654. Code 1654 confirms the system has entered the blink code mode. The ECM will flash code 1654 (3) times before displaying the actual DTC code that may be set. Example: One short blink (pause) six short blinks (pause) five short blinks (pause) four short blinks.
6-38
•
If no DTC codes are found, the ECM will continue to flash 1654 only. This means no stored DTC codes were found.
•
If one of the numbers in the DTC code is zero (0), no flash will occur to represent the zero value-it will be represented as a short pause.
6 — DIAGNOSTIC SCAN TOOL
Diagram 1
When using the DST program to clear a DTC, always select the “Clear All Faults” function to immediately turn the MIL OFF after a successful repair (as shown in diagram 1 above).
6-39
6 — DIAGNOSTIC SCAN TOOL
INTERMITTENT PROBLEMS Intermittent fuel system problems can prove to be the most challenging to repair. It is most important to remember when looking to find the cause of these problems, to operate the system in the condition when and where the problem occurs. An example of this would be, if the DST showed a lean fuel mixture at full load, one of the first things to look at would be the fuel pressure. The fuel pressure would need to be monitored while the machine is operating at full load, not at idle because the leaning effect does not occur at idle. Electrical problems should be treated the same way. One excellent tool for finding intermittent electrical problems is the DST plot/log function. Set up the plot for the code that sets. An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot. While watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The resolution of the plot screen is such that you will be able to see any unstable voltages that you would otherwise not see with a standard DVOM. Caution should be used when pressure washing the under hood of any electrical system. Avoid direct pressure spray on the system electrical connectors. They are splash proof, but if water is sprayed directly at the connector moisture can become trapped behind the connector seal and cause serious system problems. Extra care must be taken when probing electrical pins and terminals. Do not bend or spread these terminals as this can also be a source of intermittent problems cause by improper handling of these connectors.
6-40
7 — ENGINE WIRING SCHEMATIC
ELECTRICAL FLOW DIAGRAM 1. Wire colors and gauges written adjacent to wire line (if all wires on a spliced circuit are the same gauge and color, then only one call-out will be shown).
3. Connector cavity numbers listed at connector. 4. Continuation of circuit on another page indicated by arrow and connector/page call-out. 5. Hard-wired connections indicated by wire line contacting component call-out box.
2. Component name and connector number written inside of box (solid line indicates all connector circuits are shown in view— dashed line indicates not all circuits are included in view).
6. Fuse power supply conditions written adjacent to supply wire line.
(6) ECM POWER, POWER RELAY CONTROLS & ECM GROUND CIRCUITS BATTERY + C019 HOT AT ALL TIMES
POWER RELAY 85
87
30
RED 16
14 RED/TAN
86
RED 10
VSW FUSE (F1) 5A
RED 14
ECM FUSE (F2) 20A
10 RED
FROM C012-A PAGE ECM-5
HOT IN ON OR START PINK 18
TO MAXI FUSE
TO ALT C021-A
16 RED
TO EPR FUSE PAGE ECM-6 TO C003-B PAGE ECM-4
FROM C018-6 PAGE ECM-6
16 P/DK GRN
16 RED/TAN
16 P/DK GRN
RED/TAN 16
16 RED
14 PINK/DK GRN TO STARTER FUSE PAGE ECM-3
TO IGN FUSE PAGES ECM-2&4
(4)
FROM C011-C PAGE ECM-4
45
(2) (1)
71
BLK 16
WH/LT BLUE 18
60
PINK/TAN 18
GROUND C010
79
(5)
69
81
7-5
GND TEMP
GND TEMP
ECM C001
RELAY
VSW
VBAT
VBAT
(3)
7 — ENGINE WIRING SCHEMATIC
7-6
7 — ENGINE WIRING SCHEMATIC
ECM POWER, POWER RELAY CONTROLS & ECM GROUND CIRCUITS PAGE ECM-1 BATTERY + C019 HOT AT ALL TIMES
POWER RELAY 2
3
5
RED 16
14 RED/TAN
1
RED 10
VSW FUSE (F1) 5A
RED 14
ECM FUSE (F2) 20A
10 RED
FROM C012-A PAGE ECM-5
HOT IN ON OR START PINK 18
TO MAXI FUSE
TO ALT C021-A
14 RED
TO C003-B PAGE ECM-4
FROM C018-6 PAGE ECM-6
16 P/DK GRN
16 P/DK GRN
16 RED/TAN
TO EPR FUSE PAGE ECM-6
16 RED
14 PINK/DK GRN
RED/TAN 16
TO STARTER FUSE PAGE ECM-3
TO IGN FUSE PAGES ECM-2&4 FROM C011-C PAGE ECM-4
7-7
81 GND TEMP
BLK 16
69
GND TEMP
WH/LT BLUE 18
ECM C001
71
RELAY
45
VSW
60 VBAT
VBAT
79
PINK/TAN 18
GROUND C010
7 — ENGINE WIRING SCHEMATIC
ECM ENGINE / FUEL SENSOR CIRCUITS (1) PAGE ECM-2 FROM POWER RELAY HOT IN ON OR START 4
2
TMAP C006
16 PINK/DK GRN
IGN FUSE (F4) 15A
TO C014-2 PAGE ECM-6
TO ALTERNATOR
ECT C007
TO C009-A & C011-A PAGE ECM-4
B
A
B
A
7-8
LT GRN/RED 18
20
19
5V EXT 1
BLK/LT GRN 18
41
5V RTN
ECM C001
40
WH/RED 18
73
EGT
TAN/WH 18
A
ECT
2
D
BLK/YEL 18
B
DK GRN/WH 18
C
EGOH 2
EGOH 1
72
HEGO-2 C004
EGO 2
D
BLK/WH 18
A
DK GRN/ORANGE 18
LPG TEMP C002
C
HEGO-1 C005
EGO 1
FROM C012-L PAGE ECM-5
FROM C014-1 PAGE ECM-6
1
B
1
TO C012-M PAGE ECM-5
3
7 — ENGINE WIRING SCHEMATIC
ECM ENGINE / FUEL SENSOR CIRCUITS (2) PAGE ECM-3
SEE BATTERY CIRCUIT PAGE ECM-1
FROM C012-F PAGE ECM-5
OIL PRESSURE SWITCH C008
3 ELEC THROTTLE C017
LT BLUE/PINK 18
RED/TAN 16
STARTER FUSE (F6) 20A
87
86
STARTER RELAY 6
7-9
LT GRN 18
39
7
MAP
89
YEL/GRAY 18
53
IAT
ECM C001
5
PINK/BLK 18
6
LT BLUE 18
24
OIL PRES
PUR/OR 18
23
85
STARTER SOLENOID C013
A
CMP -
GRAY/BR 18
22
B
CMP +
WH/PUR 18
B
CKP -
21
CKP +
PUR/WH 18
C
PUR/LT BLUE 18
CMP C016
TPS 1
CKP C015
LT BLUE/DK BLUE 18
C
TPS 2
A
30
(STARTER) AUX PWM 4
5
16 WHITE
2
7 — ENGINE WIRING SCHEMATIC
ECM ACTUATOR CIRCUITS PAGE ECM-4 FROM POWER RELAY PAGE ECM-1 HOT IN ON OR START
FROM C012-A PAGE ECM-5 HOT IN ON OR START
IGN FUSE (F4) 15A 16 PINK/DK GRN
VSW FUSE (F1) 5A
TO C005-B & C004-C PAGE ECM-2 TO ALT SEE ECM GROUND CIRCUITS PAGE ECM-1 A
B
A
IGN COIL C009
LOCKOFF C003
IGN MODULE C011
A
B
D
B
C
YEL/BLK 18
7-10
PINK/TAN 18
75
45
VSW
ECM C001
WH/BLK 18
31
EGOH 4
82
YEL 18
GROUND C010
SPARK COIL 1A
PINK/WH 18
4
DBW +
83
DBW -
TAN/OR 18
1
BLK 16
ELECTRONIC THROTTLE C017
8
88
46
10
9
FPP2 IVS
FPP1
80
AUX ANA PU1
MIL
77
AUX ANA PD1 AUX PWM 2
87
PWM 5
AUX PWM 1
ECM C001
7-11
G H J K
SEE STARTER RELAY PAGE ECM-3
SEE 5V RTN PAGE ECM-2
SEE 5V EXT 1 PAGE ECM-2
P
25
26
LT GRN/PUR 18
M N
LT GRN/BLK 18
L
50
5V EXT 2
F
5V RTN 2
TO VSW FUSE PAGES ECM-1&4 E
SPEED -
D 18 LT GRN/RED
C 18 BLK/LT GRN
B
RED/BLK 18
RED/WH 18
18 PINK 18 LT BLUE/PINK
A
SPEED +
DK BLUE/OR 18
PUR/YEL 18
DK BLUE/YEL 18
GRN/YEL 18
DK BLUE 18
TAN/DK GRN 18
BR/WH 18
TAN 18
7 — ENGINE WIRING SCHEMATIC
ECM INTERFACE CONNECTOR CIRCUITS PAGE ECM-5
INTERFACE CONNECTOR C012 Q R
49
7 — ENGINE WIRING SCHEMATIC
ECM EPR AND DIAGNOSTIC CONNECTOR CIRCUITS PAGE ECM-6
FROM POWER RELAY PAGE ECM-1 HOT IN ON OR START 16 PINK/DK GRN
SEE 5V EXT 1 PAGE ECM-2 SEE 5V RTN PAGE ECM-2
EPR FUSE (F5) 10A
1
2
3
4
7
16 RED/LT BLUE
DIAGNOSTIC CONNECTOR C014 8
7
16 BLK
3
6
SEE ECM GROUND CIRCUITS PAGE ECM-1
WH/OR 18
BLUE/WH 18
CAN -
15
13 CAN TERM +
BLUE/PINK 18
14 CAN +
56 PC RX
55 PC TX
19
OR 18
DK GRN 18
LT GRN/RED 18
GROUND C010
5V EXT 1
BLK/LT GRN 18
5V RTN
20
2
18 BLUE/PINK
1
18 WH
EPR C018
ECM C001
7-12
Electrical System Schematic Engine (2007-01~up)
Schematic No.
Used for
Truck Model
GC35K, 40K GC40K-STR GC45-SWB ES019-84122 99789-84122 GC45K, 55K GC55K-STR GC60K, 70K GC70K-STR
Pub No. 99789-84122 7-1
Serial No.
AT87A-10231-up
AT88A-10231-up
AT89A-10231-up
Electrical System Schematic Chassis (2007-01~up)
Used for
Truck Model
AT89A-10231-up
AT88A-10231-up
AT87A-10231-up
Serial No.
*a Diodes are taped inside harness under the righthand toe plate P/N 91404-11600. *b Relay and fuse taped together under left side of dash inside harness. *c Relay taped inside harness under floor plate, approximately 2 feet from battery on right-hand side of truck. *d Relay and diode taped to harness on left side of truck near speed sensor.
Schematic No.
GC35K, 40K GC40K-STR GC45-SWB 93704-21000 99789-84122 GC45K, 55K GC55K-STR GC60K, 70K GC70K-STR
Pub No. 99789-84122 7-3
8 — ENGINE WIRE HARNESS REPAIR ENGINE WIRE HARNESS REPAIR
ON-VEHICLE SERVICE WIRE HARNESS REPAIR
REPAIRING TWISTED/SHIELDED CABLE
The ECM harness electrically connects the ECM to a various components in both the engine and passenger compartments. Wire harnesses should be replaced with proper part number harnesses. When wires are spliced into a harness, use wire with high temperature insulation only.
1. Remove outer jacket 2. Unwrap aluminum/Mylar tape. Do not remove Mylar.
Low current and voltage levels are used in the system, so it is important that the best possible bond at all wire splices be made by soldering the splices.
3. Untwist conductors, strip insulation as necessary.
CONNECTORS AND TERMINALS Use care when probing a connector or replacing terminals in them to prevent shorting opposite terminals and damage certain components. Always use jumper wires between connectors, for circuit checking. Do not probe through the Weather-Pack seals with oversized wire probes. Use tachometer adapter J 35812 (or equivalent) which provides an easy hook up of the tach lead. The connector test adapter kit J 35616 (or equivalent), contains an assortment of exible connectors used to probe terminals during diagnosis. Fuse remover and test tool BT 8616, or equivalent, is used for removing a fuse and to adapt fuse holder, with a meter, for diagnosis. Do not solder oxygen sensor wire terminals as these wire ends are used for the sensors oxygen reference.
4. Splice wire using splice clips and rosin core solder. Wrap each splice to insulate. 5. Wrap with Mylar and drain wire (uninsulated) wire.
6. Tape over entire juncture and secure.
Open circuits are often difficult to locate by sight due to dirt, oxidation, or terminal misalignment. Merely wiggling a connector on a sensor, or in the wiring harness, may correct the open circuit condition. This should always be considered, when an open circuit, or failed sensor is indicated. Intermittent problems may also be caused by oxidized or loose connections. Before making a connector repair, be certain of the type of connector. Weather-Pack and Compact Three connectors look similar, but are serviced differently.
8-1
8 — ENGINE WIRE HARNESS REPAIR
METRI-PACK Some connectors use terminals called MetriPack Series 150. They are also called “Pull-ToSeat” terminals because of the method of installation. The wire is inserted through the seal and connector, the terminal is crimped on the wire and then pulled back into the connector to seat it in place.
REPAIRING TWISTED LEADS
1. Locate Damaged Wire. 2. Remove insulation as required.
3. Splice two wires together suing splice clips and rosin core solder.
4. Cover splice with tape to insulated from other wires. 5. Retwist as before and tape with electrical tape and hold in place.
MICRO-PACK
Metri-Pack Series 150 Terminal Removal
Refer to Figure 2 and repair procedure for replacement of a Micro-Pack terminal.
1. Slide the seal back on the wire. 2. Insert tool BT-8518, or J 35689, or equivalent, as shown in insert “A” and “B” to release the terminal locking tab (2). 3. Push the wire and terminal out through the connector. If reusing the terminal, reshape the locking tab (2).
WEATHER-PACK A Weather-Pack connector can be identified by a rubber seal, at the rear of the connector. The connector is used in the engine compartment to protect against moisture and dirt that may oxidize and/or corrode the terminals. Given the low voltage and current levels found in the electronic system, this protection is necessary to ensure a good connection.
Micropack Connector
1. 2. 3. 4.
Cable Terminal Locking Tang Tool J33095/BT8234-A 8-2
8 — ENGINE WIRE HARNESS REPAIR WEATHER-PACK TERMINAL REPAIR
Use tool J M28742, or BT8234-A or equivalent to remove the pin and sleeve terminals. If the removal is attempted with an ordinary pick, there is a good chance that the terminal will be bent, or deformed. Unlike standard blade type terminals, these terminals cannot be straightened once they are bent. Verify that the connectors are properly seated and all of the sealing rings in place, when connecting leads. The hinge type ap provides a backup, or secondary locking feature for the connector. They are used to improve the connector reliability by retaining the terminals, if the small terminal lock tabs are not positioned properly.
1. Open secondary lock hinge on connector.
2. Remove terminal using tool.
Weather-Pack connections cannot be replaced with standard connections. Additional instructions are provided with Weather-Pack connector and terminal packages. 3. Cut wire immediately behind cable seal
4. Replace terminal. a. Slip new seal onto wire b. Strip 5 mm (.2”) of insulation from wire. c. Crimp terminal over wire and seal. 5. Push terminal and connector and engage locking tangs. 6. Close secondary lock hinge.
8-3
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 8-4
9 — DIAGNOSTIC TROUBLE CODES (DTCs) DIAGNOSTIC TROUBLE CODES (DTCs)
OBD SYSTEM CHECK/MIL (MALFUNCTION INDICATOR LAMP)
ECM
C012 MIL G
GRN/YEL
80
+12 volts in start and run Ground
Circuit Description
position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not illuminate with the vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON.
The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has an overhead guard leg mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTC’s that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON
9-1
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
IGNITION CONTROL SYSTEM DIAGNOSTIC CHART
Before using the Ignition Control Diagnostic chart be sure to check the following items: Spark plug wires
System power fuses
Be sure spark plug wires are in good condition. Check for cuts, breaks, burns, hardness or swelling. LPG fuel requires much higher peak firing voltages compared to gasoline. Check spark plug electrical continuity using a DVOM. Wires should Ohm out to no more than 1,000 Ohms per foot of wire length.
Check the system power fuses. These sources supply the ignition coil and module system power. Check that the power and ground terminals are clean and in the proper location.
Distributor cap and rotor Check the cap and rotor assembly for moisture, corrosion or carbon tracking. The ignition timing is not adjustable. Turning the distributor assembly will not change the ignition timing, but will alter the rotor phase. Wipe away dust and debris from the ignition coil tower.
9-2
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
IGNITION CONTROL SYSTEM DIAGNOSTIC CHART Step
Action
Value(s)
Yes
No
-
Go to Step (2)
Go to OBD System Check Section
125 RPM
Go to step (5)
Go to step (3)
1
Did you perform the On-Board (OBD) System Check?
2
DST connected and in the system data mode. Crank the engine and observe the engine speed signal on the DST Is the value greater than the specified value?
3
Check the DST for historical code sets. (Always diagnose and repair codes with the lowest numerical value first). Run the diagnostic chart for DTC-337 Did you find and correct the problem?
Go to step (16)
Go to step (4)
4
Run the diagnostic chart for DTC-342 Did you find and correct the problem?
Go to step (16)
Go to step (5)
5
Disconnect the ignition module connector C011 Using an LED type test lamp check for a signal between the ignition module connector pin B and battery positive Crank the engine Does the LED test lamp flash while cranking the engine?
Go to step (6)
Go to step (10)
6
Using a DVOM check for power between the ignition module connector pin A and engine ground Do you have power?
Go to step (7)
Repair the system power circuit. Check all system fuses and power relay connections
7
Disconnect the ignition coil connector C009 Using a digital LED test lamp check for a signal between the ignition coil connector pin B and battery positive Crank the engine Does the LED test lamp flash while cranking the engine?
Go to step (8)
Go to step (13)
8
Using a DVOM check for voltage between the ignition coil connector pin A and engine ground Does the DVOM show voltage?
Go to step (9)
Repair the system power circuit. Check all system fuses and power relay connections
9
Replace the ignition coil Is the replacement complete?
Go to step (16)
_
9-3
System voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
10
Value(s)
Yes
No
Key OFF Disconnect the ECM connector C001 Using a DVOM check for continuity between ignition module connector pin B and ECM connector pin 31 Do you have continuity between them?
Go to step (11)
Repair the open ignition control circuit. See wiring harness repair section.
11
Using a DVOM check for continuity between ignition module connector pin B and engine ground Do you have continuity between them?
Repair the shorted to ground ignition control circuit. See wiring harness repair section.
Go to step (12)
12
Replace ECM Is the replacement complete?
Go to step (16)
-
13
Disconnect coil. Using a DVOM check for continuity between the ignition module connector pin C and engine ground Do you have continuity?
Go to step (14)
Repair the open ignition module ground circuit. See wring harness repair.
14
Using a DVOM check for continuity between the ignition module connector pin D and ignition coil connector pin B Do you have continuity?
Go to step (15)
Repair the open ignition module circuit. See wiring harness repair.
15
Replace the ignition module. Is the replacement complete?
Go to step (16)
-
16
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to OBD System Check
9-4
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-5
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-16 — NEVER CRANK SYNCED AT START
Conditions for setting the DTC •
Crankshaft Position Sensor
•
Check Condition — Engine cranking
•
Fault Condition — Cranking rpm above 90 and more than 4 cranking revolutions without synchronization
•
MIL Command — ON
Circuit Description The Crankshaft Position Sensor is a 5 volt powered sensor mounted to the lower front engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems. This fault will set if the ECM detects cranking revolutions without synchronization of the CMP and CKP sensors. Diagnostic Aid Reversed sensor wires, poor wire connections or faulty system ground are most frequently the cause of this code set.
9-6
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-16 — NEVER CRANK SYNCED AT START Step
Action
1
Did you perform the On-Board (OBD) System Check?
2
•
3
• •
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (3)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
•
Key On, Engine OFF Disconnect the CKP (Crankshaft position) Sensor connector C015 Using A DVOM check for voltage at the CKP sensor connector pin A or 1 and engine ground
5.0 volts
(CHECK THIS BEFORE THE POWER RELAY SHUTS OFF.) Do you have voltage? 4
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin B or 2 and ECM connector pin 22
(CHECK THIS BEFORE THE POWER RELAY SHUTS OFF.)
Do you have continuity between them? 5
•
Using a DVOM check for continuity between CKP connector pin C or 3 and ECM connector pin 21
(CHECK THIS BEFORE THE POWER RELAY SHUTS OFF.) Do you have continuity between them? 6
•
Inspect the CKP connector C015 terminals for damage, corrosion or contamination Did you find a problem?
9-7
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
7
•
Inspect the ECM connector C001 terminals 19, 21 and 22 for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
8
• Replace CKP sensor Is the replacement complete?
Go to Step (10)
—
9
• Replace ECM Is the replacement complete?
Go to Step (11)
—
10
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-16 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-16 check for any stored codes. Does the engine operate normally with no stored codes?
9-8
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-9
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-107 — MAP LOW VOLTAGE
Conditions for Setting the DTC
Circuit Description
•
Manifold Absolute Pressure Sensor
•
Check Condition — Engine cranking or running
•
Fault Condition — MAP voltage less than 0.050 with throttle position greater than 5% and engine RPM less than 3000.
•
MIL — ON
•
Adaptive — Disabled
•
Fueling is based on RPM and TPS Limp — Home Condition during this fault.
The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake manifold. It is used to measure the pressure of air in the manifold prior to induction. The pressure reading is used in conjunction with other inputs to estimate the airflow rate to the engine, which determines the fuel flow rate. This fault will set if the MAP voltage is less than 0.050 with TPS greater than 5% and engine RPM is less than 3000. The adaptive Learn will be disabled for the remainder of the key on cycle and the MIL command is on.
9-10
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-107 — MAP LOW VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine running. DSC (Diagnostic Scan Tool) connected in System Data Mode Does DST display MAP voltage of 0.050 or less with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Key OFF Disconnect the TMAP sensor connector C006 from the wiring harness • Jump the 5 volt reference pin 3 and MAP signal circuit pin 4 together • Key ON Does the DST display MAP voltage of 4.5 volts or greater?
Go to Step (4)
Go to Step (8)
4
•
Inspect TMAP connector and pins for corrosion, contamination or mechanical damage Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• • •
Key OFF Disconnect ECM connector C001 Check for continuity between TMAP sensor connector signal pin 4 and ECM MAP signal pin 7. Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Check for continuity between TMAP sensor connector 5 volt supply signal pin 3 and ECM 5 volt supply pin 19 Do you have continuity between them?
Go to Step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
7
•
Go to Step (17)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Check for continuity between TMAP sensor connector ground pin 1 and ECM sensor ground pin 20 Do you have continuity between them?
9-11
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
8
•
Probe MAP connector signal circuit pin 4 with a test light connected to battery voltage Does the DST display MAP voltage of 4.0 or greater?
Go to Step (9) Go to Step (13)
9
• • •
Key OFF Disconnect ECM connector Check for continuity between TMAP sensor connector pin 3 and ECM 5 volt pin 19. Do you have continuity between them?
Go to Step (10)
10
•
Check for continuity between TMAP sensor connector 5 volt reference pin 3 and engine ground Do you have continuity?
Go to Step (11) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
11
•
Inspect ECM and TMAP wire harness connector and terminals for corrosion, contamination or mechanical damage Any problems found?
Repair the Go to Step (16) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
12
•
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (17)
—
13
• •
Disconnect ECM connector Check for continuity between TMAP sensor connector signal circuit pin 4 and ECM signal pin 7 Do you have continuity between them?
Go to Step (14)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
14
•
Check for continuity between TMAP sensor connector signal pin 4 and engine ground Do you have continuity?
Repair the Go to Step (15) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
15
•
Repair the Go to Step (16) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Inspect ECM connector and wire harness connector terminals for corrosion, contamination or mechanical damage Any problems found?
9-12
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
16
•
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (18)
—
17
• Replace TMAP sensor Is the replacement complete?
Go to Step (18)
—
18
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-107 check for any stored codes. Does the engine operate normally with no stored codes?
9-13
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-108 — MAP HIGH PRESSURE
Conditions for Setting the DTC •
MAP pressure test
•
Check condition — engine running and greater than 600 rpm
•
Fault Condition — MAP greater than 12.00 psia with TPS less than 10% and engine rpm greater than 600.
•
MIL — On
•
Adaptive — disabled
Circuit Description The MAP (Manifold Absolute Pressure) is estimated from the TMAP sensor. The MAP pressure value is used for fuel, airflow and spark calculations. This fault will set in the event the MAP value is greater than 12.00 psia when the TPS is less than 10% with engine rpm greater than 600.
9-14
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-108 — MAP HIGH PRESSURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
•
Key On, Engine running at full operating temperature. • DST (Diagnostic Scan Tool) connected in • System Data Mode Does DST display MAP pressure of 12.00 psia or greater with the engine running above 600 rpm and TPS value less than 10%?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Key OFF • Disconnect the TMAP sensor connector C006 • Key ON Does the DST display MAP pressure less than 0.05 psia?
Go to Step (4)
Go to Step (6)
4
•
Probe TMAP connector ground pin 1 with a test light connected to battery voltage. Does the test light come on?
Go to Step (5)
Go to Step (8)
5
•
Check TMAP mechanical vacuum connection for correct mounting or possible damage causing leakage. Is the TMAP sensor mechanical connection Ok?
Go to Step (6) Go to Step (10)
6
• Key OFF Disconnect ECM connector and inspect terminals for damage corrosion or contamination. Is the connection Ok?
Go to Step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
7
Replace TMAP sensor. Is the repair complete?
Go to Step (11)
—
8
•
Disconnect ECM connector and check for continuity between TMAP connector sensor ground pin 1 and ECM sensor ground pin 20. Do you have continuity between them?
Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
•
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (11)
—
10
• Correct TMAP mechanical connection. Has the TMAP mechanical connection problem been corrected?
Go to Step (11)
—
9-15
—
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 11
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-108 check for any stored codes. Does the engine operate normally with no stored codes?
9-16
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-17
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-111 — IAT HIGHER THAN EXPECTED 1
Conditions for Setting the DTC •
Intake Air Temperature
•
Check Condition — Engine Running
•
Fault Condition — Intake Air Temperature greater than 200 degrees F. with engine rpm greater than 600
•
MIL — On
•
Adaptive — Disabled during active fault
•
Power derate level 1
will be in force and effect limiting maximum power output. Diagnostic Aid
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. This fault will set if the Intake Air Temperature is greater than 200 degrees F. with engine speed greater than 600 rpm. Power derate level one 9-18
•
This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged.
•
Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system
•
If none of the above can be found, follow the diagnostic steps for DTC-112 — IAT Low Voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-19
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-112 — IAT LOW VOLTAGE
BL K/LT GRN
1 2 3 4
YEL/GRY
L T GRN/RED
LT GRN
20
Sensor Ground IAT Signal
39
5V
19
5 Volts
7
MA P Signal ECM
Conditions for Setting the DTC
Circuit Description
•
Intake Air Temperature
•
Check Condition Engine Cranking or Running
•
Fault Condition — IAT Sensor Voltage less than 0.050
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is less than 0.050 volts for 1 second anytime the engine is cranking or running. The ECM will use the default value for the IAT sensor in the event of this fault.
9-20
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-112 — IAT LOW VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On. DST (Diagnostic Scan Tool) connected in System Data Mode. Does DST display IAT voltage of 0.050 or less?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Key Off • Disconnect the TMAP sensor connector C006 • Key ON Does the DST display IAT voltage of 4.90 volts or greater?
Go to Step (4)
Go to Step (5)
4
• Replace TMAP sensor. Is the replacement complete?
Go to Step (9)
—
5
• • •
Key OFF Disconnect ECM wire harness connector C001 Check for continuity between TMAP sensor connector ground pin 1 and TMAP sensor connector signal pin 2 Do you have continuity between them?
—
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
•
Check for continuity between TMAP sensor connector signal circuit pin 2 and engine ground. Do you have continuity?
—
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
—
Go to Step (8)
—
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
9-21
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 8
Action • • • • • • • •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-112 check for any stored codes.
Does the engine operate normally with no stored codes?
9-22
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-23
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-113 — IAT HIGH VOLTAGE
BLK /LT GRN
1 YEL/GRY
2 3
20 39
LT GRN/RED
4
LT GRN
Sensor Ground IAT Signal 5V
19
5 Volts
7
MAP Signal ECM
Conditions for Setting the DTC •
Intake Air Temperature
•
Check Condition — Engine Running
•
Fault Condition — IAT Sensor Voltage greater than 4.950 volts
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is greater than 4.950 volts anytime the engine is running. The ECM will use a default value for the IAT sensor in the event of this fault.
9-24
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-113 — IAT HIGH VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display IAT voltage of 4.950 or greater?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Key Off Disconnect the TMAP sensor connector C006 and jump pins 1 and 2 together • Key On Does the DST display IAT voltage of 0.1 volts or less?
Go to Step (9)
Go to Step (4)
4
• •
Key OFF Jump TMAP sensor connector signal pin 2 to engine ground • Key ON Does DST display IAT voltage of 0.1 volts or less?
Go to Step (7)
Go to Step (6)
5
Replace TMAP sensor. Is the replacement complete?
Go to Step (11)
—
6
• •
Key OFF Disconnect the ECM wire harness connector C001. • Check for continuity between TMAP sensor connector signal pin 2 and ECM IAT signal pin 39 Do you have continuity between them?
—
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
7
•
Check for continuity between TMAP sensor connector ground circuit pin 1 and ECM sensor ground circuit pin 20 Do you have continuity between them?
—
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
• Replace the ECM. Is the replacement complete?
—
Go to Step (11)
—
9
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
Go to Step (5)
Re-check wire harness and TMAP sensor connector for damage corrosion or contamination Any problems found?
9-25
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
10
•
Re-check wire harness and TMAP sensor connectors for damage corrosion or contamination Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
Go to Step (8)
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-113 check for any stored codes. Does the engine operate normally with no stored codes?
9-26
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-27
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-117 — ECT/CHT LOW VOLTAGE
Signal
TAN/WHT
A
B
BLK/LT GR N
5 v olts
40
Sensor Ground
20
ECM
Conditions for Setting the DTC
Circuit Description
•
Engine Coolant Temperature
•
Check Condition — Engine Running
•
Fault Condition — ECT sensor voltage less than 0.050
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant passage. It is used for the engine airflow calculation, gasoline cold enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is less than 0.050 volts anytime the engine is running. The ECM will use a default value for the ECT sensor in the event of this fault.
Temp (Deg F)
Ohms
Temp (Deg F)
Ohms
242.4
101
102.4
1,556
231.9
121
78.9
2,689
211.6
175
49.9
5,576
201.4
209
23.5
11,562
181.9
302
-5.7
28,770
163.1
434
-21.2
49,715
144.9
625
-30.8
71,589
127.4
901
-40.0
99,301
Temperature vs. ECT Resistance 9-28
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-117 — ECT/CHT LOW VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key On • DST (Diagnostic Scan Tool) connected in • System Data Mode Does DST display ECT voltage of 0.050 or less?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Key Off Disconnect the ECT wire harness connector C007 • Key ON Does the DST display ECT voltage of 4.90 volts or greater?
Go to Step (4)
Go to Step (5)
4
• Replace ECT sensor. Is the replacement complete?
Go to Step (8)
—
5
• • •
Key OFF Disconnect ECM wire harness connector C001 Check for continuity between ECT sensor connector signal pin A and ECT sensor ground pin B Do you have continuity between them?
—
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
•
Check for continuity between ECT sensor connector signal circuit pin A and engine ground. Do you have continuity?
—
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
—
Go to Step (8)
—
8
• •
System OK
Go to OBD System Check
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-117 check for any stored codes. Does the engine operate normally with no stored codes? 9-29
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-118 — ECT/CHT HIGH VOLTAGE
Signal
A
B
TAN/WHT
BLK/LT GR N
5 v olts
40
Sensor Ground
20
ECM
Conditions for Setting the DTC
Circuit Description
•
Engine Coolant Temperature
•
Check Condition — Engine Running
•
Fault Condition — ECT sensor voltage exceeds 4.950 volts
•
MIL — On during active fault
•
Adaptive — Disabled
The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant passage. It is used for the engine airflow calculation, gasoline cold enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is greater than 4.950 volts anytime the engine is running. The ECM will use a default value for the ECT sensor in the event of this fault.
Temp (Deg F)
Ohms
Temp (Deg F)
Ohms
242.4
101
102.4
1,556
231.9
121
78.9
2,689
211.6
175
49.9
5,576
201.4
209
23.5
11,562
181.9
302
-5.7
28,770
163.1
434
-21.2
49,715
144.9
625
-30.8
71,589
127.4
901
-40.0
99,301
Temperature vs. ECT Resistance 9-30
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-118 — ECT/CHT HIGH VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display ECT voltage of 4.95 or greater?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Key Off Disconnect the ECT sensor connector C007 and Jump terminals A and B together • Key On Does the DST display ECT voltage of 0.05 volts or less?
Go to Step (4)
Go to Step (8)
4
•
Using a DVOM check the resistance between the See resistance chart vs. two terminals of the ECT sensor and compare temperature in the resistance reading to the chart the DTC-118 Is the resistance value correct? circuit description
Go to Step (6)
Go to Step (5)
5
• Replace ECT sensor Is the replacement complete?
Go to Step (14)
—
6
Inspect the ECT wire harness connector terminals A and B for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• • •
Key OFF Disconnect ECM wire harness connector C001 Inspect ECM connector pins 20 and 40 for damage corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Intermittent problem Go to Intermittent section
8
•
Go to Step (9) Go to Step (12)
Jump the ECT signal pin A at the ECT connector to engine ground Does DST display ECT voltage of 0.05 or less?
9-31
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between ECT sensor ground pin B and ECM connector pin 20 Do you have continuity between them?
Go to Step (10)
10
•
Inspect ECM connector pins 20 and 40 for damage, corrosion or contamination Did you find a problem?
Go to Step (11) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
11
• Replace ECM Is the replacement complete?
Go to Step (14)
—
12
• • •
Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between ECT connector signal pin A and ECM connector terminal 40 Do you have continuity between them?
Go to Step (13)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
13
•
Inspect ECM connector pins 20 and 40 for damage, corrosion or contamination Did you find a problem?
Repair the Go to Step (11) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
14
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-118 check for any stored codes. Does the engine operate normally with no stored codes?
9-32
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-33
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-121 — TPS 1 LOWER THAN TPS 2
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
tle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if TPS 1 is 20% (or more) lower than TPS 2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. Power derate level 1, low rev limit and forced idle will be enforced limiting maximum power output.
Conditions for Setting the DTC •
Throttle Position Sensor 1 & 2
•
Check Condition — Key On
•
Fault Condition — TPS 1 20% lower than TPS 2
•
MIL — On for remainder of key on cycle
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throt-
9-34
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-121 — TPS 1 LOWER THAN TPS 2 Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2 voltage?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • • •
Key OFF Disconnect electronic throttle connector C017 Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 less than 0.1 volts?
Go to Step (5)
Go to Step (4)
4
• • • •
Key OFF Disconnect ECM wiring harness connector C001 Key ON Using a DVOM check for voltage between ECM connector TPS 1 signal pin 5 and engine ground Do you have voltage?
Repair the TPS 1 circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (9)
5
•
Jump TPS 1 signal pin 6 to the 5 volt reference pin 3 at connector C017 Does DST display TPS 1 voltage over 4.90 volts
Go to Step (6)
Go to Step (8)
6
•
Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• Replace the electronic Throttle Is the replacement complete?
Go to Step (12)
—
8
• • •
Go to Step (9)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM connector TPS 1 signal pin 5
• Do you have continuity between them?
9-35
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
•
Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM connector signal ground pin 20 Do you have continuity between them?
Go to Step (10)
10
•
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Go to Step (11) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
11
• Replace ECM Is the replacement complete?
Go to Step (12)
—
12
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-121 check for any stored codes. Does the engine operate normally with no stored codes?
9-36
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-37
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-122 — TPS 1 SIGNAL VOLTAGE LOW
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 1 voltage is less than 0.200 volts. The MIL command is ON. Power derate level 1, low rev limit and forced idle will be enforced limiting maximum power output.
Conditions for Setting the DTC •
Throttle Position Sensor 1
•
Check Condition — Cranking or Running
•
Fault Condition — TPS sensor less than 0.200 volts
•
MIL — On during active fault
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle
9-38
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-122 — TPS 1 SIGNAL VOLTAGE LOW Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 1 voltage of 0.200 volts or less with the throttle closed?
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever fall below 0.200 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• •
Key OFF Disconnect the electronic throttle connector C017 • Jump the 5 volt reference circuit pin 3 and TPS 1 signal circuit pin 6 together at the throttle connector • Key ON Does DST display TPS 1 voltage of 4.0 volts or greater?
Go to Step (7)
Go to Step (5)
5
• • •
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check continuity between the electronic throttle connector signal pin 6 and ECM connector TPS 1 signal pin 5 Do have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
• Replace ECM Is the replacement complete?
Go to Step (9)
—
7
•
Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
8
• Replace the electronic throttle Is the replacement complete?
Go to Step (9)
—
9-39
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 9
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-122 check for any stored codes. Does the engine operate normally with no stored codes?
9-40
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-41
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-123 — TPS 1 SIGNAL VOLTAGE HIGH
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 1 voltage exceeds 4.800 volts. The MIL command is ON. Power derate level 1, low rev limit and forced idle will be enforced limiting maximum power output.
Conditions for Setting the DTC •
Throttle Position Sensor 1
•
Check Condition — Cranking or Running
•
Fault Condition — TPS sensor voltage exceeds 4.800 volts
•
MIL — On during active fault
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle
9-42
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-123 — TPS 1 SIGNAL VOLTAGE HIGH Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF. • DST (Diagnostic Scan Tool) connected Does the DST display TPS 1 voltage of 4.800 volts or greater with the throttle closed?
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever exceed 4.800 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• Key OFF • Disconnect electronic throttle connector C017 • Key ON Does DST display TPS 1 voltage less than 0.2 volts?
Go to Step (7)
Go to Step (5)
5
• • • •
Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between TPS 1 signal at the ECM connector pin 5 and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
• Replace ECM Is the replacement complete?
Go to Step (11)
—
7
•
Back probe sensor ground circuit at the ECM side of the wire harness pin 20 with a test light connected to battery voltage Does the test light come on?
Go to Step (8) Go to Step (10)
8
•
Inspect the electronic throttle connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (9)
9
• Replace the electronic throttle Is the replacement complete?
Go to Step (11)
—
10
• • •
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between the electronic throttle connector sensor ground pin 2 and ECM connector TPS 1 sensor ground pin 20 Do have continuity between them?
9-43
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 11
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-123 check for any stored codes. Does the engine operate normally with no stored codes?
9-44
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-127 — IAT HIGHER THAN EXPECTED 2
BLK/LT GRN
1 2 3 4
YEL/GRY
20 Sensor Ground IAT Signal 39
LT GRN/RED
LT GRN
5V
19
5 Volts
7
MAP Signal ECM
Conditions for Setting the DTC •
Intake Air Temperature
•
Check Condition — Engine Running
•
Fault Condition — Intake Air Temperature greater than 210 degrees F. with engine speed greater than 600 rpm
•
MIL — On for active fault
•
Engine Shut Down
on during this active fault and the engine will shut down. Diagnostic Aid This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged. Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads a higher voltage, and lower when warm. This fault will set if the Intake Air Temperature is greater than 210 degrees F. with engine speed greater than 600 rpm. The MIL light command is
* If none of the above can be found, follow the diagnostic steps for DTC-112 — IAT Low Voltage.
9-45
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-129 — BP LOW PRESSURE
BLK/LT GRN
1 2 3 4
YEL/GRY
L T GRN/RED
L T GRN
20
Sensor Ground IAT Signal
39
5V
19
5 Volts
7
MAP Signal ECM
Conditions for Setting the DTC •
Barometric Pressure
•
Check Condition — Key On
•
Fault Condition — BP less than 8.30 psia
•
MIL — On for active fault
•
Adaptive — Disabled
Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of the normal range.
9-46
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-129 — BP LOW PRESSURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key On. • DST (Diagnostic Scan Tool) connected in • System Data Mode Does DST display BP pressure of 8.30 psia or less?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • •
Key OFF Disconnect the TMAP sensor connector C006 Jump the 5 volt reference pin 3 and MAP signal pin 4 together • Key ON Does the DST display BP pressure of 16.00 psia or greater?
Go to Step (4)
Go to Step (8)
4
•
Inspect TMAP connector and wire harness connector terminals for corrosion, contamination or mechanical damage Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• • •
Key OFF Disconnect ECM connector C001 Check for continuity between TMAP sensor connector pin 4 and ECM connector pin 7 Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Check for continuity between TMAP sensor connector 5 volt supply pin 3 and ECM connector pin 19 Do you have continuity between them?
Go to Step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
7
•
Go to Step (17)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Check for continuity between TMAP sensor connector ground pin 1 and ECM connector pin 20 Do you have continuity between them?
9-47
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
8
•
Remove the Jumper that was installed during step 3 • Probe TMAP connector signal circuit pin 4 with a test light connected to battery voltage Does the DST display BP pressure of 16.00 psia or greater?
Go to Step (9) Go to Step (13)
9
• • •
Key OFF Disconnect ECM connector C001 Check for continuity between TMAP sensor connector pin 3 and ECM connector pin 19 Do you have continuity between them?
Go to Step (10)
10
•
Check for continuity between TMAP sensor connector 5 volt reference pin 3 and engine ground Do you have continuity?
Go to Step (11) Repair the open ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
11
•
Inspect TMAP and ECM connector pins for corrosion, contamination or mechanical damage Any problems found?
Repair the Go to Step (16) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
12
•
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (17)
—
13
• •
Disconnect ECM connector C001 Check for continuity between TMAP sensor connector pin 4 and ECM pin 7 Do you have continuity between them?
Go to Step (14)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
14
•
Repair the Go to Step (15) open ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Check for continuity between TMAP sensor connector pin 4 and engine ground Do you have continuity?
9-48
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
14
•
Check for continuity between TMAP sensor connector pin 4 and engine ground Do you have continuity?
Repair the Go to Step (15) open ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
15
•
Inspect ECM connector and wire harness connector pins for corrosion, contamination or mechanical damage Any problems found?
Repair the Go to Step (16) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
16
•
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
Go to Step (18)
—
17
• Replace TMAP sensor Is the replacement complete?
Go to Step (18)
—
18
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-129 check for any stored codes. Does the engine operate normally with no stored codes?
9-49
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-134 — EGO 1 PRE CAT OPEN/LAZY
Conditions for Setting the DTC •
Heated Oxygen Sensor
•
Check condition — Engine running
•
Fault condition — EGO 1 pre catalyst persistently cold for more than 50 seconds
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
•
Closed Loop — Disabled during active fault
Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the Adaptive multiplier. This fault will set if EGO 1 is cold, non-responsive, or inactive for more than 50 seconds.
9-50
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-134 — EGO 1 PRE CAT OPEN/LAZY Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Run engine to full operating temperature and then idle for a minimum of 2 minutes Does DST display EGO 1 voltage fixed between 0.4 and 0.5 volts after at least 2 minutes of idle run time?
Go to Step (3)
Intermittent problem. See Electrical Section Intermittent Electrical Diagnosis
3
• • • •
Go to Step (8)
Go To Step (4)
4
• •
Go to Step (5)
Repair system power relay open circuit
5
• •
Disconnect ECM connector C001 Using a DVOM check for continuity between EGO 1 connector pin D and ECM connector pin 72 Do you have continuity?
Go to Step (6)
Repair open heater ground circuit
6
•
Inspect wire harness connector C005 pins A and A and C001 pins 1 and 72 for damage, corrosion or contamination Did You find a problem?
Correct the problem as required see Electrical Section wire harness repair
Go to Step (7)
7
• Replace ECM Is the replacement complete?
Go to Step (11)
—
8
• • •
Go to Step (9)
Repair open EGO 1 circuit
Key OFF Disconnect EGO 1 connector C005 Key ON Using a DVOM check for voltage between EGO 1 connector pins A and B (Check must be made within 30 seconds or before power relay shuts down) Do you have voltage? Key OFF Using a DVOM check for voltage between EGO 1 connector pin A and engine ground • Key ON (Check must be made within 30 seconds or before power relay shuts down) Do you have voltage?
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between EGO 1 pin C and ECM connector pin 1 Do you have continuity?
9-51
System Voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
9
•
Using a DVOM check for continuity between EGO 1 pin D and ECM connector pin 20 Do you have continuity?
Go to Step (10)
Repair open EGO 1 signal ground
10
• Replace EGO 1 sensor Is the replacement complete?
Go to Step (11)
—
11
• •
System Ok
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-134 check for any stored codes. Does the engine operate normally with no stored codes?
9-52
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-53
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-154 — EGO 2 POST CAT OPEN/LAZY
Conditions for Setting the DTC •
Heated Oxygen Sensor
•
Check condition — Engine running
•
Fault condition — EGO 2 post catalyst sensor cold persistently more than 50 seconds
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
•
Closed Loop — Disabled during active fault
Circuit Description The EGO 2 sensor is used to optimize transient fuel mixture control. This fault will set if EGO 2 post catalyst sensor is cold, non-responsive, or inactive for more than 50 seconds.
9-54
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-154 — EGO 2 POST CAT OPEN/LAZY Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Run engine to full operating temperature and then idle for a minimum of 2 minutes Does DST display EGO 2 voltage fixed between 0.4 and 0.5 volts after at least 2 minutes of idle run time?
Go to Step (3)
Intermittent problem. See Electrical Section Intermittent Electrical Diagnosis
3
• • • •
Go to Step (8)
Go To Step (4)
4
• •
Go to Step (5)
Repair system fused power relay open circuit
5
• •
Disconnect ECM connector C001 Using a DVOM check for continuity between EGO 2 connector pin D and ECM connector pin 73 Do you have continuity?
Go to Step (6)
Repair open heater ground circuit
6
•
Inspect EGO 2 connector pins A,B,C,D and ECM pins 2, 73 and 20 for damage, corrosion or contamination Did You find a problem?
Correct the problem as required see Electrical Section wire harness repair
Go to Step (7)
7
• Replace ECM Is the replacement complete?
Go to Step (11)
—
8
• • •
Go to Step (9)
Repair open EGO 2 circuit
Key OFF Disconnect EGO 2 connector C004 Key ON Using a DVOM check for voltage between EGO 2 connector pins C and D (Check must be made within 30 seconds or before power relay shuts down) Do you have voltage? Key OFF Using a DVOM check for voltage between EGO 2 connector pin C and engine ground • Key ON (Check must be made within 30 seconds or before power relay shuts down) Do you have voltage?
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between EGO 2 pin B and ECM connector pin 2 Do you have continuity?
9-55
System Voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
9
•
Using a DVOM check for continuity between EGO 2 pin A and ECM connector pin 20 Do you have continuity?
Go to Step (10)
Repair open EGO 2 signal ground
10
• Replace EGO 2 sensor Is the replacement complete?
Go to Step (11)
—
11
• •
System Ok
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-154 check for any stored codes. Does the engine operate normally with no stored codes?
9-56
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-57
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-187 — FT VOLTAGE LOW
Signal
A
B
W HT/RED
BLK/LT GR N
5 Volts 41
20
Sensor Ground
ECM
Conditions for Setting the DTC •
Fuel Temperature
•
Check Condition — Engine Running
•
Fault Condition — FT sensor voltage less than 0.050 volts
•
MIL — On
•
Adaptive — Disabled
Temperature Sensor Temperature Degrees F.
Resistance Tolerance ± 10% Ohms
-40
99318
-20
48300
0
24705
20
13214
40
7357
Circuit Description
60
4259
The FT (Fuel Temperature) sensor is a temperature sensitive resistor located near the fuel outlet of the electronic pressure regulator. It is used to help determine fuel charge density for accurate fuel mixture control. The ECM provides a voltage divider circuit so that when the sensor is cool the signal reads a higher voltage, and lower when warm. This fault will set if the signal voltage is less than 0.050 volts anytime the engine is running.
70
3284
80
2554
100
1582
120
1008
140
660.6
160
444.1
170
367.3
180
305.5
190
255.4
200
214.6
220
153.7
9-58
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-187 — FT VOLTAGE LOW Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key On • DST (Diagnostic Scan Tool) connected in • System Data Mode Does DST display FT voltage of 0.050 or less?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Key Off • Disconnect the FT wire harness connector C002 • Key ON Does the DST display FT voltage of 4.90 volts or greater?
Go to Step (4)
Go to Step (5)
4
• Replace FT sensor. Is the replacement complete?
Go to Step (8)
—
5
• • •
Key OFF Disconnect ECM wire harness connector C001 Check for continuity between fuel temperature sensor connector signal pins A and B Do you have continuity between them?
—
Repair the shorted circuit as Repairs in Engine Electrical.
Go to Step (6)
6
•
Check for continuity between the fuel temperature sensor connector signal circuit pin A and engine ground. Do you have continuity?
—
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
—
Go to Step (8)
—
8
• •
System OK
Go to OBD System Check
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-187 check for any stored codes. Does the engine operate normally with no stored codes?
9-59
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-188 — FT VOLTAGE HIGH
Signal
A
B
W HT/RED
BLK/LT GR N
5 Volts 41
20
Sensor Ground
ECM
Conditions for Setting the DTC
Temperature Sensor Temperature Degrees F.
Resistance Tolerance ± 10% Ohms
-40
99318
-20
48300
0
24705
20
13214
40
7357
Circuit Description
60
4259
The FT (Fuel Temperature) sensor is a temperature sensitive resistor located near the fuel outlet of the electronic pressure regulator. It is used to help determine fuel charge density for accurate fuel mixture control. The ECM provides a voltage divider circuit so that when the sensor is cool the signal reads a higher voltage, and lower when warm. This fault will set if the signal voltage is greater than 4.950 volts anytime the engine is running.
70
3284
80
2554
100
1582
120
1008
140
660.6
160
444.1
170
367.3
180
305.5
190
255.4
200
214.6
220
153.7
•
Fuel Temperature
•
Check Condition — Engine Running
•
Fault Condition — FT sensor voltage exceeds 4.950
•
MIL — On
•
Adaptive — Disabled during active fault
9-60
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-188 — FT VOLTAGE HIGH Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display FT voltage of 4.950 or greater?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Go to Step (4)
Go to Step (8)
4
•
Go to Step (6)
Go to Step (5)
5
• Replace FT sensor Is the replacement complete?
Go to Step (14)
—
6
•
Inspect the FT sensor connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• • •
Key OFF Disconnect ECM wire harness connector C001 Inspect ECM connector pins 20 and 41 for damage corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Intermittent problem Go to Intermittent section
8
•
Go to Step (9) Go to Step (12)
Key Off Disconnect the FT sensor connector C002 and jump connector terminals A and B together • Key On Does the DST display FT voltage of 0.05 volts or less? Using a DVOM check the resistance between the two terminals of the FT sensor and compare the resistance reading to the chart Is the resistance value correct?
Jump the fuel temperature sensor connector signal pin A to engine ground Does DST display FT voltage of 0.05 or less?
9-61
See temperature vs. resistance chart in the DTC-188 schematic page.
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
• • •
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between fuel temperature sensor ground pin B and ECM connector pin 20 Do you have continuity between them?
Go to Step (10)
10
•
Inspect ECM connector pins 20 and 41 for damage, corrosion or contamination Did you find a problem?
Go to Step (11) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
11
• Replace ECM Is the replacement complete?
Go to Step (14)
—
12
• • •
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between the fuel temperature connector signal pin A and ECM connector terminal 41 Do you have continuity between them?
Go to Step (13)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
13
•
Inspect ECM connector pins 20 and 41 for damage, corrosion or contamination Did you find a problem?
Repair the Go to Step (11) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
14
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-188 check for any stored codes. Does the engine operate normally with no stored codes?
9-62
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-63
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-219 — MAX GOVERN SPEED OVERRIDE
Electronic Throttle
ECM 4
PNK/WHT
82
DBW +
Motor
1 TPS1
6
2 TPS2
5 3
TAN/ORN
PPL/LT BLU
BLK/LT GRN
LT BLU/DK BLU
LT GRN/RED
C017
Conditions for Setting the DTC •
Max Govern Speed Override
•
Check Condition — Engine Running
•
Fault Condition — Engine rpm greater than 3100
•
MIL — On during active fault
Circuit description This fault will set anytime the engine rpm exceeds 3100. The MIL command is ON during this active fault Diagnostic Aid Check for other stored DTC codes before using the following DTC chart for this code set. Always diagnose and repair any existing codes starting with the lowest numerical code first.
9-64
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-219 — MAX GOVERN SPEED OVERRIDE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST connected Are any other DTC codes present with DTC-219?
Go to Step (3)
Go to Step (4)
3
•
Diagnose and repair any other DTC codes stored before proceeding with this chart. Have any other DTC codes been diagnosed and repaired?
Go to Step (4)
—
4
•
Check the service part number on the ECM to ensure the correct calibration is in use Is the Service Part Number Correct?
Go to Step (6)
Go to Step 5
5
• Replace ECM with correct service part number Is the replacement complete?
Go to Step (9)
—
6
• Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK?
Go to Step (8)
Go to Step (7)
7
•
Correct mechanical operation of the throttle. Refer to Engine & Component section Has the mechanical operation of the throttle been corrected?
Go to Step (9)
—
8
•
Go to Step (9)
Go to OBD System Check Section
9
• •
System OK
Go to OBD System Check
Check engine for large manifold vacuum leaks. Refer to Symptom Diagnostic section Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-219 check for any stored codes. Does the engine operate normally with no stored codes?
9-65
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-221 — TPS 1 HIGHER THAN TPS 2
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
tle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if TPS 1 is 20% (or more) higher than TPS 2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. The MIL command is ON. Power derate level 1, low rev limit and forced idle will be enforced limiting maximum power output.
Conditions for Setting the DTC •
Throttle Position Sensor 1 & 2
•
Check Condition — Key On
•
Fault Condition — TPS 1 20% higher than TPS2
•
MIL — On for remainder of key on cycle
•
Power Derate 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read lower voltage when closed and TPS 2 will read higher voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throt-
9-66
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-221 — TPS 1 HIGHER THAN TPS 2 Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Key OFF • Disconnect electronic throttle connector C017 • Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 less than 0.1 volts?
Go to Step (5)
Go to Step (4)
4
• • • •
Key OFF Disconnect ECM wiring harness connector C001 Key ON Using a DVOM check for voltage between ECM connector TPS 1 signal pin 5 and engine ground Do you have voltage?
Repair the TPS 1 circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (9)
5
•
Jump TPS 1 signal pin 6 to the 5 volt reference pin 3 at connector C025 Does DST display TPS 1 voltage over 4.900 volts
Go to Step (6)
Go to Step (8)
6
•
Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• Replace the electronic Throttle Is the replacement complete?
Go to Step (12)
—
8
• • •
Go to Step (9)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM connector TPS 1 signal pin 5 Do you have continuity between them?
9-67
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
•
Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM connector signal ground pin 20 Do you have continuity between them?
Go to Step (10)
10
•
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Go to Step (11) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical
11
• Replace ECM Is the replacement complete?
Go to Step (12)
—
12
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-221 check for any stored codes. Does the engine operate normally with no stored codes?
9-68
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-69
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-222 — TPS 2 SIGNAL VOLTAGE LOW
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 2 voltage is less than 0.200 volts for more than .500 seconds. The MIL command is ON. Power derate level 1, low rev limit and forced idle will be enforced limiting maximum power output.
Conditions for Setting the DTC •
Throttle Position Sensor 2
•
Check Condition — Cranking or Running
•
Fault Condition — TPS 2 sensor voltage less than 0.200 volts
•
MIL — ON during active fault
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle
9-70
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-222 — TPS 2 SIGNAL VOLTAGE LOW Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 2 voltage of 0.200 volts or less with the throttle closed
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever fall below 0.200 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• • •
Key OFF Disconnect electronic throttle connector C017 Jumper the 5 volt reference circuit pin 3 and TPS 2 signal circuit pin 5 together at the throttle connector • Key ON Does DST display TPS 2 voltage of 4.0 volts or greater?
Go to Step (7)
Go to Step (5)
5
• • •
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check continuity between TPS 2 connector signal pin 5 and ECM connector TPS 2 • Signal pin 6 Do have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
• Replace ECM Is the replacement complete?
Go to Step (9)
—
7
•
Inspect the electronic throttle wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
8
• Replace the electronic throttle Is the replacement complete?
Go to Step (9)
—
9-71
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 9
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-222 check for any stored codes. Does the engine operate normally with no stored codes?
9-72
Yes System OK
No Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-73
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-223 — TPS 2 SIGNAL VOLTAGE HIGH
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 2 voltage is greater than 4.800 volts for more than .500 seconds. Power derate level 1, low rev limit and forced idle will be enforced limiting maximum power output.
Conditions for Setting the DTC •
Throttle Position Sensor 2
•
Check Condition — Cranking or Running
•
Fault Condition — TPS 2 sensor exceeds 4.800 volts
•
MIL — On during active fault
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle
9-74
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-223 — TPS 2 SIGNAL VOLTAGE HIGH Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 2 voltage of 4.800 volts or greater with the throttle closed?
Go to Step (4)
Go to Step (3)
3
•
Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever exceed 4.800 volts?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• Key OFF • Disconnect electronic throttle connector C017 • Key ON Does DST display TPS 2 voltage less than 0.2 volts?
Go to Step (7)
Go to Step (5)
5
• • • •
Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between electronic throttle connector TPS 2 signal pin 5 and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
• Replace ECM Is the replacement complete?
Go to Step (11)
—
7
•
Probe sensor ground circuit at the ECM side of the wire harness pin 20 with a test light connected to battery voltage Does the test light come on?
Go to Step (8) Go to Step (10)
8
•
Inspect the electronic throttle wire harness connector and terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (9)
9
• Replace electronic throttle Is the replacement complete?
Go to Step (11)
—
9-75
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between throttle connector C017 sensor ground pin 2 and ECM connector sensor ground pin 20 Do have continuity between them?
Yes
No
10
• • •
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-223 check for any stored codes. Does the engine operate normally with no stored codes?
9-76
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-77
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-336 — CRANK SYNC NOISE
ECM
C015 LT GRN/RED
19
A
Crankshaft C rankshaft
C rank Sens or
WHT/PPL B PPL/WHT C
Conditions for setting the DTC •
Crankshaft Position sensor
•
Check Condition — Engine running
•
Fault Condition — 1 invalid crank re-sync in less than 800 ms
•
MIL — On during active fault
•
Adaptive — Disabled
Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems. This fault will set If no signal is present for 800ms or longer.
9-78
22
21
5 volts +
C rank -
Crank +
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-336 — CRANK SYNC NOISE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (3)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
1
Did you perform the On — Board (OBD) System Check?
2
•
3
• •
4
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin B and ECM connector pin 22 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
5
•
Using a DVOM check for continuity between CKP connector pin C and ECM connector pin 21 Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
Key On, Engine OFF Disconnect the CKP (Crankshaft position) Sensor connector C015 • Using A DVOM check for voltage at the CKP sensor connector pin A and engine ground (CHECK THIS BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage?
Inspect the CKP connector C015 terminals for damage, corrosion or contamination Did you find a problem?
9-79
5.0 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
7
•
Inspect the ECM connector C001 terminals 19, 21 and 22 for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
8
• Replace CKP sensor Is the replacement complete?
Go to Step (10)
—
9
• Replace ECM Is the replacement complete?
Go to Step (11)
—
10
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-336 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-336 check for any stored codes. Does the engine operate normally with no stored codes?
9-80
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-81
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-337 — CRANK LOSS
ECM
C015 LT GRN/RED
19
1
Crankshaft Crankshaft
Crank Sensor
WHT/PPL 2 PPL /WHT 3
Conditions for Setting the DTC •
Crankshaft position sensor
•
Check Condition — Engine cranking
•
Fault Condition — 6 cam pulse signals without crankshaft activity
•
MIL — On during active fault
•
Adaptive — Disabled
Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems. The ECM must see a valid Crankshaft position signal while cranking. If no crankshaft signal is present for 6 cam pulses this fault will set.
9-82
22
21
5 volts +
Crank -
C rank +
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-337 — CRANK LOSS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (3)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
1
Did you perform the On-Board (OBD) System Check?
2
•
3
• •
4
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin 2 or B and ECM connector pin 22 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
5
•
Using a DVOM check for continuity between CKP connector pin 3 or C and ECM connector pin 21 Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Inspect the CKP connector C015 terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
Key OFF Disconnect the CKP (Crankshaft Position) Sensor connector C015 • Using A DVOM check for voltage at the CKP sensor connector pin 1 or A and engine ground (CHECK THIS BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage?
Inspect the ECM connector C001 terminals 19, 21 and 22 for damage, corrosion or contamination Did you find a problem
9-83
5.0 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
8
• Replace the CKP sensor Is the replacement complete?
Go to Step (10)
—
9
• Replace ECM Is the replacement complete?
Go to Step (11)
—
10
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-337 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-337 check for any stored codes. Does the engine operate normally with no stored codes?
9-84
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-85
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-341 — CAMSHAFT SYNC NOISE
A D ist./C am Sens or
B
C
PPL/ORN
GR Y/BR N
LT GR N/R ED
24
23
Cam C am +
5 v olts 19 EC M
Conditions for Setting the DTC •
Camshaft position sensor
•
Check Condition — Cranking or Running
•
Fault Condition — 1 invalid cam re-sync in 700ms or less
•
MIL — On
Circuit Description The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems. This fault will set if the ECM detects erroneous pulses from the camshaft position sensor causing invalid cam re-sync.
9-86
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-341 — CAMSHAFT SYNC NOISE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (3)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
1
Did you perform the On-Board (OBD) System Check?
2
•
3
• •
4
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CMP connector pin A and ECM connector pin 24 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
5
•
Using a DVOM check for continuity between CMP connector pin B and ECM connector pin 23 Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
6
•
Inspect the CMP connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
Key OFF Disconnect the CMP (Camshaft position) Sensor connector • Using A DVOM check for voltage at the CMP sensor connector pin C and engine ground Do you have voltage?
Inspect the ECM connector C001 terminals 19, 23 and 24 for damage, corrosion or contamination Did you find a problem
9-87
5.0 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
8
• Replace CMP sensor Is the replacement complete?
Go to Step (10)
—
9
• Replace ECM Is the replacement complete?
Go to Step (11)
—
10
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-341 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-341 check for any stored codes. Does the engine operate normally with no stored codes?
9-88
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-89
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-342 — CAMSHAFT SENSOR LOSS
A D ist./C am Sens or
B
C
PPL/ORN
GR Y/BR N
LT GR N/R ED
24
23
Cam C am +
5 v olts 19 EC M
Conditions for Setting the DTC •
CMP (Camshaft Position Sensor)
•
Check Condition — Engine Cranking or Running
•
Fault Condition — No cam pulse in 2.5 cycles with engine speed greater than 600 rpm
•
MIL — On for active fault
•
Adaptive — Disabled
Circuit Description The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems. This fault will set if the ECM does not detect a cam pulse in 2.5 engine cycles whenever the engine is greater than 600 rpm. The engine may not run with this fault present.
9-90
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-342 — CAMSHAFT SENSOR LOSS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (3)
Repair the circuit as necessary. Refer to wiring harness repair section.
Go to Step (4)
Repair the circuit as necessary. Refer to wiring harness repair section.
1
Did you perform the On-Board (OBD) System Check?
2
•
3
• •
Key OFF Disconnect the CMP (Camshaft Position) Sensor connector • Key ON • Using A DVOM check for voltage at the CMP sensor connector pin C and engine ground (RUN THIS VOLTAGE CHECK BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage?
4
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CMP connector pin A and ECM connector pin 24 Do you have continuity between them?
Go to Step (5)
Repair the circuit as necessary. Refer to wiring harness repair section.
5
•
Using a DVOM check for continuity between CMP connector pin B and ECM connector pin 23 Do you have continuity between them?
Go to Step (6)
Repair the circuit as necessary. Refer to wiring harness repair section.
6
•
Inspect the CMP connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to wiring harness repair section.
Go to Step (7)
7
•
Inspect the ECM connector terminals 19, 23 and 24 for damage, corrosion or contamination Did you find a problem
Repair the circuit as necessary. Refer to wiring harness repair section.
Go to Step (8)
8
• Replace the CMP. Is the replacement complete?
Go to Step (10)
—
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean tight and in the proper location?
9-91
5.0 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
Go to Step (11)
—
9
• Replace ECM Is the replacement complete?
10
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-342 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
Go to Step (9)
11
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-342 check for any stored codes. Does the engine operate normally with no stored codes?
9-92
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-93
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-359 — FUEL RUN-OUT LONGER THAN EXPECTED
WHT/BLK
75
Ground
A
LPG shut off valve B
ECM Fuse ( F1) 5 AMP
PN K/TAN
Conditions for Setting the DTC •
LPG shut off valve
•
Check Condition — Key OFF
•
Fault Condition — Engine run down time greater than 20 seconds
•
MIL — On
Circuit Description The LPG shut off valve is supplied system battery power from the VSW fused source. The ECM then provides a path to ground to turn the valve on. This fault will set in the event the engine continues to run for more than 20 seconds after the key is turned off. This fault indicates a possible problem with the electric LPG shut off solenoid.
9-94
VSW power source
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-359 — FUEL RUN-OUT LONGER THAN EXPECTED Step
Action
Value(s)
Yes
No
—
Go to Step (2)
System Voltage
Go to Step (3)
Go to Step (5)
1
Did you perform the On-Board (OBD) System Check?
2
•
3
• •
Turn off the LPG manual valve at the fuel tank Start the engine and let it idle until the engine stops. (THIS MAY TAKE SEVERAL MINUTES) Did the engine ever stop?
Intermittent problem. See intermittent problems in the electrical section of this manual.
Go to Step (4)
4
• Replace the LPG shut off solenoid Is the replacement complete?
Go to Step (8)
—
5
• •
Repair the LPG solenoid control short to ground
Go to Step (6)
6
•
Inspect the ECM wire harness and connector for damage corrosion or contamination Did you find a problem?
Correct the problem as required. See wire harness repair.
Go to Step (7)
7
• Replace the ECM Is the replacement complete?
Go to Step (8)
—
8
• •
System OK
Go to OBD System Check
Disconnect the LPG shut off solenoid connector C003 • Using a DVOM check for power across terminals A and B while cranking the engine, then turn the key to the OFF position Did the voltage immediately turn OFF with the key cycle?
Key OFF Disconnect the ECM wire harness connector C001 • Using a DVOM check for continuity between ECM pin 75 and engine ground Do you have continuity?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-359 check for any stored codes. Does the engine operate normally with no stored codes?
9-95
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-524 — OIL PRESSURE LOW
ECM + 5 volts LT BLU
53
Oil Pressure Voltage
C008 Oil Pressure Switc h
Conditions for Setting the DTC
Circuit Description
•
Engine Oil Pressure low
•
Check Condition — Engine running for 20 seconds or more with engine speed greater than 600 rpm.
•
Fault Condition — Closed pressure switch circuit/voltage less than 2.500 volts
•
MIL — On during active fault and for 3 seconds after active fault
•
Engine Shut Down
The Oil Pressure Switch is used to communicate a low oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM uses an analog voltage input with an internal 5 volt reference. If the oil pressure circuit is grounded, the input voltage will be near zero. If it is open, the input will be near 5 volts. The switch is normally closed. This fault will set if the switch remains closed with the engine running. The MIL command is ON and the engine will shut down in the event of this fault to help prevent possible engine damage.
9-96
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-524 — OIL PRESSURE LOW Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
•
Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceeding with this chart. See Engine Specifications Section 1F. Does the engine have oil pressure above 5 psi?
Go to Step (3)
Repair faulty Oiling System
3
•
Key On, Engine Running DST connected in System Data Mode • Clear DTC-524 • Warm the engine by idling until the ECT temperature is above 160 degrees F. and has been running for at least 20 seconds • Increase engine speed above 600 RPM Does DTC-524 reset and cause the engine to shut down?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• •
Key OFF Disconnect oil pressure switch harness connector C005 • Clear DTC-524 • Start engine, let idle for at least one minute with ECT over 160 degrees F. • Increase engine speed above 600 RPM Does DTC-524 reset?
Go to Step (6)
Go to Step (5)
5
• Replace oil pressure switch Is the replacement complete?
Go to Step (9)
—
6
• • • •
Key OFF Disconnect ECM harness connector C001 Disconnect oil pressure switch connector C008 Using a DVOM check for continuity between oil pressure switch connector C008 LT BLU wire and engine ground Do you have continuity between them?
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
Inspect ECM connector pin 53 for damage corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
8
Replace ECM Is the replacement complete?
Go to Step (9)
—
9-97
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 9
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-524 check for any stored codes. Does the engine operate normally with no stored codes?
9-98
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-99
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-562 — SYSTEM VOLTAGE LOW
BLK GROUND
BLK
RED/TAN
VBAT
RED/TAN
Conditions for Setting the DTC •
System Voltage to ECM
•
Check Condition — Key on with engine speed greater than 600 RPM
•
Fault Condition — Battery voltage at ECM less than 9.50 volts
•
MIL — On for active fault
•
Adaptive — Disabled
Circuit Description The battery voltage powers the ECM and must be measured to correctly to properly operate injector drivers, solenoid valves and ignition coils. This fault will set if the ECM detects system voltage less than 9.50 volts while the alternator should be charging. The adaptive learn is disabled during this fault.
9-100
ECM 69
81
60 79
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-562 — SYSTEM VOLTAGE LOW Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
—
Go to Step (2)
Go to OBD System Check Section
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display system voltage greater than 9.50 volts?
—
Intermittent problem Go to Engine Electrical Intermittent section
Go to Step (3)
3
• Check battery condition Is it OK?
—
Go to Step (4)
Replace Battery
4
• Check charging system Is it Ok?
—
Go to Step (5)
Repair charging System
5
• • •
Key OFF Disconnect the ECM connector C001 Check the voltage between ECM connector C001 pins 60, 79 and engine ground. • Measure voltage with DVOM between each pin and engine ground Is the voltage greater than for each pin 9.50 volts?
—
Repair ECM Ground circuit. Go to Power and Ground section in engine Electrical
Go to Step (6)
6
•
Check the voltage at ECM connector pins 69 and 81 • Measure voltage with DVOM between each pin and battery positive Is the voltage greater than 9.50 volts?
—
Repair ECM power circuit. Go to Power and Ground section in engine Electrical
Go to Step (7)
7
• Replace ECM Is the replacement complete?
—
Go to Step (8)
—
8
• •
—
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-562 check for any stored codes. Does the engine operate normally with no stored codes?
9-101
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-563 — SYSTEM VOLTAGE HIGH
BLK GROUND
BLK
RED/TAN
VBAT
RED/TAN
Conditions for Setting the DTC •
System Voltage to ECM
•
Check Condition — Cranking or Running
•
Fault Condition — System battery voltage at ECM greater than 16 volts
•
MIL — On for active fault
•
Adaptive — Disabled
Circuit Description The battery voltage powers the ECM and must be measured to correctly operate injector drivers, trim valves and ignition coils. This fault will set if the ECM detects voltage greater than 16 volts anytime the engine is cranking or running. The adaptive learn function is disabled during this fault. The ECM will shut down with internal protection if the system voltage ever exceeds 26 volts.
9-102
ECM 69
81
60 79
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-563 — SYSTEM VOLTAGE HIGH Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
—
Go to Step (2)
Go to OBD System Check Section
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Run engine greater than 1500 rpm. Does DST display system voltage greater than 16 volts?
—
Go To Step (3)
Intermittent problem Go to Engine Electrical Intermittent section
3
•
Check voltage at battery terminals with DVOM with engine speed greater than 1500 rpm Is it greater than 16 volts?
—
Go to Step (4)
Go to Step (5)
4
• Repair the charging system Has the charging system been repaired?
—
Go to Step (6)
—
5
• Replace ECM Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-563 check for any stored codes. Does the engine operate normally with no stored codes?
9-103
—
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-601 — FLASH CHECKSUM INVALID
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power.
9-104
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-601 — FLASH CHECKSUM INVALID Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-601 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-601 check for any stored codes. Does the engine operate normally with no stored codes?
9-105
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-604 — RAM FAILURE
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power output.
9-106
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-604 — RAM FAILURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-604 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-604 check for any stored codes. Does the engine operate normally with no stored codes?
9-107
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-606 — COP FAILURE
ECM Microprocesso Microprocess or r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power output.
9-108
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-606 — COP FAILURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-606 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-606 check for any stored codes. Does the engine operate normally with no stored codes?
9-109
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-642 — EXTERNAL 5 VOLT REFERENCE LOW
LT GRN/RED 19
+ 5 V ol ts
ECM
Conditions for Setting the DTC •
External 5 volt reference
•
Check Condition — Engine cranking or running
•
Fault Condition — 5 volt reference voltage lower than 4.60 volts
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
important to the accuracy of the powered sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded, shorted, or otherwise out of specification by monitoring the 5 volt supply. This fault will set if the 5 volt reference is below 4.60 volts. Adaptive Learn will be disabled during this fault.
Circuit Description The External 5 volt supply powers many of the sensors and other components of the fuel system. The accuracy of the 5 volt supply is very important to the accuracy of the powered sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded, shorted, or otherwise out of specification by monitoring the 5 volt supply. This fault will set if the 5 volt reference is below 4.60 volts. Adaptive Learn will be disabled during this fault. The External 5 volt supply powers many of the sensors and other components of the fuel system. The accuracy of the 5 volt supply is very
9-110
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-642 — EXTERNAL 5 VOLT REFERENCE LOW Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Fault Mode Does DST display DTC-642?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • •
Key OFF Disconnect ECM connector C001 Using DVOM check for continuity between ECM 5 volt reference pin 19 and engine ground Do you have continuity?
Go to Step (5)
Go to Step (4)
4
• Replace ECM Is the replacement complete?
Go to Step (7)
—
5
•
While monitoring DVOM for continuity between ECM 5 volt reference and engine ground • Disconnect each sensor (below) one at a time to find the shorted 5 volt reference. When continuity to ground is lost the last sensor disconnected is the area of suspicion. Inspect the 5 volt reference supply wire leads for shorts before replacing the sensor. • ECT • TMAP • Electronic Throttle • Gasoline Sensor • LPG temperature sensor • FPP • TPS 1 • TPS 2 • Crankshaft Sensor • Camshaft Sensor While disconnecting each sensor one at a time did you loose continuity?
Go to Step (6) Repair shorted wire harness
6
• Replace the last disconnected sensor Is the replacement complete?
Go to Step (7)
9-111
—
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 7
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-642 check for any stored codes. Does the engine operate normally with no stored codes?
9-112
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-113
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-643 — EXTERNAL 5 VOLT REFERENCE HIGH
LT GRN/RED 19
+5 Volts
ECM
Conditions for Setting the DTC •
External 5 volt reference
•
Check Condition — Engine cranking or running
•
Fault Condition — 5 volt reference higher than 5.40 volts
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
Circuit Description The External 5 volt supply powers many of the sensors and other components in the fuel system. The accuracy of the 5 volt supply is very important to the accuracy of the powered sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded, shorted, or otherwise out of specification by monitoring the 5 volt supply. This fault will set if the 5 volt reference is greater than 5.40 volts anytime the engine is cranking or running. Adaptive Learn will be disabled during this fault.
9-114
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-643 — EXTERNAL 5 VOLT REFERENCE HIGH Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine running DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display DTC-643?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Check all ECM ground connections. Refer to Engine electrical power and ground distribution. Are the ground connections Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • • •
Key OFF Disconnect ECM connector C001 Key ON Using DVOM check for Voltage between ECM harness wire pin 19 and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Replace ECM Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-643 check for any stored codes. Does the vehicle engine normally with no stored codes?
9-115
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-650 — MIL CONTROL OPEN
ECM
C012 MIL G
GRN/YEL
80
+12 volts in start and run Ground
Conditions for setting the DTC •
MIL check
•
Check Condition — Key ON engine OFF
•
Fault Condition — ECM MIL circuit open
•
MIL Command — ON
vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON. This fault will set if the ECM MIL control circuit is open.
Circuit Description The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has an overhead guard leg mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTC’s that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not illuminate with the 9-116
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-650 — MIL CONTROL OPEN Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code • Key OFF • Key ON Does DTC-650 reset?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• •
Remove the MIL bulb or driver circuit Using a DVOM check for continuity through the bulb or driver device Do you have continuity?
Go to Step (5)
Go to Step (4)
4
• Replace the open bulb or driver device Is the replacement complete?
Go to Step (8)
—
5
• • • •
Key OFF Re-install the bulb or driver device Disconnect vehicle interface connector C012 Using a DVOM check for continuity between vehicle interface connector pin G and battery positive • Key ON Do you have continuity?
Go to Step (6)
Repair the open circuit as required. See wire harness repair
6
• •
Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between ECM harness connector pin 80 and vehicle interface connector pin G Do you have continuity?
Go to Step (7)
Repair the open circuit as required. See wire harness repair
7
•
Correct the problem as required. See wiring harness repair
Go to Step (8)
Inspect ECM wire harness connector pin 80 and vehicle interface connector pin G for damage, corrosion or contamination Did you find a problem?
9-117
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 8
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-650 check for any stored codes. Does the engine operate normally with no stored codes?
9-118
Yes
No
System OK
Go to OBD System check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-119
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-652 — EXTERNAL 5 VOLT 2 REFERENCE LOW
Conditions for Setting the DTC •
External 5 volt reference
•
Check Condition—Engine cranking or running
•
Fault Condition—5 volt reference voltage lower than 4.00 volts
•
MIL—On during active fault
•
Adaptive—Disabled during active fault
Circuit Description The External 5 volt supply is normally dedicated to the FPP sensor 5 volt supply circuit. The accuracy of the 5 volt supply is very important to the accuracy of the FPP sensor circuit. The ECM is able to determine if the circuit is open, shorted, or otherwise out of specification by monitoring this 5 volt supply. This fault will set if the 5 volt reference is below 4.00 volts. Adaptive Learn will be disabled during this fault.
9-120
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-652 — EXTERNAL 5 VOLT 2 REFERENCE LOW Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
•
Key ON, Engine Running
Go to Step (3)
•
DST (Diagnostic Scan Tool) connected in System Fault Mode
Intermittent problem Go to Intermittent section
Go to Step (5)
Go to Step (4)
Go to Step (7)
-
Go to Step (6)
Repair shorted wire harness
Go to step (7)
-
Does DST display DTC-652? 3
•
Key OFF
•
Disconnect ECM connector C001
•
Using DVOM check for continuity between ECM 5 volt reference pin 49 and engine ground
Do you have continuity? 4
•
Replace ECM
Is the replacement complete? 5
•
While monitoring DVOM for continuity between ECM 5 volt reference and engine ground
•
Disconnect each sensor (below) one at a time to find the shorted 5 volt reference. When continuity to ground is lost the last sensor disconnected is the area of suspicion. Inspect the 5 volt reference supply wire leads for shorts before replacing the sensor.
•
FPP
While disconnecting each sensor one at a time did you loose continuity? 6
•
Replace the last disconnected sensor
Is the replacement complete?
9-121
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 7
Action
Value(s)
•
Remove all test equipment except the DST.
•
Connect any disconnected components, fuses, etc.
•
Using the DST clear DTC information from the ECM.
•
Turn the ignition OFF and wait 30 seconds.
•
Start the engine and operate the vehicle to full operating temperature
•
Observe the MIL
•
Observe engine performance and driveability
•
After operating the engine within the test parameters of DTC-652 check for any stored codes.
Does the engine operate normally with no stored codes?
9-122
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-123
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-653 — EXTERNAL 5 VOLT 2 REFERENCE HIGH
Conditions for Setting the DTC •
External 5 volt reference
•
Check Condition-Engine cranking or running
•
Fault Condition-5 volt reference higher than 5.40 volts
•
MIL-On during active fault
•
Adaptive-Disabled during active fault
Circuit Description The External 5 volt supply is normally dedicated to the FPP sensor 5 volt supply circuit. The accuracy of the 5 volt supply is very important to the accuracy of the FPP sensor circuit. The ECM is able to determine if the circuit is open, shorted, or otherwise out of specification by monitoring this 5 volt supply. This fault will set if the 5 volt reference is above 5.40 volts. Adaptive Learn will be disabled during this fault.
9-124
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-653 — EXTERNAL 5 VOLT 2 REFERENCE HIGH Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section
2
•
Key ON, Engine running
Go to Step (3)
•
DST (Diagnostic Scan Tool) connected in System Data Mode
Intermittent problem Go to Intermittent section
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
Go to Step (6)
-
System OK
Go to OBD System Check
Does DST display DTC-653? 3
•
Check all ECM ground connections. Refer to Engine electrical power and ground distribution.
Are the ground connections Ok?
4
•
Key OFF
•
Disconnect ECM connector C001
•
Key ON
•
Using DVOM check for Voltage between ECM harness wire pin 49 and engine ground
Do you have voltage? 5
•
Replace ECM
Is the replacement complete? 6
•
Remove all test equipment except the DST.
•
Connect any disconnected components, fuses, etc.
•
Using the DST clear DTC information from the ECM.
•
Turn the ignition OFF and wait 30 seconds.
•
Start the engine and operate the vehicle to full operating temperature
•
Observe the MIL
•
Observe engine performance and driveability
•
After operating the engine within the test parameters of DTC-653 check for any stored codes.
Does the vehicle engine normally with no stored codes?
9-125
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-685 — RELAY COIL OPEN
Conditions for Setting the DTC •
Power relay check
•
Check Condition — Key ON
•
Fault Condition — Relay coil open
Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system. This fault will set if the ECM detects an open circuit on the relay control output. Diagnostic Aid Relay coil resistance changes with temperature. The following diagnostic charts have steps to measure relay coil resistance values. When checking the resistance values be sure the relay is at a reasonable temperature, between +20 and +100 degrees F.
9-126
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-685 — RELAY COIL OPEN Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• • • •
DST connected and in the system data mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between terminals 2 and 1 Is the resistance value less than 100 ohms?
Go to Step (4)
Go to Step (3)
3
• Replace the power relay Is the replacement complete?
Go to Step (9)
—
4
• Check fuse F2 Is the fuse open?
Replace fuse F2
Go to Step (5)
5
• •
Disconnect ECM connector C001 Using a DVOM check for continuity between ECM pin 71 and fuse block cavity for relay terminal 2 Do you have continuity?
Go to Step (6)
Repair the open circuit as required. See wiring harness repairs
6
• •
Remove fuse F2 Using a DVOM check for continuity between fuse block cavity for relay terminal 1 and the power out of the F2 fuse holder Do you have continuity?
Go to Step (7)
Repair the open circuit as required. See wiring harness repairs
7
• •
Check all system fuses. Check all relay placement positions in fuse block. • Run complete pin to pin checks on chassis wiring to fuel system harness. • See complete fuel system schematic for further details Did you find the problem?
Go to Step (9)
Go to Step (8)
8
• Replace the ECM Is the replacement complete?
Go to Step (9)
—
9-127
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 9
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-685 check for any stored codes. Does the engine operate normally with no stored codes?
9-128
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-129
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-686 — RELAY CONTROL GROUND SHORT
Conditions for Setting the DTC •
Power relay ground control
•
Check Condition — Key ON
•
Fault Condition — Relay control shorted to ground
Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system. This fault will set if the ECM detects a short to ground on the relay control output. Diagnostic Aid Relay coil resistance changes with temperature. The following diagnostic charts have steps to measure relay coil resistance values. When checking the resistance values be sure the relay is at a reasonable temperature, between +20 and +100 degrees F.
9-130
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-686 — RELAY CONTROL GROUND SHORT Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
3
•
Key On, DST connected in the System Data mode • Clear DTC-686 • Start the engine Does DTC-686 re-set?
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• •
Disconnect ECM connector C001 Using a DVOM check the resistance value between ECM pin 71 and engine ground Is the resistance less than 60 ohms?
Go to Step (5)
Go to Step (7)
5
• •
Remove the power relay from the fuse block Using a DVOM check the resistance value again between ECM pin 71 and engine ground Is the resistance less than 60 ohms?
Repair the shorted to ground relay control circuit as necessary. See wiring harness repairs
Go to Step (6)
6
• Replace the power relay Is the replacement complete?
Go to Step (8)
—
7
• Replace ECM Is the replacement complete?
Go to Step (8)
—
8
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-686 check for any stored codes. Does the engine operate normally with no stored codes?
9-131
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-687 — RELAY COIL SHORT TO POWER
Conditions for Setting the DTC •
Power relay check
•
Check Condition — Key ON
•
Fault Condition — Relay coil shorted to power
Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system. This fault will set if the ECM detects a short circuit to power on the relay control output. Diagnostic Aid Relay coil resistance changes with temperature. The following diagnostic charts have steps to measure relay coil resistance values. When checking the resistance values be sure the relay is at a reasonable temperature, between +20 and +100 degrees F.
9-132
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-687 — RELAY COIL SHORT TO POWER Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• • • •
DST connected and in the system data mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between terminals 2 and 1 Is the resistance value less than 60 ohms?
Go to Step (3)
Go to Step (4)
3
• Replace the power relay Is the replacement complete?
Go to Step (9)
—
4
•
Go to Step (3)
Go to Step (5)
5
• • •
Go to Step (6) System battery Repair the voltage short to power. See wiring harness repair.
6
• Replace the power relay Is the replacement complete?
Go to Step (7)
—
7
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-687 check for any stored codes. Does DTC-687 still re-set?
Go to Step (8)
Go to Step (9)
8
• Replace the ECM Is the replacement complete?
Go to Step (9)
—
Using a DVOM check for continuity between relay terminals 2 and 5 Do you have continuity between them? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for power between ECM pin 71 and engine ground with the key ON Do you have power?
9-133
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 9
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-687 check for any stored codes. Does the engine operate normally with no stored codes?
9-134
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-135
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1111 — FUEL REV LIMIT
Electronic Throttle
ECM 4
PNK/WHT
82
DBW +
Motor
1 TPS1
6
2 TPS2
5 3
TAN/ORN
PPL/LT BLU
BLK/LT GRN
LT BLU/DK BLU
LT GRN/RED
C017
Conditions for Setting the DTC •
Fuel Rev Limit
•
Check Condition — Engine Running
•
Fault Condition — Engine rpm greater than 3200
•
MIL — On during active fault
Circuit Description This fault will set anytime Engine rpm is greater than 3200. When these conditions are met the ECM cuts off fueling to limit speed. This is to help prevent engine or equipment damage. The MIL will be on during this active fault. Diagnostic Aid Always check for other stored DTC codes before using the following DTC chart for this code set. Repair any existing codes starting with the lowest numerical code first.
9-136
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1111 — FUEL REV LIMIT Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST in Active Fault Mode Are any other DTC codes present with DTC-1111?
Go to Step (3)
Go to Step (4)
3
•
Diagnose and repair any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired?
Go to Step (4)
—
4
•
Check the service part Number on the ECM to ensure correct calibration is in use Is the service part Number Correct?
Go to Step (6)
Go to Step 5
5
•
Replace ECM with the correct service part number Is the replacement complete?
Go to Step (9)
—
6
• Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK?
Go to Step (8)
Go to Step (7)
7
•
Correct mechanical operation of the throttle. Refer to Engine & Component section Has the mechanical operation of the throttle been corrected?
Go to Step (9)
—
8
•
Go to Step (9)
Go to OBD System Check Section
9
• •
System OK
Go to OBD System Check
Check engine for large manifold vacuum leaks. Refer to Fuel Systems symptom diagnostics Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1111 check for any stored codes. Does the engine operate normally with no stored codes?
9-137
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1112 — SPARK REV LIMIT
Electronic Throttle
ECM 4
PNK/WHT
82
DBW +
Motor
1 TPS1
6
2 TPS2
5 3
TAN/ORN
PPL/LT BLU
BLK/LT GRN
LT BLU/DK BLU
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
Conditions for Setting the DTC
Diagnostic Aid
•
Spark Rev Limit
•
Check Condition — Engine running
•
Fault Condition — Engine RPM greater than 3300
Always check for other stored DTC codes before using the following DTC chart for this code set. Repair any existing codes starting with the lowest numerical code first.
•
MIL — On during active fault
•
Engine Shut Down
Circuit description This fault will set anytime the engine RPM exceeds 3300. During this condition the ECM will shut off spark to the engine. This is to help prevent engine or equipment damage. The MIL command is ON during this active fault and the engine will shut down.
9-138
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1112 — SPARK REV LIMIT Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST connected Are any other DTC codes present with DTC-1112?
Go to Step (3)
Go to Step (4)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired?
Go to Step (4)
—
4
•
Check the service part number on the ECM to ensure correct calibration is in use Is the service part number Correct?
Go to Step (6)
Go to Step 5
5
• Replace ECM with correct service part Number Is the replacement complete?
Go to Step (9)
—
6
• Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK?
Go to Step (8)
Go to Step (7)
7
•
Correct mechanical operation of the throttle. Refer to Engine & Component section Has the mechanical operation of the throttle been corrected?
Go to Step (9)
—
8
•
Go to Step (9)
Go to OBD System Check Section
9
• •
System OK
Go to OBD System Check
Check engine for large manifold vacuum leaks. Refer to Fuel Systems section Symptom Diagnostics Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1112 check for any stored codes. Does the engine operate normally with no stored codes?
9-139
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1121 — FPP 1 AND 2 REDUNDANCY LOST
Conditions for Setting the DTC
Diagnostic Aid
•
Foot pedal position sensor 1 and 2
•
Check Condition — Key On
•
Fault Condition — FPP1 and FPP 2 redundancy lost
•
MIL — On
•
Power derate level 2
•
Force idle
•
Low rev limit
It is very likely that in the event this code sets, other codes will set along with it. Always diagnose and repair codes starting with the lowest numerical value first. It is possible that by correcting the lower code sets first the problem will be corrected. FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
Circuit Description The foot pedal position sensor uses variable resistors to determine signal voltage based on foot pedal position. Although the voltage outputs are different, the calculated throttle position values should be very close to the same. This fault will set if FPP 1 or FPP 2 positions are 20% greater or 20% less than the expected throttle position target. The MIL command is On. Forced idle, low rev limit and power derate level 2 are in effect during this fault limiting full power output.
9-140
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1121 — FPP 1 AND 2 REDUNDANCY LOST Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
Go to Step (2)
Go to OBD System Check
2
•
Diagnose any other lower numerical value codes that may be present first. Did this resolve the problem?
Go to Step (7)
Go to Step (3)
3
• Follow the diagnostic chart for DTC-2126 Did the chart resolve the problem?
Go to Step (7)
Go to Step (4)
4
• Follow the diagnostic chart for DTC-2121 Did the chart resolve the problem?
Go to Step (7)
Go to Step (5)
5
•
Inspect FPP and C012 connector pins for damage corrosion or contamination Did you find the problem?
Correct the problem as required. See wiring harness repair.
Go to Step (6)
6
• •
Correct the problem as required. See wiring harness repair.
—
7
• •
System Ok
Go to OBD System Check
Key OFF Disconnect ECM connector C001. Inspect pins 9, 10, 19, 20, 49 and 50 for damage corrosion or contamination. Did you find a problem? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1121 check for any stored codes. Does the engine operate normally with no stored codes?
9-141
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1151 — CLOSED LOOP MULTIPLIER HIGH LPG
Conditions for Setting the DTC
Diagnostic Aid
•
Heated Oxygen Sensor
•
Check Condition — Engine running
Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold.
•
Fault Condition — Closed Loop multiplier out of range (greater than 35%)
•
MIL — ON
Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition at especially at light load. Fuel Mixer System can be lean due to faulty EPR (Electronic Pressure Regulator) or faulty fuel mixer.
Circuit description The EG01 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation and cannot correctly modify the fuel flow within its limits.
Fuel Pressure Low fuel pressure, faulty fuel regulator or contaminated fuel filter can cause fuel the system to run lean Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past the 02 sensor causing a false lean condition. Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean. Ground Problem ECM grounds must be clean, tight and in the proper location.
9-142
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1151 — CLOSED LOOP MULTIPLIER HIGH LPG Step
Action
Value(s)
Yes
No
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
Go to Step (2)
2
• •
Visually and physically check the following items: The air intake duct for being collapsed or restricted • The air filter for being plugged • The EGO 1 sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires • ECM grounds must be clean and tight. Refer to Engine Electrical Power and Ground Distribution • Fuel System Diagnostics. Refer to Fuel System Diagnostics Was a repair made?
Go to Step (9)
Go to Step (4)
3
•
Go to Step (9)
Go to Step (4)
4
• •
5
• •
Key OFF Disconnect EGO 1 sensor wire harness connector C005 • Disconnect ECM wire harness connector C001 • Key ON • Using a high impedance DVOM check for continuity between EGO 1 connector signal pin A and engine ground Do you have continuity?
Repair the Go to Step (6) signal shorted to ground. Refer to Wiring harness repair.
6
•
Using a high impedance DVOM check for continuity between EGO 1 connector signal ground pin C and EGO 1 signal pin A Do you have continuity?
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
Go to Step (8)
Repair the open EGO heater ground circuit
Diagnose any other DTC codes before proceeding with this chart. Always repair existing codes starting with the lowest numerical code set first. Have any other DTC codes been detected, diagnosed and repaired?
Disconnect EGO1 connector C005 System voltage Go to Step (5) Repair the Using a DVOM check for voltage between EGO 1 circuit as connector pin B and engine ground necessary. • Key ON Refer to Wiring Repairs in (CHECK MUST BE MADE WITHIN 30 SECONDS Engine OR BEFORE POWER RELAY SHUTS DOWN) Do you have voltage? Electrical.
Using a high impedance DVOM check for continuity between EGO 1 connector heater ground pin D and ECM pin 72 Do you have continuity?
9-143
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
8
• Replace EGO 1 sensor Is the replacement complete?
9
• •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1151 check for any stored codes. Does the engine operate normally with no stored codes?
9-144
Yes
No
Go to Step (9)
—
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-145
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1152 — CLOSED LOOP MULTIPLIER LOW LPG
Conditions for Setting the DTC
Diagnostic Aid
•
Heated Oxygen Sensor
•
Functional Fault — Closed Loop multiplier out of range (at limit of -35%)
Fuel System High secondary fuel pressure will cause the system to run rich. A worn fuel mixer, faulty EPR (Electronic Pressure Regulator) may also cause the system to run rich.
•
MIL Disabled
Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the fuel system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is used.
Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation. When the multiplier cannot correctly modify the fuel flow within its limits, it is limited at -35%.
Air Filter A plugged, damaged or modified air filter may cause the system to run rich.
9-146
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1152 — CLOSED LOOP MULTIPLIER LOW LPG Step
Action
Value(s)
Yes
No
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
Go to Step (2)
2
• •
Visually and physically check the following items: The air intake duct for being collapsed or restricted • The air filter for being plugged • The EGO sensor installed securely and the wire leads not damaged contacting the secondary ignition wires • ECM grounds for being clean and tight. • Run the fuel system diagnostic checks Was a repair made?
Go to Step (6)
Go to Step (4)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired?
Go to Step (6)
Go to Step (4)
4
• • • • •
Key OFF Disconnect EGO sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage at the EGO 1 connector C005 signal pin A and engine ground Do you have voltage?
Go to Step (5) Repair the circuit short to voltage as necessary. Refer to wiring harness repair.
5
• Replace EGO sensor Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1152 check for any stored codes. Does the engine operate normally with no stored codes?
9-147
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1161 — ADAPTIVE LEARN HIGH LPG
Conditions for Setting the DTC
Diagnostic Aid
•
Heated Oxygen Sensor
•
Check Condition — Engine Running
Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold.
•
Fault Condition — Adaptive multiplier out of range greater than 30%
•
MIL — On
Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition, especially at light load. Fuel Mixer System can be lean due to faulty EPR (Electronic Pressure Regulator) or faulty fuel mixer.
Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier exceeds the limits of normal operation. Always run the fuel system diagnostic checks before using the following diagnostic chat.
Fuel Pressure Low fuel pressure, faulty fuel regulator or contaminated fuel filter can cause fuel the system to run lean Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past the 02 sensor causing a false lean condition. Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean. Ground Problem ECM grounds must be clean, tight and in the proper location.
9-148
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1161 — ADAPTIVE LEARN HIGH LPG Step
Action
Value(s)
Yes
No
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
Go to Step (2)
2
• •
Visually and physically check the following items: The air intake duct for being collapsed or restricted • The air filter for being plugged • The EGO 1 sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires • ECM grounds must be clean and tight. Refer to Engine Electrical Power and Ground Distribution • Fuel System Diagnostics. Refer to Fuel System Diagnostics Was a repair made?
Go to Step (8)
Go to Step (4)
3
•
Go to Step (8)
Go to Step (4)
4
• •
5
• •
Key OFF Disconnect EGO 1 sensor wire harness connector C005 • Disconnect ECM wire harness connector C001 • Key ON • Using a high impedance DVOM check for continuity between EGO 1 connector signal pin A and engine ground Do you have continuity?
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
•
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
Diagnose any other DTC codes before proceeding with this chart. Always repair existing codes starting with the lowest numerical code set first. Have any other DTC codes been detected, diagnosed and repaired?
Disconnect EGO1 connector C005 System voltage Go to Step (5) Repair the Using a DVOM check for voltage between EGO 1 circuit as connector pin B and engine ground necessary. • Key ON Refer to Wiring Repairs in (CHECK MUST BE MADE WITHIN 30 SECONDS Engine OR BEFORE POWER RELAY SHUTS DOWN) Do you have voltage? Electrical.
Using a high impedance DVOM check for continuity between EGO 1 connector signal ground pin C and EGO 1 signal pin A Do you have continuity?
9-149
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
7
•
8
• Replace EGO 1 sensor Is the replacement complete?
9
• •
Value(s)
Using a high impedance DVOM check for continuity between EGO 1 connector heater ground pin D and ECM pin 72
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1161 check for any stored codes. Does the engine operate normally with no stored codes?
9-150
Yes
No
Go to Step (8)
Repair the open EGO heater ground circuit
Go to Step (9)
—
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-151
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1162 — ADAPTIVE LEARN LOW LPG
Conditions for Setting the DTC •
Heated Oxygen Sensor
•
Check Condition — Engine running
•
Fault Condition — Adaptive multiplier out of range greater than -30%
•
MIL — On
faulty EPR (Electronic Pressure Regulator) may also cause the system to run rich. Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the fuel system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is used. Air Filter A plugged, damaged or modified air filter may cause the system to run rich.
Circuit Description The EGO1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier exceeds the limits of normal operation. Always run the fuel system diagnostics before using the following diagnostic chart. Diagnostic Aid Fuel System High secondary fuel pressure will cause the system to run rich. A worn fuel mixer,
9-152
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1162 — ADAPTIVE LEARN LOW LPG Step
Action
Value(s)
Yes
No
1
• Perform the On-Board (OBD) System Check? Are any other DTCs present?
Go to Step (3)
Go to Step (2)
2
• •
Visually and physically check the following items: The air intake duct for being collapsed or restricted • The air filter for being plugged • The EGO sensor installed securely and the wire leads not damaged contacting the secondary ignition wires • ECM grounds for being clean and tight. • Run the fuel system diagnostic checks Was a repair made?
Go to Step (6)
Go to Step (4)
3
•
Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired?
Go to Step (6)
Go to step (4)
4
• • • • •
Key OFF Disconnect EGO sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage at the EGO 1 connector C005 signal pin A and engine ground Do you have voltage?
Go to Step (5) Repair the circuit short to voltage as necessary. Refer to wiring harness repair.
5
• Replace EGO sensor Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1162 check for any stored codes. Does the engine operate normally with no stored codes?
9-153
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1171 — EPR PRESSURE HIGHER THAN EXPECTED
Conditions for Setting the DTC •
EPR delivery pressure
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition — EPR actual pressure greater than 1.0 inches above commanded pressure
•
Adaptive disabled
higher than the actual commanded pressure. Adaptive learn is disabled and the MIL command is ON during this fault. Diagnostic Aid Always run the fuel system diagnostic pressure check before proceeding with the following diagnostic chart. High secondary fuel pressure due to a worn or damaged primary or secondary seat may cause this fault to set
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set in the event the actual pressure is 1.0 inches water pressure
9-154
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1171 — EPR PRESSURE HIGHER THAN EXPECTED Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (4)
Go to Step 3
1
Did you perform the On-Board (OBD) System Check?
2
•
3
•
Run the EPR pressure test in the fuel system diagnostic section Did the EPR pass the fuel pressure test specifications?
Go to Step (4) Follow the EPR service recommendati ons from the fuel pressure test chart.
4
•
Inspect the EPR electrical connector pins C018 for damage, corrosion or contamination. Did you find a problem?
Repair the circuit as necessary. Refer to wire harness repair section.
Go to Step (5)
5
• Replace or repair the EPR Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Did you run the fuel pressure diagnostic test in the fuel system diagnostic section with no problems found?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1171 check for any stored codes. Does the engine operate normally with no stored codes?
9-155
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1172 — EPR PRESSURE LOWER THAN EXPECTED
Conditions for Setting the DTC •
EPR delivery pressure
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition — EPR actual pressure less than 1.0 inches below commanded pressure
•
Adaptive disabled
Adaptive is disabled and the MIL command is ON during this fault. Diagnostic Aid Always run the fuel system diagnostic pressure check before proceeding with the following diagnostic chart. Low secondary fuel pressure due to a fuel restriction or faulty regulator may cause this fault.
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set in the event the actual pressure is 1.0 inches water pressure lower than the actual commanded pressure.
9-156
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1172 — EPR PRESSURE LOWER THAN EXPECTED Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (4)
Go to Step 3
1
Did you perform the On-Board (OBD) System Check?
2
•
3
•
Run the EPR pressure test in the fuel system diagnostic section Did the EPR pass the fuel pressure test specifications?
Go to Step (4) Follow the EPR service recommendati ons from the fuel pressure test chart.
4
•
Inspect the EPR electrical connector C018 for damage, corrosion or contamination. Did you find a problem?
Repair the circuit as necessary. Refer to wire harness repair section.
Go to Step (5)
5
• Replace or repair the EPR Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Did you run the fuel pressure diagnostic test in the fuel system diagnostic section with no problems found?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1172 check for any stored codes. Does the engine operate normally with no stored codes?
9-157
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1173 — EPR COMMUNICATION LOST
Conditions for Setting the DTC •
EPR CAN communication
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition — No packets received within 500 ms
•
Adaptive disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set in the event communication with the ECM is lost. The MIL command is on.
9-158
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1173 — EPR COMMUNICATION LOST Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON DST (Diagnostic Scan Tool) connected in the system data mode • Clear DTC-1173 • Key OFF • Key ON, and attempt to start the engine Does DTC-1173 re-set?
Go to Step (3)
Intermittent problem. Go to Intermittent Problem section in the electrical section of this manual.
3
• • • •
System battery Key OFF voltage Disconnect EPR electrical connector C018 Key ON Using a DVOM check for system power between EPR connector pin 7 and engine ground • (Be sure to activate relay control ON using the DST function or check before ECM relay control times out) Do you have power?
Go to Step (7)
Go to Step (4)
4
• Check the 10A (F5) fuse Is the fuse open?
Go to Step (5)
Go to Step (6)
5
• Replace the F5 fuse Is the replacement complete?
Go to Step (17)
—
6
•
7
•
Using a DVOM check for continuity between EPR connector pin 6 and engine ground Do you have continuity?
Go to Step (8)
Repair the open ground circuit as necessary. Refer to wiring repairs in engine electrical
8
• • • •
Go to Step (9)
Repair the open circuit as necessary. Refer to wiring repairs in engine electrical
Using a DVOM check for system power at power System battery Repair the Repair the relay terminal 3 voltage open circuit power relay • (Be sure to activate relay control ON using the between power circuit as DST function or check before ECM relay control relay pin 3 and required times out) EPR pin 7 Go to Step (17) Do you have power? Go to Step (17)
Key OFF Disconnect the EPR connector C018 Disconnect the ECM connector C001 Using a DVOM check for continuity between EPR pin 1 and ECM pin 15 Do you have continuity?
9-159
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
9
•
Using a DVOM check for continuity between EPR pin 2 and ECM pin 14 Do you have continuity?
Go to Step (10)
Repair the open circuit as necessary. Refer to wiring repairs in engine electrical
10
•
Using a DVOM check for continuity between EPR pin 3 and ECM pin 14 Do you have continuity?
Go to Step (11)
Repair the open circuit as necessary. Refer to wiring repairs in engine electrical
11
•
Using a DVOM check for continuity between EPR pin 6 and ECM pin 69 Do you have continuity?
Go to Step (12)
Repair the open circuit as necessary. Refer to wiring repairs in engine electrical
12
•
Using a DVOM check for continuity between EPR pin 6 and ECM pin 81 Do you have continuity?
Go to Step (13)
Repair the open circuit as necessary. Refer to wiring repairs in engine electrical
13
• •
Disconnect DST from the DLC connector C014 Using a DVOM check for continuity between engine ground and EPR pins 1 and 3 Do you have continuity?
Repair the Go to Step (14) shorted to ground CAN circuit as necessary. Refer to wiring repairs in engine electrical
14
• Replace the EPR Is the replacement complete?
Go to Step (15)
9-160
—
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
15
•
Remove all test equipment and reconnect the DST. • Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1173 check for any stored codes. Does DTC-1173 still re-set?
Go to Step (16)
System OK
16
• Replace the ECM Is the replacement complete?
Go to Step (17)
—
17
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1173 check for any stored codes. Does the engine operate normally with no stored codes?
9-161
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1174 — EPR SUPPLY VOLTAGE HIGH
mixture control. This code will set if the EPR internal supply voltage is too high.
Conditions for Setting the DTC •
EPR supply voltage
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition — internal EPR supply voltage too high
•
Adaptive disabled
•
Closed loop disabled
Diagnostic Aid This DTC indicates abnormal EPR internal voltages that are not measurable externally. Check the system charging voltage to be sure this DTC and other over voltage DTC’s are not present. Repair the charging system if it is found to be out of specification for high charge voltage. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first.
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise
9-162
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1174 — EPR SUPPLY VOLTAGE HIGH Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Go to Step (3)
Repair the charging system
Go to Step (4)
Go to Step (5)
1
Did you perform the On-Board (OBD) System Check?
2
• DST connected and in the system data mode • Engine running • Check the system battery voltage. Is the charging voltage within specifications?
3
•
4
• Replace the EPR Is the replacement complete?
Go to Step (6)
—
5
• Replace the ECM Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Using a DVOM compare the system battery voltage to the DST display. Is the voltage reading within 1 volt between the two of them?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1174 check for any stored codes. Does the engine operate normally with no stored codes?
9-163
1 volt
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1175 — EPR SUPPLY VOLTAGE LOW
Conditions for Setting the DTC
Diagnostic Aid
•
EPR supply voltage
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition — EPR internal supply voltage low
•
Adaptive disabled
This DTC indicates abnormal EPR internal voltages that are not measurable externally. Check the system charging voltage to be sure this DTC and other low voltage DTC’s are not present. Repair the charging system if it is found to be out of specification for low charge voltage. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first.
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the internal EPR supply voltage is low. Adaptive is disabled and the MIL command is ON.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1175 — EPR SUPPLY VOLTAGE LOW Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• DST connected and in the system data mode • Engine running • Check the system battery voltage. Is the charging voltage within specifications?
Go to Step (3)
Repair the charging system
3
• • •
Key OFF Disconnect the EPR electrical connector C018 Using a DVOM check for power between the EPR connector pin 7 and engine ground. • Key ON • Record the voltage reading. • (Be sure to activate relay control ON using the DST function or check before ECM relay control times out) • Using a DVOM check the system battery power at the battery terminals and record the voltage reading. Are the recorded voltage readings within 1 volt of each other?
Go to Step (6)
Go to Step (4)
4
•
Inspect the EPR connector and F5 fuse holder terminals for damage corrosion or contamination Did you find a problem?
Correct the problem as necessary. See wiring harness repair in the electrical section of this manual
Go to Step (5)
5
•
Correct the problem as necessary. See wiring harness schematic in the electrical section of this manual
—
6
• • •
Go to Step (7)
Repair the poor EPR power ground circuit. See wiring harness repair in the electrical section of this manual
Check the power relay circuit. Check the power relay connections for damage corrosion or contamination Did you find a problem?
Key OFF Disconnect the ECM connector C001 Using a DVOM check the resistance reading between EPR connector pin 6 and ECM connector pin 69 and 81. (Do not forget to subtract any resistance value that may be present in you test cables) Is the resistance reading less than 0.5 ohms?
9-165
Less than 0.5 Ohms
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
7
• Replace the EPR Is the replacement complete?
Go to Step (8)
—
8
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1175 check for any stored codes. Does DTC-1175 still re-set?
Go to Step (9)
System OK
9
• Replace the ECM Is the replacement complete?
Go to Step (10)
—
10
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1175 check for any stored codes. Does the engine operate normally with no stored codes?
9-166
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-167
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1176 — EPR INTERNAL ACTUATOR FAULT
Conditions for Setting the DTC
Circuit Description
•
EPR internal actuator test
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition — Failed actuator
•
Adaptive disabled
The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the ECM detects an internal actuator fault with the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first. In most instances the EPR will need to be replaced in the event of this code set.
9-168
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1176 — EPR INTERNAL ACTUATOR FAULT Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• DST connected and in the system data mode • Check for any other current or active DTCs Does the DST show any other codes set?
Go to Step (3)
Go to Step (6)
3
•
Repair any other DTC’s set starting with the lowest DTC number first Have the other DTC’s set been corrected?
Go to Step (4)
—
4
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1176 check for any stored codes. Does DTC-1176 still re-set?
Go to Step (5)
System OK
5
• Replace the EPR Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1176 check for any stored codes. Does the engine operate normally with no stored codes?
9-169
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1177 — EPR INTERNAL CIRCUITRY FAULT
Conditions for Setting the DTC
Circuit Description
•
EPR internal circuitry test
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition
•
Adaptive disabled
The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the ECM detects an internal circuitry fault in the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first. In most instances the EPR will need to be replaced in the event of this code set.
9-170
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1177 — EPR INTERNAL CIRCUITRY FAILURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• DST connected and in the system data mode • Check for any other current or active DTCs Does the DST show any other codes set?
Go to Step (3)
Go to Step (6)
3
•
Repair any other DTC’s set starting with the lowest DTC number first Have the other DTC’s set been corrected?
Go to Step (4)
—
4
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1177 check for any stored codes. Does DTC-1177 still re-set?
Go to Step (5)
System OK
5
• Replace the EPR Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1177 check for any stored codes. Does the engine operate normally with no stored codes?
9-171
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1178 — EPR INTERNAL COMMUNICATION ERROR
Conditions for Setting the DTC
Circuit Description
•
EPR internal communication test
•
Check condition — Engine running or cranking
•
MIL — On during active fault
•
Fault condition
•
Adaptive disabled
The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the ECM detects an internal communication error in the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first. In most instances the EPR will need to be replaced in the event of this code set.
9-172
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1178 — EPR INTERNAL COMMUNICATION ERROR Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• DST connected and in the system data mode • Check for any other current or active DTCs Does the DST show any other codes set?
Go to Step (3)
Go to Step (6)
3
•
Repair any other DTC’s set starting with the lowest DTC number first Have the other DTC’s set been corrected?
Go to Step (4)
—
4
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1178 check for any stored codes. Does DTC-1178 still re-set?
Go to Step (5)
System OK
5
• Replace the EPR Is the replacement complete?
Go to Step (6)
—
6
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1178 check for any stored codes. Does the engine operate normally with no stored codes?
9-173
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1511 — AUX ANALOG PU1 HIGH
Conditions for Setting the DTC
Diagnostic Aids
•
Check Condition — Engine running
•
AUX PU1 voltage high
•
Fault Condition — Aux PU1 greater than 5.100 volts
•
MIL — On during active fault
The use of the OEM chassis wiring schematic is recommended for the proper repair and diagnosis of components located after the vehicle interface connector C012. It is likely that this code may be accompanied by other DTC codes. Always diagnose and repair the code with the lowest numerical value first.
Circuit Description The transmission temperature switch is used to communicate a high temperature condition to the ECM. Transmission damage can occur if the transmission is operated at high temperature. The temperature switch is normally open and should close at 122C and remain closed until the temperature drops to 115C. The fault will set if the AUX Analog PU1 circuit voltage is greater than 5.100 volts.
9-174
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1511 — AUX ANALOG PU1 HIGH Step
Action
Value(s)
Yes
No
1
Did you perform the On Board (OBD) System Check?
—
Go to Step (2)
Go to OBD System Check Section
2
Did you follow the Diagnostic Aid checks for DTC1511?
Go to step (3)
Perform the Diagnostic Aid checks for DTC1511
3
• • • • •
Key Off Disconnect the ECM connector C001 Disconnect the vehicle interface connector CO12 Key ON Using a high impedance DVOM check for voltage between ECM pin 46 and engine ground Do you have voltage?
Repair the circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
4
•
Go to Step (5)
Repair the circuit as required. See chassis electrical system section.
5
• •
System OK
Go to Step (6)
6
• Replace the ECM Is the replacement complete?
Go to Step (7)
—
Verify transmission temperature relay and indicator lamp circuit is in proper working order and not shorted to ground. Is the transmission temperature relay and indicator lamp circuit ok? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC-1511 previously set. • Observe the MIL • Observe engine performance and drive ability • After operating the engine within the test parameters of DTC-1511 check for any stored codes. Does the engine operate normally without setting DTC-1511?
9-175
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 7
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC-1511 previously set. • Observe the MIL • Observe engine performance and drive ability • After operating the engine within the test parameters of DTC-1511 check for any stored codes. Does the engine operate normally with no stored codes?
9-176
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-177
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1512 — AUX ANALOG PU1 LOW
Conditions for Setting the DTC
Diagnostic Aids
•
Check Condition — Engine running
•
AUX PU1 voltage high
•
Fault Condition — Aux PU1 less than 1.500 volts
•
MIL — On during active fault
The use of the OEM chassis wiring schematic is recommended for the proper repair and diagnosis of components located after the vehicle interface connector C012. It is likely that this code may be accompanied by other DTC codes. Always diagnose and repair the code with the lowest numerical value first.
•
Power derate level 2
Circuit Description The transmission temperature switch is used to communicate a high temperature condition to the ECM. Transmission damage can occur if the transmission is operated at high temperature. The temperature switch is normally open and should close at 122C and remain closed until the temperature drops to 115C. The fault will set if the AUX Analog PU1 circuit voltage is less than 1.500 volts.
9-178
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1512 — AUX ANALOG PU1 LOW Step
Action
Value(s)
Yes
No
1
Did you perform the On Board (OBD) System Check?
—
Go to Step (2)
Go to OBD System Check Section
2
Did you follow the Diagnostic Aid checks for DTC-1512?
Go to step (3)
Perform the Diagnostic Aid checks for DTC1512
3
• • • •
Key Off Disconnect the ECM connector C001 Disconnect the vehicle interface connector CO12 Using a high impedance DVOM check for continuity between ECM pin 46 and engine ground Do you have voltage?
Repair the circuit shorted to ground as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (4)
4
•
Go to Step (5)
Repair the circuit as required. See chassis electrical system section.
5
• •
System OK
Go to Step (6)
6
Replace the ECM Is the replacement complete?
Go to Step (7)
—
Verify transmission temperature relay and indicator lamp circuit is in proper working order and not shorted to ground. Is the transmission temperature relay and indicator lamp circuit ok?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC-1512 previously set. • Observe the MIL • Observe engine performance and drive ability • After operating the engine within the test parameters of DTC-1512 check for any stored codes. Does the engine operate normally without setting DTC-1512?
9-179
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 7
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC-1512 previously set. • Observe the MIL • Observe engine performance and drive ability • After operating the engine within the test parameters of DTC-1512 check for any stored codes. Does the engine operate normally with no stored codes?
9-180
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-181
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1521 — CHT HIGHER THAN EXPECTED 1
Signal
A
B
TAN/WHT
5 v olts
40
BLK/LT GR N
20
Sensor Ground
ECM
Conditions for Setting the DTC
Diagnostic Aid
•
Cylinder head temperature
•
Check Condition — Engine running
•
Fault Condition — CHT greater than 220 degrees F. with engine rpm greater than 600
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
•
Power Derate Level 1
Different terms are used for the engine coolant temperature sensor depending on the location of the sensor in the application. The engine coolant temperature sensor may also be referred to as a cylinder head temperature sensor when it is located in the cylinder head coolant passage. The temperature scaling characteristics are different in the ECM calibration, but the sensor is generally the same.
Circuit Description The CHT (Cylinder Head Temperature) sensor is a temperature sensitive resistor located at the cylinder head coolant passage. It is used for the engine airflow calculation, gasoline cold enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm. This fault will set if the cylinder head temperature exceeds 220 degrees F. with engine speed greater than 600 rpm.
9-182
Temp (deg F)
Ohms
Temp (deg F)
Ohms
242.4
101
102.4
1,556
231.9
121
78.9
2,689
211.6
175
49.9
5,576
201.4
209
23.5
11,562
181.9
302
-5.7
28,770
163.1
434
-21.2
49,715
144.9
625
-30.8
71,589
127.4
901
-40.0
99,301
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1521 — CHT HIGHER THAN EXPECTED 1 Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• • • • •
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Repair the Cooling system.
Go to Step (4)
4
Verify ECT circuit function. Follow the DTC chart procedure for DTC-117 ECT/CHT Low Voltage
—
—
Key On DST (Diagnostic Scan Tool) connected in System Data Mode Clear DTC-1521 Run the engine above 600 rpm until DTC-1521 re-sets Does DST display ECT temperature of 220 degrees F. or greater with the engine running over 600 rpm? Verify with a temperature gauge that the engine coolant is 220 degrees F. or greater Does the temperature gauge indicate 220 degrees F. or greater?
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1522 — CHT HIGHER THAN EXPECTED 2
Signal
A
B
TAN/WHT
5 v olts
40
BLK/LT GR N
20
Sensor Ground
ECM
Conditions for Setting the DTC
Diagnostic Aid
•
Cylinder head temperature
•
Check Condition — Engine running
•
Fault Condition — CHT greater than 235 degrees F. with engine rpm greater than 600
•
MIL — On during active fault
•
Adaptive — Disabled during active fault
•
Engine shutdown
Different terms are used for the engine coolant temperature sensor depending on the location of the sensor in the application. The engine coolant temperature sensor may also be referred to as a cylinder head temperature sensor when it is located in the cylinder head coolant passage. The temperature scaling characteristics are different in the ECM calibration, but the sensor is generally the same.
Circuit Description The CHT (Cylinder Head Temperature) sensor is a temperature sensitive resistor located at the cylinder head coolant passage. It is used for the engine airflow calculation, gasoline cold enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm. This fault will set if the cylinder head temperature exceeds 235 degrees F. with engine speed greater than 600 rpm. The MIL command is ON and the engine will shut down.
9-184
Temp (deg F)
Ohms
Temp (deg F)
Ohms
242.4
101
102.4
1,556
231.9
121
78.9
2,689
211.6
175
49.9
5,576
201.4
209
23.5
11,562
181.9
302
-5.7
28,770
163.1
434
-21.2
49,715
144.9
625
-30.8
71,589
127.4
901
-40.0
99,301
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1522 — CHT HIGHER THAN EXPECTED 2 Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• • • • •
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Repair the Cooling system.
Go to Step (4)
4
Verify ECT circuit function. Follow the DTC chart procedure for DTC-117 ECT/CHT Low Voltage
—
—
Key On DST (Diagnostic Scan Tool) connected in System Data Mode Clear DTC-1521 Run the engine above 600 rpm until DTC-1522 re-sets Does DST display ECT temperature of 235 degrees F. or greater with the engine running over 600 rpm? Verify with a temperature gauge that the engine coolant is 235 degrees F. or greater Does the temperature gauge indicate 235 degrees F. or greater?
9-185
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1612 — RTI 1 LOSS
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1612 — RTI 1 LOSS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1612 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1612 check for any stored codes. Does the engine operate normally with no stored codes?
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1613 — RTI 2 LOSS
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1613 — RTI 2 LOSS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1613 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1613 check for any stored codes. Does the engine operate normally with no stored codes?
9-189
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1614 — RTI 3 LOSS
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1614 — RTI 3 LOSS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1614 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1614 check for any stored codes. Does the engine operate normally with no stored codes?
9-191
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1615 — A/D LOSS
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1615 — A/D LOSS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1615 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1615 check for any stored codes. Does the engine operate normally with no stored codes?
9-193
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1616 — INVALID INTERRUPT
ECM Microprocesso Mic roproces sor r Ram
RAM Flash
Conditions for Setting the DTC •
Engine Control Module
•
Check Condition — Key on
•
Fault Condition — Internal microprocessor error
•
MIL — On
•
Adaptive — Disabled for the remainder of the key-ON cycle
•
Power Derate level 2
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced limiting maximum power.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1616 — INVALID INTERRUPT Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1616 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• Check ECM power and ground circuits Did the power and ground circuits check Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• Replace ECM Is the replacement complete?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1616 check for any stored codes. Does the engine operate normally with no stored codes?
9-195
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1626 — CAN TX FAILURE
Conditions for Setting the DTC •
CAN Tx
•
Check Condition — Engine running
•
Fault Condition — CAN Tx error 100 packets lost within 1 second
•
MIL — ON
Circuit description The CAN bus (controller area network) is used by the ECM to communicate with other digital devices used throughout the fuel system. Information is sent over the CAN bus in digital information “packets” that contain information for various control functions. This fault will set if the ECM detects 100 packets lost within a one second time period. The MIL command is ON.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1626 — CAN TX FAILURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1626 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Check that the ECM power connections C019, C020 are clean and tight. • Check that the ECM ground connections C019, C022 and C023 are clean and tight. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • •
Key OFF Disconnect ECM harness connector C001 Using a DVOM check for continuity between ECM connector pin 13 and 14 Do you have continuity?
Go to Step (5)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
5
•
Using a DVOM check for continuity between ECM pins 14 and 15 Do you have continuity between them?
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
•
Using a DVOM check for continuity to engine round on pins 14 and 16 Do have continuity to engine ground?
Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
Using a DVOM check for continuity to battery positive on pins 14 and 16 Do have continuity them?
9-197
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
8
• Replace the ECM Is the replacement complete?
9
• •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1626 check for any stored codes. Does the engine operate normally with no stored codes?
9-198
Yes
No
Go to Step (9)
—
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-199
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1627 — CAN RX FAILURE
Conditions for Setting the DTC •
CAN Rx
•
Check Condition — Engine running
•
Fault Condition — CAN Rx error 100 packets lost within 1 second
•
MIL — ON
Circuit description The CAN bus (controller area network) is used by the ECM to communicate with other digital devices used throughout the fuel system. Information is sent over the CAN bus in digital information “packets” that contain information for various control functions. This fault will set if the ECM detects 100 packets lost within a one second time period. The MIL command is ON.
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1627 — CAN RX FAILURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1627 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
•
Check that the ECM power connections C019 and C020 are clean and tight. • Check that the ECM ground connections C010, C022 and C023 are clean and tight. Are the power and ground circuits Ok?
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
4
• • •
Key OFF Disconnect ECM harness connector C001 Using a DVOM check for continuity between ECM connector pin 13 and 14 Do you have continuity?
Go to Step (5)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
5
•
Using a DVOM check for continuity between ECM pins 14 and 15 Do you have continuity between them?
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (6)
6
•
Using a DVOM check for continuity to engine ground on pins 14 and 16 Do have continuity to engine ground?
Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
•
Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (8)
Using a DVOM check for continuity to battery positive on pins 14 and 16 Do have continuity them?
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
8
• Replace the ECM Is the replacement complete?
9
• •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1627 check for any stored codes. Does the engine operate normally with no stored codes?
9-202
Yes
No
Go to Step (9)
—
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-203
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1628 — CAN ADDRESS CONFLICT
Conditions for Setting the DTC •
CAN Rx
•
Check Condition — Engine running
•
Fault Condition — 5 or more address conflict errors
•
MIL — ON
Circuit description The CAN bus (controller area network) is used by the ECM to communicate with other digital devices used throughout the fuel system. Information is sent over the CAN bus in digital information “packets” that contain information for various control functions. Individual devices are assigned network addresses. This fault will set if the ECM detects an address conflict, such as two devices with the same address. This is usually not due to an in field failure and may be the results of “add on” CAN devices.
9-204
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1628 — CAN ADDRESS CONFLICT Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key On, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode • Clear system fault code Does DTC-1628 reset with the engine idling?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • • •
Key OFF Disconnect one CAN device Clear DTC-1628 Key ON (start engine if possible if not continue cranking for at least 3 seconds) • Wait 5 seconds Does DTC-1628 re-set
Repeat step 3 until all CAN devices have been disconnected one at a time
Contact the CAN device manufacturer for additional CAN address information Go to Step (4)
4
Has the CAN device been replaced or address conflict resolved?
Go to Step (5)
—
5
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-1628 check for any stored codes. Does the engine operate normally with no stored codes?
9-205
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1645 — MIL CONTROL GROUND SHORT TO POWER
ECM
C012 MIL G
GRN/YEL
80
+12 volts in start and run Ground
Conditions for setting the DTC •
MIL check
•
Check Condition — Key ON engine OFF
•
Fault Condition — ECM MIL output shorted to voltage
•
MIL Command — ON
the lamp is in proper working order. If the lamp does not illuminate with the vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON. This fault will set if the ECM MIL control is shorted to voltage.
Circuit Description The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has an OHG MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTC’s that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that
9-206
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-1645 — MIL CONTROL GROUND SHORT TO POWER Step
Action
1
Did you perform the On-Board (OBD) System Check?
2
•
Key On, Engine Running
•
DST (Diagnostic Scan Tool) connected in System Data Mode
3
•
Clear system fault code
•
Key OFF
•
Key ON
Does DTC 1645 reset? • Key OFF •
Value(s)
Yes
—
Go to Step (2)
Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section
Go to step (4)
Disconnect the ECM wire harness connector C001
•
Using a DVOM check for voltage between ECM connector pin 80 and engine ground
•
Key ON
No
Intermittent problem Go to Intermittent section
Do you have voltage? 4
• •
Disconnect vehicle interface connector C012 Using a DVOM check for voltage between ECM connector pin 80 and engine ground
Do you have voltage?
Repair the shorted to voltage circuit between the ECM connector and engine ground. Then go to step (6)
Repair the MIL control wire short to voltage between the vehicle interface connector and vehicle chassis. Then go to step (6)
5
•
Replace the ECM
Go to step (7)
Is the replacement complete?
9-207
—
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
6
Action • • • • • • • •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1645 check for any stored codes.
Yes
No
System OK
Go to step (5)
System OK
Go to OBD System check
Does the engine operate normally with no stored codes? 7
• • • • • • • •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1645 check for any stored codes.
Does the engine operate normally with no stored codes?
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9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-209
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2111 — UNABLE TO REACH LOWER TPS
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
lated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if the actual throttle position is 20% greater than the throttle command. During this active fault the MIL command is ON and adaptive learn is disabled. Power derate level 1, low rev limit and forced idle will be in effect during this fault.
Conditions for Setting the DTC •
Throttle Position Sensor
•
Check Condition — Cranking or Running
•
Fault Condition — Actual throttle position is 20% greater than the throttle command
•
MIL — On during active fault
•
Adaptive disabled
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calcu-
9-210
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2111 — UNABLE TO REACH LOWER TPS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive By Wire) test mode • Depress Foot Pedal until the Throttle Command is between 63%–68% Is the TPS 1 voltage greater than 2.0 volts?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • •
Key OFF Disconnect electronic throttle connector C017 Probe TPS 1 signal pin 6 with a test light connected to battery voltage • Key ON Does DST display TPS 1 voltage less than 0.2 volts
Go to Step (6)
Go to Step (4)
4
• • • •
Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between throttle connector TPS 1 signal pin 6 and engine ground Do you have voltage?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
5
• Replace ECM Is the replacement complete?
Go to Step (13)
—
6
•
Probe sensor ground circuit at ECM connector C001 with a test light connected to battery voltage Does the test light come on?
Go to Step (9)
Go to Step (7)
7
• • •
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM signal ground circuit pin 20 Do you have continuity between them?
Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
8
• Replace ECM Is the replacement complete?
Go to Step (13)
—
9
• Check throttle for foreign object in bore Did you find a foreign object in the bore?
Go to Step (10) Go to Step (11)
10
• Remove foreign object Is the removal complete?
Go to Step (13)
9-211
—
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
11
•
Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find the problem?
Repair the Go to Step (12) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
12
• Replace throttle Is the replacement complete?
Go to Step (13)
—
13
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2111 check for any stored codes. Does the engine operate normally with no stored codes?
9-212
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-213
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2112 — UNABLE TO REACH HIGHER TPS
Electronic Throttle
ECM PNK/WHT
4
82
DBW +
Motor
TAN/ORN
1 TPS1
PPL/LT BLU
6
BLK/LT GRN
2 TPS2
5
LT BLU/DK BLU
3
LT GRN/RED
83
5
20
6
19
DBW -
TPS 1 Signal
Sensor Ground
TPS 2 Signal
5 Volts
C017
lated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if the actual throttle position is 20% less than the throttle command. During this active fault the MIL command is ON and adaptive learn is disabled. Power derate level 1, low rev limit and forced idle will be in effect during this fault.
Conditions for Setting the DTC •
Throttle Position Sensor
•
Check Condition — Cranking or Running
•
Fault Condition — Actual throttle position is 20% less than the throttle command
•
MIL — On during active fault
•
Adaptive disabled
•
Power derate level 1
•
Low rev limit
•
Forced idle
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calcu-
9-214
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2112 — UNABLE TO REACH HIGHER TPS Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive By Wire) test mode • Depress foot pedal until the throttle command is 63%–68% Is the TPS voltage less than 2.0 volts?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
• • •
Key OFF Disconnect electronic throttle connector C017 Probe TPS 1 signal circuit pin 6 with test light connected to battery voltage • Key ON Is TPS voltage 4.0 volts or greater?
Go to Step (4)
Go to Step (8)
4
• Check throttle bore for foreign object Did you find a problem?
Go to Step (5)
Go to Step (6)
5
1. Remove the foreign object
Go to Step (11)
—
Has the object been removed? 6
•
Check the electronic throttle connector terminals for damage corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
7
• Replace throttle Is the replacement complete?
Go to Step (11)
—
8
• • •
Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM TPS 1 signal pin 5 Do you have continuity between them?
Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
9
•
Go to Step (10) Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and engine ground Do you have continuity between them?
9-215
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
10
• Replace ECM Is the replacement complete?
11
• •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2112 check for any stored codes. Does the engine operate normally with no stored codes?
9-216
Yes
No
Go to Step (11)
—
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-217
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2121 — FPP 1 LOWER THAN FPP 2
Conditions for Setting the DTC
Diagnostic Aid
•
Foot pedal position sensor 1 and 2
•
Check Condition — Key On
•
Fault Condition — FPP1 sensor higher than FPP 2
•
MIL — On
•
Force idle
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
•
Low rev limit
Circuit Description The foot pedal position sensor uses variable resistors to determine signal voltage based on foot pedal position. Although the voltage outputs are different, the calculated throttle position values should be very close to the same. This fault will set if FPP 1 is 20% or more greater than the FPP 2. The MIL command is On. Forced idle and low rev limit are in effect during this fault limiting full power output.
9-218
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2121 — FPP 1 LOWER THAN FPP 2 Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
•
DST (Diagnostic Scan Tool) connected and in the system data mode • Clear DTC-2126 • Start and run the engine to full operating temperature • Depress the foot pedal from idle to the wide open position several times Does DTC-2121 re-set?
Go to Step (4)
Go to Step (3)
3
• •
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• •
Go to Step (5)
Go to Step (7)
5
•
Inspect the FPP and vehicle interface connectors for damage corrosion or contamination Did you find a problem?
Repair the circuit as required. See wiring harness repair section
Go to Step (6)
6
• Replace the FPP sensor Is the replacement complete?
Go to Step (12)
—
7
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between C017 pin 3 and ECM 5 volt pin 19 Do you have continuity?
Go to Step (8)
Repair the open 5 volt circuit as required. See wiring harness repair section
8
•
Go to Step (9)
Repair the open signal circuit as required. See wiring harness repair section
Key OFF Slowly depress the foot pedal from idle to the wide open position while observing the FPP1 and FPP 2 calculated percentage positions Does the DST display a 20% or more difference between FPP1 and FPP2 calculated positions? Disconnect FPP sensor connector Jump the pins that lead from the FPP sensor connector to C012 signal pin K and 5 volt supply pin M pin 3 Does the DST show FPP 1 voltage above 0.200 volts?
Using a DVOM check for continuity between C012 signal pin K and ECM signal pin 9 Do you have continuity?
9-219
Greater than 0.200 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
9
•
Using a DVOM check for continuity between ECM connector signal pin 9 and engine ground Do you have continuity?
Repair the Go to Step (10) signal shorted to ground circuit as required. See wiring harness repair section
10
•
Inspect FPP connector and ECM connector pins for damage corrosion or contamination Did you find a problem?
Repair the Go to Step (11) circuit as required. See wiring harness repair section
11
• Replace ECM Is the replacement complete?
Go to Step 12
—
12
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2121 check for any stored codes. Does the engine operate normally with no stored codes?
9-220
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-221
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2122 — FPP 1 HIGH VOLTAGE
FPP 1
C012 *
M
*
K
*
L
LT GRN/RED
19
DK BLU/ORN
9
BLK/LT GRN
20
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
5 volts
S ignal
Sensor Ground
ECM
Conditions for Setting the DTC
Diagnostic Aid
•
Foot Pedal Position
•
Check Condition — Key On
•
Fault Condition — FPP1 sensor voltage exceeds 4.800 volts
•
MIL — On during active fault
•
Low rev limit
•
Force idle
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP connection must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete foot pedal sensor assembly must be replaced.
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. This fault will set if the FPP 1 voltage exceeds 4.800 volts at any operating condition while the key is on. If the voltage exceeds 4.800 volts the FPP is considered to be out of specification. The MIL command is ON. Forced idle and low rev limit will be in effect during this code set limiting full power output.
9-222
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2122 — FPP 1 HIGH VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Greater than 4.800 volts
Go to Step (3)
Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section
Go to Step (5)
Go to Step (6)
1
Did you perform the On-Board (OBD) System Check?
2
• •
3
•
4
• Disconnect the FPP sensor connector Does the DST now show FPP 1 voltage below 0.200 volts?
5
• Replace FPP sensor Is the replacement complete?
Go to Step (10)
—
6
• • • •
Go to Step (7)
Repair the open ground circuit as required
7
• •
Repair the signal shorted to voltage circuit
Go to Step (8)
8
•
Repair the circuit as required. See wire harness repair section
Go to Step (9)
9
• Replace ECM Is the replacement complete?
Go to Step (10)
—
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected System Data Mode Does the DST display FPP voltage of 4.800 volts or greater with the foot pedal in the idle position? Slowly increase FPP while observing FPP 1 voltage Does DST FPP voltage ever exceed 4.800 volts?
Below 0.200 volts
Key OFF Disconnect ECM connector C001 Disconnect vehicle interface connector C012 Using a DVOM check continuity between connector C012 pin L and ECM sensor ground pin 20 Do you have continuity? Key ON Using a DVOM check for voltage between the FPP connector pin K and engine ground Do you have voltage? Inspect ECM and FPP connectors for damage corrosion or contamination Did you find a problem
9-223
No voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 10
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2122 check for any stored codes. Does the engine operate normally with no stored codes?
9-224
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-225
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2123 — FPP 1 LOW VOLTAGE
FPP 1
C012 *
M
*
K
*
L
LT GRN/RED
19
DK BLU/ORN
9
BLK/LT GRN
20
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
5 volts
S ignal
Sensor Ground
ECM
Conditions for Setting the DTC
Diagnostic Aid
•
Foot Pedal Position
•
Check Condition — Key On
•
Fault Condition — FPP sensor voltage less than 0.200
•
MIL — On during active
•
Low rev limit
•
Force idle
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP connection must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete foot pedal sensor assembly must be replaced.
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. This fault will set if the FPP 1 voltage is less than 0.299 volts at any operating condition while the key is on. If the voltage drops below 0.299 volts the FPP is considered to be out of specification. The MIL command is ON. Forced idle and low rev limit will be in effect during this code set limiting full power output.
9-226
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2123 — FPP 1 LOW VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Less than 0.299 volts
Go to Step (3)
Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section
Go to Step (5)
Go to Step (7)
1
Did you perform the On-Board (OBD) System Check?
2
• •
3
•
4
• •
5
•
Inspect FPP 1 and C012 connectors for damage corrosion or contamination Did you find a problem?
Repair the circuit as required. See wiring harness repair section
Go to Step (6)
6
• Replace FPP 1 sensor Is the replacement complete?
Go to Step (12)
—
7
• • •
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between ECM 5 volt pin 19 and FPP connector pin that leads to C012 pin M Do you have continuity?
Go to Step (8)
Repair the open circuit as required. See wiring harness repair section
8
•
Using a DVOM check for continuity between ECM signal pin 9 and FPP connector pin that leads to C012 pin K Do you have continuity?
Go to Step (9)
Repair the open circuit as required. See wiring harness repair section
9
Key ON • Using a DVOM check for continuity between ECM connector signal pin 9 and engine ground Do you have continuity?
Repair the Go to Step (10) signal shorted to ground circuit as required. See wiring harness repair section
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP 1 voltage of less than 0.299 volts with the foot pedal in the idle position? Slowly increase FPP while observing the FPP 1 voltage Does the DST ever display FPP voltage below 0.299 volts? Disconnect the FPP sensor connector Jump the FPP sensor pins at the FPP 1 connector that lead to C012 5 volt pin M and signal pin K Does the DST now show FPP 1 voltage above 0.299 volts?
9-227
Greater than 0.299 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
10
•
Inspect FPP1, C012 and ECM connectors for damage corrosion or contamination Did you find a problem?
Repair the Go to Step (11) circuit as required. See wiring harness repair section
11
• Replace ECM Is the replacement complete?
Go to Step 12
—
12
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2123 check for any stored codes. Does the engine operate normally with no stored codes?
9-228
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-229
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2126 — FPP 1 HIGHER THAN FPP 2
Conditions for Setting the DTC
Diagnostic Aid
•
Foot pedal position sensor 1 and 2
•
Check Condition — Key On
•
Fault Condition — FPP 1 20% higher than FPP 2
•
MIL — On
•
Force idle
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
•
Low rev limit
Circuit Description The foot pedal position sensor uses variable resistors to determine signal voltage based on foot pedal position. Although the voltage outputs are different, the calculated throttle position values should be very close to the same. This fault will set if FPP 1 is 20% or more higher that FPP 2. The MIL command is On. Forced idle and low rev limit are in effect during this fault limiting full power output.
9-230
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2126 — FPP 1 HIGHER THAN FPP 2 Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
•
DST (Diagnostic Scan Tool) connected in System Data Mode. • Clear DTC-2126. • Start the engine and run to full operating temperature. • Depress the foot pedal from idle to wide open throttle several times. Does DTC-2126 re-set?
Go to Step (4)
Go to Step (3)
3
• •
Go to Step (4)
Intermittent problem Go to Intermittent section
4
• Disconnect FPP sensor connector Does the DST now show FPP 1 voltage below 0.200 volts?
Go to Step (5)
Go to Step (6)
5
• Replace the FPP sensor Is the replacement complete?
Go to Step (10)
—
6
• • • •
Go to Step (7)
Repair the open ground circuit as required
7
• •
Repair the signal shorted to voltage
Go to Step (8)
8
•
Repair the circuit as required. See wire harness repair section
Go to Step (9)
9
• Replace ECM Is the replacement complete?
Go to Step (10)
—
Key OFF Slowly depress the foot pedal from idle to the wide open position while observing the FPP1 and FPP 2 calculated percentage positions Does the DST display a 20% or more difference between FPP1 and FPP2 calculated positions? Below 0.200 volts
Key OFF Disconnect ECM connector C001 Disconnect vehicle interface connector C012 Using a DVOM check continuity between the interface connector pin L and ECM sensor ground pin 20 Do you have continuity? Key ON Using a DVOM check for voltage between the FPP connector that leads to the vehicle interface connector signal pin K and engine ground Do you have voltage? Inspect ECM and FPP connectors for damage corrosion or contamination Did you find a problem
9-231
No voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 10
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2126 check for any stored codes. Does the engine operate normally with no stored codes?
9-232
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-233
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2127 — FPP 2 LOW VOLTAGE
FPP 2
C 012
*
S
*
J
*
R
LT GRN/PPL
PPL/YEL
LT GRN/BLK
49
10
50
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
5 volts
FPP 2 Signal
Sensor Ground
ECM
Conditions for Setting the DTC
Diagnostic Aid
•
Foot Pedal Position
•
Check Condition — Key On
•
Fault Condition — FPP sensor voltage less than 0.244
•
MIL — On
•
Low Rev Limit
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
•
Force Idle
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. This fault will set if the FPP 2 voltage is less than 0.244 volts at any operating condition while the key is on. If the voltage drops below 0.244 volts the FPP is considered to be out of specification. The MIL command is ON. Low rev limit and forced idle will be effect during this fault limiting power output.
9-234
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2127 — FPP 2 LOW VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Less than 0.200 volts
Go to Step (3)
Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section
Go to Step (5)
Go to Step (7)
1
Did you perform the On-Board (OBD) System Check?
2
• Key ON, Engine OFF • DST (Diagnostic Scan Tool) connected in • System Data Mode Does the DST display FPP 2 voltage of less than 0.244 volts with the foot pedal in the idle position?
3
•
4
• •
5
•
Inspect the FPP and C012 connectors for damage corrosion or contamination Did you find a problem?
Repair the circuit as required. See wiring harness repair section
Go to Step (6)
6
• Replace FPP sensor Is the replacement complete?
Go to Step (12)
—
7
• • • •
Key OFF Disconnect ECM connector C001 Disconnect the vehicle interface connector C012 Using a DVOM check for continuity between C012 pin S and ECM 5 volt pin 49 Do you have continuity?
Go to Step (8)
Repair the open 5 volt circuit as required. See wiring harness repair section
8
•
Using a DVOM check for continuity between C012 signal pin J and ECM signal pin 10 Do you have continuity?
Go to Step (9)
Repair the open signal circuit as required. See wiring harness repair section
9
•
Repair the Go to Step (10) signal shorted to ground circuit as required. See wiring harness repair section
Slowly increase the FPP while observing the FPP 2 voltage Does the DST ever display FPP voltage below 0.244 volts? Disconnect the FPP sensor connector Jump the pins from the FPP sensor connector that leads to C012 signal pin J and 5 volt supply pin S Does the DST now show FPP 1 voltage above 0.244 volts?
Using a DVOM check for continuity between ECM connector signal pin 10 and engine ground Do you have continuity?
9-235
Greater than 0.200 volts
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
Value(s)
Yes
No
10
•
Inspect FPP connector C012 and ECM connector pins for damage corrosion or contamination Did you find a problem?
Repair the Go to Step (11) circuit as required. See wiring harness repair section
11
• Replace ECM Is the replacement complete?
Go to Step 12
—
12
• •
System OK
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2127 check for any stored codes. Does the engine operate normally with no stored codes?
9-236
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________________
9-237
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2128 — FPP 2 HIGH VOLTAGE
FPP 2
C012
*
S
*
J
*
R
LT GRN/PPL
49
PPL/YEL
10
LT GRN/BLK
50
*Check OEM chassis wiring diagr am for specific pin numbers and wire colors
5 volts
FPP 2 Signal
Sensor Ground
ECM
Conditions for Setting the DTC
Diagnostic Aid
•
Foot pedal position sensor 2
•
Check Condition — Key On
•
Fault Condition — FPP2 sensor voltage exceeds 3.004 volts
•
MIL — On
•
Forced idle
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
•
Low rev limit
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on foot pedal position. This fault will set if the FPP 2 voltage exceeds 3.004 volts at any operating condition while the key is on. If the voltage exceeds 3.004 volts the FPP is considered to be out of specification. The MIL command is On. Forced idle and low rev limit will be in effect limiting power output during this fault.
9-238
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2128 FPP 2 HIGH VOLTAGE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
Greater than 3.004 volts
Go to Step (3)
Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section
Go to Step (5)
Go to Step (6)
1
Did you perform the On-Board (OBD) System Check?
2
• •
3
•
4
• Disconnect the FPP sensor connector Does the DST now show FPP 2 voltage below 0.200 volts?
5
• Replace FPP sensor Is the replacement complete?
Go to Step (10)
—
6
• • • •
Go to Step (7)
Repair the open ground circuit as required
7
• •
Repair the signal shorted to voltage circuit
Go to Step (8)
8
•
Repair the circuit as required. See wire harness repair section
Go to Step (9)
9
• Replace ECM Is the replacement complete?
Go to Step (10)
—
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP voltage of 3.004 volts or greater with the foot pedal in the idle position? Slowly increase FPP while observing FPP 2 voltage Does DST FPP voltage ever exceed 3.004 volts?
Below 0.200 volts
Key OFF Disconnect ECM connector C001 Disconnect vehicle interface connector C012 Using a DVOM check continuity between connector C012 pin R and ECM sensor ground pin 50 Do you have continuity? Key ON Using a DVOM check for voltage between the FPP connector pin J and engine ground Do you have voltage? Inspect ECM and FPP connectors and pins for damage corrosion or contamination Did you find a problem
9-239
No voltage
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 10
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2128 check for any stored codes. Does the engine operate normally with no stored codes?
9-240
Yes
No
System OK
Go to OBD System Check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-241
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2229 — BP HIGH PRESSURE
BLK/LT GRN
1 2 3 4
YEL/GRY
L T GRN/RED
L T GRN
20
Sensor Ground IAT Signal
39
5V
19
5 Volts
7
MAP Signal ECM
Conditions for Setting the DTC •
Barometric Pressure
•
Check Condition — Key On
•
Fault Condition — BP greater than 16 psia
•
MIL — On for active fault
•
Adaptive — Disabled
Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of the normal range.
9-242
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2229 — BP HIGH PRESSURE Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• Key On • DST (Diagnostic Scan Tool) connected in • System Data Mode Does DST display MAP pressure of 16 psia or greater?
Go to Step (3)
Intermittent problem Go to Intermittent section
3
Replace TMAP sensor. Is the repair complete?
Go to Step 4
—
4
• •
System Ok
Go to OBD System Check
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2229 check for any stored codes. Does the engine operate normally with no stored codes?
9-243
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2300 — PRIMARY LOOP OPEN/LOW SIDE SHORT TO GROUND
Conditions for Setting the DTC •
Ignition Control Check
•
Check condition — Engine running or cranking
•
Fault condition — Adaptive or total dwell greater than 3.0 ms
•
MIL — On during active fault
•
Adaptive — Disabled
•
Closed Loop — Disabled
Circuit Description The ECM triggers the ignition module by providing ground to the ignition module pin B. The ignition module then completes the ignition coil primary circuit ground from pin D to fire the coil. This code will set if the ECM low side driver pin 31 is open or shorted to ground.
9-244
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2300 — PRIMARY LOOP OPEN/LOW SIDE SHORT TO GROUND Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode • Clear DTC-2300 • Crank the engine Does DTC-2300 re-set?
Go to Step (3)
Intermittent problem. See Electrical Section Intermittent Electrical Diagnosis
3
• Remove and check the F4 fuse Is the fuse OK?
Go to Step (5)
Go to Step (4)
4
• Replace the F4 fuse Is the replacement complete?
Go to Step (12)
—
5
• •
Key ON Using a DVOM check for voltage at the F4 fuse terminal power IN (CHECK THIS BEFORE THE POWER RELAY CIRCUIT SHUTS DOWN) Do you have voltage?
Go to Step (6)
Repair the open power circuit. See wiring harness repairs
6
• • •
Key OFF Disconnect the ignition module connector C011 Using a DVOM check for voltage between ignition module connector A and engine ground Do you have voltage?
Go to Step (7)
Repair the open power circuit. See wiring harness repairs
7
• •
Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between ECM connector pin 31 and engine ground Do you have continuity?
Repair the shorted to ground coil 1 circuit
Go To Step (8)
8
•
Using a DVOM check for continuity between ECM connector pin 31 and ignition module connector C011 pin B Do you have continuity?
Go to Step (9)
Repair the open ignition module circuit. See wiring harness repairs.
9
• Replace the ignition module Is the replacement complete?
Go to Step (10)
—
9-245
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step
Action
10
• •
11
• Replace the ECM Is the replacement complete?
12
• •
Value(s)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2300 check for any stored codes. Does the engine operate normally with no stored codes?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2300 check for any stored codes. Does the engine operate normally with no stored codes?
9-246
Yes
No
System Ok
Go to Step (11)
Go to Step (12)
—
System Ok
Go to OBD system check
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
9-247
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2301 — PRIMARY COIL SHORTED
3
3
Conditions for Setting the DTC *
Ignition Control Check
*
Check condition — Engine running or cranking
*
Fault condition — Adaptive or total dwell less than -3.0 ms
*
MIL — On during active fault
*
Adaptive — Disabled
*
Closed Loop — Disabled
Circuit Description The ECM triggers the ignition module by providing ground to the ignition module pin B. The ignition module then completes the ignition coil primary circuit ground from pin D to fire the coil. This code will set if the ECM low side driver pin 31 remains high or is shorted to voltage.
9-248
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
DTC-2301 — PRIMARY COIL SHORTED Step
Action
Value(s)
Yes
No
—
Go to Step (2)
Go to OBD System Check Section
1
Did you perform the On-Board (OBD) System Check?
2
• •
Go to Step (3)
Intermittent problem. See Intermittent problems in the electrical section.
3
• • • •
Repair the shorted to voltage coil 1 circuit
Go to Step (4)
4
• Replace the ignition module Is the replacement complete?
Go to Step (6)
—
5
• •
System OK
Go to Step (6)
6
• Replace the ECM Is the replacement complete?
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode • Clear DTC-2301 • Crank the engine Does DTC-2301 re-set? Key OFF Disconnect ignition module connector C001 Disconnect ignition module connector C011 Using a DVOM check for voltage between ignition module pin B and engine ground Do you have voltage?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2301 check for any stored codes. Does the engine operate normally with no stored codes?
Go to Step (7)
9-249
9 — DIAGNOSTIC TROUBLE CODES (DTCs)
Step 7
Action
Value(s)
• •
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. • Using the DST clear DTC information from the ECM. • Turn the ignition OFF and wait 30 seconds. • Start the engine and operate the vehicle to full operating temperature • Observe the MIL • Observe engine performance and driveability • After operating the engine within the test parameters of DTC-2301 check for any stored codes. Does the engine operate normally with no stored codes?
9-250
Yes
No
System OK
Go to OBD system check
10 — SERVICING THE FUEL SYSTEM INSTALLATION PROCEDURE
SERVICING THE FUEL SYSTEM
ENGINE CONTROL MODULE This procedure relates to removal and installation of the ECM—see Diagnostic Scan Tool for accessing ECM software.
IMPORTANT
The ECM is calibrated for each engine. Verify you have the correct controller by noting the P/N on the ECM label. The calibration number can also be found by connecting the DST and finding the calibration number on the Gauge page.
REMOVAL PROCEDURE 1. Disconnect Negative battery cable. 2. Push connector lock back to unlock connector, unplug the Wire Harness from ECM and remove. 3. Remove four bolts mounting the controller to the mounting bracket.
1. Mount controller into mounting bracket with four screws. Torque to 7.5 N•m (5.5 ft. lbs.) 2. Plug connector into controller. 3. Push lock into place. 4. Reconnect the negative battery cable. 5. Install Diagnostic Service Tool. 6. Start engine and let run until it reaches normal operating temperature. 7. Check for any DTC codes and clear. 8. Verify engine is in closed loop and no MIL light is present.
ECM and its Four Mounting Bolts
10-1
10 — SERVICING THE FUEL SYSTEM
ENGINE WIRE HARNESS REPLACEMENT
FUEL TEMPERATURE (FT) SENSOR REPLACEMENT
1. Disconnect negative battery cable.
1. Disconnect the negative battery cable.
2. Lay out the new wire harness, noting the location, type of connectors, and identifying markings. Take special note of identical or similar connectors (such as the ignition coils or HEGO Sensors) to avoid crossing connections during installation. Note the routing of the existing wire harness in and around the engine and the vehicle. Refer the Electrical Schematic.
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
!
3. Locate the Fuel Temperature Sensor on the lower right port on the EPR. 4. Remove retaining clip holding the FT and remove the sensor from the EPR port. 5. Inspect the EPR for debris or “heavy ends” and remove with a Safety Solvent if necessary.
CAUTION
Ensure that all connections are made to the correct locations on the engine and its components. Crossing connections may cause poor engine performance, a MIL warning and/or permanent damage to the ECM.
!
WARNING
Only use a Safety Solvent to clean any part of the fuel system. Harsh cleaners such as carb or brake cleaners may damage gaskets, O-rings, seals and other non-metallic components in the fuel system.
3. Remove all wire harness connectors on the vehicle. 4. Remove all clips and brackets holding the wire harness and remove harness from vehicle.
INSTALLATION 1. Lubricate O-rings on the sensor with petroleum jelly or Vaseline.
5. Lay the new wire harness over the engine and route each end to its connection. Verify that all connectors match prior to installation.
!
6. Connect all connectors and ring terminals.
CAUTION
The HEGO is sensitive to silicone based products an can become contaminated. Avoid using silicone sealers/lubricants.
7. Install all clips and brackets to hold down the harness. 8. Reconnect negative battery cable.
2. Install the sensor into the EPR port. Lock in place with retaining clip.
9. Start the vehicle. 10. Check MIL.
3. Reconnect the negative battery cable. 4. Using the DST, clear DTC information from the ECM. 5. Turn the ignition OFF and wait 30 seconds.
10-2
10 — SERVICING THE FUEL SYSTEM 6. Start the vehicle and let run until it reaches normal operating temperature.
DISTRIBUTOR
7. If a DTC code is found, refer to the Electrical Section for further diagnosis.
REMOVAL PROCEDURE
OIL PRESSURE SENDER
2. Remove spark plug wires from distributor cap by pulling and twisting each spark plug wire boot ∫ turn.
REMOVAL PROCEDURE
3. Remove ignition coil wire.
1. Disconnect the negative battery cable.
4. Remove the electrical connector from the base of the distributor.
1. Turn OFF ignition.
2. Locate the Oil Pressure Sender on the rear of the engine block by the distributor.
5. Remove the two screws that hold the distributor cap to the housing and remove cap.
3. Remove electrical connection from sender. 4. Remove the Sender (do not remove the brass adapter from the engine block). INSTALLATION PROCEDURE 1. Apply Loctite 567 (or equivalent high-temp thread locker/sealer) to the threads on the Oil Pressure Sender. 2. Install Oil Pressure Sender. Torque until tight. 3. Plug in electrical connector. 4. Reconnect negative battery cable. 5. Using the DST, clear DTC information from the ECM. 6. Turn the ignition OFF and wait 30 seconds.
Distributor Cap Removal
7. Start the vehicle and let run until it reaches normal operating temperature.
6. Using a grease pencil or similar marking tool, mark the location of the rotor on the distributor housing and intake manifold.
8. If a DTC code is found, refer to the Electrical Section for further diagnosis.
10-3
10 — SERVICING THE FUEL SYSTEM
IMPORTANT
Do not engage the starter, or change the positions of the cam or crankshaft, timing gears or any other internal engine components while the distributor is removed. Any change in the position of these components will alter the timing.
INSTALLATION PROCEDURE 1. Align the rotor with the second mark made on the distributor housing (the location of the rotor when it was removed) and place into the engine in line with the mark on the intake manifold. The rotor should rotate approximately 42 degrees and return the position of the first mark. If the rotor does not return to the position of the first mark, remove and repeat procedure.
Marking Position of Rotor Prior to Removal
7. Remove the mounting clamp hold down bolt. 8. Carefully remove the distributor, noting the final position of the rotor in the housing. Using a grease pencil or similar marking tool, mark the location of the rotor on the distributor housing.
Distributor Installation
2. Install the distributor mounting clam bolt and tighten to 25 N•m (18 ft. lbs.). Verify that the rotor remains in line with the first mark.
Marking Position of Rotor Upon Removal from Engine
3. Install distributor cap. 4. Connect the electrical connection to the base of the distributor. 5. Connect spark plug wires to distributor cap. 6. Connect ignition coil wire to distributor cap. 7. Start engine. Check for MIL illumination. 10-4
10 — SERVICING THE FUEL SYSTEM
TEMPERATURE MANIFOLD PRESSURE SENSOR (TMAP) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Locate the TMAP Sensor on the Adapter between the throttle body and intake manifold and disconnect the TMAP electrical connector. 3. Remove the two retaining bolts. INSTALLATION PROCEDURE 1. Install the TMAP and torque the retaining screw to 2.1 N•m (19 in. lbs.). 2. Reconnect the negative battery cable. 3. Using the DST, clear DTC information from the ECM. 4. Turn the ignition OFF and wait 30 seconds. 5. Start the vehicle and let run until it reaches normal operating temperature. 6. If a DTC code is found, refer to the Electrical Section for further diagnosis.
10-5
10 — SERVICING THE FUEL SYSTEM
FT150 FUEL MIXER MIXER DISASSEMBLY 1. Remove four tamper resistant Screws (19) and Washers (18) from the Mixer (2) using a T25H Tamper Resistant Torx tool bit. 2. Remove bottom of Lower Adapter (17), Spring (15) and Air Gas Valve Assembly (14) from Body (13). 3. Clean the Mixer Body (13), Air Gas Valve (14), Spring (15), Lower Adapter (17) and any other affected components with Safety Solvent to remove dirt, residue or any other type of contamination.
!
WARNING
Use only Safety Solvents for the cleaning of the regulator and its components. Solvents such as carburetor or brake cleaners may damage gaskets, seals, Orings, diaphragms or other non-metal components.
FT150 Mixer Components Item #
Description
Qty. Used
13
Body, 150 carb, 20 Series
1
14
Air Valve, 150 Series
1
15
Spring, 150 Series
1
16
Gasket, Compression*
1
17
Adapter, Lower 150
1
18
Washer, Split Loc SS
4
19
Screw, Butt HD, Torx Tamper Resistant
4
Component View of the FT150 Mixer
*Included in Repair Kit
10-6
10 — SERVICING THE FUEL SYSTEM INSTALLATION PROCEDURE
4. Place two new O-rings (11) on the Fuel Hose Fitting (1), lightly lubricate with Vaseline or petroleum jelly and insert fuel hose fitting into the Mixer (2). Secure with Retaining Pin (10).
1. Assemble the Air Gas Valve Assembly (14), Spring (15), Gasket (16) and Lower Adapter (17) and secure with four Screws (18) and Washers (19). Using a T25H Tamper Resistant Torx tool bit, torque screws to 2.5-3.0 Nm (22-27 in. lbs).
5. Install the air intake duct. 6. Install 3/8” hose to the 90˚ Brass Fitting (3).
2. Lightly lubricate new O-ring (5) with Vaseline or petroleum jelly prior to installation.
7. Reconnect the negative battery cable. 8. Open LPG tank manual shut-off valve.
!
9. Turn ignition to ON for approximately 30 seconds, then OFF.
WARNING
10. Leak check the LPG fuel system at each serviced fitting.
Contamination of the HEGO sensor can result from the use of an inappropriate RTV sealer or silicone spray products. Do not use silicone sprays or hoses which are assembled using silicone lubricants. Always use “oxygen sensor safe” RTV sealant for repair procedures. Silicon contamination will cause a high but false HEGO signal voltage (rich exhaust indication). The ECM will then reduce the amount of fuel delivery to the engine, causing a severe driveability problem. If silicone contamination is suspected, remove and visually inspect the sensor element. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Always be sure to eliminate the cause of contamination before replacing the sensor.
11. Start the vehicle and leak check the LPG fuel system at each serviced fitting. 12. Test drive vehicle to ensure it operates correctly at all throttle ranges.
!
CAUTION
Never use an open flame of any type to check for LPG leaks.
IMPORTANT
Always inspect the LPG fuel system for leaks after performing service. Check for leaks at the fittings of the serviced or replaced component. Use a commercially available liquid leak detector or an electronic leak detector. When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector
3. Place Plastic Sleeve (6), new O-ring (5) and Mixer (2) on top of the Throttle Body and align to screw holes. Secure the assembly with the four Screws (19). Torque to 12 N•m (106 in. lb.). NOTE
Replace O-ring (8) between the Throttle Body and Intake Adapter if the Throttle Body was removed from the Intake Adapter during disassembly.
10-7
10 — SERVICING THE FUEL SYSTEM
VACUUM LINE
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
REMOVAL PROCEDURE 1. Disconnect the negative battery cable.
REMOVAL PROCEDURE
2. Remove the Vacuum Line from each fitting.
1. Disconnect the negative battery cable.
3. Start engine and check for leaks.
2. Locate the Engine Coolant Temperature Sensor on the right side of the engine.
INSTALLATION PROCEDURE
!
CAUTION
The ECT is located close to the exhaust manifold. Verify that the engine and the exhaust manifold are not hot prior to accessing the Sensor to prevent skin burn from contact.
IMPORTANT
DO NOT use a hose other than the OEM specified part. 1. Reinstall the Fuel Vapor Hose to each fitting.
3. Remove electrical connector.
2. Reconnect negative battery cable.
4. Drain the cooling system
3. Start engine and check for leaks.
5. Remove the sensor.
10-8
10 — SERVICING THE FUEL SYSTEM
HEATED EXHAUST GAS OXYGEN SENSOR (HEGO)
INSTALLATION PROCEDURE 1. Apply a minimal amount of pipe thread sealer to threads on the Engine Coolant Temperature Sensor. Remove any excess sealer on threads or the sensor.
REPLACEMENT 1. Disconnect Negative battery cable.
2. Install Engine Coolant Temperature Sensor. Torque to 20 N•m (15 ft. lbs.).
2. Locate the affected Oxygen Sensor on the three way catalytic converter/muffler assembly. There are two sensors: one between the engine and catalytic brick (upstream) and one between the catalytic brick and tail pipe (downstream). 3. Disconnect the Oxygen sensor electrical connector.
Installing the Coolant Temperature Sensor
3. Refill the cooling system.
4. Using an Oxygen Sensor socket remove the Oxygen Sensor.
4. Reconnect electrical connector. 5. Reconnect the negative battery cable.
INSTALLATION PROCEDURE
6. Start engine. Check for MIL illumination.
IMPORTANT
Before install the Oxygen sensor lubricate threads with anti-seize compound GM P/N 5613695 or equivalent. Avoid contaminating sensor tip with compound. 1. Install Oxygen Sensor Torque to 41 N•m (30 ft. lbs.). 2. Reconnect electrical connector to the Oxygen Sensor. 3. Reconnect the negative battery cable. 4. Start engine. Check MIL. 10-9
10 — SERVICING THE FUEL SYSTEM
PROPANE FUEL SYSTEM PRESSURE RELIEF
FUEL MIXER REMOVAL PROCEDURE
!
1. Disconnect the negative battery cable.
CAUTION
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
The propane fuel system operates at pressure up to 21.5 bar (312 psi). To minimize personal injury, relieve the propane fuel system pressure before servicing the propane fuel system components.
3. Remove the air intake duct. 4. Remove the retaining pin holding the fuel hose fitting and remove fuel hose. 5. Remove 3/8” hose from 90˚ brass fitting.
1. Close the manual shut-off valve (MSV) on the propane fuel tank.
6. Remove the four screws under the Adapter Mounting Bracket.
2. Start and run the vehicle until the engine stalls.
7. Remove and discard the mixer to throttle body assembly O-ring.
3. Turn the ignition switch to OFF. 4. Disconnect the negative battery cable.
!
INSTALLATION PROCEDURE 1. Place new O-ring on top of the Throttle Body and align to screw holes. Install the Mixer and secure with the four retaining screws. Torque to 9 N•m (80 in. lb.).
WARNING
Residual vapor pressure will be present in the fuel system. Ensure the work area is well ventilated before disconnecting any fuel line.
2. Install the fuel hose fitting into the Mixer and hold with the retaining pin. 3. Install the air intake duct.
!
4. Install 3/8” hose to the 90˚ brass fitting.
CAUTION
5. Reconnect the negative battery cable.
Never use an open flame of any type to check for propane leaks.
6. Open propane tank manual shut-off valve. 7. Turn ignition to ON for approximately 30 seconds, then OFF.
IMPORTANT
8. Leak check the propane fuel system at each serviced fitting.
Always inspect the propane fuel system for leaks after performing service. Check for leaks at the fittings of the serviced or replaced component. Use a commercially available liquid leak detector or an electronic leak detector. When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector
9. Start the vehicle and leak check the propane fuel system at each serviced fitting. 10. Test drive vehicle to ensure it operates correctly at all throttle ranges.
10-10
10 — SERVICING THE FUEL SYSTEM
ELECTRONIC PRESSURE REGULATOR (EPR)
FUNCTIONAL CHECK Any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy load, etc., is exhausted into the air cleaner and is drawn back into the engine.
REMOVAL PROCEDURE 1. Disconnect the negative battery cable.
Proper operation of the crankcase ventilation system depends on a sealed engine. If irregular oil flow or dilution is noted and the crankcase ventilation system is functioning properly, check the engine for another possible cause. Correct any of these problems first.
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 3. Disconnect Shut-Off Valve electrical connector.
If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner element, or plugged hose. Replace any faulty items found. Use the following procedure:
4. Disconnect the LPG fuel inlet line from the Shut-Off Valve fitting. 5. Clamp both coolant lines near the EPR fittings.
1. Remove the PCV hose from the rocker arm cover.
6. Disconnect the supply and return coolant lines from the EPR.
2. Operate the engine at idle.
7. Disconnect the EPR electrical connector.
3. Place your thumb over the end of the hose in order to check for vacuum. If there is no vacuum at the hose end, inspect for plugged hoses and/or clogged or damaged manifold vacuum port.
8. Remove the retaining pins from the water inlet and outlet fittings, fuel hose and Temperature Sensor. 9. Remove coolant inlet and outlet fittings, fuel hose and Temperature Sensor.
4. Turn the engine OFF.
10. Remove the nuts securing the EPR to the lower EPR Mounting Bracket.
5. Inspect the PCV orifice in the valve cover for debris or blockage. Clean with carburetor cleaner as necessary.
11. Remove the EPR and bracket assembly. 12. Remove the bolts attaching the EPR to the upper EPR bracket 13. Remove the screw from the top of the ShutOff Valve and remove the coil. 14. Remove Shut-Off Valve from the EPR with brass fittings and as a single assembly. 15. Remove Vibration mounts from EPR.
10-11
10 — SERVICING THE FUEL SYSTEM INSTALLATION PROCEDURE
11. Inspect coolant level and add coolant as necessary.
1. Attach the coil to the Shut-Off Valve and retain with screw.
12. Reconnect the negative battery cable.
2. Apply Loctite 567 (or equivalent high-temp thread locker/sealer) to the threads of the Shut-Off valve 90˚ fitting. Install the Shut-Off valve fitting to the EPR and turn until finger tight plus 1 to 2 turns, ensuring the Shut-Off Valve is in the correct position.
!
13. Open manual shut-off valve on Propane tank. 14. Turn ignition ON for approximately 30 seconds, then OFF. 15. Leak check the propane fuel system at each serviced fitting. 16. Start the vehicle and leak check the propane fuel system at each serviced fitting.
CAUTION
17. Check for MIL illumination.
Do not use Teflon tape on any fuel fitting. Use a liquid pipe thread sealant when installing threaded fittings.
18. Test drive vehicle to ensure correct operation.
3. Mount the EPR to the upper EPR Mounting Bracket and secure with bolts. Torque to 15 N•m (11 ft. lbs.). 4. Install EPR assembly to lower EPR bracket and retain with nuts. 5. Connect the EPR electrical connector. 6. Install the fuel inlet line. Torque to 27 N•m (20 ft. lbs.). 7. Connect the Shut-Off Valve electrical connector. 8. Lubricate the O-rings on each of the fittings and Temperature Sensor with petroleum jelly or Vaseline.
!
CAUTION
The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/ lubricants. 9. Install the inlet and outlet water fittings, Fuel Hose and Temperature Sensor. Secure with retaining pins. 10. Remove clamps from coolant hoses.
10-12
10 — SERVICING THE FUEL SYSTEM
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
10-13
10 — SERVICING THE FUEL SYSTEM
ELECTRONIC PRESSURE REGULATOR (EPR)—SERVICE A Repair Kit is available to service and replace the following components in the Spectrum III Electronic Pressure Regulator (EPR):
Expanded View of the EPR Regulator and the Repair Kit Components.
1. Seal, Clamp Plate
6. Clip, Primary
2. Seat, Secondary
7. Diaphragm, Primary
3. Gasket, Body Secondary
8. O-ring
4. Pin, Primary
9. O-ring
5. Spring, Primary
!
NOTE
WARNING
The Repair Kit consists of the only serviceable components for the Spectrum III EPR. Do not use any other components or regulator repair kits to service the Spectrum III EPR. The Kit is specifically designed for the Spectrum III EPR and is not compatible with other regulators.
The Repair Kit consists of nine parts which are not available separately. These are the only serviceable components of the EPR. Any attempt to service other components may damage or cause the EPR to malfunction, and void warranty coverage.
10-14
10 — SERVICING THE FUEL SYSTEM REPAIR INSTRUCTIONS DISASSEMBLY OF EPR 1. Disconnect negative battery cable. 2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 3. Disconnect electrical connector from EPR. 4. Remove three nuts securing EPR to Mounting Bracket. 5. Inspect the outside of the EPR assembly for cracks, signs of leakage, corrosion, electrolysis, damage, stripped threads, etc. If damage is found, the EPR assembly is not repairable and must be replaced.
The two major components of the EPR Assembly: Regulator and the Actuator.
6. Remove the six screws that connect the Regulator to the Actuator.
NOTE
!
Be sure to identify the type of screw and its location during each stage of disassembly to ensure proper placement during reassembly.
WARNING
Care must be used when removing regulator from the actuator to prevent damage to the lever and diaphragm. Neither part is serviceable and if damaged, the entire EPR assembly must be replaced.
7. Gently pull the Regulator away from the Actuator. If necessary, tap around the edge of the face plate with the handle of a plastic screwdriver to break the regulator free. Note that the lever from the primary valve slides into a slot of the secondary diaphragm, requiring the Regulator to be moved sideways to free the tab from the diaphragm. Remove and discard Clamp Plate Seal.
8. Place Regulator face down and remove the retaining screw holding the secondary lever. 9. Remove secondary lever, fulcrum pin and spring. 10. Inspect lever and fulcrum pin for excessive wear. If the pin diameter is reduced at any point or if the holes in the lever are irregular (oblong), the EPR assembly is not repairable and must be replaced. 11. Turn the Regulator over and remove the seven screws from the face of the Regulator. Remove cover. 12. Remove the primary diaphragm. 13. Remove the body cover plate and C-clip from the primary valve pin.
10-15
10 — SERVICING THE FUEL SYSTEM 14. Turn the plate over and remove pin and spring. Discard pin and keep the spring.
REASSEMBLY OF EPR 1. Inspect all parts to ensure the Repair Kit is complete and all components are free of deterioration, cracks, tears, etc.
15. Remove the secondary body gasket. 16. Inspect the Regulator body and cover plates for debris, deposits or “heavy ends” and remove using a Safety Solvent as necessary. Ensure all mating surfaces are clean.
2. Place the new primary valve pin into the cover plate orifice. 3. Holding the valve pin in place, turn the body cover plate over. Place the valve pin spring over the valve pin and install C-clip or retaining clip.
Optional: If leaks are detected or if the replacement of the O-rings on the Coolant Hose(s), Fuel Temperature Sensor or the Fuel Vapor Hose is deemed necessary, the follow the additional steps. Otherwise, continue to Reassembly.
4. Place a new secondary body gasket ensuring the small hole in the gasket is aligned with the small hole in the body cover. Place body cover and gasket on the front of Regulator body, ensuring the holes in the gasket are aligned with all screw holes.
17. Release coolant pressure. 18. Clamp off the two radiator hoses near the point where they connect to the EPR.
5. Set new primary diaphragm on the face of the body cover using the screw hole for proper alignment.
19. Remove Coolant Hoses, Fuel Temperature Sensor and Fuel Vapor Hose by first removing Retaining Clips, then pulling each out of the EPR ports.
6. Place the Regular face over the diaphragm and hand thread all seven screws through the face plate and body cover into the Regulator body. Torque the screws to 4.5 N•m (40 in. lbs.) in a criss-cross pattern.
20. Remove O-rings from the Temperature Sensor, both Coolant Hose fittings, and the Fuel Vapor Hose. Clean Temperature Sensor EPR ports and hose fittings as necessary using a Safety Solvent.
!
7. Using side-cutters, cut off the nose of the soft secondary seat and remove from secondary lever.
WARNING
8. Push the nose or button of the new secondary seat through the hole of the secondary lever.
Use only Safety Solvents for the cleaning of the regulator and its components. Solvents such as carburetor or brake cleaners may damage gaskets, seals, Orings, diaphragms or other non-metal components.
9. Set the secondary spring on its seat on the back of the Regulator body, then position the secondary lever and fulcrum pin assembly on top of the secondary spring. Push down, compressing the spring until the fulcrum pin can be slid into place. 10. Insert screw to hold lever and torque to 4.5 N•m (40 in. lbs.). 11. Verify the secondary lever height by placing a straight edge over the mating surface (rim) of the Regular body. The distance between the rim of the Regulator (as determined by a straight edge) and lever should be 1/32”
10-16
10 — SERVICING THE FUEL SYSTEM (.794mm). If the measurement does not meet this specification, the EPR cannot be repaired and must be replaced.
20. Clean Shut-Off Valve fitting, apply LPG compatible pipe thread sealer and install into EPR assembly.
12. Place the EPR Actuator facing upward and place the new clamp plate seal into the open end of the Actuator.
!
13. Place the Regulator above the Actuator, noting the position of the lever tab and slot on the secondary diaphragm. Carefully slide the lever tab into the slot of the secondary diaphragm and align the Regulator to the Actuator. Place the Regulator on top the Actuator, aligning the screw holes.
Do not use Teflon tape to seal any LPG fittings. 21. Reconnect negative battery cable. 22. Open manual shut-off valve on the LPG tank.
14. Insert the six screws through the Actuator holes and into the Regulator. Finger tighten as many screws as possible.
23. Turn Key to the ON position for several seconds, then turn back to OFF. Using a liquid or electronic leak detection tool, inspect the EPR, fuel hoses and all serviced fittings for leaks.
15. Holding the Regulator to the Actuator, turn the assembly over so that it is resting on its face. Torque screws to 4.5 N•m (40 in. lbs.). Optional: If hoses and O-rings were removed during the Removal Procedure, then follow the additional steps 17–20; otherwise, continue to Step 21. 16. Lubricate new O-rings using petroleum jelly or Vaseline. Mount new O-rings on the Temperature Sensor and hose fittings.
!
WARNING
WARNING
Never use silicone based lubricants on any component related to the fuel system. The use of silicone may contaminate and/or damage the HEGO. 17. Mount EPR assembly in vehicle and reconnect electrical connector to EPR. 18. Insert Temperature Sensor and hose fittings into EPR and lock each into place using original retaining clips. 19. Remove clamps on coolant hoses. Check coolant fluid level.
10-17
10 — SERVICING THE FUEL SYSTEM
MIXER TO THROTTLE BODY O-RING REPLACEMENT
MIXER TO THROTTLE PLASTIC THROTTLE BODY SLEEVE REPLACEMENT
REMOVAL PROCEDURE 1. Disconnect the negative battery cable.
REMOVAL PROCEDURE
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
1. Disconnect the negative battery cable. 2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
3. Remove four screws on Mixer that secure the Mixer to the Throttle Body. 4. Lift up Mixer and remove O-ring from Throttle Body.
3. Remove four screws on Mixer that secure the Mixer to the Throttle Body. Torque to 12 N•m (106 in. lbs.)
INSTALLATION PROCEDURE
4. Lift up Mixer and remove O-ring from Throttle Body.
1. Lightly lubricate new O-ring with petroleum jelly or Vaseline.
INSTALLATION PROCEDURE 1. Lightly lubricate new O-ring with petroleum jelly or Vaseline.
!
CAUTION
!
The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/ lubricants on any fuel or exhaust related components.
CAUTION
The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/ lubricants on any fuel or exhaust related components.
2. Inspect plastic Throttle Body Sleeve and replace if necessary.
2. Inspect plastic Throttle Body Sleeve and replace if necessary.
3. Place Mixer on Throttle Body and secure with four screws. Torque to 12 N•m (106 in. lbs.)
3. Place Mixer on Throttle Body and secure with four screws.
4. Install 3/8” hose from 90˚ brass fitting on Mixer.
4. Install 3/8” hose from 90˚ brass fitting on Mixer.
5. Attach fuel hose to Mixer and secure with retaining pin.
5. Attach fuel hose to Mixer and secure with retaining pin.
6. Attach air hose to the air intake duct from the Mixer.
6. Attach air hose to the air intake duct from the Mixer.
7. Reconnect negative battery cable.
7. Reconnect negative battery cable.
8. Turn on MSV.
8. Open manual shut-off valve on the LPG tank.
9. Start Engine.
9. Start Engine. 10-18
10 — SERVICING THE FUEL SYSTEM
THROTTLE BODY REPLACEMENT
THROTTLE BODY-ADAPTER O-RING REPLACEMENT
REMOVAL PROCEDURE 1. Disconnect the negative battery cable.
REMOVAL PROCEDURE
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
1. Disconnect the negative battery cable. 2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
3. Remove four screws on Mixer that secure the Mixer to the Throttle Body. 4. Lift up Mixer.
3. Remove four screws on Mixer that secure the Mixer to the Throttle Body.
5. Lift up Throttle Body and remove.
4. Lift up Mixer. 5. Lift up Throttle Body and remove O-ring.
INSTALLATION PROCEDURE INSTALLATION PROCEDURE
1. Inspect Throttle Body gasket. Replace if necessary.
1. Replace O-ring between Throttle Body and Adapter.
2. Inspect Throttle Body Sleeve and O-ring. Replace if necessary. 3. Place Throttle Body on Adapter and align Throttle Body Gasket and Throttle Body to Adapter, then secure with four screws. Torque to 12 N•m (106 in. lbs.).
IMPORTANT
Lightly Lubricate the O-ring of the Throttle Body to the Adapter with petroleum jelly or Vaseline prior to installa-
IMPORTANT
!
Lightly Lubricate the O-ring of the Throttle Body to the Adapter with petroleum jelly or Vaseline prior to installation.
!
CAUTION
The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/ lubricants on any fuel or exhaust related components.
CAUTION
2. Inspect Throttle Body Sleeve and O-ring. Replace if necessary.
The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/ lubricants on any fuel or exhaust related components.
3. Place Throttle Body on Adapter and align Throttle Body Gasket and Throttle Body to Adapter, then secure with four screws. Torque to 12 N•m (106 in. lbs.).
4. Reconnect negative battery cable.
4. Reconnect negative battery cable.
5. Open manual shut-off valve on the LPG tank.
5. Open manual shut-off valve on the LPG tank.
6. Start Engine.
6. Start Engine. 10-19
10 — SERVICING THE FUEL SYSTEM
REPLACEMENT OF ADAPTERINTAKE MANIFOLD GASKETS
FUEL VAPOR HOSE—(EPR) TO FUEL MIXER
REMOVAL PROCEDURE
REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
1. Disconnect negative battery cable.
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
2. Remove retaining clip from EPR end of hose and remove hose from EPR port. 3. Remove retaining clip from Mixer end of hose and remove hose from Mixer.
3. Remove the four nuts that secure the Adapter to the Intake Manifold. 4. Lift up Adapter and remove the first gasket from the EPR Mounting Bracket.
IMPORTANT
5. Lift up EPR Mounting Bracket and remove second gasket from the Intake Manifold.
Hoses are designed for specific applications, DO NOT use hose material or length other than specified by the OEM.
INSTALLATION PROCEDURE 1. Place new gasket on intake manifold.
INSTALLATION PROCEDURE
2. Place EPR Mounting Bracket on intake manifold.
1. Lightly lubricate O-rings on both ends of the hose.
3. Place new gasket on EPR Mounting Bracket. 4. Place Adapter back in place and secure nuts. Torque to 12 N•m (106 in. lbs.).
!
CAUTION
The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/ lubricants on any fuel or exhaust related components.
5. Reconnect negative battery cable. 6. Open manual shut-off valve on the LPG tank. 7. Start Engine.
2. Reinstall hose at both ends and secure using retaining pins. 3. Reconnect negative battery cable. 4. Open manual shut-off valve on the LPG tank. 5. Turn Key to the ON position for several seconds, then turn back to OFF. Using a liquid or electronic leak detection tool, inspect the EPR, fuel hoses and all serviced fittings for leaks. 6. Start engine and check for leaks.
10-20
10 — SERVICING THE FUEL SYSTEM
SHUT-OFF VALVE REPLACEMENT
INSTALLATION PROCEDURE
REMOVAL PROCEDURE
1. Add pipe thread sealer to male threads on the 90˚ elbow and brass fitting. 2. Connect elbow and brass fitting, making sure that the elbow has the correct orientation to the Shut-Off Valve.
1. Disconnect the negative battery cable. 2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
3. Connect elbow, Shut-Off Valve and fitting assembly to the EPR. 4. Connect Shut-Off Valve electrical connector.
!
CAUTION
5. Connect the LPG fuel inlet line from the Shut-Off Valve fitting.
The propane fuel system operates at pressure up to 21.5 bar (312 psi). To minimize personal injury, relieve the propane fuel system pressure before servicing the propane fuel system components.
6. Reconnect negative battery cable. 7. Open manual shut-off valve on the LPG tank. 8. Turn Key to the ON position for several seconds, then turn back to OFF. Using a liquid or electronic leak detection tool, inspect the EPR, fuel hoses and all serviced fittings for leaks.
3. Disconnect Shut-Off Valve electrical connector. 4. Disconnect the LPG fuel inlet line from the Shut-Off Valve fitting.
9. Start engine and check for leaks.
5. Remove screw retaining coil on top of the shut-off valve, then remove coil 6. Remove Shut-Off Valve, 90˚ elbow and fitting as an assembly by unscrewing the elbow at the threaded port located at the top of the EPR. 7. Remove 90˚ elbow and brass fitting from the Shut-Off Valve.
10-21
10 — SERVICING THE FUEL SYSTEM
EPR MOUNTING BRACKET
INSTALLATION PROCEDURE
REMOVAL PROCEDURE
1. Secure the EPR Mounting Bracket to the vehicle frame with screws. Torque to 33.9 N•m (25ft-lbs).
1. Disconnect the negative battery cable.
2. Mount ECM to mounting bracket with four screws. Torque to 7.5 N•m (5.5 ft. lbs.).
2. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
3. Connect the negative battery cable.
3. Remove the four nuts that secure the Adapter to the Intake Manifold.
LPG FUEL SYSTEM PRESSURE CHECK
4. Lift up Adapter and remove the first gasket from the EPR Mounting Bracket.
1. Turn ignition to OFF.
5. Remove EPR Mounting Bracket.
2. Remove plug on front of EPR listed as “PRIMARY PRESSURE TEST.”
INSTALLATION PROCEDURE
3. Install Pressure Gauge.
1. Inspect gaskets and replace if necessary.
4. Turn ignition to ON and note value on gauge.
2. Place gasket on intake manifold.
5. Remove Gauge
3. Place EPR Mounting Bracket on intake manifold.
6. Replace Plug.
4. Place gasket on EPR Mounting Bracket.
LPG FUEL CONTROL SYSTEM CHECK
5. Place Adapter back in place and secure nuts. Torque to 12 N•m (106 in. lbs.).
The fuel system can be thoroughly diagnosed by use of the DST tool. See section DIAGNOSTIC SCAN TOOL.
6. Reconnect negative battery cable. 7. Open manual shut-off valve on the LPG tank. 8. Start engine.
ECM MOUNTING BRACKET REMOVAL PROCEDURE 1. Disconnect the negative battery cable 2. Remove the four screws securing the ECM to the Bracket. 3. Remove the screws attaching the bracket to the vehicle frame.
10-22
10 — SERVICING THE FUEL SYSTEM
PROPANE FUEL SYSTEM LEAK TEST Use a commercially available liquid leak detector or an electronic leak detector and follow the manufacturer’s instructions. INSTALLATION PROCEDURE
IMPORTANT
When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector.
RESTRICTED EXHAUST SYSTEM DIAGNOSIS PROCEDURE:
1. Back Pressure Gauge
1. Carefully remove the pre-catalyst or upstream HEGO.
2. Heated Exhaust Gas Oxygen (HEGO) Sensor
2. Install Exhaust Back Pressure Test Gauge (J35314-A) in place of the HEGO.
3. Three-Way Catalytic Muffler Exhaust Back Pressure Test
3. With the engine idling at normal operating temperature, observe the exhaust system back pressure reading on the gauge. Reading should not exceed 8.6 kPa (1.25 psi).
CATALYTIC CONVERTER
4. Increase engine speed to 2000 RPM and observe gauge. Reading should not exceed 20.7 kPa (3 psi).
REMOVAL PROCEDURE 1. Remove the Catalytic Converter using the OEM end product processes
5. If the back pressure at either speed exceeds specification, a restricted exhaust system is indicated. 6. Inspect the entire exhaust system for a collapsed pipe, heat distress or possible internal catalytic converter failure. 7. If there are no obvious reasons for the excessive back pressure, the catalytic converter is likely damaged and should be replaced. 8. Check for MIL and clear using the DST
10-23
10 — SERVICING THE FUEL SYSTEM INSTALLATION PROCEDURE
INSTALLATION PROCEDURE
IMPORTANT
IMPORTANT
The Catalytic Converter (a component of the muffler) is specifically designed to meet the emission control of the certified engine. Use only the OEM specified part.
Coolant hoses are specifically designed for their application. DO NOT use hose material or length other than the OEM specified parts. 1. DO NOT mix the inlet or outlet hoses when reinstalling
Install the Catalytic Converter using the OEM end product processes.
2. Remove retaining clips and hose from EPR port.
1. Start engine
3. Remove the coolant inlet hose from opposite end, either by removing retaining clip or hose clamp.
2. Check for any DTC codes and clear 3. Verify engine is in closed loop and no MIL lights are present.
4. Refill with coolant. 5. Start engine and check for coolant leaks.
EPR COOLANT HOSE REPLACEMENT REMOVAL PROCEDURE 1. Drain coolant. 2. Remove Hose Clamps from both ends of the Coolant Hose and remove hose. 3. Remove the coolant inlet hose from opposite end, by removing hose clamp. 4. Remove the coolant outlet hose from opposite end, by removing hose clamp.
!
CAUTION
The coolant may be hot. Use caution when removing hose(s) to prevent contact.
10-24
11 — LPG PARTS DIAGRAM LPG PARTS DIAGRAM
MIXER AND THROTTLE BODY ASSEMBLY (NEW)
Item #
Description
Qty. Used
1
Fitting, 70-Degree, 3/4” OD
1
2
Carburetor ASM, 20-150
1
3
Fitting, 1/8 NPT 3/8 Hs 90 El Brass
3
4
Screw, Hex Sock Cap
4
5
O-Ring Nitrile, #225
1
6
Sleeve, Plastic Bosch Throttle
1
7
Bosch Throttle Body, 40mm
1
8
O-Ring Nitrile, #032
1
9
Adapter, Elbow, 4.3L Lx-Bos SIII LP
1
10
Stud, 5/16-18 X 1 Ω”, Torx
4
11
Gasket, Carb Mounting, 2bbl, 4.3L
1
12
Plug, 1/8 NPT 3/16 Hex Sch Brass
1
13
Retaining Pin
1
14
Nut, 5/16-18, Flanged
4
15
Washer, Conical, Spring 6 mm
4
16
Nut, Hex, Flange Serrated M6 X 1.0”
4
11-1
11 — LPG PARTS DIAGRAM
MIXER AND THROTTLE BODY ASSEMBLY (FORMER)
Item #
Description
Qty. Used
1
Fitting, 70-Degree, 3/4" OD
1
2
Carburetor ASM, 20-150
1
3
Fitting, 1/8 NPT 3/8 Hs 90 El Brass
3
4
Screw, Hex Sock Cap
4
5
O-Ring Nitrile, #225
1
6
Sleeve, Plastic Bosch Throttle
1
7
Bosch Throttle Body, 40mm
1
8
O-Ring Nitrile, #032
1
9
Adapter, Elbow, 4.3L Lx-Bos SIII LP
1
10
Stud, 5/16-18 X 1 3/4", Torx
4
11
Gasket, Carb Mounting, 2bbl, 4.3L
1
12
Plug, 1/8 Npt 3/16 Hex Sch Brass
1
13
Retaining Pin
1
14
Nut, 5/16-18, Flanged
4
11-2
11 — LPG PARTS DIAGRAM
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________
11-3
11 — LPG PARTS DIAGRAM
EPR ASSEMBLY
11-4
11 — LPG PARTS DIAGRAM
EPR ASSEMBLY
Item #
Description
Qty. Used
1
Fitting, π Npt 3/8 Flare Brass
1
2
Valve, LPG Shut-Off
1
3
Fitting, π NPT Street 90 Elbow Brass
1
4
Electronic Pressure Regulator, EPR
1
5
Fitting, 90 Deg. 1/8 NPT X 3/8
1
6
Fitting Assembly, 20 Degree
2
7
Retaining Clip
4
8
Fitting Assy, Straight, 3/4"Od
1
9
Temperature Sensor Assy
1
10
Nut, Hex Flange, Serrated
3
11
Bracket, EPR-Upper
1
12
Mount Vibration, 2 Studs
3
13
Bracket, Mtg EPR, 2bbl, 4.3l
1
14
Screw, Hex Flange-M8x1.25x16
2
15
Screw, Hex Flange-M8 X 1.25 X 12
1
16
Plug, 1/8 NPT 3/16" Hex Sch Brass
1
17
Gasket, Carb Mounting, 2bbl, 4.3L
1
11-5
11 — LPG PARTS DIAGRAM
REGULATOR REPAIR
Item#
Description
Qty. Used
1
Seal, Clamp Plate, EPR
1
2
Seat, Secondary
1
3
Gasket, Body Secondary
1
4
Pin, Primary
1
5
Spring, Primary
1
6
Clip, Primary
1
7
Diaphragm, Primary
1
8
O-ring
4
9
O-ring
4
10
Kit, Repair Regulator Assembly
1
11-6
11 — LPG PARTS DIAGRAM
HOSE ASSEMBLIES COOLANT/VACUUM/FUEL
Item #
Description
Qty. Used
1
Elbow, Vent GM
1
2
Balance Hose, Assy 350mm
1
3
Clamp, Loop Cushioned, 8mm hole x 32mm
1
4
Bracket, Fuel Line Support 4.3L
1
5
Coolant Hose, Assy 300 mm
1
6
Fitting, 1/2NPT X 5/8 Hose
1
7
3/8"-16x5/8" Bolt Fn Gr5
2
8
Fitting, Bulkhead #6 SAE-45deg
1
9
Washer-Lock, Internal Tooth 5/8
1
10
Nut, Hex Jam - 5/8-11
1
11
LPG Hose Assy, CGA 340mm
1
12
Clamp, Loop Cushioned, 5/16" Bolt X .63" ID
2
13
Nut, Clip M6
5
14
Coolant Hose Assy, 750mm
1
15
Vapor Hose Assy, 290mm
1
16
PCV Hose Assy, 310mm
1
17
Screw, Hex, Flange, M6 X 16mm
3
18
Bracket, Air Pipe, 4.3L, MCFA
1
11-7
11 — LPG PARTS DIAGRAM
ENGINE CONTROL MODULE
NOTE
ECM Part Numbers 93721-13200 is applicable to chassis serial numbers on cover of this manual. 93721-23200 changed at engine serial number 43LT. 42489 08-up. Chassis serial number break not available.
Item #
Description
Qty. Used
1
Engine Control Module (ECM)
1
2
Bracket, ECM
1
3
Bolt, M6-1.0 x 32 M
4
4
Clamp, L, Cushioned-8mm Hole x 32mm
1
5
Bolt, M8-1.25 x 20mm, Flange
1
11-8
11 — LPG PARTS DIAGRAM
SENSORS
2
1
5
3
4 6
Item #
Description
Qty. Used
1
HEGO, Post Catalyst
1
2
HEGO, Pre-Catalyst
1
3
Sensor, TMAP
1
4
Oil Pressure Switch
1
5
LPG Temp Sensor
1
6
Coolant Temp Sensor
1
11-9
11 — LPG PARTS DIAGRAM
EXHAUST SYSTEM
Item #
Description
Qty. Used
1
Catalytic Converter
1
11-10
11 — LPG PARTS DIAGRAM
SERVICE TOOLS The tools required to service the 2007 Impco fuel system include the 2004 GM 4.3L system tool kit, plus a test fitting which is used to measure fuel pressure at the electronic pressure regulator (EPR), diagnostic software and a T20 Torx-Plus Tamper Resistant bit which is used to service the EPR. The regulator has a service repair kit available for the 2007 system. The new diagnostic software will not work on the 2004 system. See the Service Engineering folder on the web site for the software download.
The 2007 system has a factory installed diagnostic port adapter harness which allows the use of the 2004 system four pin diagnostic cable. Do not remove this adapter harness from the engine. If it is lost or damaged the replacement part number is 93768-02100. If you already have the 2004 system kit the only parts required are the test fitting and the T20 Torx-Plus tamper resistant. Tool Part Numbers
11-11
2004 System Kit
93768-00010
Test Fitting
93768-02400
Tamper Resistant T20 Torx bit
93768-02500
NOTES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 11-12
12 — APPENDIX APPENDIX
ALTITUDE vs. BAROMETRIC PRESSURE Altitude Measured In Feet (ft)
Kilopascals (kpa)
Pounds Per Square Inch (PSIA)
14,000
56-64
8.1-9.2
13,000
58-66
8.4-9.6
12,000
61-69
8.8-10.0
11,000
64-72
9.3-10.4
10,000
66-74
9.6-10.7
9,000
69-77
10.0-11.2
8,000
71-79
10.3-11.4
7,000
74-82
10.7-11.9
6,000
77-85
11.2-12.3
5,000
80-88
11.6-12.8
4,000
83-91
12.0-13.2
3,000
87-95
12.6-13.8
2,000
90-98
13.0-14.2
1,000
94-102
13.6-14.8
0
96-104
13.9-15.0
-1,000
101-105
14.6-15.2
IGNITION SYSTEM SPECIFICATIONS Firing Order
1-6-5-4-3-2
Spark Plug Type
R44LTS (AC Plug)
Spark Plug Gap
.035 in (0.889 mm)
Spark Plug Torque
11 lb ft (15 N·m)
Spark Plug Wire Resistance
1000 Ohms per ft.
12-1
12 — APPENDIX
EXTENDED ECT TEMPERATURE vs. RESISTANCE Degrees F.
Degrees C.
Ohms ±10%
302
150
47
284
140
60
266
130
77
248
120
100
230
110
132
212
100
177
194
90
241
176
80
332
158
70
467
140
60
667
122
50
973
113
45
1188
104
40
1459
95
35
1802
86
30
2238
77
25
2796
68
20
3520
59
15
4450
50
10
5670
41
5
7280
32
0
9420
23
-5
12300
14
-10
16180
5
-15
21450
-4
-20
28680
-22
-30
52700
-40
-40
100700
12-2
Cat Lift Trucks
Service Manual
GM 4.3L, G6 Fuel System Supplement
99789-84122
Service Manual GM 4.3L, G6 Engine LPG Fuel System Supplement GC35K GC40K GC40K-STC GC45KC GC45K-STC
AT87A-30231-up AT87B-00001-up AT87A-30231-up AT87B-00001-up AT87A-30231-up A7 7B-00001-up AT87A-30231-up AT87B-00001-up AT87A-30231-up AT87B-00001-up
For use with the GM 4.3L, G6 Engine and GC35K-GC70K Chassis Service Manuals
GC55K GC55K-STC GC60K GC70K GC70K-STC
AT88A-30231-up AT88B-00001-up AT88A-30231-up AT88B-00001-up AT89A-30231-up AT89B-00001-up AT89A-30231-up AT89B-00001-up AT89A-30231-up AT89B-00001-up
99789-84133
Table of Contents General Information .......................................................................................................................................... 7 Proper Use Of This Service Manual, Tools And Equipment ....................................................................... 9 Maintenance .................................................................................................................................................... 11 Serpentine Belt System ............................................................................................................................... 12 Cooling System ........................................................................................................................................... 12 Coolant ........................................................................................................................................................ 13 Engine Electrical System Maintnance ........................................................................................................ 13 Engine Crankcase Oil ................................................................................................................................. 13 Oil Recommendation .............................................................................................................................. 13 Synthetic Oils .......................................................................................................................................... 13 Checking/Filling Engine Oil Level ......................................................................................................... 13 Changing The Engine Oil ....................................................................................................................... 14 Lpg Fuel System ..................................................................................................................................... 15 Inspection And Maintenance Of The Fuel Storage Cylinder ................................................................. 15 Inspection And Replacement Of The Fuel Filter .................................................................................... 15 Replacing The Fuel Filter: ...................................................................................................................... 15 Direct Electronic Pressure Regulator (Depr) Maintenance And Inspection ........................................... 16 Checking/Draining Oil Build-Up In The Vaporizer Regulator .............................................................. 16 Air Fuel Mixer/Throttle Control Device Maintenance And Inspection ................................................. 17 Exhaust System And Catalytic Converter Inspection And Maintenance ............................................... 17 LPG Certified Engine Maintenance Requirements .................................................................................... 18 LPG Fuel System ............................................................................................................................................ 19 Mobile Engine Lpg Fuel System Schematic............................................................................................... 20 Description And Operation Of The Fuel Systems ...................................................................................... 21 Ng & Lpl Fuel System ............................................................................................................................ 21 Service Lines........................................................................................................................................... 21 Fuel Filter ................................................................................................................................................ 21 Electric Fuel Lock-Off Valve ................................................................................................................. 21 Direct Electronic Pressure Regulator (Depr) .......................................................................................... 21 Air Fuel Mixer ........................................................................................................................................ 22 Electronic Throttle Control Device (Etc)—............................................................................................ 23 Three-Way Catalytic Converter .............................................................................................................. 23 Heated Exhaust Gas Oxygen Sensors ..................................................................................................... 24 The Heat Exhaust Gas Oxygen (HEGO) Sensor .................................................................................... 25 Tmap Sensor ........................................................................................................................................... 25 Coolant Temperature Sensor .................................................................................................................. 25 Oil Pressure Sender ................................................................................................................................. 25 Fuel System Diagnosis.................................................................................................................................... 27 Fuel System Description ............................................................................................................................. 28 Diagnostic Aids........................................................................................................................................... 28 Pressure Gauges .......................................................................................................................................... 28 Test Description .......................................................................................................................................... 29 How the Correction Factors Work .............................................................................................................. 29
Determining Total Fuel Correction............................................................................................................. 29 Normal & Abnormal Fuel Correction ......................................................................................................... 30 Fuel System Symptom Diagnostics ................................................................................................................ 31 Intermittent.................................................................................................................................................. 32 No Start ....................................................................................................................................................... 33 Hard Start .................................................................................................................................................... 35 Cuts Out, Misses ......................................................................................................................................... 37 Hesitation, Sag, Stumble ............................................................................................................................. 38 Backfire ....................................................................................................................................................... 39 Lack of Power, Sluggishness, or Sponginess ............................................................................................. 40 Rough, Unstable, or Incorrect Idle, Stalling ............................................................................................... 41 Diagnostic Scan Tool (DST)Contents ............................................................................................................ 43 Contents .......................................................................................................................................................... 44 DST Installation Instructions ...................................................................................................................... 44 Password Login........................................................................................................................................... 48 Password Dialog Box Functions ................................................................................................................. 48 Connecting the Pc to the Engine Wire Harness .......................................................................................... 50 Connecting the DST cable .......................................................................................................................... 50 Gauge Page ................................................................................................................................................. 53 Raw Volts Page ........................................................................................................................................... 54 Tests Page ................................................................................................................................................... 55 Spark Kill ................................................................................................................................................ 55 Injector Kill ............................................................................................................................................. 55 DBW Test Mode ..................................................................................................................................... 56 External Power Test ................................................................................................................................ 56 Faults Page .................................................................................................................................................. 56 Plot/Log Menu Functions ........................................................................................................................... 57 DST Plot Interface Functions ..................................................................................................................... 60 Snapshot Hot Key Functions .................................................................................................................. 60 DST Logger .................................................................................................................................................... 61 Malfunction Indicator Lamp (MIL) ............................................................................................................ 61 Diagnostic Trouble Codes (DTC) ............................................................................................................... 61 DLC Communication Error .................................................................................................................... 62 Blink Code Function ............................................................................................................................... 63 Engine Wire Harness Repair........................................................................................................................... 65 On-Vehicle Service ..................................................................................................................................... 66 Wire Harness Repair ................................................................................................................................... 66 Connectors and Terminals .......................................................................................................................... 66 Metri-Pack .............................................................................................................................................. 67 Weather-Pack .......................................................................................................................................... 67 Weather-Pack Terminal Repair .............................................................................................................. 68 Diagnostic Trouble Codes (DTCs) ................................................................................................................. 69 Malfunction Indicator Lamp (MIL) Operation ........................................................................................... 70 OBD System Check/MIL (Malfunction Indicator Lamp) .......................................................................... 70 HVS Ignition Control System Diagnostics ................................................................................................. 72 Ignition Control System Diagnostic Chart.................................................................................................. 73 DTC 11 – Intake cam / distributor position error ....................................................................................... 75
DTC 16-Never Crank Synchronized at Start .............................................................................................. 76 DTC 107-MAP Low Voltage ..................................................................................................................... 79 DTC 107-MAP Low Voltage ..................................................................................................................... 80 DTC 108-MAP High Pressure .................................................................................................................... 83 DTC 111-IAT Higher Than Expected 1 ..................................................................................................... 86 DTC 112-IAT Low Voltage ....................................................................................................................... 88 DTC 113-IAT High Voltage ....................................................................................................................... 91 DTC 116-ECT Higher Than Expected 1 .................................................................................................... 94 DTC 117-ECT/CHT Low Voltage ............................................................................................................. 96 DTC 118-ECT/CHT High Voltage ............................................................................................................. 99 DTC 121-TPS 1 Lower Than TPS 2 ......................................................................................................... 102 DTC 122-TPS 1 Low Voltage .................................................................................................................. 105 DTC 123-TPS 1 High Voltage.................................................................................................................. 108 DTC 127-IAT Higher Than Expected 2 ................................................................................................... 111 DTC 129-BP Low Pressure ...................................................................................................................... 113 DTC 134-EGO 1 Pre Cat Open/Lazy ....................................................................................................... 117 DTC 154-EGO 2 Pre Cat Open/Lazy ....................................................................................................... 120 DTC 217-ECT Higher Than Expected 2 .................................................................................................. 123 DTC 219-Max Govern Speed Override .................................................................................................... 125 DTC 221-TPS 1 Higher Than TPS 2 ........................................................................................................ 127 DTC 222-TPS 2 Signal Voltage Low ....................................................................................................... 130 DTC 223-TPS 2 Signal Voltage High ...................................................................................................... 133 DTC 336-Crank Sync Noise ..................................................................................................................... 136 DTC 337-Crank Loss ................................................................................................................................ 139 DTC 341-Camshaft Sync Noise ............................................................................................................... 142 DTC 342-Camshaft Sensor Loss .............................................................................................................. 145 DTC-359 Fuel Run-out Longer Than Expected ....................................................................................... 148 DTC 520-Oil Pressure Low Stage 1 ......................................................................................................... 150 DTC 521- Oil Pressure High .................................................................................................................... 153 DTC 522- Oil Pressure Sender low voltage.............................................................................................. 155 DTC 523- Oil Pressure Sender high voltage ............................................................................................ 157 DTC 524-Oil Pressure Low Stage 2 ......................................................................................................... 159 DTC 562-System Voltage Low ................................................................................................................ 162 DTC 562-System Voltage Low ................................................................................................................ 163 DTC 563-System Voltage High ................................................................................................................ 164 DTC 563-System Voltage High ................................................................................................................ 165 DTC 601-Flash Checksum Invalid ........................................................................................................... 166 DTC 604-RAM Failure ............................................................................................................................. 168 DTC 606-COP Failure .............................................................................................................................. 170 DTC- 642-External 5 Volt 1 Reference Low............................................................................................ 172 DTC 643-External 5 Volt 1 Reference High ............................................................................................ 175 DTC 650-MIL Control Open .................................................................................................................... 177 DTC 652-External 5 Volt 2 Reference Low ............................................................................................. 180 DTC 653-External 5 Volt 2 Reference High ............................................................................................ 182 DTC 685-Relay Coil Open ....................................................................................................................... 184 DTC 686-Relay Control Ground Short ..................................................................................................... 187 DTC 687-Relay Coil Short to Power ........................................................................................................ 189
DTC 1111-Fuel Rev Limit ........................................................................................................................ 192 DTC 1112-Spark Rev Limit ..................................................................................................................... 194 DTC 1121 FPP 1 And 2 Redundancy Lost ............................................................................................... 196 DTC 1151-Closed Loop Multiplier High LPG ......................................................................................... 198 DTC 1152-Closed Loop Multiplier Low LPG ......................................................................................... 201 DTC 1161-Adaptive Learn High LPG...................................................................................................... 203 DTC 1162-Adaptive Learn Low (LPG).................................................................................................... 207 DTC 1165-LPG Catalyst Monitor ............................................................................................................ 209 DTC1171-EPR Pressure Higher Than Expected ...................................................................................... 210 DTC1172-EPR Pressure Lower Than Expected ....................................................................................... 212 DTC1173-EPR Communication Lost ....................................................................................................... 214 DTC1174-EPR Supply Voltage High ....................................................................................................... 218 DTC1175-EPR Supply Voltage Low ....................................................................................................... 220 DTC1176-EPR Internal Actuator Fault .................................................................................................... 223 DTC 1177-EPR internal Circuitry Fault ................................................................................................... 225 DTC 1178-EPR Internal Communication Error ....................................................................................... 227 DTC 1511- Aux Analog PU1 High .......................................................................................................... 229 DTC 1512 AUX Analog PU1 Low........................................................................................................... 231 DTC 1612-RTI 1 Loss .............................................................................................................................. 234 DTC 1613-RTI 2 Loss .............................................................................................................................. 236 DTC 1614-RTI 3 Loss .............................................................................................................................. 238 DTC 1615-A/D Loss ................................................................................................................................. 240 DTC 1616-Invalid Interrupt ...................................................................................................................... 242 DTC 1625 - J1939 Shutdown Request ..................................................................................................... 244 DTC 1626-CAN Tx Failure ...................................................................................................................... 245 DTC 1627-CAN Rx Failure ...................................................................................................................... 248 DTC 1628-CAN Address Conflict ........................................................................................................... 251 DTC 1644-MIL Control Ground Short ..................................................................................................... 253 DTC 1645-MIL Control Ground Short To Power .................................................................................... 256 DTC 2111-Unable To Reach Lower TPS ................................................................................................. 259 DTC 2112-Unable To Reach Higher TPS ................................................................................................ 262 DTC 2121-FPP 1 Lower Than FPP 2 ....................................................................................................... 265 DTC 2121 FPP 1 Lower than FPP 2 ......................................................................................................... 266 DTC 2122-FPP 1 High Voltage ................................................................................................................ 268 DTC 2123-FPP 1 Low Voltage ................................................................................................................ 271 DTC 2126-FPP 1 Higher Than FPP 2 ...................................................................................................... 274 DTC 2127-FPP 2 Low Voltage ................................................................................................................ 277 DTC 2128-FPP 2 High Voltage ................................................................................................................ 280 DTC 2135: TPS1/2 simultaneous voltages out-of-range .......................................................................... 283 DTC 2229-BP High Pressure .................................................................................................................... 286 Parts Illustration ............................................................................................................................................ 294 Wiring Schematic ......................................................................................................................................... 295
General Information
7
GENERAL INFORMATION
Introduction This service manual has been developed to provide the service technician with the basic understanding of the certified fuel and emission systems for their GM engine line. This manual should be used in conjunction with the base engine manual and the OEM service manual when diagnosing fuel or electrical problems.
Do not allow LPG to contact the skin. LPG is stored in the fuel tank as a liquid. When LPG contacts the atmosphere, it immediately expands into a gas, resulting in a refrigeration effect that can cause severe burns to the skin.
Servicing Your Emissions Certified Engine Any maintenance and repair should be performed by trained and experienced service technicians. Proper tools and equipment should be used to prevent injury to the servicing technician and damage to the vehicle or components. Service repairs should always be performed in a safe environment and the technician should always wear protective clothing to prevent injury.
Do not allow LPG to accumulate in areas below ground level such as in a service pit or underground ventilation systems. LPG is heavier than air and can displace oxygen, creating a dangerous condition
Fuel Quality LPG engines and fuel systems are designed to operate on HD-5 or HD-10 specification LPG fuel. Fuel other than HD-5 or HD-10 may cause harm to the engine‘s emission control system and a warranty claim may be denied on this basis if operators can readily find the proper fuel. Gasoline engines should use 87 octane or higher. E85 fuel is not permitted for use in the gasoline engine. Use of any other fuel may result in your engine no longer operating in compliance with CARB or EPA emissions requirements.
Do not make repairs to the LPG fuel system if you are not familiar with or trained to service LPG fuel system. Contact the dealer who sold you the vehicle to locate a repair facility with trained technicians to repair your fuel system Warnings, Cautions And Notes
Fuel System Cautions
This manual contains several different Warnings, Cautions, and Notes that must be observed to prevent personal injury and or damage to the vehicle, the fuel system or personal property.
Do not smoke, carry lighted tobacco or use a lighted flame of any type when working on or near any fuel related component. Highly flammable air-fuel mixtures may be present and can be ignited causing personal injury
A ―WARNING― is an advisement that by performing a process or procedure listed in this manual improperly may result in serious bodily injury, death and/or serious damage to the vehicle or property.
8
GENERAL INFORMATION
Proper Use Of This Service Manual, Tools And Equipment To reduce the potential for injury to the technician or others and to reduce damage to the equipment during service repairs the technician should observe the following steps:
Always leak check any fuel system connection after servicing! Use an electronic leak detector and/or a liquid leak detection solution. Failure to leak check could result in serious bodily injury, death, or serious property damage.
The service procedures defined in this manual, when followed, have been found to be a safe and efficient process to repair the fuel system. In some cases special tools may be required to perform the necessary procedures to safely remove and replace a failed component.
The installed fuel system has been certified with the Environmental Protection Agency (EPA) and complies with the regulation in effect at the time of certification. When servicing the fuel and emission control system you should follow all the recommended service and repair procedures to insure the fuel and emissions system is operating as designed and certified. Purposely or knowingly defeating or disabling any part or the fuel and emission system may be in violation of the anti-tampering provision of the EPA‘s Clean Air Act.
Tools identified in this manual with the prefix ―J‖ or ―BT‖ can be procured through SPX in Warren, Michigan.
Other special tools identified in this manual can be acquired through the equipment OEM.
IMPORTANT It is important to remember that there may be a combination of Metric and Imperial fasteners used in the installation of the fuel system. Check to insure proper fit when using a socket or wrench on any fastener to prevent damage to the component being removed or injury from ―slipping off‖ the fastener.
9
Memo
______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ 10
Maintenance
11
Maintenance
IMPORTANT: The use of ―belt dressing‖ or ―anti-slipping agents‖ on belts is not recommended.
The maintenance of an engine and related components are critical to its operating performance and lifespan. Industrial engines operate in environments that often include hot and cold temperatures and extreme dust. The recommended maintenance schedule is listed in this section, however, environmental operating conditions and additional installed equipment may require more frequent inspection and servicing. The owner and/or service agent should review the operating conditions of the equipment to determine the inspection and maintenance intervals.
Cooling System It is important that the cooling system of the engine be maintained properly to ensure proper performance and longevity.
Do not remove the cooling system pressure cap (radiator cap) when the engine is hot. Allow the engine to cool and then remove the cap slowly to allow pressure to vent. Hot coolant under pressure may discharge violently.
When performing maintenance on the engine, turn the ignition OFF and disconnect the battery negative cable to avoid injury or damage to the engine.
Note that there may be an LPG vaporizer connected to the cooling system and the fuel system may be adversely affected by low coolant levels and restricted or plugged radiator cores. Therefore, the cooling system must be maintained according to the recommend maintenance schedule in this section and also include:
The engine installed in this equipment uses a drive belt that drives the water pump, alternator and additional pumps or devices. It is important to note that the drive belt is an integral part of the cooling and charging system and should be inspected according to the maintenance schedule in this section. When inspecting the belts check for:
Cracks Chunking of the belt Splits Material hanging loose from the belt Glazing, hardening
If any of these conditions exist the belt should be replaced with the recommended OEM replacement belt.
Serpentine Belt System Serpentine belts utilize a spring-loaded tensioner to keep the belt properly adjusted. Serpentine belts should be checked according to the maintenance schedule in this section.
12
The regular removal of dust, dirt and debris from the radiator core and fan shroud. Inspection of coolant hoses and components for leaks, especially at the radiator hose connections. Tighten hose clamps if necessary. Check radiator hoses for swelling, separation, hardening, cracks or any type of deterioration. If any of these conditions exist the hose should be replaced with a recommended OEM replacement part. Inspect the radiator cap to ensure proper sealing.
Coolant
The engine manufacturer recommends the cooling system be filled with a 50/50 mixture of antifreeze and water. The use of DexCool ―Long Life‖ type coolant is required. This antifreeze is typically a bright orange in color and should meet the requirements issued. Coolant should have a minimum boiling point of 300F (149c) and a freezing point no higher than -34F (-37c). Do not add plain water. Replace coolant per the recommended schedule.
Engine Crankcase Oil Oil Recommendation To achieve proper engine performance and durability, it is important that you only use engine lubricating oils displaying the American Petroleum Institute (API) ―Starburst‖ Certification Mark ‗FOR GASOLINE ENGINES‘ on the container.
IMPORTANT: The manufacturers of the engine and fuel system do not recommend the use of ―stop leak‖ additives to repair leaks in the cooling system. If leaks are present the radiator should be removed and repaired or replaced.
Engine Electrical System Maintnance
Gasoline engines that are converted to run on LPG or NG fuels must use oils labeled for gasoline engines. Oils specifically formulated for Heavy Duty or Natural Gas Engines are not acceptable
The engine‘s electrical system incorporates an electronic control module (ECM) to control various related components. The electrical system connections and ground circuits require good connections. Follow the recommended maintenance schedule in this section to maintain optimum performance. When inspecting the electrical system check the following:
curely mounted to the engine or chassis. Verify that any additional electrical services installed by the owner are properly installed in the system. Verify that the MIL, charging, and oil pressure lights illuminate momentarily during engine start.
IMPORTANT: Oils recommended by the engine manufacturer already contain a balanced additive treatment. Oils containing ―solid‖ additives, non-detergent oils, or low quality oils are not recommended by the engine manufacturer. Supplemental additives added to the engine oil are not necessary and may be harmful. The engine and fuel system supplier do not review, approve or recommend such products.
Check Positive and Negative cables for corrosion, rubbing, chafing, burning and to ensure tight connections at both ends. Check battery for cracks or damage to the case and replace if necessary. Inspect engine wire harness for rubbing, chafing, pinching, burning, and cracks or breaks in the wiring. Verify that engine harness connectors are correctly locked in by pushing in and then pulling the connector halves outward. Inspect ignition coil wire for hardening, cracking, arcing, chafing, burning, separation, split boot covers. Check spark plug wires for hardening, cracking, chafing, arcing or burning, separation, and split boot covers. Replace spark plugs at the required intervals per the recommended maintenance schedule. Verify that all electrical components are se-
Synthetic Oils Synthetic oils have been available for use in industrial engines for a relatively long period of time and may offer advantages in cold and hot temperatures. However, it is not known if synthetic oils provide operational or economic benefits over conventional petroleum-based oils in industrial engines. Use of synthetic oils does not permit the extension of oil change intervals. Checking/Filling Engine Oil Level IMPORTANT: Care must be taken when checking engine oil lev-
13
el. Oil level must be maintained between the ―ADD‖ mark and the ―FULL‖ mark on the dipstick. To ensure that you are not getting a false reading, make sure the following steps are taken before checking the oil level.
An overfilled crankcase (oil level being too high) can cause an oil leak, a fluctuation or drop in oil pressure. When overfilled, the engine crankshafts splash and agitate the oil, causing it to aerate or foam.
1. Stop engine. 2. Allow approximately several minutes for the oil to drain back into the oil pan. 3. Remove the dipstick. Wipe with a clean cloth or paper towel and reinstall. Push the dipstick all the way into the dipstick tube. 4. Remove the dipstick and note the amount of oil on the dipstick. The oil level must be between the ―FULL‖ and ―ADD‖ marks.
IMPORTANT: Change oil when engine is warm and the old oil flows more freely. 2. Stop engine IMPORTANT: Engine oil will be hot. Use protective gloves to prevent burns. Engine oil contains chemicals which may be harmful to your health. Avoid skin contact. 3. Remove drain plug and allow the oil to drain. 4. Remove and discard oil filter and its sealing ring. 5. Coat sealing ring on the new filter with clean engine oil, wipe the sealing surface on the filter mounting surface to remove any dust, dirt or debris. Tighten filter securely (follow filter manufacturers instructions). Do not over tighten. 6. Check sealing ring on drain plug for any damage, replace if necessary, wipe plug with clean rag, wipe pan sealing surface with clean rag and re-install plug into the pan. Tighten to specification. 7. Fill crankcase with oil. 8. Start engine and check for oil leaks. 9. Dispose of oil and filter in a safe manner.
Figure 2 Engine Oil Dip tick (Typical) 5. If the oil level is below the ―ADD‖ mark reinstall the dipstick into the dipstick tube and proceed to Step 6. 6. Remove the oil filler cap from the valve cover. 7. Add the required amount of oil to bring the level up to, but not over, the ―FULL‖ mark on the dipstick Reinstall the oil filler cap to the valve rocker arm cover and wipe any excess oil clean. Changing The Engine Oil IMPORTANT: When changing the oil, always change the oil filter. 1. Start the engine and run until it reaches normal operating temperature.
14
Fuel System Inspection And Maintenance Lpg Fuel System The fuel system installed on this industrial engine has been designed to meet the mobile engine emission standard applicable for the 2010 and later model years. To ensure compliance to these standards, follow the recommended maintenance schedule contained in this section.
Replacing The Fuel Filter: 1. Move the equipment to a well ventilated area and verify that sparks, ignition and any heat sources are not present. 2. Start the engine. 3. Close the manual valve. 4. When the engine stalls when it runs out of fuel, turn the ignition key to the OFF position and disconnect the battery negative cable.
Inspection And Maintenance Of The Fuel Storage Cylinder The fuel storage cylinder should be inspected daily or at the beginning of each operational shift for any leaks, external damage, adequate fuel supply and to ensure the manual service valve is open. Fuel storage cylinders should always be securely mounted, inspect the securing straps or retaining devices for damage ensure that all locking devices are closed and locked. Check to ensure that the fuel storage cylinder is positioned with the locating pin in the tank collar on all horizontally mounted cylinders this will ensure the proper function of the cylinder relief valve.
IMPORTANT: A small amount of fuel may still be present in the fuel line. Use gloves and proper eye protection to prevent burns. If liquid fuel continues to flow from the connections when removed, make sure the manual valve is fully closed. 5. Slowly loosen the inlet fitting and disconnect. 6. Slowly loosen the outlet fitting and disconnect. 7. Remove the filter housing form the equipment. 8. Check for contamination. 9. Tap the opening of the filter on a clean cloth. 10. Check for debris. 11. Check canister for proper mounting direction. 12. Reinstall the filter housing to the equipment. 13. Tighten the inlet and outlet fittings to specification. 14. Open the manual valve.
When refueling or exchanging the fuel cylinder, check the quick fill valve for thread damage. Also verify O-ring is in place and inspect for cracks, chunking or separation. If damage to the o-ring is found, replace prior to filling. Check the service line quick coupler for any thread damage. IMPORTANT: When refueling the fuel cylinder, wipe both the female and male connection with a clean rag prior to filling to prevent dust, dirt and debris from being introduced to the fuel cylinder. Inspection And Replacement Of The Fuel Filter The fuel system on this emission certified engine may utilize an in-line replaceable fuel filter element. This element should be replaced, at the intervals specified in the recommended maintenance schedule. When inspecting the fuel filter check the following:
Check to make sure filter is securely mounted. Check filter housing for external damage or distortion. If damaged replace fuel filter.
Check for leaks at the inlet and outlet fittings, using a soapy solution or an electronic leak detector and repair if necessary.
15
will help the oils to flow freely from the regulator.
Direct Electronic Pressure Regulator (Depr) Maintenance And Inspection
To drain the regulator, follow the steps below:
IMPORTANT: The Direct Electronic Pressure Regulator (DEPR) components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine.
1. Move the equipment to a well ventilated area and ensure no external ignition sources are present. 2. Start the engine. 3. With the engine running close the manual valve. 4. When the engine runs out of fuel turn OFF the key when the engine stops and disconnect the negative battery cable.
If the DEPR fails to operate or develops a leak, it should be repaired or replaced with the OEM recommended replacement parts. When inspecting the system check for the following items:
IMPORTANT: A small amount of fuel may still be present in the fuel line, use gloves to prevent burns, wear proper eye protection. If liquid fuels continues to flow from the connections when loosened check to make sure the manual valve is fully closed.
Check for any fuel leaks at the inlet and outlet fittings. Check for any fuel leaks in the IEPR body. Check the inlet and outlet fittings of the coolant supply lines for water leaks if applicable. Check to ensure the IEPR is securely mounted and the mounting bolts are tight. Check IEPR for external damage. Check IEPR electrical connection to ensure the connector is seated and locked.
5. Loosen the hose clamp at the inlet and outlet hoses and remove the hoses. 6. Remove the regualtor mounting bolts. 7. Place a small receptacle in the engine compartment. 8. Rotate the regulator to 90° so that the outlet fitting is pointing down into the receptacle and drain the regulator. 9. Inspect the secondary chamber for any large dried particles and remove. 10. Remove the receptacle and reinstall the regulator retaining bolts and tighten to specifications. 11. Reinstall the fuel hoses.. 12. Reconnect any other hoses removed during this procedure. 13. Slowly open the manual service valve. IMPORTANT: The fuel cylinder manual valve contains an ―Excess Flow Check Valve‖ open the manual valve slowly to prevent activating the ―Excess Flow Check Valve.‖
Checking/Draining Oil Build-Up In The Vaporizer Regulator During the course of normal operation for LPG engines oil or ―heavy ends‖ may build inside the secondary chamber of the Vaporizer Regulator. These oil and heavy ends may be a result of poor fuel quality, contamination of the fuel, or regional variation of the fuel make up. A significant build up of oil can affect the performance of the secondary diaphragm response. The Recommended Maintenance Schedule found in this section recommends that the oil be drained periodically. This is the minimum requirement to maintain the emission warranty. More frequent draining of the Vaporizer Regulator is recommended where substandard fuel may be a problem. Cat Lift Trucks recommends the Vaporizer Regulator be drained at every engine oil change if contaminated or substandard fuel is suspected or known to be have been used or in use with the emission complaint fuel system. This is known as special maintenance, and failure to follow this recommendation may be used to deny a warranty claim.
14. Check for leaks at the inlet and outlet fittings using a soapy solution or an electronic leak detector. If leaks are detected make repairs. Check coolant line connections to ensure no leaks are present. 15. Start engine recheck for leaks at the regulator. 16. Dispose of any drained material in safe and proper manner.
IMPORTANT: Draining the regulator when the engine is warm
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Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
The HEGO sensor is sensitive to silicone based products. Do not use silicone sprays or hoses which are assembled using silicone lubricants. Silicone contamination can cause severe damage to the HEGO.
IMPORTANT: The Air Fuel Mixer components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine. The mixer should not be disassembled or rebuilt. If the mixer fails to operate or develops a leak the mixer should be replaced with the OEM recommended replacement parts.
When inspecting the Exhaust system check the following:
Exhaust manifold at the cylinder head for leaks and that all retaining bolts and shields (if used) are in place. Manifold to exhaust pipe fasteners to ensure they are tight and that there are no exhaust leaks repair if necessary. HEGO electrical connector to ensure connector is seated and locked, check wires to ensure there is no cracking, splits chafing or ―burn through.‖ Repair if necessary. Exhaust pipe extension connector for leaks tighten if necessary If the engine is equipped with a catalytic converter inspect the converter to ensure it is securely mounted. Check for any leaks at the inlet and outlet of the converter.
When inspecting the mixer check for the following items:
Leaks at the inlet fitting. Fuel inlet hose for cracking, splitting or chaffing, replace if any of these condition exist. Ensure the mixer is securely mounted and is not leaking vacuum at the mounting gasket or surface. Inspect air inlet hose connection and clamp. Also inspect inlet hose for cracking, splitting or chafing. Replace if any of these conditions exist. Inspect Air cleaner element according to the Recommended Maintenance Schedule found in this section. Check Fuel lines for cracking, splitting or chafing. Replace if any of these conditions exist. Check for leaks at the throttle body and intake manifold.
Exhaust System And Catalytic Converter Inspection And Maintenance IMPORTANT: The exhaust system on this emission certified engine contains a Heated Exhaust Gas Oxygen Sensor (HEGO) which provides feed back to the ECM on the amount of oxygen present in the exhaust stream after combustion. The oxygen in the exhaust stream is measured in voltage and sent to the ECM. The ECM then makes corrections to the fuel air ratio to ensure the proper fuel charge and optimum catalytic performance. Therefore, it is important that the exhaust connections remain secured and air tight.
IMPORTANT:
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LPG Certified Engine Maintenance Requirements Daily General Maintenance Section Visual check for fluid leaks Check engine oil level Check coolant level Change engine oil and filter Check LPG system for leaks Inspect accessory drive belts for cracks, breaks, splits or glazing Inspect electrical system wiring for cuts, abrasions or corrosion Inspect all vacuum lines and fittings for cracks, breaks or hardening Engine Coolant Section Clean debris from radiator core Change coolant Inspect coolant hoses for cracks, swelling or deterioration Engine Ignition System Inspect Battery case for leaks or damage Inspect battery cables for damage corrosion or contamination Check all electrical connector retainer locks Replace spark plugs Replace distributor cap and rotor Clean secondary ignition coil tower Check spark plug wires for cuts abrasions or hardening Replace spark plug wires Fuel System Maintenance Inspect air cleaner Replace filter element Replace fuel filter Inspect Shut-off Valve for leaks and closing Check throttle linkage for sticking Leak check fuel lines Check air induction for leaks Check manifold for vacuum leaks Check injector & rails for leaks Inspect EPR for coolant leaks Drain EPR oil build up Engine Exhaust System Inspect exhaust manifold for leaks Inspect exhaust piping for leaks Check HEGO sensor connector and wires for burns, cuts or damage Inspect catalyst for mechanical damage
1000
1500
2000
Interval Hours 2500 3000 3500
4000
4500
5000
X X X X
X X X X X
Every 200 hours or 30 days of operation Prior to any service or maintenance activity X X X X X X X Every 200 hours or 3 months of operation Every 1200 hours or 6 months, whichever comes first X X X X X X X X X X
X X X X
X X X X X X
X
X X X X
X
X
Every 200 hours, or every 100 hours in dusty environments Annually, or Bi-annually in dusty environments X X X X X X X X X X X X X X X Annually or every 2000 hours Every 2500 hrs X X X X
X X X X
Perform the following maintenance on the engine at the hours indicated and at the equivalent hour intervals thereafter. This maintenance schedule represents the manufacturer’s recommended maintenance intervals to maintain proper engine/equipment function. Federal, State, or Local regulations may require additional or more frequent inspection or maintenance intervals than those specified above. Check with the authority having jurisdiction for details.
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X
LPG Fuel System
19
Mobile Engine Lpg Fuel System Schematic
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Description And Operation Of The Fuel Systems
Electric Fuel Lock-Off Valve
Ng & Lpl Fuel System
The primary components of the fuel system are the fuel supply, direct electronic pressure regulator (DEPR), fuel mixer, electronic throttle control (ETC) device, 2-Stage convertor, engine control module (ECM), and a catalytic converter. The system operates on a slightly positive fuel pressure. Primary fuel pressure can be measured at the LD 2-Stage convertor. Secondary fuel pressure command and actual fuel pressure is monitored by the ECM. You can view these pressures using the diagnostic service tool. Service Lines
The Electric Fuel lock-off valve is an integrated assembly consisting of a 12 volt solenoid and a normally closed valve. When energized, the solenoid opens the valve and allows the fuel to flow through the device. The valve opens during cranking and engine run cycles.
ELECTRIC FUEL LOCK-OFF
Fuel flows from the fuel supply to the electric lock off valve. The service lines are not supplied by the engine manufacturer. Please contact the equipment manufacturer regarding fuel service lines
Voltage to the Electric Lock-Off Valve is controlled by the engine control module (ECM).
Direct Electronic Pressure Regulator (Depr)
Fuel Filter
LP, fuel like all other motor fuels is subject to contamination from outside sources. Refueling of the equipment tank and removal of the tank from the equipment can inadvertently introduce dirt and other foreign matter into the fuel system. It is therefore necessary to filter the fuel prior to entering the fuel system components down stream of the tank. An inline fuel filter has been installed in the fuel system to remove the dirt and foreign matter from the fuel, which is replaceable as a unit only. Maintenance of the filter is critical to proper operation of the fuel system and should be replaced according to the maintenance schedule or more frequently under severe operating conditions.
The ECI engine management system uses the DEPR to control fuel delivery for the precise fuel metering necessary for optimum combustion, fuel economy and transient response. The DEPR is available in either a 19 or a 28 mm size. The DEPR is a single-stage microprocessor based electromechanical fuel pressure regulator that incorporates a high speed/fast acting actuator. It communicates with the Engine Control Module (ECM) over a Controller Area Network (CAN) link, receiving fuel pressure commands and broadcasting DEPR operating parameters back to the ECM. The DEPR can regulate fuel pressure from -18 to +13 inches of water column above the Mixer air inlet pressure, providing sufficient control authority to stall an engine either rich or lean. When the DEPR receives an output pressure command from the ECM, the valve is internally driven to attain targeted fuel pressure, the DEPR then closes the loop inter-
Inline Fuel Filter
21
nally using a built in fuel pressure sensor to tain target fuel pressure/fuel flow rate, until another external command from the ECM is received (intervals < 10 ms). The DEPR has an integral fuel temperature sensor that is used by the ECM to correct for variations in fuel density. This strategy provides an extremely accurate method for open loop fuel control. Then with the addition of the preand post-cat oxygen sensors, the pressure command transmitted form the ECM can be further adjusted using closed loop feedback
air valve diaphragm between the air valve vacuum chamber and the atmospheric pressure below the diaphragm. The vacuum being created is referred to as Air Valve Vacuum (AVV). As the air valve vacuum reaches the imbalance point, the air valve begins to lift against the air valve spring. The amount of AVV generated is a direct result of the throttle position. At low engine speed the air valve vacuum and the air valve position is low thus creating a small venturi for the fuel to flow. As the engine speed increases the AVV increases and the air valve is lifted higher thus creating a much larger venturi. This air valve vacuum is communicated from the mixer venturi to the IEPR via the fuel supply hose. The mixer is equipped with a low speed mixture adjustment retained in a tamper proof housing. The mixer has been preset at the factory and should not require adjustment. In the event that the idle adjustment should need to be adjusted refer to the Fuel System Repair section of this manual.
The air/fuel mixer is an emission control device. Components inside the mixer are specifically calibrated to meet the engine’s emissions requirements and should never be disassembled or rebuilt. If the mixer fails to function correctly, replace with an OEM replacement part.
Direct Electronic Pressure Regulator
The IEPR is an emission control device and should only be serviced by qualified technicians. Air Fuel Mixer The air valve mixer is a self-contained air-fuel metering device. The mixer is an air valve design, utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking speeds to full load. The mixer is mounted in the air stream ahead of the throttle control device. When the engine begins to crank it draws in air with the air valve covering the inlet, and negative pressure begins to build. This negative pressure signal is communicated to the top of the air valve chamber through vacuum ports in the air valve assembly. A pressure/force imbalance begins to build across the
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Air Valve Mixer
Light Duty 2-Stage Vaporizer
The tier 3 certified mobile products utilize a 2stage vaporizer as part of the fuel system. The primary function of this part is to convert liquid LP fuel into a propane vapor. The vapor is then introduced into the DEPR where the pressures are regulated. Converting the fuel from a liquid to a vapor is accomplished by passing the propane through a heat exchanger inside the convertor. Coolant flows through the convertor as part of the heat exchange process.
engine ECM when the operator depresses or release the foot pedal. The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air/fuel charge to the engine. The electronic throttle control device incorporates two internal Throttle Position Sensors (TPS) which provide output signals to the ECM as to the location of the throttle shaft and blade. The TPS information is used by the ECM to correct for speed and load control as well as emission.
LD 2-Stage Vaporizer Electronic Throttle Control Device Electronic Throttle Control Device (Etc)—
Three-Way Catalytic Converter
Engine speed is controlled by the ECM and the Electronic Throttle Control device which is an automotive style throttle. The ECM controls engine speed one of several ways depending on the equipment manufacturer‘s requirement. Engine speed can be controlled by discrete speed governing, whereby the OEM sends an open, high or low voltage signal to an ECM pin. The ECM then targets the preprogrammed speed for that pin. The other two modes are through the use of a foot pedal or a hand throttle controller. In both cases the foot pedal or hand throttle controller will send a 0-5 volt signal to the ECM. The ECM is programmed with an idle and high speed and interprets speed in between the two based on voltage.
The Catalytic Converter is a component of the emissions system which is designed to meet the emission standards in effect for the Tier 3 mobile certified product.
When the engine is running electrical signals are sent from the foot pedal position sensor to the
Three Way Catalytic Converter Engine Control Module
The exhaust gases pass through the honeycomb catalyst which is coated with a mixture of precious group metals to oxidize and reduce CO, HC and NOX emission gases.
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technician can than utilize a computerized diagnostic scan tool to retrieve the stored diagnostic code and by using the diagnostic charts in this manual to determine the cause of the malfunction. In the event a technician does not have the computerized diagnostic tool, the MIL light can be used to identify the diagnostic code to activate the ―blink‖ feature and count the number of blinks to determine the diagnostic code number to locate the fault in the system.
To obtain maximum effect from the catalyst and accurate control of the air fuel ratio, the emission certified engine is equipped with an onboard computer or Engine Control Module (ECM). The ECM is a 32 bit controller which receives input data from sensors mounted to the engine and fuel system and then outputs various signals to control engine operation.
Heated Exhaust Gas Oxygen Sensors The Heated Exhaust Gas Oxygen (HEGO) Sensors are mounted in the exhaust system, one upstream and one downstream of the catalytic converter. Models that do not use a catalyst assembly will only use one HEGO sensor. The HEGO sensors are used to measure the amount of oxygen present in the exhaust stream to determine whether the air-fuel ratio is to rich or to lean. It then communicates this measurement to the ECM. If the HEGO sensor signal indicates that the exhaust stream is too rich, the ECM will decrease or lean the fuel mixture during engine operation. If the mixture is too lean, the ECM will richen the mixture. If the ECM determines that a rich or lean condition is present for an extended period of time which cannot be corrected, the ECM will set a diagnostic code and turn on the MIL light in the dash. By monitoring output from the sensor upstream and the sensor downstream of the catalytic converter, the ECM can determine the performance of the catalyst.
Engine Control Module (ECM) One specific function of the controller is to maintain a closed loop fuel control which is accomplished by use of the Heated Exhaust Gas Oxygen sensor (HEGO) mounted in the exhaust system. The HEGO sensor sends a voltage signal to the controller which then outputs signals to the EPR to change the amount of fuel being delivered from the regulator or mixer to the engine. The controller also performs diagnostic functions on the fuel system and notifies the operator of engine malfunctions by turning on a Malfunction Indicator Light (MIL) mounted in the dash. Malfunctions in the system are identified by a Diagnostic Trouble Code (DTC) number. In addition to notifying the operator of the malfunction in the system, the controller also stores the information about the malfunction in its memory. A
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Coolant Temperature Sensor The Engine Coolant Temperature sensor or ECT is a variable resistance thermistor that changes resistance as the engine's coolant temperature changes. The sensor's output is monitored by the ECM to determine a cold start condition and to regulate various fuel and emission control functions via a closed loop emission system. The Heat Exhaust Gas Oxygen (HEGO) Sensor
Oil Pressure Sender
HEGO1 (upstream or before the catalytic converter) and HEGO2 (downstream) voltage output.
The Engine Oil Pressure sensor is designed to ensure adequate lubrication throughout the engine. It provides a pressure value for the oil pressure gauge and is monitored by the ECM. If the pressure drops, an MIL will occur.
The Heated Exhaust Gas Oxygen Sensor (HEGO) is an emissions control component. In the event of a failure, the HEGO should only be replaced with the recommended OEM replacement part. The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers or air or fuel hoses treated with a silicone based lubricant. Tmap Sensor The Temperature Manifold Absolute Pressure or TMAP sensor is a variable resistor used to monitor the difference in pressure between the intake manifold and outside or atmospheric pressure and the temperature. The ECM monitors the resistance of the sensor to determine engine load (the vacuum drops when the engine is under load or at wide open throttle). When the engine is under load, the computer may alter the fuel mixture to improve performance and emissions. The temperature is also monitored by the ECM, primarily to richen the fuel/air mixture during a cold start.
Closed-Loop Fuel Control
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Fuel System Diagnosis
27
FUEL SYSTEM DIAGNOSIS
Direct Electronic Pressure Regulator Assembly ment operating on LPG. If the equipment will not continue to run, refer to Hard Start for preliminary checks.
Fuel System Description The Engine Control Module (ECM) receives information from various engine sensors in order to control the operation of the Direct Electronic Pressure Regulator (DEPR) and lock-off Valve. The lock-off Valve solenoid prevents fuel flow unless the engine is cranking or running.
Inspect the fuel supply lines to verify they are properly connected and do not have any kinks or damage
Verify the fuel lock off valve is operating properly. Refer to the OEM for information on the fuel shut off valve.
At Key ON, the DEPR valve receives a two (2) second prime pulse from the ECM, allowing time for the fuel to flow through the fuel filter and fuel lines to the DEPR.
Tools Required: DST
Fuel travels from the lock-off to the light duty 2stage regulator into the DEPR.
Engine cranking generates vacuum which provided lift for the mixer air valve and is commonly referred to as air valve vacuum. Once in the mixer, the fuel is combined with air and is drawn into the engine for combustion.
Diagnostic Scan Tool (DST)
Pressure Gauges
Diagnostic Aids This procedure is intended to diagnose equip-
28
Part Number: o 93768-10010 - Kit, Service Tool GM
will require additional diagnosis.
Test Description The basis of the fuel system test is to determine if the fuel is operating within proper fuel control parameters. This fuel control system operates on the basis of short term and long term fuel correction to compensate for the normal operation and aging of the engine. Abnormal operation of the engine, due to a component issue or lack of maintenance will cause fuel system control parameters to operate outside of the normal range.
How the Correction Factors Work The correction factors are displayed in the DST as a positive or negative percent. The numbers will range between -35% and +35%. A negative fuel correction number indicates the removal of fuel.
The fuel system correction factors are viewable using the laptop based Diagnostic Service Tool (DST).
An outside condition causing the system to be rich, such as a restricted air cleaner, can cause a negative short term and long term fuel correction. An outside condition causing the system to be lean, such as a vacuum leak, can cause a positive fuel correction.
The short term correction factor is a percentage based fuel correction that will immediately be applied once the engine reaches the closed loop fuel control mode. The short term correction factor is known as ―Closed Loop 1‖ on the DST.
Determining Total Fuel Correction
The long term correction factor writes the short term correction into long term memory so it is available immediately on the next start/run cycle. The long term correction factor is known as ―Adaptive 1‖ on the DST.
The total fuel correction is the sum of the short term correction (Closed Loop 1) and the long term correction (Adaptive 1).
Closed Loop 1 and Adaptive 1 can be viewed on the Closed Loop Control panel on the Faults Page of the DST.
For instance, a Closed Loop 1 reading of -1.5% and an Adaptive 1 reading of -3.5% would mean a total fuel correction of -5% was taking place at that time. The system is removing 5% fuel at that time. A Closed Loop 1 reading of 1.5% and an Adaptive 1 reading of 3.5% (note both are positive numbers) would mean that a total fuel correction of 5% was taking place at that time. The system is adding 5% fuel.
Closed Loop 1 & Adaptive 1
Any parameter found to be out of conformance
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Normal & Abnormal Fuel Correction If total fuel correction is found to be operating outside of the normal range additional diagnostic procedure will be required to determine the cause. Follow the appropriate Symptom Routine or DTC Chart for additional help.
Generally, the system is operating within specification when total fuel correction falls between 15% and +15%. Operation outside of this range will require further diagnosis to determine the system level issue affecting fuel control. The system will set Diagnostic Trouble Codes (DTC‘s) for correction factors in the +/- 30%-35% range.
Total Fuel Correction Chart System Removing Fuel -35%
-30%
-25%
-20%
-15%
System Adding Fuel -10%
-5%
0%
5%
10%
= Normal Fuel Correction = Abnormal Fuel Correction without DTC = Abnormal Fuel Correction with DTC
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15%
20%
25%
30%
35%
Fuel System Symptom Diagnostics Checks
Action Before using this section, you should have performed On Board Diagnostic (OBD) Check and determined that:
Before Using This Section
1. The ECM and MIL are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check. These checks are very important as they can lead to prompt diagnosis and correction of a problem.
Fuel System Check
1. Verify the customer complaint. 2. Locate the correct symptom table. 3. Check the items indicated under that symptom. 4. Operate the equipment under the conditions the symptom occurs. Verify HEGO switching between lean and rich. IMPORTANT! Normal HEGO switching indicates the fuel system is in closed loop and operating correctly at that time. 5. Take a data snapshot using the DST under the condition that the symptom occurs to review at a later time.
Check all ECM system fuses and circuit breakers. Check the ECM ground for being clean, tight and in its proper location. Check the vacuum hoses for splits, kinks and proper connections. Check thoroughly for any type of leak or restriction. Check for air leaks at all the mounting areas of the intake manifold sealing surfaces. Check for proper installation of the mixer assembly. Check for air leaks at the mixer assembly. Visual and Physical Checks
Check the ignition wires for the following conditions: Cracking Hardening Proper routing Carbon tracking. Check the wiring for the following items: proper connections, pinches or cuts. The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the DST readings do not indicate a problem, then proceed in a logical order, easiest to check or most likely to cause the problem.
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Intermittent Checks
Action
DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables with this condition may result in the replacement of good parts. Faulty electrical connections or wiring can cause most intermittent problems. Check the suspected circuit for the following conditions:
Faulty Electrical Connections or Wiring
Operational Test
Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully seated in the connector (backed out). Terminals not properly formed or damaged. Wire terminals poorly connected. Terminal tension is insufficient. Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the connector terminals in the problem circuit in order to ensure the proper contact tension (except those noted as ―Not Serviceable‖). See section Wiring Schematics. Checking for poor terminal to wire connections requires removing the terminal from the connector body.
If a visual and physical check does not locate the cause of the problem, operate the vehicle with the DST connected. When the problem occurs, an abnormal voltage or scan reading indicates a problem circuit. The following components can cause intermittent MIL and no DTC(s):
Intermittent MIL Illumination
A defective relay. Switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating. The improper installation of add on electrical devices, such as lights, 2way radios, electric motors, etc. The ignition secondary voltage shorted to a ground. The MIL circuit or the Diagnostic Test Terminal intermittently shorted to ground. The MIL wire grounds.
To check for the loss of the DTC Memory:
Loss of DTC Memory
1. Disconnect the TMAP sensor. 2. Idle the engine until the MIL illuminates. 3. The ECM should store a TMAP DTC which should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store and remain, the ECM is faulty.
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No Start Checks Action DEFINITION: The engine cranks OK but does not start. Preliminary Checks None Use the DST to : Check for proper communication with both the ECM Check all system fuses engine fuse holder. Refer to Engine Controls ECM Checks Schematics. Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for each. Check the TMAP sensor. Sensor Checks Check the cam angle sensor for output (RPM). Important: A closed LPG manual fuel shut off valve will create a no start condition. Fuel System Checks
Check for air intake system leakage between the mixer and the throttle body. Verify proper operation of the low pressure lock-off solenoids. Verify proper operation of the fuel control solenoids. Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis. Check for proper mixer air valve operation.
Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. 1. Check for the proper ignition voltage output with J 26792 or the equivalent. 2. Verify that the spark plugs are correct for use with LPG. Ignition System Checks
Check the spark plugs for the following conditions: Wet plugs. Cracks. Wear. Improper gap. Burned electrodes. Heavy deposits. Check for bare or shorted ignition wires. Check for loose ignition coil connections at the coil.
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No Start Checks
Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system.
Engine Mechanical Checks
Exhaust System Checks
Check for the following: Vacuum leaks. Improper valve timing. Low compression. Improper valve clearance. Worn rocker arms. Broken or weak valve springs. Worn camshaft lobes. Check the exhaust system for a possible restriction: Inspect the exhaust system for damaged or collapsed pipes: Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
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Hard Start Checks
Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. Preliminary Checks
Make sure the vehicle‘s operator is using the correct starting procedure.
Sensor Checks
Check the Engine Coolant Temperature sensor with the DST. Compare the engine coolant temperature with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 10 degrees greater or less than the ambient air temperature on a cold engine, check for high resistance in the coolant sensor circuit. Check the cam angle sensor. Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor connections.
Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition. Fuel System Checks
Check mixer assembly for proper installation and leakage. Verify proper operation of the low pressure lock-off solenoid. Verify proper operation of the EPR. Check for air intake system leakage between the mixer and the throttle body. Check the fuel system pressures. Refer to the Fuel System Diagnosis. Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
Ignition System Checks
Verify the excess flow valve is not tripped or that the manual shut-off valve is not closed.
Check for the proper ignition voltage output with J 26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped.
Check the spark plugs for the following conditions: Wet plugs. Cracks. Wear. Burned electrodes. Heavy deposits Check for bare or shorted ignition wires. Check for moisture in the distributor cap. Check for loose ignition coil connections. Important: 1. If the engine starts but then immediately stalls, check the cam angle sensor. 2. Check for improper gap, debris or faulty connections.
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Hard Start Checks
Action Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system.
Engine Mechanical Checks
Check for the following: Vacuum leaks Improper valve timing Low compression Improper valve clearance. Worn rocker arms Broken or weak valve springs Worn camshaft lobes. Check the intake and exhaust manifolds for casting flash. Check the exhaust system for a possible restriction:
Exhaust System Checks
Inspect the exhaust system for damaged or collapsed pipes. Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
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Cuts Out, Misses Checks Action DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks
None 1. 2. 3. 4.
Start the engine. Check for proper ignition output voltage with spark tester J 26792. Check for a cylinder misfire. Verify that the spark plugs are the correct type and properly gapped.
Remove the spark plugs and check for the following conditions:
Ignition System Checks
Insulation cracks. Wear. Improper gap. Burned electrodes. Heavy deposits.
Visually/Physically inspect the secondary ignition for the following: Ignition wires for arcing and proper routing. Cross-firing. Ignition coils for cracks or carbon tracking Perform a cylinder compression check. Check the engine for the following:
Engine Mechanical Checks
Fuel System Checks
Additional Check
Improper valve timing. Improper valve clearance. Worn rocker arms. Worn camshaft lobes. Broken or weak valve springs. Check the intake and exhaust manifold passages for casting flash. Check the fuel system:
Plugged fuel filter. Low fuel pressure, etc. Refer to LPG Fuel System Diagnosis. Check the condition of the wiring to the low pressure lock-off solenoid.
Check for Electromagnetic Interference (EMI), which may cause a misfire condition. Using the DST, monitor the engine RPM and note sudden increases in rpms displayed on the scan tool but with little change in the actual engine rpm. If this condition exists, EMI may be present. Check the routing of the secondary wires and the ground circuit.
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Hesitation, Sag, Stumble Checks Action DEFINITION: The engine has a momentary lack of response when putting it under load. The condition can occur at any engine speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks None. Check the fuel pressure. Refer to LPG Fuel System Diagnosis. Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a faulty low pressure regulator or a restriction in the fuel system. Fuel System Checks Check the TMAP sensor response and accuracy. Check Shut-Off electrical connection. Check the mixer air valve for sticking or binding. Check the mixer assembly for proper installation and leakage. Check the EPR. Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly. Ignition System Checks
Additional Check
Check for the proper ignition voltage output with J 26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped. Check for faulty spark plug wires. Check for fouled spark plugs. Check for manifold vacuum or air induction system leaks. Check the alternator output voltage.
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Backfire Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Check None. Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire. Ignition System Checks
Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent. Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires. Check the connection at ignition coil. Check for deteriorated spark plug wire insulation.
Remove the plugs and inspect them for the following conditions: Wet plugs. Cracks. Wear. Improper gap. Burned electrodes. Heavy deposits. Important! The LPG Fuel system is more sensitive to intake manifold leakage than a gasoline fuel supply system.
Engine Mechanical Check
Fuel System Checks
Check the engine for the following: Improper valve timing. Engine compression. Manifold vacuum leaks. Intake manifold gaskets. Sticking or leaking valves. Exhaust system leakage. Check the intake and exhaust system for casting flash or other restrictions. Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
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Lack of Power, Sluggishness, or Sponginess Checks
Action
DEFINITION: The engine delivers less than expected power. Preliminary Checks Fuel System Checks
Sensor Checks
Exhaust System Checks
Engine Mechanical Check
Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent. Check for proper installation of the mixer assembly. Check all air inlet ducts for condition and proper installation. Check for fuel leaks between the EPR and the mixer. Verify that the LPG tank manual shut-off valve is fully open. Verify that liquid fuel (not vapor) is being delivered to the EPR. Check the Heated Exhaust Gas Oxygen Sensors (HEGO) for contamination and performance. Check for proper operation of the TMAP sensor. Check for proper operation of the TPS and FPP sensors.
Check the exhaust system for a possible restriction: Inspect the exhaust system for damaged or collapsed pipes. Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter. Check the engine for the following: Engine compression. Valve timing. Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
Additional Check
Refer to the LPG Fuel system OBD System Check. Compare the customer‘s vehicle with a similar unit to verify customer has an actual problem. Do not compare the power output of the vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics. Remove the air filter and check for dirt or restriction. Check the vehicle transmission. Refer to the OEM transmission diagnostics.
Check the ECM grounds for being clean, tight, and in their proper locations. Check the alternator output voltage.
If all procedures have been completed and no malfunction has been found, review and inspect the following items: Visually and physically, inspect all electrical connections within the suspected circuit and/or systems. Check the DST data.
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Rough, Unstable, or Incorrect Idle, Stalling Checks
Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine may shake. Preliminary Check
Sensor Checks
None. Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance: Check for silicone contamination from fuel or improperly used sealant. If contaminated, the sensor may have a white powdery coating result in a high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe driveability problem. Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks
Ignition System Checks
Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem. Check for a sticking mixer air valve. Verify proper operation of the EPR. Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual. Check the EPR fuel pressure. Refer to the LPG Fuel System Diagnosis. Check mixer assembly for proper installation and connection. Check for the proper ignition output voltage using the spark tester J26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped.
Remove the plugs and inspect them for the following conditions: Wet plugs. Cracks. Wear. Improper gap. Burned electrodes. Blistered insulators. Heavy deposits. Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the wires. Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system.
Additional Checks
Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command. Check the ECM grounds for being clean, tight, and in their proper locations. Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality.
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Rough, Unstable, or Incorrect Idle, Stalling Checks
Engine Mechanical Check
Action Check the engine for: Broken motor mounts. Improper valve timing. Low compression. Improper valve clearance. Worn rocker arms. Broken or weak valve springs. Worn camshaft lobes.
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Diagnostic Scan Tool (DST)
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Contents
Installation of the DST package to a personal computer (PC). Software login and password functionality. DST service pages. Updating the ECM calibration using a MOT file. DTC pages.
Examples and snapshots used in this manual are based off of the initial DST tool release as of July, 2007. This tool is frequently updated and the illustrations may vary depending on the changes included in any updated DST display Interface. For example, the Electronic Pressure Regulator (EPR) may be referred to as the ―megajector.‖ Terms, names and descriptions of parts and servicing procedures will be updated based on trade, brand, or common description to more accurately describe the part or service procedure. DST Installation Instructions Before installing the DST software, please be sure your computer meets the minimum system requirements. Supported operating systems are:
Windows Vista Windows XP Windows 2000
Minimum processor speed:
Pentium II 450 MHz Pentium III 1.0 GHz for Windows Vista
Minimum RAM requirement:
Windows Vista 512 MB Windows XP 256 MB Windows 2000 128 MB
* At least one available RS232 serial or USB port. * ECOM cable supports USB port only.
Part Number: o 93768-11900 – Diagnostic Cable, USB
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Insert the CD into your computer and select LATEST_GCP_DISPLAY
Open the ECOM_Driver Folder
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Double Click the setup.exe file - - - > This will launch the installation wizard Select ―NEXT‖ until you finish the installation as shown below
Return to the LATEST_GCP_DISPLAY folder
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Select the PC Display folder
Select the GCP Display icon
Select the GCP Display icon - - - > This will launch the installation wizard
Select NEXT until it says you are finish
Restart your PC
Go to the START button on the lower left corner and find the GCP Display Program
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Password Login Figure 1 shows the password dialog box, which is displayed when a software session begins. Login can be accomplished in two ways. 1. Enter an ―All S/N Password‖ which is a password applicable to all ECMs of a given original equipment manufacture (OEM). 2. Enter a ―Single S/N Password‖ and corresponding ECM serial number for a single ECM. A Single Serial Number password is unique to a specific ECM serial number and permits authorized service personnel to make changes or view information for a specific ECM. 3. In most instances the top ―all‖ serial number boxes should be used for password entry. In this case, do not check the single serial number box. Each password is a 16-character alphanumeric string specific to each Spectrum customer and determines which pages and variables are visible through the software. Passwords are assigned by the OEM support group and may change periodically. Check the ―save password‖ box to automatically retain the password for future use. Note: The password is printed on the CD disk. If it does not have a password or you have questions please contact the OEM.
Figure 1: Populated Password Dialog Box
Password Dialog Box Functions Clear Password Button Erases the current password from the password field. Paste Password Button Allows the user to copy a 16-character string from any word processor and paste the string in the password field. Single Serial Number Access Checkbox Tells the software that the password is applicable for single serial number access. Serial Number Field Only applicable when Single Serial Number Access Checkbox is checked. The entry field must be populated for the 6-digit serial number for which the Single Serial Num-
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ber Access password applies (NOTE: Leading zeros included in the serial number are not quired). Save Password and S/N Checkbox Retains the password, and serial number (if applicable) for the next software session. Should an invalid password be entered, the error prompt shown in figure (2) will be displayed and the software will not load. This prompt signifies the following:
The All S/N password is invalid. The Single S/N password is incorrect for the Single Serial Number entered. An All S/N password is entered for Single Serial Number use. The Single Serial Number password is valid; however, the Single Serial Number Access Checkbox is not checked.
Figure 2: Password Error Prompt If the Single S/N password entered is correct for the software but does not match the entered S/N of the targeted ECM, the prompt in Figure 3 will be displayed.
Figure 3: Incorrect Serial Number Message
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Figure 4 shows the communication status if a valid software password is entered when attempting to connect to an ECM with a different key. In this instance the software will load but will not connect to the target (ECM).
Figure 4: Not Authorized to Connect Message In the event you receive this error message call your OEM support group for more information.
Connecting the Pc to the Engine Wire Harness
Connecting the DST cable A laptop computer, with the diagnostic cable and software is the required tool for performing proper diagnostic testing of the fuel system. It is also used to monitor sensor and actuator values and to read and clear Diagnostic Trouble codes. The DST software also performs several special tests. Connect the system diagnostic cable to the USB port on the back of the computer. Connect the diagnostic cable to the DLC (diagnostic link connector) labeled in the electrical schematic. The DLC is located on the engine harness. The new 8 pin DLC requires the use of the 4 to 8 pin adapter. Turn the computer ON. Start Windows. From the start menu select Programs → PSI GCP Display → PSI GCP Display Place the ignition key in the ON position.
Within several seconds the system Gauge screen should now appear and a green banner in the upper left hand will read ―Connected.‖
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Connecting to the PC using the ECOM cable
To connect using the ECOM cable you must select ECOM from the COM Port drop down menu.
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You will now need to configure the ECOM communication protocol.
Select the CAN for systems with CAN enabled or serial for all others. Then select OK. You are now ready to connect using the ECOM USB DLC cable.
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DST Service Pages
Gauge Page Provides system data in large easy to read displays. Displays ECM configuration information for the ECM software, hardware, serial numbers and calibration dates.
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Raw Volts Page The raw volts page displays the sensor inputs and outputs in a raw voltage format. This page is most commonly used to check values in the diagnostic trouble shooting charts.
Service 1
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The Service 1 screen is used to clear the adaptive learn, shows the MIL status and provides a display for rpm, coolant temperature and spark advance. It also provides a large display to monitor the closed loop mixture control.
Tests Page Provides diagnostic information voltages and sensor outputs and includes diagnostic engine tools such as spark and injector kill controls. Please note that not all features are available for all applications. The disabled item menus are grayed out or rendered inoperative. Spark Kill The spark kill mode allows the technician to disable the ignition on individual cylinders. If the Spark Kill diagnostic mode is selected with the engine running below 1000 rpm, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Spark System Test mode is selected with the engine running above 1000 rpm, the throttle will continue to operate normally. Disabling Ignition Outputs to disable the ignition system for an individual cylinder, use the mouse to highlight the ―Spark Kill‖ button and select the desired coil. The spark output can be re-enabled by using the mouse to highlight the ―Spark Kill‖ button and selecting ―Normal.‖ If the engine is running below 1000 rpm, the spark output will stay disabled for 15 seconds and then re-set. If the engine is running above 1000 rpm, the spark output will stay disabled for 5 seconds and then re-set. This test mode has a timeout of 10 minutes. Record the rpm drop related to each spark output disabled. The spark outputs are arranged in the order which the engine fires, not by cylinder number. Injector Kill The Injector Kill mode is used to disable individual fuel injectors. If the Injector Kill mode is selected with the engine running below 1000 rpm, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Injector Kill mode is selected with the engine running above 1000 rpm, the throttle will continue to operate normally. To disable an injector, use the mouse to select the desired injector. The word ―Normal‖ will change to the Injector you have selected. The injector driver can be re-enabled by selecting again. If the en-
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gine is running below 1000 rpm, the injector driver will stay disabled for 15 seconds and then reset. If the engine is running above 1000 rpm, the injector driver will stay disabled for 5 seconds and then re-set. Record the change in rpm while each driver is disabled. DBW Test Mode The DBW (Drive by Wire) test mode allows the technician to control the throttle directly with the foot pedal or throttle input and is used during the diagnostic routines specified for FPP and TPS for Spectrum systems that use DBW control. FPP position displays the current position of the foot pedal as a percentage. FPP volts display the voltage which the ECM is reading from the FPP sensor. TPS Command displays the commanded throttle position expressed as a percentage, which is being sent to the throttle. TPS Position is the actual percent of throttle opening being sent to the ECM from the throttle. TPS volts display the actual TPS signal voltage the ECM is receiving from the throttle. To select this test mode the engine must be off and the key must be in the ON position. External Power Test The external power test manually activates relays (relay power, fuel pump, and drive-by wire power) controlled by the ECM while the engine is in the ―Stopped‖ or ―Running‖ states. Reverts to normal operation if ―Automatic‖ state is selected or ignition voltage is cycled from high to low.
Faults Page Stores DTC codes that may have occurred in the past (Historic Faults) or current set codes (Active Faults). Includes useful system voltages and sensor readings used while working with the fuel and emission trouble shooting charts. Shows power derate mode status. To erase a historic DTC code, double click on the code with the left mouse button. Then choose to ―Clear All Faults.‖
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Plot/Log Menu Functions The Plot/Log menu allows the user to graphically plot or numerically log variables that have been tagged for plotting/logging. To plot or log variables, a tag must be assigned to each variable of interest. A variable is tagged for plotting/logging through a single right-mouse click in the variable‘s vicinity. Once a variable has been tagged for plotting/logging, it is highlighted in green. Figure 5 shows an example of variables that have been tagged. A maximum of twenty (20) variables may be tagged for logging and a maximum of ten (10) variables may be tagged for plotting. The maximum achievable sample frequency/minimum period is dependent on the number of variables tagged.
Figure 5: Tagged Variables for Plot/Log Once the variables have been tagged as highlighted by the green color fill, select the ―Plot/Log‖ function in the top menu bar as shown below in figure 6.
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Figure 6 Select ―Plot Tags‖ to open the snapshot window Other functions available from the Plot/Log menu include: Clear Tags: Releases all plot/log variables. Plot Tags (Ctrl + P, or P): Graphically plot all tagged variables. Load Plot Setup: Loads and tags variables for plotting/logging that have been stored in a plot file (.plt). Log Tags (Ctrl + L): Numerically log all variables that have been tagged for plotting/logging. Once the Plot Tags menu item has been selected, tagged variables are graphically plotted in a strip chart interface. An example of a plot is shown in Figure 7. Capabilities of the plotter are outlined in Table 1. Start/Stop Button
Start or stop plotting of selected variables
Save Button
Save plotted data displayed in the plot to a comma-separated value file (CSV) on the PC hard drive. Format must not be altered if the Load function is to be used.
Snapshot Button
Convert the plot into a snapshot that may be panned, zoomed, scrolled, and saved
Close Button
Close the DST Plot interface
Load Setup Button
Load tags from a previously saved plot (.plt) file to allow for similar plots and logs to be generated
Load Plot Button
Load a previously saved plot from the PC into the DST Plot interface
Variable Selector Menu
Selects the active variable for axis scaling
Single Shot Acquisition Checkbox*
When checked, this does not allow the plot to scroll past the ‗Time Interval‘ thereby preserving plotted data for post-processing.
Exclusive Serial Use Checkbox*
When checked, this allows exclusive serial communication for the plot variables. Other variables on the active page are not updated.
Min Y Value Field*
Specify the minimum Y-axis scaling for the active variable
Max Y Value Field*
Specify the maximum Y-axis scaling for the active variable
Sample Interval (ms) Field*
Define the sample period for recording and display Frequency (Hz.) = 1000/Sample Interval (ms)
Time Interval (s) Field*
Defines the total sample acquisition time for the plot. *Accessible only when plotter is not running.
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Start plot
Variable selector
Figure 7: DST Plot Click on the ―Start‖ button to start the DST plot function. Click on the variable selector button to view selected sensors
Figure 8: DST Plot Snapshot Click on the ―Save‖ button to save the snapshot as a file. To replay the saved file, open the edis_saplot program from the windows start menu.
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Start Menu → Programs → PSI GCP Display → edis_saplot
DST Plot Interface Functions A graphic tool incorporated in the plotter is the snapshot function. This function allows data collected in a plot to be transferred into a second window for quick graphical post-processing. The snapshot allows the user to zoom in/out, pan left/right, and move cursors along the signal traces to measure the variable values in virtual real-time. An example of a snapshot is shown in Figure 8. Any CSV file in plot format (.plt) may be loaded into the snapshot. Table 2 outlines the available hot key functions of the snapshot screen. Snapshot Hot Key Functions Command <Single, left-click on trace> <Ctrl + Up/Down Arrows> <Ctrl + Left/Right Arrows> <Ctrl+Shift + Up/Down Arrows> <Ctrl+Shift + Left/Right Arrows> <Ctrl + Home> <Ctrl + Page Up> <Ctrl + Page Down> <Page Up> <Page Down> <Left/Right Arrow> <Up/Down Arrow> <Shift + Left/Right Arrow> <Shift + Up/Down Arrow> <Home> <End> <Shift + Up/Down Arrow>
Function Snap closest cursor to data Move/pan plot along y axis Move/pan plot along t axis Zoom plot in and out in y axis Zoom plot in and out in t axis Resize plot to default settings Zoom out by 10% Zoom in by 10% Toggle to previous cursor Toggle to next cursor Follow selected data along trace Follow selected data along trace Move 10 points along trace Move 10 points along trace Go to first visible point on current plot Advance to last visible point on current plot Toggle between traces/variables Table 1
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DST Logger Another data capture function incorporated in the software is the DST logger. This tool serves as a PC data logger for any variable available in the ECM through the interface software. Figure 9 shows the interface display for configuring the DST Log. The interface allows the user to create the filename, set the sample rate for acquisition, set the time interval for sampling, and display the progress of acquisition. A maximum of twenty (20) variables may be tagged for the log. The amount of data stored is only limited by available PC RAM. The resulting text file may then be viewed by any standard Windows text editor/reader program. To create a log file select the ―Log Tags‖ in the drop down menu as shown in figure 6.
Figure 9: DST Log Interface
Malfunction Indicator Lamp (MIL) The Fuel system has built-in diagnostics for system trouble shooting. The system has a dash mounted malfunction indicator lamp (MIL) that provides indications of engine or fuel system related problem. Most engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC) diagnostic trouble code and illuminate the MIL. The MIL serves as notification to the operator of a problem related to the emission control system so the driver can arrange for service as soon as possible. It will also display DTCs that have been stored due to a system malfunction. The MIL should illuminate when the key is in the ON position and the engine is not running. This feature verifies that the lamp is in proper working order. If the MIL does not illuminate with the vehicle key ON/engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the MIL should turn off. If the lamp remains on while the engine is in the start or run mode a diagnostic trouble code may be set. The MIL will be turned OFF after three (3) consecutive run cycles or by clearing the active code with the Diagnostic Scan Tool (DST).
Diagnostic Trouble Codes (DTC) Diagnostic Trouble Codes are set when the Spectrum ECM (Electronic Control Module) runs a diagnostic self test and the test fails. When a DTC is set, the ECM will illuminate the MIL on the instrument panel and also save the DTC in memory. The ECM will continue to run the self test. If the system continues to fail the test, the lamp will stay illuminated and the DTC is stored as an active DTC. If the self test runs and passes, the DTC will be stored as historic DTC. All DTCs are
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stored as historic faults until they are cleared. Most DTCs will automatically clear from memory if the DTC does not reset within 50 to 100 consecutive engine run cycles. While a Diagnostic Trouble Code is current for a sensor, the ECM may assign a default ―limp home‖ value and use that value in its control algorithms. All of the system diagnostic self-tests run continuously during normal vehicle operation. The Diagnostic Trouble Codes can be read by using either the MIL lamp or a laptop computer. Diagnostic Trouble Codes can be cleared from memory with a laptop computer, or by turning the ignition key to the OFF position and removing the ECM power fuse or battery cable for at least 15 seconds. If more than one DTC is detected, start the diagnostic repair with the lowest DTC number set. Diagnose each problem to correction unless directed to do otherwise by the diagnostic chart. The DTCs are numbered in order of importance. Both DTC 112 and DTC122 pertain to the oxygen sensor, so it is possible that a repair that corrects DTC 112 may also correct the problem causing the DTC 122. Diagnostic test charts contained in this manual refer to the DST to be connected and in the ―System Data Mode.‖ This simply means that the DST is connected and communicating with the PC. In some instances the chart will call out a special test mode. An example of this would be instructions for the DST to be connected and in the DBW (drive by wire) mode. Always be sure to follow the special instructions to avoid a false diagnosis of fuel system components.
DLC Communication Error The ECM 5 volt reference circuit powers the Spectrum diagnostic link cable. In the event that the 5 volt reference signal is open or shorted to ground, you will not be able to connect to the system. If you are unable to connect, follow the quick checks listed below: Be sure you are using the correct password and latest software for the system you are connecting to. Check the ECM system power and ground circuits. Refer to DTC 562 for the power schematic. Also check for +12 volts switched power at ECM pin 45 with the ignition key ON. Check for power at the DLC connector for + 5 volts between pin 1 (BLK /LT GRN) and pin 2 (LT GRN RED) with the ignition key in the ON position. You may still be able to retrieve a code using the blink code function if none of the above recommendations prove useful. In the event of a 5 volt reference signal malfunction, DTC 642 or DTC 643 should set. If you find one of these codes using the blink code function, follow the DTC diagnostic chart recommendations for that specific DTC.
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Blink Code Function Although the DST is considered a required tool to access the DTC codes, codes may be retrieved without a laptop computer using the blink code function. To enable this function follow the steps below:
Jump pins 1 and 4 at the DLC connector (see illustration below)
Turn the ignition key to the on position
The system will now enter the self diagnostic blink code mode. Be ready with pen and paper to write down any codes that may be stored.
The ECM will flash the MIL indicator with a pause between represented numbers that represent DTC codes. The sequence starts with code 1654. Code 1654 confirms the system has entered the blink code mode. The ECM will flash code 1654 (3) times before displaying the actual DTC code that may be set. Example: One short blink (pause) six short blinks (pause) five short blinks (pause) four short blinks.
If no DTC codes are found, the ECM will continue to flash 1654 only. This means no stored DTC codes were found. If one of the numbers in the DTC code is zero (0), no flash will occur to represent the zero value—it will be represented as a short pause.
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Diagram 1 When using the DST program to clear a DTC, always select the ―Clear All Faults‖ function to immediately turn the MIL OFF after a successful repair (as shown in diagram 1 above). Intermittent Problems Intermittent fuel system problems can prove to be the most challenging to repair. It is most important to remember when looking to find the cause of these problems, to operate the system in the condition when and where the problem occurs. An example of this would be, if the DST showed a lean fuel mixture at full load, one of the first things to look at would be the fuel pressure. The fuel pressure would need to be monitored while the machine is operating at full load, not at idle because the leaning effect does not occur at idle. Electrical problems should be treated the same way. One excellent tool for finding intermittent electrical problems is the DST plot/log function. Set up the plot for the code that sets. An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot. While watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The resolution of the plot screen is such that you will be able to see any unstable voltages that you would otherwise not see with a standard DVOM. Caution should be used when pressure washing the under hood of any electrical system. Avoid direct pressure spray on the system electrical connectors. They are splash proof, but if water is sprayed directly at the connector moisture can become trapped behind the connector seal and cause serious system problems. Extra care must be taken when probing electrical pins and terminals. Do not bend or spread these terminals as this can also be a source of intermittent problems cause by improper handling of these connectors.
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Engine Wire Harness Repair
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On-Vehicle Service Wire Harness Repair
REPAIRING TWISTED/SHIELDED CABLE
The ECM harness electrically connects the ECM to a various components in both the engine and passenger compartments. Wire harnesses should be replaced with proper part number harnesses. When wires are spliced into a harness, use wire with high temperature insulation only.
1. Remove outer jacket 2. Unwrap aluminum/Mylar tape. Do not remove Mylar.
Low current and voltage levels are used in the system, so it is important that the best possible bond at all wire splices be made by soldering the splices. 3. Untwist conductors, strip insulation as necessary.
Connectors and Terminals Use care when probing a connector or replacing terminals in them to prevent shorting opposite terminals and damage certain components. Always use jumper wires between connectors, for circuit checking. Do not probe through the Weather-Pack seals with oversized wire probes. Use tachometer adapter J 35812 (or equivalent) which provides an easy hook up of the tach lead. The connector test adapter kit J 35616 (or equivalent), contains an assortment of flexible connectors used to probe terminals during diagnosis. Fuse remover and test tool BT 8616, or equivalent, is used for removing a fuse and to adapt fuse holder, with a meter, for diagnosis. Do not solder oxygen sensor wire terminals as these wire ends are used for the sensors oxygen reference.
4. Splice wire using splice clips and rosin core solder. Wrap each splice to insulate. 5. Wrap with Mylar and drain wire (uninsulated) wire.
6.
Open circuits are often difficult to locate by sight due to dirt, oxidation, or terminal misalignment. Merely wiggling a connector on a sensor, or in the wiring harness, may correct the open circuit condition. This should always be considered, when an open circuit, or failed sensor is indicated. Intermittent problems may also be caused by oxidized or loose connections. Before making a connector repair, be certain of the type of connector. Weather-Pack and Compact Three connectors look similar, but are serviced differently.
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Tape over entire juncture and secure.
Metri-Pack
REPAIRING TWISTED LEADS
Some connectors use terminals called MetriPack Series 150. They are also called ―Pull-ToSeat‖ terminals because of the method of installation. The wire is inserted through the seal and connector, the terminal is crimped on the wire and then pulled back into the connector to seat it in place.
1. Locate Damaged Wire. 2. Remove insulation as required.
3. Splice two wires together suing splice clips and rosin core solder.
4. Cover splice with tape to insulate from other wires. 5. Retwist as before and tape with electrical tape and hold in place. MICRO-PACK Refer to Figure 2 and repair procedure for replacement of a Micro-Pack terminal.
Metri-Pack Series 150 Terminal Removal 1. Slide the seal back on the wire. 2. Insert tool BT-8518, or J 35689, or equivalent, as shown in insert ―A‖ and ―B‖ to release the terminal locking tab (2). 3. Push the wire and terminal out through the connector. If reusing the terminal, reshape the locking tab (2). Weather-Pack A Weather-Pack connector can be identified by a rubber seal, at the rear of the connector. The connector is used in the engine compartment to protect against moisture and dirt that may oxidize and/or corrode the terminals. Given the low voltage and current levels found in the electronic system, this protection is necessary to ensure a good connection.
Micropack Connector 1. 2. 3. 4.
Cable Terminal Locking Tang Tool J33095/BT8234-A
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4. Replace terminal. a. Slip new seal onto wire b. Strip 5 mm (.2‖) of insulation from wire. c. Crimp terminal over wire and seal.
Weather-Pack Terminal Repair
5. Push terminal and connector and engage locking tangs. 6. Close secondary lock hinge. 1. Open secondary lock hinge on connector.
Use tool J M28742, or BT8234-A or equivalent to remove the pin and sleeve terminals. If the removal is attempted with an ordinary pick, there is a good chance that the terminal will be bent, or deformed. Unlike standard blade type terminals, these terminals cannot be straightened once they are bent.
2. Remove terminal using tool.
Verify that the connectors are properly seated and all of the sealing rings in place, when connecting leads. The hinge type flap provides a backup, or secondary locking feature for the connector. They are used to improve the connector reliability by retaining the terminals, if the small terminal lock tabs are not positioned properly.
3. Cut wire immediately behind cable seal
Weather-Pack connections cannot be replaced with standard connections. Additional instructions are provided with Weather-Pack connector and terminal packages.
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Diagnostic Trouble Codes (DTCs)
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Malfunction Indicator Lamp (MIL) Operation The emissions control system utilizes a MIL to warn the operator or technician of a possible issue with the engine or emissions control system. The system will keep the MIL illuminated for the entire key cycle in which the trouble code was set. It will keep the MIL illuminated for three additional engine start cycles. If the vehicle is not service by a technician and the condition causing the MIL illumination (DTC) no longer exists, the MIL will remain illuminated for the 3 additional start cycles. The MIL will go out on the 4th start cycle if the condition does not reoccur. If the condition is serviced by a technician and the DTC is cleared using a Diagnostic Service Tool (DST), the MIL will go out immediately. Diagnostic Trouble Codes (DTC) are permanently retained in the historic DTC section until cleared with a DST or the auto clear requirements are met. The auto clear feature will clear out historic faults after 40 start cycles. There are some DTCs that have a ―never forget‖ feature enabled. This causes the ECM to permanently retain the DTC in its memory for future reference. Engine overheat codes often have this feature turned on.
OBD System Check/MIL (Malfunction Indicator Lamp) 70
ECM
C012 MIL G
GRN/YEL
+12 volts in start and run
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Ground
Circuit Description The fuel system is equipped with OBD (On-Board Diagnostics). The system has a dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an engine or fuel system related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTCs that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not illuminate with the vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON.
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HVS Ignition Control System Diagnostics
Before using the Ignition Control Diagnostic chart be sure to check the following items: Spark plug wires: Be sure spark plug wires are in good condition. Check for cuts, breaks, burns, hardness or swelling. LPG fuel requires much higher peak firing voltages compared to gasoline. Check spark pug electrical continuity using a DVOM. Wires should ohm out to no more than 1,000 ohms per foot of wire length. Distributor cap and rotor: Check the cap and rotor assembly for moisture, corrosion or carbon tracking. The ignition timing is not adjustable. Turning the distributor assembly will not change the ignition timing, but will alter the rotor phase. Wipe away dust and debris from the ignition coil tower. System power fuses: Check the system power fuses. These sources supply the ignition coil and module system power. Check that the power and ground terminals are clean and in the proper location.
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Ignition Control System Diagnostic Chart Step 1
2
3
4
5
6
7
8
9
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
DST connected and in the system data mode. Crank the engine and observe the engine speed signal on the DST Is the value greater than the specified value? Check the DST for historical code sets. (Always diagnose and repair codes with the lowest numerical value first). Run the diagnostic chart for DTC 337 Did you find and correct the problem? Run the diagnostic chart for DTC 342 Did you find and correct the problem? Disconnect the ignition module connector C011 Using an LED type test lamp check for a signal between the ignition module connector pin B and battery positive Crank the engine Does the LED test lamp flash while cranking the engine? Using a DVOM check for power between the ignition module connector pin A and engine ground Do you have power?
125 RPM
Go to Step (5)
Disconnect the ignition coil connector C009 Using a digital LED test lamp check for a signal between the ignition coil connector pin B and battery positive Crank the engine Does the LED test lamp flash while cranking the engine? Using a DVOM check for voltage between the ignition coil connector pin A and engine ground Does the DVOM show voltage?
Replace the ignition coil Is the replacement complete?
Go to Step (16)
Go to Step (4)
Go to Step (16) Go to Step(6)
Go to Step (5)
Go to Step (7)
Go to Step (8)
System voltage
Go to Step (9)
Go to Step (16)
73
No Go to OBD System Check Section Go to Step (3)
Go to Step (10)
Repair the system power circuit. Check all system fuses and power relay connections Go to Step (13)
Repair the system power circuit. Check all system fuses and power relay connections _
Step
10
11
12
13
14
15
16
Action Key OFF Disconnect the ECM connector C001 Using a DVOM check for continuity between ignition module connector pin B and ECM connector pin 31 Do you have continuity between them? Using a DVOM check for continuity between ignition module connector pin B and engine ground Do you have continuity between them?
Replace ECM Is the replacement complete? Disconnect coil. Using a DVOM check for continuity between the ignition module connector pin C and engine ground Do you have continuity?
Value(s)
Yes Go to Step (11)
No Repair the open ignition control circuit. See wiring harness repair section.
Repair the shorted to ground ignition control circuit. See wiring harness repair section. Go to Step (16) Go to Step (14)
Go to Step (12)
Using a DVOM check for continuity between the ignition module connector pin D and ignition coil connector pin B Do you have continuity?
Go to Step (15)
Replace the ignition module. Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine check for any stored codes. Does the engine operate normally with no stored codes?
Go to Step (16) System OK
74
Repair the open ignition module ground circuit. See wring harness repair. Repair the open ignition module circuit. See wiring harness repair. Go to OBD System Check
DTC 11 – Intake cam / distributor position error
Conditions for setting the DTC Camshaft Position sensor Check Condition- Engine cranking Fault Condition- Engine RPM‘s greater than 2,000 and difference between the desired CAM position and actual CAM position is greater than 30 CAD MIL Command-ON Circuit Description The CAM position sensor is utilized to distinguish the cylinder event (compression or exhaust), thus making the cylinder identification available to the ECM. The camshaft position sensor is a 3 wire hall effect sensor. One wire for current feed (5v), one for ground, and one for the output signal (CAM 1). The sensor must have a good 5v reference and ground to operate properly. The CAM position and CAM Position desired value is displayed on the ―TESTS‖ page in the GCP display software. This code will set when these two values are more than 30 CAD BTDC apart. To change the CAM position you should rotate the distributor. If rotating the distributor does not correct the issue you should troubleshoot sensor, wiring, and ECM for issues.
75
DTC 16-Never Crank Synchronized at Start
Conditions for setting the DTC Crankshaft Position sensor Check Condition- Engine cranking Fault Condition- Cranking rpm above 90 and more than 4 cranking revolutions without synchronization Adaptive Disabled MIL Command-ON Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems. This fault will set if the ECM detects cranking revolutions without synchronization of the CMP and CKP sensors. Reversed sensor wires, poor wire connections or a faulty system ground are most frequently the cause of this code set.
76
DTC 16 Crank Sync Noise Step
Action
Value(s)
Yes
No
-
1
Did you perform the On-Board (OBD) System Check?
Go to Step (2)
Go to OBD System Check Section Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
Go to Step (3)
2
3
4
Key On, Engine OFF Disconnect the CKP (Crankshaft position) Sensor connector C015 Using A DVOM check for voltage at the CKP sensor connector pin 1 and engine ground (CHECK THIS BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage? Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin 2 and ECM connector pin 22 Do you have continuity between them?
5.0 volts
Go to Step (4)
Go to Step (5)
Using a DVOM check for continuity between CKP connector pin 3 and ECM connector pin 21 Do you have continuity between them?
Go to Step (6)
Inspect the CKP connector C015 terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (10)
5
6
7
8
Inspect the ECM connector C001 terminals 19, 21 and 22 for damage, corrosion or contamination Did you find a problem?
Replace CKP sensor Is the replacement complete?
77
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (7)
Go to step (8)
-
Step 9
10
11
Action
Value(s)
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-16 check for any stored codes. Does the engine operate normally with no stored codes? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-16 check for any stored codes. Does the engine operate normally with no stored codes?
78
Yes
No
Go to Step (11) System OK
-
System OK
Go to Step (9)
Go to OBD System Check
DTC 107-MAP Low Voltage
Conditions for Setting the DTC Manifold Absolute Pressure Sensor Check Condition-Engine cranking or running Fault Condition-MAP voltage less than 0.050 with throttle position greater than 2.0% and engine RPM less than 3000. MIL-ON Adaptive-Disabled Fueling is based on RPM and TPS Limp-Home Condition during this fault. Circuit Description The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake manifold. It is used to measure the pressure of air in the manifold prior to induction. The pressure reading is used in conjunction with other inputs to estimate the airflow rate to the engine, which determines the fuel flow rate. This fault will set if the MAP voltage is less than 0.050 with TPS greater than 2% and engine RPM is less than 3000. The Adaptive Learn will be disabled for the remainder of the key on cycle and the MIL command is on.
79
DTC 107-MAP Low Voltage Step 1
2
3
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine running. DSC (Diagnostic Scan Tool) connected in System Data Mode Does DST display MAP voltage of 0.050 or less with the engine running below 3000 rpm and TPS above 2.0 %? Key OFF Disconnect the MAP sensor connector C006 from the wiring harness Jump the 5 volt reference pin 3 and MAP signal circuit pin 4 together Key ON Does the DST display MAP voltage of 4.5 volts or greater? Inspect MAP connector and pins for corrosion, contamination or mechanical damage Any problems found?
4
5
6
Key OFF Disconnect ECM connector C001 Check for continuity between MAP sensor connector signal pin 4 and ECM MAP signal pin 7. Do you have continuity between them? Check for continuity between MAP sensor connector 5 volt supply signal pin 3 and ECM 5 volt supply pin 19 Do you have continuity between them?
80
Value(s) -
Yes Go to Step (2) Go to Step (3)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to Step (4)
Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6)
Go to Step (5)
Go to Step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
7
8
9
10
11
12
Action Check for continuity between MAP sensor connector ground pin 1 and ECM sensor ground pin 20 Do you have continuity between them?
Value(s)
Yes Go to Step (17)
Probe MAP connector signal circuit pin 4 with a test light connected to battery voltage. Does the DST display MAP voltage of 4.0 or greater?
Go to Step (9)
Key OFF Disconnect ECM connector Check for continuity between MAP sensor connector pin 3 and ECM 5 volt pin 19. Do you have continuity between them?
Go to Step (10)
Check for continuity between MAP sensor connector 5 volt reference pin 3 and engine ground Do you have continuity?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (17)
Inspect ECM and MAP wire harness connector and terminals for corrosion, contamination or mechanical damage Any problems found?
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
81
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (13)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to Step (16)
-
Step
13
Action Disconnect ECM connector Check for continuity between MAP sensor connector signal circuit pin 4 and ECM signal pin 7. Do you have continuity between them?
Check for continuity between MAP sensor connector signal pin 4 and engine ground Do you have continuity? 14
15
Inspect ECM connector and wire harness connector terminals for corrosion, contamination or mechanical damage Any problems found?
Value(s)
Yes Go to Step (14)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (18)
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (15)
Go to Step (16)
16
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
17
Replace MAP sensor Is the replacement complete?
Go to Step (18)
-
System OK
Go to OBD System Check
18
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-107 check for any stored codes. Does the engine operate normally with no stored codes? 82
-
DTC 108-MAP High Pressure
Conditions for Setting the DTC MAP pressure test Check condition-engine running Fault Condition-MAP greater than 17.00 psia with TPS less than 8% and engine rpm greater than 800. MIL-ON Adaptive-disabled Circuit Description The MAP (Manifold Absolute Pressure) is estimated from the MAP sensor. The MAP pressure value is used for fuel, airflow and spark calculations. This fault will set in the event the MAP value is greater than 17.00 psia when the TPS is less than 8% with engine rpm greater than 800.
83
DTC 108-MAP High Pressure Step 1
2
3
4
5
6
7
8
9
10
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON, Engine running at full operating temperature. DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display MAP pressure of 17 psia or greater with the engine running above 800 rpm with a TPS value less than 8%? Key OFF Disconnect the MAP sensor connector C006 Key ON Does the DST display MAP pressure less than 0.05 psia? Probe MAP connector ground pin 1 with a test light connected to battery voltage. Does the test light come on? Check MAP mechanical vacuum connection for correct mounting or possible damage causing leakage. Is the MAP sensor mechanical connection OK? Key OFF Disconnect ECM connector and inspect terminals for damage corrosion or contamination. Is the connection OK?
Replace MAP sensor. Is the repair complete? Disconnect ECM connector and check for continuity between MAP connector sensor ground pin 1 and ECM sensor ground pin 20. Do you have continuity between them?
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? Correct MAP mechanical connection Has the MAP mechanical connection problem been corrected? 84
Yes Go to Step (2)
Go to Step (3)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to Step (4) Go to Step (6)
Go to Step (5) Go to Step (8)
__
Go to Step (6)
Go to Step (10)
Go to Step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. -
Go to Step (11) Go to Step (9)
Go to Step (11) Go to Step (11)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. -
-
Step
11
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-108 check for any stored codes. Does the engine operate normally with no stored codes?
85
Value(s)
Yes System OK
No Go to OBD System Check
DTC 111-IAT Higher Than Expected 1
Conditions for Setting the DTC
Intake Air Temperature Check Condition-Engine Running Fault Condition-Intake Air Temperature greater than 200 degrees F. with engine rpm greater than 700 Condition must be present for a minimum of 60 seconds MIL-ON Adaptive-Disabled during active fault Derate level 1 will occur
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the air intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. This fault will set if the Intake Air Temperature is greater than 200 degrees F. with engine speed greater than 700 rpm. The engine will go into a level 1 derate mode to prevent engine damage.
86
DTC 111-IAT Higher Than Expected 1 Diagnostic Aid This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system.
Ensure that the air inlet is not obstructed, modified or damaged. Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system If none of the above can be found, follow the diagnostic steps for DTC 112-IAT Low Voltage.
87
DTC 112-IAT Low Voltage
Conditions for Setting the DTC
Intake Air Temperature Check Condition Engine Cranking or Running Fault Condition-IAT Sensor Voltage less than 0.050 MIL-ON during active fault Adaptive-Disabled during active fault
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP is located in the engine‘s air intake or intake manifold. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is less than 0.050 volts for 1 second anytime the engine is cranking or running. The ECM will use the default value for the IAT sensor in the event of this fault.
88
DTC 112-IAT Voltage Low Step 1
2
3
4
5
6
7
Action Did you perform the On-Board (OBD) System Check?
Value(s) _
Key ON DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display IAT voltage of 0.050 or less? Key OFF Disconnect the TMAP sensor connector. Key ON Does the DST display IAT voltage of 4.90 volts or greater? Replace TMAP sensor. Is the replacement complete? Key OFF Disconnect ECM wire harness connector C001 Check for continuity between TMAP sensor connector ground pin 1 and TMAP sensor connector signal pin 2 Do you have continuity between them?
__
Check for continuity between TMAP sensor connector signal circuit pin 2 and engine ground. Do you have continuity?
__
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
_
89
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Go to Step (5)
Go to Step (9) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8)
_ Go to Step (6)
Go to Step (7)
_
Step
8
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-112 check for any stored codes. Does the engine operate normally with no stored codes?
90
Value(s)
Yes System OK
No Go to OBD System Check
DTC 113-IAT High Voltage
Conditions for Setting the DTC
Intake Air Temperature Check Condition-Engine Running Fault Condition-IAT Sensor Voltage greater than 4.950 volts MIL-ON during active fault Adaptive-Disabled during active fault
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP is located in the engine‘s air intake or intake manifold.. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm. This fault will set if the signal voltage is greater than 4.950 volts for 1 second or longer. The ECM will use a default value for the IAT sensor in the event of this fault.
91
DTC 113-IAT Voltage High Step
1
2
3
4
5
6
7
8
Action
Value(s)
Yes
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Key ON DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display IAT voltage of 4.950 or greater? Key OFF Disconnect the TMAP sensor connector C006 and jump pins 1 and 2 together Key ON Does the DST display IAT voltage of 0.1 volts or less? Key OFF Jump TMAP sensor connector signal pin 2 to engine ground Key ON Does DST display IAT voltage of 0.1 volts or less? Replace TMAP sensor. Is the replacement complete? Key OFF Disconnect the ECM wire harness connector C001. Check for continuity between TMAP sensor connector signal pin 2 and ECM IAT signal pin 39 Do you have continuity between them?
Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (9) Go to Step (4)
Go to Step (7) Go to Step (6)
__
Go to Step (11) Go to Step (10)
Check for continuity between TMAP sensor connector ground circuit pin 1 and ECM sensor ground circuit pin 20 Do you have continuity between them?
__
Go to Step (10)
Replace the ECM. Is the replacement complete?
_
Go to Step (11)
92
No
_ Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. _
Step
9
10
11
Action
Value(s)
Re-check wire harness and TMAP sensor connector for damage corrosion or contamination Any problems found?
Re-check wire harness and TMAP sensor connectors for damage corrosion or contamination Any problems found?
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-113 check for any stored codes. Does the engine operate normally with no stored codes?
93
Yes
No
Repair the Go to Step (5) circuit as necessary. Refer to Wiring Repairs in Engine Electrical Repair the Go to Step (8) circuit as necessary. Refer to Wiring Repairs in Engine Electrical System OK Go to OBD System Check
DTC 116-ECT Higher Than Expected 1
Conditions for Setting the DTC Engine Coolant Temperature Check Condition-Engine Running Fault Condition-Engine Coolant Temperature reading or estimate greater than 236 degrees F. for greater than 20 seconds MIL-On Power derate (level 1) Adaptive-Disabled during active fault
Circuit Description The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant sensor that is located in the coolant passage. The ECT is used for engine airflow calculation, fuel enrichment, and ignition timing control and to enable certain other temperature dependant operations. This code set is designed to help prevent engine damage from overheating. The ECM provides a voltage divider circuit so when the sensor reading is cool the sensor reads higher voltage, and lower when warm. This fault will set when the coolant exceeds 236 degrees F. for more than 20 seconds. Power derate level one will be enforced during this fault limiting the maximum throttle position to 50%.
94
DTC 116-ECT Higher Than Expected 1
95
DTC 117-ECT/CHT Low Voltage
Conditions for Setting the DTC
Engine Coolant Temperature Check Condition-Engine Running Fault Condition-ECT sensor voltage less than 0.050 MIL-ON during active fault Adaptive-Disabled during active fault
Temp Ohms (deg F) +/-10%
Circuit Description The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant passage. It is used for the engine airflow calculation, cold fuel enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm (see table). This fault will set if the signal voltage is less than 0.050 volts for any period longer than 1 second. The ECM will use a default value for the ECT sensor in the event of this fault.
96
242.4 231.9 211.6 201.4 181.9 163.1 144.9 127.4 102.4 78.9 49.9 23.5 -5.7 -21.2 -30.8 -40.0
101 121 175 209 302 434 625 901 1,556 2,689 5,576 11,562 28,770 49,715 71,589 99,301
DTC 117-ECT/CHT Voltage Low Step 1
2
3
4
5
6
7
Action Did you perform the On-Board (OBD) System Check?
Value(s) _
Key ON DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display ECT voltage of 0.050 or less? Key OFF Disconnect the ECT wire harness connector C007 Key ON Does the DST display ECT voltage of 4.90 volts or greater? Replace ECT sensor. Is the replacement complete? Key OFF Disconnect ECM wire harness connector C001 Check for continuity between ECT sensor connector signal pin A and ECT sensor ground pin B Do you have continuity between them?
__
Check for continuity between ECT sensor connector signal circuit pin A and engine ground. Do you have continuity?
__
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete?
_
97
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Go to Step (5)
Go to Step (8) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8)
_ Go to Step (6)
Go to Step (7)
_
Step
8
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-117 check for any stored codes. Does the engine operate normally with no stored codes?
98
Value(s)
Yes System OK
No Go to OBD System Check
DTC 118-ECT/CHT High Voltage
Conditions for Setting the DTC
Engine Coolant Temperature Check Condition-Engine Running Fault Condition-ECT sensor voltage exceeds 4.950 volts MIL-ON during active fault Adaptive-Disabled
Circuit Description The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant passage. It is used for the engine airflow calculation, cold fuel enrichment and to enable other temperature dependant features. The ECM provides a voltage divider circuit so that when the coolant is cool, the signal reads higher voltage, and lower when warm (see table). This fault will set if the signal voltage is greater than 4.950 volts anytime the engine is running. The ECM will use a default value for the ECT sensor in the event of this fault.
99
Temp Ohms (deg F) +/-10% 242.4 231.9 211.6 201.4 181.9 163.1 144.9 127.4 102.4 78.9 49.9 23.5 -5.7 -21.2 -30.8 -40.0
101 121 175 209 302 434 625 901 1,556 2,689 5,576 11,562 28,770 49,715 71,589 99,301
DTC 118-ECT/CHT Voltage High Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Key ON DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display ECT voltage of 4.95 or greater? Key OFF Disconnect the ECT sensor connector C007 and Jump terminals A and B together Key ON Does the DST display ECT voltage of 0.05 volts or less? Using a DVOM check the resistance between the two terminals of the ECT sensor and compare the resistance reading to the chart Is the resistance value correct?
Replace ECT sensor Is the replacement complete? Inspect the ECT wire harness connector terminals A and B for damage, corrosion or contamination Did you find a problem?
Key OFF Disconnect ECM wire harness connector C001 Inspect ECM connector pins 10 and 20 for damage corrosion or contamination Did you find a problem?
Jump the ECT signal pin A at the ECT connector to engine ground Does DST display ECT voltage of 0.05 or less?
100
Value(s) -
See resistance chart vs. temperature in the DTC 118 circuit description
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Go to Step (8)
Go to Step (6) Go to Step (5)
Go to Step (14) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (9)
Go to Step (7)
Intermittent problem Go to Intermittent section
Go to Step (12)
Step
9
Action Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between ECT sensor ground pin B and ECM connector pin 20 Do you have continuity between them?
Inspect ECM connector pins 40 and 20 for damage, corrosion or contamination Did you find a problem? 10
11
12
Replace ECM Is the replacement complete? Key OFF Disconnect ECM wire harness connector Using a DVOM check for continuity between ECT connector signal pin A and ECM connector terminal 40 Do you have continuity between them?
Inspect ECM connector pins 40 and 20 for damage, corrosion or contamination Did you find a problem? 13
14
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-118 check for any stored codes. Does the engine operate normally with no stored codes? 101
Value(s)
Yes Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (14) Go to Step (13)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. System OK
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to OBD System Check
DTC 121-TPS 1 Lower Than TPS 2
Conditions for Setting the DTC
Throttle Position Sensor 1 & 2 Check Condition-Key ON Fault Condition-TPS 1 20% lower than TPS 2 MIL-ON for remainder of key on cycle Engine shutdown
Circuit description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if TPS 1 is 20% (or more) lower than TPS 2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. The MIL command is on and the engine will shutdown.
102
DTC 121 TPS 1 Lower Than TPS 2 Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2 voltage? Key OFF Disconnect electronic throttle connector C017 Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 less than 0.1 volts? Key OFF Disconnect ECM wiring harness connector C001 Key ON Using a DVOM check for voltage between ECM connector TPS 1 signal pin 5 and engine ground Do you have voltage?
Jump TPS 1 signal pin 6 to the 5 volt reference pin 3 at connector C017 Does DST display TPS 1 voltage over 4.90 volts Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Replace the electronic Throttle Is the replacement complete? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM connector TPS 1 signal pin 5 Do you have continuity between them?
103
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (5)
Go to Step (4)
Repair the Go to Step (9) TPS 1 circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Go to Step (8) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (12) Go to Step (9)
Go to Step (7)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
9
10
11
12
Action Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM connector signal ground pin 20 Do you have continuity between them?
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-121 check for any stored codes. Does the engine operate normally with no stored codes?
104
Value(s)
Yes Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical Go to Step (12) System OK
No Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to OBD System Check
DTC 122-TPS 1 Low Voltage
Conditions for Setting the DTC
Throttle Position Sensor 1 Check Condition-Cranking or Running Fault Condition-TPS sensor less than 0.200 volts MIL-ON during active fault Engine shutdown
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 1 voltage is less than 0.200 volts. The MIL command is ON and the engine will shut down.
105
DTC 122 TPS 1 Signal Voltage Low Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 1 voltage of 0.200 volts or less with the throttle closed? Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever fall below 0.200 volts? Key OFF Disconnect the electronic throttle connector C017 Jump the 5 volt reference circuit pin 3 and TPS 1 signal circuit pin 6 together at the throttle connector Key ON Does DST display TPS 1 voltage of 4.0 volts or greater? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check continuity between the electronic throttle connector signal pin 6 and ECM connector TPS 1 signal pin 5 Do have continuity between them? Replace ECM Is the replacement complete? Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
Replace the electronic throttle Is the replacement complete?
106
Value(s) -
Yes Go to Step (2)
Go to Step (4)
No Go to OBD System Check Section Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section Go to Step (7) Go to Step (5)
Go to Step (6)
Go to Step (9) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8)
-
Step
9
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-122 check for any stored codes. Does the engine operate normally with no stored codes?
107
Value(s)
Yes System OK
No Go to OBD System Check
DTC 123-TPS 1 High Voltage
Conditions for Setting the DTC
Throttle Position Sensor 1 Check Condition-Cranking or Running Fault Condition-TPS sensor voltage exceeds 4.800 volts MIL-ON during active fault Engine shutdown
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 1 voltage exceeds 4.800 volts. The MIL command is ON and the engine will shut down.
108
DTC 123 TPS 1 Signal Voltage High Step 1
2
3
4
5
6 7
8
9
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected Does the DST display TPS 1 voltage of 4.800 volts or greater with the throttle closed? Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever exceed 4.800 volts? Key OFF Disconnect electronic throttle connector Key ON Does DST display TPS 1 voltage less than 0.2 volts? Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between TPS 1 signal at the ECM connector pin 5 and engine ground Do you have voltage? Replace ECM Is the replacement complete? Back probe sensor ground circuit at the ECM side of the wire harness pin 3 with a test light connected to battery voltage Does the test light come on? Inspect the electronic throttle connector terminals for damage, corrosion or contamination Did you find a problem?
Replace the electronic throttle Is the replacement complete?
109
Value(s) -
Yes Go to Step (2)
Go to Step (4)
No Go to OBD System Check Section Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section Go to Step (7) Go to Step (5)
Repair the Go to Step (6) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11) Go to Step (8) Go to Step (10) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to Step (9)
-
Step
10
11
Action Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between the electronic throttle connector sensor ground pin 2 and ECM connector TPS 1 sensor ground pin 20 Do have continuity between them? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-123 check for any stored codes. Does the engine operate normally with no stored codes?
110
Value(s)
Yes Go to Step (6)
System OK
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to OBD System Check
DTC 127-IAT Higher Than Expected 2
Conditions for Setting the DTC
Intake Air Temperature Check Condition-Engine Running Fault Condition-Intake Air Temperature greater than 210 degrees F. with engine speed greater than 700 rpm Fault condition must be active for longer than 120 seconds MIL-ON for active fault Engine will de-rate to 1,400 rpms.
Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine. It is used to monitor incoming air temperature, and the output in conjunction with other sensors is used to determine the airflow to the engine. The ECM provides a voltage divider circuit so that when the air is cool, the signal reads a higher voltage, and lower when warm. This fault will set if the intake air temperature is greater than 210 degrees F. with engine speed greater than 700 rpm. The MIL light command is on during this active fault and the engine will derate to 1,400 rpms.
111
DTC 127-IAT Higher Than Expected 2 Diagnostic Aid
This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged. Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in to the air inlet system If none of the above can be found, follow the diagnostic steps for DTC 112-IAT Low Voltage.
112
DTC 129-BP Low Pressure
Conditions for Setting the DTC
Barometric Pressure Check Condition-Key ON Fault Condition-BP less than 8.30 psia MIL-ON for active fault Adaptive-Disabled
Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of the normal range.
113
DTC 129-BP Low Pressure Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check? Key ON. DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display BP pressure of 8.30 psia or less? Key OFF Disconnect the TMAP sensor connector Jump the 5 volt reference pin 3 and MAP signal pin 4 together Key ON Does the DST display BP pressure of 16.00 psia or greater? Inspect TMAP connector and wire harness connector terminals for corrosion, contamination or mechanical damage Any problems found?
Key OFF Disconnect ECM connector C001 Check for continuity between TMAP sensor connector pin 4 and ECM connector pin 7 Do you have continuity between them? Check for continuity between TMAP sensor connector 5 volt supply pin 3 and ECM connector pin 19 Do you have continuity between them?
Check for continuity between TMAP sensor connector ground pin 1 and ECM connector pin 20 Do you have continuity between them? 7
114
Value(s) -
Yes Go to Step (2)
Go to Step (3)
No Go to OBD System Check Section Intermittent problem. Go to Intermittent section
Go to Step (4) Go to Step (8)
Repair the Go to Step (5) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step circuit as ne(6) cessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step circuit as ne(7) cessary. Refer to Wiring Repairs in Engine Electrical. Go to Step Repair the (17) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
8
9
Action Remove the Jumper that was installed during step 3 Probe TMAP connector signal circuit pin 4 with a test light connected to battery voltage Does the DST display BP pressure of 16.00 psia or greater? Key OFF Disconnect ECM connector C001 Check for continuity between TMAP sensor connector pin 3 and ECM connector pin 19 Do you have continuity between them? Check for continuity between TMAP sensor connector 5 volt reference pin 3 and engine ground Do you have continuity?
10
Inspect TMAP and ECM connector pins for corrosion, contamination or mechanical damage Any problems found? 11
12
13
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? Disconnect ECM connector C001 Check for continuity between TMAP sensor connector pin 4 and ECM pin 7 Do you have continuity between them?
Check for continuity between TMAP sensor connector pin 4 and engine ground Do you have continuity? 14
115
Value(s)
Yes Go to Step (9)
No Go to Step (13)
Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Repair the open ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step(17) Go to Step (14)
Repair the open ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (16)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (15)
Step
15
16 17
18
Action Inspect ECM connector and wire harness connector pins for corrosion, contamination or mechanical damage Any problems found?
Replace ECM. Refer to ECM replacement in the Engine Controls Section. Is the replacement complete? Replace TMAP sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-129 check for any stored codes. Does the engine operate normally with no stored codes?
116
Value(s)
Yes Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (18)
No Go to Step (16)
Go to Step (18) System OK
-
-
Go to OBD System Check
DTC 134-EGO 1 Pre Cat Open/Lazy
Conditions for Setting the DTC
Heated Oxygen Sensor Check condition-Engine running Fault condition-EGO 1 pre catalyst persistently cold for more than 120 seconds MIL-ON during active fault Adaptive-Disabled during active fault Closed Loop-Disabled during active fault
Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the Adaptive multiplier. This fault will set if EGO 1 is cold, nonresponsive, or inactive for more than 120 seconds.
117
DTC 134-EGO 1 Open/Inactive Step 1
2
3
4
5
6
7
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Run engine to full operating temperature and then idle for a minimum of 2 minutes Does DST display EGO 1 voltage fixed between 0.4 and 0.5 volts after at least 2 minutes of idle run time? Key OFF Disconnect EGO 1 connector C005 Key ON Using a DVOM check for voltage between EGO 1 connector pins C and D (Check must be made within 30 seconds or before power relay shuts down) Do you have voltage? Key OFF Using a DVOM check for voltage between EGO 1 connector pin C and engine ground Key ON (Check must be made within 30 seconds or before power relay shuts down) Do you have voltage? Disconnect ECM connector C001 Using a DVOM check for continuity between EGO 1 connector pin D and ECM connector pin 72 Do you have continuity? Inspect wire harness connector C005 pins B and D and C001 pins 1 and 72 for damage, corrosion or contamination Did You find a problem?
Replace ECM Is the replacement complete?
118
Value(s) -
Yes Go to Step (2) Go to Step (3)
Go to Step (8)
System Voltage
No Go to OBD System Check Section Intermittent problem. See Electrical Section Intermittent Electrical Diagnosis Go To Step (4)
Go to Step (5) Repair system power relay open circuit
Go to Step (6)
Repair open heater ground circuit
Correct the problem as required see Electrical Section wire harness repair Go to Step (11)
Go to Step (7)
-
Step
8
9 10
11
Action Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between EGO 1 pin B and ECM connector pin 1 Do you have continuity? Using a DVOM check for continuity between EGO 1 pin A and ECM connector pin 20 Do you have continuity? Replace EGO 1 sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-134 check for any stored codes. Does the engine operate normally with no stored codes?
119
Value(s)
Yes Go to Step (9)
No Repair open EGO 1 circuit
Go to Step (10)
Repair open EGO 1 signal ground -
Go to Step (11) System OK
Go to OBD System Check
DTC 154-EGO 2 Pre Cat Open/Lazy
120
121
122
DTC 217-ECT Higher Than Expected 2
Conditions for Setting the DTC
Engine Coolant Temperature Check Condition-Engine Running Fault Condition-Engine Coolant Temperature reading or estimate greater than 250 degrees F. for greater than 5 seconds MIL-On Engine will derate to 1,400 rpms
Circuit Description The ECT (Engine Coolant Temperature) sensor is a temperature sensitive resistor located in the engine coolant sensor that is located in the coolant passage. The ECT is used for engine airflow calculation, fuel enrichment, and ignition timing control and to enable certain other temperature dependant operations. This code set is designed to help prevent engine damage from overheating. The ECM provides a voltage divider circuit so when the sensor reading is cool the sensor reads higher voltage, and lower when warm. This fault will set when the coolant exceeds 250 degrees F. for more than 5 seconds. Engine shutdown will occur if this code occurs.
123
DTC 217-ECT Higher Than Expected 2
124
DTC 219-Max Govern Speed Override
Conditions for Setting the DTC
Max Govern Speed Override Check Condition-Engine Running Fault Condition-Engine rpm greater than 2,850 Fault condition active for 2 or more seconds MIL-ON during active fault
Circuit description This fault will set anytime the engine rpm exceeds 2,850 for longer than 2 seconds. The MIL command is ON during this active fault Diagnostic Aid Check for other stored DTC codes before using the following DTC chart for this code set. Always diagnose and repair any existing codes starting with the lowest numerical code first.
125
DTC 219-Max Govern Speed Override Step 1
2
3
4 5 6 7
8
9
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4)
Key ON, Engine OFF DST connected Are any other DTC codes present with DTC 219?
Go to Step (3)
Diagnose and repair any other DTC codes stored before proceeding with this chart. Have any other DTC codes been diagnosed and repaired? Check the service part number on the ECM to ensure the correct calibration is in use Is the Service Part Number Correct? Replace ECM with correct service part number Is the replacement complete? Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK? Correct mechanical operation of the throttle. Refer to Engine & Component section Has the mechanical operation of the throttle been corrected? Check engine for large manifold vacuum leaks. Refer to Symptom Diagnostic section Did you find and correct the vacuum leak?
Go to Step (4)
-
Go to Step (6)
Go to Step 5
Go to Step (9)
-
Go to Step (8)
Go to Step (7) -
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-219 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
126
Go to Step (9)
Go to Step (9)
Go to OBD System Check Section Go to OBD System Check
DTC 221-TPS 1 Higher Than TPS 2
Conditions for Setting the DTC
Throttle Position Sensor 1 & 2 Check Condition-Key ON Fault Condition-TPS 1 20% higher than TPS2 MIL-ON for remainder of key on cycle Engine shutdown
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read lower voltage when closed and TPS 2 will read higher voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if TPS 1 is 20% (or more) higher than TPS 2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. The MIL command is ON and the engine will shutdown.
127
DTC 221 TPS 1 Higher Than TPS 2 Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2? Key OFF Disconnect electronic throttle connector C017 Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 less than 0.1 volts? Key OFF Disconnect ECM wiring harness connector C001 Key ON Using a DVOM check for voltage between ECM connector TPS 1 signal pin 5 and engine ground Do you have voltage?
Jump TPS 1 signal pin 6 to the 5 volt reference pin 3 at connector C017 Does DST display TPS 1 voltage over 4.900 volts? Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Replace the electronic Throttle Is the replacement complete? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM connector TPS 1 signal pin 5 Do you have continuity between them?
128
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (5)
Go to Step (4)
Repair the Go to Step (9) TPS 1 circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (12) Go to Step (9)
Go to Step (7)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
9
10
11
12
Action Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM connector signal ground pin 3 Do you have continuity between them?
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-221 check for any stored codes. Does the engine operate normally with no stored codes?
129
Value(s)
Yes Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical Go to Step (12) System OK
No Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to OBD System Check
DTC 222-TPS 2 Signal Voltage Low
Conditions for Setting the DTC
Throttle Position Sensor 2 Check Condition-Cranking or Running Fault Condition-TPS 2 sensor voltage less than 0.200 volts MIL-ON during active fault
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 2 voltage is less than 0.200 volts. The MIL command is ON.
130
DTC 222 TPS 2 Signal Voltage Low Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 2 voltage of 0.200 volts or less with the throttle closed? Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever fall below 0.200 volts? Key OFF Disconnect electronic throttle connector C017 Jumper the 5 volt reference circuit pin 3 and TPS 2 signal circuit pin 5 together at the throttle connector Key ON Does DST display TPS 2 voltage of 4.0 volts or greater? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check continuity between TPS 2 connector signal pin 5 and ECM connector TPS 2 Signal pin 6 Do have continuity between them? Replace ECM Is the replacement complete? Inspect the electronic throttle wire harness connector terminals for damage, corrosion or contamination Did you find a problem?
Replace the electronic throttle Is the replacement complete?
131
Value(s) -
Yes Go to Step (2)
Go to Step (4)
No Go to OBD System Check Section Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section Go to Step (7) Go to Step (5)
Go to Step (6)
Go to Step (9) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (9)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8)
-
Step
9
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-222 check for any stored codes. Does the engine operate normally with no stored codes?
132
Value(s)
Yes System OK
No Go to OBD System Check
DTC 223-TPS 2 Signal Voltage High
Conditions for Setting the DTC
Throttle Position Sensor 2 Check Condition-Cranking or Running Fault Condition-TPS 2 sensor exceeds 4.800 volts MIL-ON during active fault
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position.TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if the TPS 2 voltage is greater than 4.800 volts. The MIL command is ON.
133
DTC 223 TPS 2 Signal Voltage High Step 1
2
3
4
5
6 7
8
9
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive by Wire) throttle test mode Does the DST display TPS 2 voltage of 4.800 volts or greater with the throttle closed? Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever exceed 4.800 volts? Key OFF Disconnect electronic throttle connector C017 Key ON Does DST display TPS 2 voltage less than 0.2 volts? Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between electronic throttle connector TPS 2 signal pin 5 and engine ground Do you have voltage? Replace ECM Is the replacement complete? Probe sensor ground circuit at the ECM side of the wire harness pin 3 with a test light connected to battery voltage Does the test light come on? Inspect the electronic throttle wire harness connector and terminals for damage, corrosion or contamination Did you find a problem?
Replace electronic throttle Is the replacement complete?
134
Value(s) -
Yes Go to Step (2)
Go to Step (4)
No Go to OBD System Check Section Go to Step (3)
Go to Step (4)
Intermittent problem Go to Intermittent section Go to Step (7) Go to Step (5)
Repair the Go to Step (6) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11) Go to Step (8) Go to Step (10) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to Step (9)
-
Step
10
11
Action Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between throttle connector C017 sensor ground pin 2 and ECM connector sensor ground pin 20 Do have continuity between them? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-223 check for any stored codes. Does the engine operate normally with no stored codes?
135
Value(s)
Yes Go to Step (6)
System OK
No Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to OBD System Check
DTC 336-Crank Sync Noise
Conditions for setting the DTC
Crankshaft Position sensor Check Condition- Engine running Fault Condition- 1 invalid crank re-sync in less than 800 ms Adaptive- Disabled MIL- On during active fault
Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems. This fault will set If no signal is present for 800ms or longer.
136
DTC 336 Crank Sync Noise Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
Key On, Engine OFF Disconnect the CKP (Crankshaft position) Sensor connector C015 Using A DVOM check for voltage at the CKP sensor connector pin 1 and engine ground (CHECK THIS BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage? Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin 2 and ECM connector pin 22 Do you have continuity between them? Using a DVOM check for continuity between CKP connector pin 3 and ECM connector pin 21 Do you have continuity between them?
Inspect the CKP connector C015 terminals for damage, corrosion or contamination Did you find a problem?
137
5.0 volts
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (4 Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (7) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
7
8 9
10
11
Action Inspect the ECM connector C001 terminals 19, 22, and 21 for damage, corrosion or contamination Did you find a problem?
Replace CKP sensor Is the replacement complete? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-336 check for any stored codes. Does the engine operate normally with no stored codes? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-336 check for any stored codes. Does the engine operate normally with no stored codes?
138
Value(s)
Yes No Repair the Go to step (8) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (10) Go to Step (11) System OK Go to Step (9)
System OK
Go to OBD System Check
DTC 337-Crank Loss
Conditions for setting the DTC
Crankshaft position sensor Check Condition- Engine cranking Fault Condition- 6 cam pulse signals without crankshaft activity MIL- On during active fault Adaptive- Disabled
Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems. The ECM must see a valid Crankshaft position signal while cranking. If no crankshaft signal is present for 6 cam pulses this fault will set.
139
DTC 337-Crank Loss Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Check that the ECM ground terminals C010, C022 and C023 are clean and tight Are the ground terminals clean and tight?
Key OFF Disconnect the CKP (Crankshaft Position) Sensor connector C015 Using A DVOM check for voltage at the CKP sensor connector pin 1 and engine ground (CHECK THIS BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage? Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CKP connector pin 2 and ECM connector pin 22 Do you have continuity between them? Using a DVOM check for continuity between CKP connector pin 3 and ECM connector pin 21 Do you have continuity between them?
Inspect the CKP connector C015 terminals for damage, corrosion or contamination Did you find a problem?
140
5.0 volts
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (4 Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (7) circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
7
8 9
10
11
Action Inspect the ECM connector C001 terminals 19, 22, and 21 for damage, corrosion or contamination Did you find a problem
Replace the CKP sensor Is the replacement complete? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-337 check for any stored codes. Does the engine operate normally with no stored codes? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-337 check for any stored codes. Does the engine operate normally with no stored codes?
141
Value(s)
Yes No Repair the Go to step (8) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (10) Go to Step (11) System OK Go to Step (9)
System OK
Go to OBD System Check
DTC 341-Camshaft Sync Noise
Conditions for Setting the DTC
Camshaft position sensor Check Condition-Cranking or Running Fault Condition-1 invalid cam re-sync in 700ms or less Adaptive Learn disabled MIL-ON
Circuit Description The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems. This fault will set if the ECM detects erroneous pulses from the camshaft position sensor causing invalid cam re-sync. MIL light will become active and Adaptive Learn will be disabled.
142
DTC 341-Camshaft Sensor Noise Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Check that the ECM ground terminal C010 is clean, tight and in the proper location Are the ground terminals clean and tight?
Key OFF Disconnect the CMP (Camshaft position) Sensor connector C016 Using A DVOM check for voltage at the CMP sensor connector pin C and engine ground Do you have voltage?
Yes Go to Step (2)
Go to Step (3)
5.0 volts
Go to Step (4)
Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CMP connector pin A and ECM connector pin 24 Do you have continuity between them?
Go to Step (5)
Using a DVOM check for continuity between CMP connector pin B and ECM connector pin 23 Do you have continuity between them?
Go to Step (6)
Inspect the CMP connector terminals for damage, corrosion or contamination Did you find a problem?
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
143
No Go to OBD System Check Section Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (7)
Step
7
8 9
10
11
Action Inspect the ECM connector C001 terminals 4, 23, and 24 for damage, corrosion or contamination Did you find a problem?
Replace CMP sensor Is the replacement complete? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-341 check for any stored codes. Does the engine operate normally with no stored codes? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-341 check for any stored codes. Does the engine operate normally with no stored codes?
144
Value(s)
Yes No Repair the Go to Step (8) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (10) Go to Step (11) System OK Go to Step (9)
System OK
Go to OBD System Check
DTC 342-Camshaft Sensor Loss
Conditions for Setting the DTC
CMP (Camshaft Position Sensor) Check Condition-Engine Cranking or Running Fault Condition-No cam pulse in 2.5 cycles with engine speed greater than 100 rpm MIL-ON for active fault Adaptive-Disabled
Circuit Description The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems. This fault will set if the ECM does not detect a cam pulse in 2.5 engine cycles whenever the engine is greater than 100 rpm. The engine may not run with this fault present.
145
DTC 342-Camshaft Sensor Loss Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Check that the ECM ground terminal C010 is clean, tight and in the proper location Is the ground terminal clean tight and in the proper location? Key OFF Disconnect the CMP (Camshaft Position) Sensor connector C016 Key ON Using A DVOM check for voltage at the CMP sensor connector pin C and engine ground (RUN THIS VOLTAGE CHECK BEFORE THE POWER RELAY SHUTS OFF) Do you have voltage? Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between CMP connector pin A and ECM connector pin 24 Do you have continuity between them? Using a DVOM check for continuity between CMP connector pin B and ECM connector pin 23 Do you have continuity between them?
Inspect the CMP connector terminals for damage, corrosion or contamination Did you find a problem?
Inspect the ECM connector terminals 2, 23 and 24 for damage, corrosion or contamination Did you find a problem?
Replace the CMP. Is the replacement complete? 146
5.0 volts
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Repair the circuit as necessary. Refer to wiring harness repair section. Go to Step (4) Repair the circuit as necessary. Refer to wiring harness repair section.
Go to Step (5)
Repair the circuit as necessary. Refer to wiring harness repair section. Go to Step (6) Repair the circuit as necessary. Refer to wiring harness repair section. Repair the Go to Step (7) circuit as necessary. Refer to wiring harness repair section. Repair the Go to Step (8) circuit as necessary. Refer to wiring harness repair section. Go to Step (10)
Step 9
10
11
Action Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-342 check for any stored codes. Does the engine operate normally with no stored codes? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-342 check for any stored codes. Does the engine operate normally with no stored codes?
147
Value(s)
Yes Go to Step (11) System OK
System OK
No Go to Step (9)
Go to OBD System Check
DTC-359 Fuel Run-out Longer Than Expected
Conditions for Setting the DTC
LPG lock-off valve Check Condition-Key OFF Fault Condition-Engine run down time greater than 20 seconds MIL-ON
Circuit Description The LPG lock off valve is supplied system battery power from the VSW fused source. The ECM then provides a path to ground to turn the valve on. This fault will set in the event the engine continues to run for more than 20 seconds after the key is turned off. This fault indicates a possible problem with the electric LPG lock off solenoid.
148
DTC-359 Fuel Run-out Longer Than Expected Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Disconnect the LPG shut off solenoid connector C003 Using a DVOM check for power across terminals A and B while cranking the engine, then turn the key to the OFF position Did the voltage immediately turn OFF with the key cycle? Turn off the LPG manual valve at the fuel tank Start the engine and let it idle until the engine stops. (THIS MAY TAKE SEVERAL MINUTES) Did the engine ever stop? Replace the LPG shut off solenoid Is the replacement complete? Key OFF Disconnect the ECM wire harness connector C001 Using a DVOM check for continuity between ECM pin 12 and engine ground Do you have continuity? Inspect the ECM wire harness and connector for damage corrosion or contamination Did you find a problem? Replace the ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and drivability After operating the engine within the test parameters of DTC-359 check for any stored codes. Does the engine operate normally with no stored codes? 149
Value(s) -
Yes Go to Step (2)
No
System Voltage
Go to Step (3)
Go to Step (5)
Intermittent problem. See intermittent problems in the electrical section of this manual. Go to Step (8)
Go to Step (4)
Repair the LPG solenoid control short to ground
Go to Step (6)
Correct the problem as required. See wire harness repair. Go to Step (8) System OK
Go to Step (7)
_
_ Go to OBD System Check
DTC 520-Oil Pressure Low Stage 1
Conditions for Setting the DTC
Engine Oil Pressure low. Check Condition-Engine running for 5 seconds or more with engine speed less than 1200 rpm. Fault Condition- Oil pressure less than 15 psi for 5 or more seconds Engine Shut Down.
Circuit Description The Oil Pressure Sender is used to communicate the oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM sends a 5v signal to the oil pressure sender. The sender will report a signal back to the ECM on the signal wire depending on the pressure that is applied on its diaphragm. The voltage is linear in comparison to the pressure applied (see chart below). The MIL command is ON and the engine will shut down in the event of this fault to help prevent possible engine damage.
150
DTC 520-Oil Pressure Low Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceeding with this chart. See Engine Specifications Section 1F. Does the engine have oil pressure above 15 psi? Key ON, Engine Running DST connected in System Data Mode Clear DTC 524 Warm the engine by idling until the ECT temperature is above 160 degrees F. and has been running for at least 20 seconds or more Increase engine speed above 600 RPM Does DTC 524 reset and cause the engine to shut down? With a volt meter, check terminal B on the sensor for a 5 volt reference from the ECM.
15 psi
Go to Step (3)
Do you have 5 volts on terminal B? With a volt meter, check terminal 19 on the ECM for a 5 volt reference. Do you have a 5v reference coming out of the ECM? With the oil pressure sender connected check for a signal coming out of terminal C. Do you have a voltage signal coming out of terminal C? With the oil pressure sender connected check for a signal at terminal 53 of the ECM. Do you have a signal voltage at pin 53 of the ECM? Replace ECM Is the replacement complete?
151
Go to Step (4)
No Go to OBD System Check Section Repair faulty Oiling System Intermittent problem Go to Intermittent section
5v
Go to Step (6) Go to Step (5)
5v
Repair faulty Go to Step (8) wiring between ECM and Oil pressure sensor Go to Step (7) Replace faulty oil pressure sender Go to Step (8)
Repair faulty wiring between terminal C and Terminal 25. Go to Step (9) -
Step
9
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-524 check for any stored codes. Does the engine operate normally with no stored codes?
152
Value(s)
Yes System OK
No Go to OBD System Check
DTC 521- Oil Pressure High
Conditions for Setting the DTC
Engine Oil Pressure low. Check Condition-Engine running for 5 seconds. Fault Condition- Oil pressure greater than 95 psi for 5 or more seconds Engine Shut Down.
Circuit Description The Oil Pressure Sender is used to communicate the oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM sends a 5v signal to the oil pressure sender. The sender will report a signal back to the ECM on the signal wire depending on the pressure that is applied on its diaphragm. The voltage is linear in comparison to the pressure applied (see chart below). The MIL command is ON and the engine will shut down in the event of this fault to help prevent possible engine damage.
153
DTC 521-Oil Pressure High Step 1
2
3
4
Action Did you perform the On-Board (OBD) System Check? Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceeding with this chart. See Engine Specifications Section 1F. Does the engine have oil pressure above 95 psi? With the engine running measure the signal voltage on terminal C of the oil pressure sender. Do you have more than 3.8v? With the engine running measure the signal voltage on terminal 25 of the IEPR / ECM. Do you have more than 3.8v?
154
Value(s) -
Yes Go to Step (2)
Repair faulty oiling system
No Go to OBD System Check Section Go to step (3)
> 3.8v.
Replace faulty oil pressure sender.
Go to step (4)
> 3.8v.
Repair faulty wiring between terminal C and 25.
Replace faulty IEPR / ECM
DTC 522- Oil Pressure Sender low voltage
Conditions for Setting the DTC
Engine Oil Pressure low. Check Condition-Engine running for 20 seconds or more with engine speed greater than 600 rpm. Fault Condition- Voltage on terminal 25 is less than 0.2v for more than 1 second MIL-ON during active fault and for 2 seconds after active fault.
Circuit Description The Oil Pressure Sender is used to communicate the oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM sends a 5v signal to the oil pressure sender. The sender will report a signal back to the ECM on the signal wire depending on the pressure that is applied on its diaphragm. The voltage is linear in comparison to the pressure applied (see chart below). The MIL command is ON and the engine will shut down in the event of this fault to help prevent possible engine damage.
155
DTC 522- Oil Pressure Sender low voltage Step 1
2
3
4
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Using the Diagnostic Service Tool (DST) check the OILP_raw value on the ― RAW VOLTS‖ page.
< 0.2v
Go to Step (3)
Is the voltage less than 0.2 volts Using a voltmeter measure the voltage at terminal 53 of the ECM
< 0.2v
Go to Step (4)
Is the voltage less than 0.2 volts? Using a voltmeter measure the voltage at terminal C at the oil pressure sender.
< 0.2v
Replace faulIntermittent ty oil pressure problem, go sender. to intermittent section
Is the voltage less than 0.2 volts?
156
No Go to OBD System Check Section Replace faulty IEPR / ECM Replace faulty IEPR / ECM
DTC 523- Oil Pressure Sender high voltage
Conditions for Setting the DTC
Engine Oil Pressure low. Check Condition-Engine running for 20 seconds or more with engine speed greater than 600 rpm. Fault Condition- Voltage on terminal 25 is greater than 4.8v for more than 1 second MIL-ON during active fault and for 2 seconds after active fault.
Circuit Description The Oil Pressure Sender is used to communicate the oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM sends a 5v signal to the oil pressure sender. The sender will report a signal back to the ECM on the signal wire depending on the pressure that is applied on its diaphragm. The voltage is linear in comparison to the pressure applied (see chart below). The MIL command is ON and the engine will shut down in the event of this fault to help prevent possible engine damage.
157
DTC 523- Oil Pressure Sender high voltage Step 1
2
3
4
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Using the Diagnostic Service Tool (DST) check the OILP_raw value on the ― RAW VOLTS‖ page.
> 4.8v
Go to Step (3)
Is the voltage over 4.8 volts Using a voltmeter measure the voltage at terminal 53 of the ECM
> 4.8v
Go to Step (4)
Is the voltage over 4.8 volts? Using a voltmeter measure the voltage at terminal C at the oil pressure sender.
> 4.8v
Replace faulIntermittent ty oil pressure problem, go sender. to intermittent section
Is the voltage over 4.8 volts?
158
No Go to OBD System Check Section Replace faulty IEPR / ECM Replace faulty IEPR / ECM
DTC 524-Oil Pressure Low Stage 2
Conditions for Setting the DTC
Engine Oil Pressure low. Check Condition-Engine running for 5 seconds or more with engine less than 1200 rpm. Fault Condition- Oil pressure less than 8 psi for 5 or more seconds Engine Shut Down.
Circuit Description The Oil Pressure Sender is used to communicate the oil pressure condition to the ECM. Engine damage can occur if the engine is operated with low oil pressure. The ECM sends a 5v signal to the oil pressure sender. The sender will report a signal back to the ECM on the signal wire depending on the pressure that is applied on its diaphragm. The voltage is linear in comparison to the pressure applied (see chart below). The MIL command is ON and the engine will shut down in the event of this fault to help prevent possible engine damage.
159
DTC 524-Oil Pressure Low Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceeding with this chart. See Engine Specifications Section 1F. Does the engine have oil pressure above 8 psi? Key ON, Engine Running DST connected in System Data Mode Clear DTC 524 Warm the engine by idling until the ECT temperature is above 160 degrees F. and has been running for at least 20 seconds or more Increase engine speed above 600 RPM Does DTC 524 reset and cause the engine to shut down? With a volt meter, check terminal B on the sensor for a 5 volt reference from the ECM.
8 psi
Go to Step (3)
Do you have 5 volts on terminal B? With a volt meter, check terminal 19 on the ECM for a 5 volt reference. Do you have a 5v reference coming out of the ECM? With the oil pressure sender connected check for a signal coming out of terminal C. Do you have a voltage signal coming out of terminal C? With the oil pressure sender connected check for a signal at terminal 53 of the ECM. Do you have a signal voltage at pin 53 of the ECM? Replace ECM Is the replacement complete?
160
Go to Step (4)
No Go to OBD System Check Section Repair faulty Oiling System Intermittent problem Go to Intermittent section
5v
Go to Step (6) Go to Step (5)
5v
Repair faulty Go to Step (8) wiring between ECM and Oil pressure sensor Go to Step (7) Replace faulty oil pressure sender Go to Step (8)
Repair faulty wiring between terminal C and Terminal 25. Go to Step (9) -
Step
9
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-524 check for any stored codes. Does the engine operate normally with no stored codes?
161
Value(s)
Yes System OK
No Go to OBD System Check
DTC 562-System Voltage Low
Conditions for Setting the DTC
System Voltage to ECM Check Condition-Key on with engine speed greater than 1000 RPM Fault Condition-Battery voltage at ECM less than 9.0 Fault Condition is present for longer than 5 seconds. MIL-ON for active fault Adaptive-Disabled
Circuit Description The battery voltage powers the ECM and must be measured to correctly to properly operate injector drivers, solenoid valves and ignition coils. This fault will set if the ECM detects system voltage less than 9.00 volts while the alternator should be charging. The adaptive learn is disabled during this fault.
162
DTC 562-System Voltage Low Step 1
2
3 4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display system voltage greater than 9.50 volts?
-
Check battery condition Is it OK? Check charging system Is it OK? Key OFF Disconnect the ECM connector C001 Check the voltage between ECM connector C001 pins 60, 79 and engine ground. Measure voltage with DVOM between each pin and engine ground Is the voltage greater than for each pin 9.50 volts? Check the voltage at ECM connector pins 69 and 81 Measure voltage with DVOM between each pin and battery positive Is the voltage greater than 9.50 volts?
-
Intermittent problem Go to Engine Electrical Intermittent section Go to Step (4)
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-562 check for any stored codes. Does the engine operate normally with no stored codes?
-
163
-
-
-
No Go to OBD System Check Section Go to Step (3)
Replace Battery Go to Step (5) Repair charging System Repair ECM Go to Step (6) Ground circuit. Go to Power and Ground section in engine Electrical Repair ECM Go to Step (7) power circuit. Go to Power and Ground section in engine Electrical Go to Step (8) System OK
Go to OBD System Check
DTC 563-System Voltage High
Conditions for Setting the DTC
System Voltage to ECM Check Condition-Cranking or Running Fault Condition-System battery voltage at ECM greater than 18 volts Fault must be present for 3 or more seconds MIL-ON for active fault Adaptive-Disabled
Circuit Description The battery voltage powers the ECM and must be measured to correctly operate injector drivers, trim valves and ignition coils. This fault will set if the ECM detects voltage greater than 18 volts anytime the engine is cranking or running. The adaptive learn function is disabled during this fault. The ECM will shut down with internal protection if the system voltage ever exceeds 26 volts.
164
DTC 563-System Voltage High Step 1
2
3 4 5
6
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Run engine greater than 1500 rpm. Does DST display system voltage greater than 18 volts? Check voltage at battery terminals with DVOM with engine speed greater than 1500 rpm Is it greater than 18 volts? Repair the charging system Has the charging system been repaired? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-563 check for any stored codes. Does the engine operate normally with no stored codes?
-
165
-
No Go to OBD System Check Section Go To Step Intermittent (3) problem Go to Engine Electrical Intermittent section Go to Step (4) Go to Step (5)
-
Go to Step (6)
-
Go to Step (6)
-
System OK
Go to OBD System Check
-
Yes Go to Step (2)
DTC 601-Flash Checksum Invalid
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Engine Shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown when this fault occurs.
166
DTC 601-Flash Checksum Invalid Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 601 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-601 check for any stored codes. Does the engine operate normally with no stored codes?
167
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC 604-RAM Failure
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Engine Shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown if this fault occurs.
168
DTC 604-RAM Failure Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 604 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-604 check for any stored codes. Does the engine operate normally with no stored codes?
169
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC 606-COP Failure
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Engine Shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown if this fault occurs.
170
DTC 606-COP Failure Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 606 reset with the engine idling? Check ECM power and ground circuits Are the power and ground circuits OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-606 check for any stored codes. Does the engine operate normally with no stored codes?
171
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC- 642-External 5 Volt 1 Reference Low
Conditions for Setting the DTC
External 5 volt reference Check Condition-Engine cranking or running Fault Condition-5 volt reference voltage lower than 4.60 volts MIL-ON during active fault Adaptive-Disabled during active fault
Circuit Description The External 5 volt supply powers many of the sensors and other components of the fuel system. The accuracy of the 5 volt supply is very important to the accuracy of the powered sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded, shorted, or otherwise out of specification by monitoring the 5 volt supply. This fault will set if the 5 volt reference is below 4.60 volts. Adaptive Learn will be disabled during this fault
172
DTC 642 External 5 Volt 1 Reference Low Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Fault Mode Does DST display DTC 642? Key OFF Disconnect ECM connector C001 Using DVOM check for continuity between ECM 5 volt reference pin 19 and engine ground Do you have continuity? Replace ECM Is the replacement complete? While monitoring DVOM for continuity between ECM 5 volt reference and engine ground Disconnect each sensor (below) one at a time to find the shorted 5 volt reference. When continuity to ground is lost the last sensor disconnected is the area of suspicion. Inspect the 5 volt reference supply wire leads for shorts before replacing the sensor. TMAP Electronic Throttle FPP Crankshaft Sensor Camshaft Sensor While disconnecting each sensor one at a time did you loose continuity? Replace the last disconnected sensor Is the replacement complete?
173
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (5) Go to Step (4)
Go to Step (7)
-
Go to Step (6)
Repair shorted wire harness
Go to Step (7)
-
Step
7
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-642 check for any stored codes. Does the engine operate normally with no stored codes?
174
Value(s)
Yes System OK
No Go to OBD System Check
DTC 643-External 5 Volt 1 Reference High
Conditions for Setting the DTC
External 5 volt reference Check Condition-Engine cranking or running Fault Condition-5 volt reference higher than 5.40 volts MIL-ON during active fault Adaptive-Disabled during active fault
Circuit Description The External 5 volt supply powers many of the sensors and other components in the fuel system. The accuracy of the 5 volt supply is very important to the accuracy of the powered sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded, shorted, or otherwise out of specification by monitoring the 5volt supply. This fault will set if the 5 volt reference is greater than 5.40 volts anytime the engine is cranking or running. Adaptive Learn will be disabled during this fault
175
DTC 643 External 5 Volt 1 Reference High Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine running DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display DTC 643? Check all ECM ground connections Refer to Engine electrical power and ground distribution. Are the ground connections OK?
Key OFF Disconnect ECM connector C001 Key ON Using DVOM check for Voltage between ECM harness wire pin 19 and engine ground Do you have voltage? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-643 check for any stored codes. Does the vehicle engine normally with no stored codes?
176
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (5) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) System OK
Go to OBD System Check
DTC 650-MIL Control Open
Conditions for setting the DTC
MIL check Check Condition-Key ON engine OFF Fault Condition-ECM MIL circuit open MIL Command-ON
Circuit Description The fuel system is equipped with OBD (On-Board Diagnostics). The system has a dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTCs that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not illuminate with the vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON. This fault will set if the ECM MIL control circuit is open.
177
DTC 650-MIL Control Open Step 1
2
3 4
5
6
7
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Key OFF Key ON Does DTC 650 reset? Remove the MIL bulb or driver circuit Using a DVOM check for continuity through the bulb or driver device Do you have continuity? Replace the open bulb or driver device Is the replacement complete? Key OFF Re-install the bulb or driver device Disconnect vehicle interface connector C012 Using a DVOM check for continuity between vehicle interface connector pin G and battery positive Key ON Do you have continuity? Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between ECM harness connector pin 80 and vehicle interface connector pin G Do you have continuity? Inspect ECM wire harness connector pin 80 and vehicle interface connector pin G for damage, corrosion or contamination Did you find a problem?
178
Value(s) -
Yes Go to Step (2)
Go to Step (3)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to Step (5) Go to Step (4)
Go to Step (8)
_
Go to Step (6)
Repair the open circuit as required. See wire harness repair
Go to Step (7)
Repair the open circuit as required. See wire harness repair Go to Step (8)
Correct the problem as required. See wiring harness repair
Step
Action
Value(s)
8
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-650 check for any stored codes. Does the engine operate normally with no stored codes?
179
Yes
No
System OK
Go to OBD System check
DTC 652-External 5 Volt 2 Reference Low
LT GRN/PPL 49
+ 5 Volts
ECM
Conditions for Setting the DTC
External 5 volt reference Check Condition-Engine cranking or running Fault Condition-5 volt reference voltage lower than 3.00 volts MIL-On during active fault Adaptive-Disabled during active fault
Circuit Description The External 5 volt supply is normally dedicated to the FPP sensor 5 volt supply circuit. The accuracy of the 5 volt supply is very important to the accuracy of the FPP sensor circuit. The ECM is able to determine if the circuit is open, shorted, or otherwise out of specification by monitoring this 5 volt supply. This fault will set if the 5 volt reference is below 3.00 volts. Adaptive Learn will be disabled during this fault.
180
DTC 652 External 5 Volt 2 Reference Low Step 1
2
3
4
5
6
7
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Fault Mode Does DST display DTC 652? Key OFF Disconnect ECM connector C001 Using DVOM check for continuity between ECM 5 volt reference pin 49 and engine ground Do you have continuity? Replace ECM Is the replacement complete? While monitoring DVOM for continuity between ECM 5 volt reference and engine ground Disconnect each sensor (below) one at a time to find the shorted 5 volt reference. When continuity to ground is lost the last sensor disconnected is the area of suspicion. Inspect the 5 volt reference supply wire leads for shorts before replacing the sensor. FPP While disconnecting each sensor one at a time did you loose continuity? Replace the last disconnected sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-652 check for any stored codes. Does the engine operate normally with no stored codes? 181
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (5) Go to Step (4)
Go to Step (7)
-
Go to Step (6)
Repair shorted wire harness
Go to step (7)
-
System OK
Go to OBD System Check
DTC 653-External 5 Volt 2 Reference High
LT GRN/PPL 49
+ 5 Volts
ECM
Conditions for Setting the DTC
External 5 volt reference Check Condition-Engine cranking or running Fault Condition-5 volt reference higher than 5.40 volts MIL-On during active fault Adaptive-Disabled during active fault
Circuit Description The External 5 volt supply is normally dedicated to the FPP sensor 5 volt supply circuit. The accuracy of the 5 volt supply is very important to the accuracy of the FPP sensor circuit. The ECM is able to determine if the circuit is open, shorted, or otherwise out of specification by monitoring this 5 volt supply. This fault will set if the 5 volt reference is above 5.40 volts. Adaptive Learn will be disabled during this fault.
182
DTC 653 External 5 Volt 2 Reference High Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine running DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display DTC 653? Check all ECM ground connections. Refer to Engine electrical power and ground distribution. Are the ground connections Ok?
Key OFF Disconnect ECM connector C001 Key ON Using DVOM check for Voltage between ECM harness wire pin 49 and engine ground Do you have voltage? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-653 check for any stored codes. Does the vehicle engine normally with no stored codes?
183
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (5) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) System OK
Go to OBD System Check
DTC 685-Relay Coil Open
Conditions for Setting the DTC
Power relay check Check Condition-Key ON Fault Condition-Relay coil open
Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system. This fault will set if the ECM detects an open circuit on the relay control output. Diagnostic Aid Relay coil resistance changes with temperature. The following diagnostic charts have steps to measure relay coil resistance values. When checking the resistance values be sure the relay is at a reasonable temperature, between +20 and +100 degrees F.
184
DTC 685-Relay Coil Open Step 1
2
3 4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? DST connected and in the system data mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between terminals 1 and 2 Is the resistance value less than 100 ohms? Replace the power relay Is the replacement complete? Check fuse F2 Is the fuse open? Disconnect ECM connector C001 Using a DVOM check for continuity between ECM pin 71 and fuse block cavity for relay terminal 2 Do you have continuity?
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4) Go to Step (3)
Go to Step (9)
_
Replace fuse F2 Go to Step (6)
Go to Step (5) Repair the open circuit as required. See wiring harness repairs Repair the open circuit as required. See wiring harness repairs
Remove fuse F2 Using a DVOM check for continuity between fuse block cavity for relay terminal 1 and the power out of the F2 fuse holder Do you have continuity?
Go to Step (7)
Check all system fuses. Check all relay placement positions in fuse block. Run complete pin to pin checks on chassis wiring to fuel system harness. See complete fuel system schematic for further details Did you find the problem? Replace the ECM Is the replacement complete?
Go to Step (9)
Go to Step (8)
Go to Step (9)
_
185
Step
9
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-685 check for any stored codes. Does the engine operate normally with no stored codes?
186
Value(s)
Yes System OK
No Go to OBD System Check
DTC 686-Relay Control Ground Short
Conditions for Setting the DTC
Power relay ground control Check Condition-Key ON Fault Condition-Relay control shorted to ground
Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system. This fault will set if the ECM detects a short to ground on the relay control output. Diagnostic Aid Relay coil resistance changes with temperature. The following diagnostic charts have steps to measure relay coil resistance values. When checking the resistance values be sure the relay is at a reasonable temperature, between +20 and +100 degrees F.
187
DTC 686-Relay Control Ground Short Step 1
2
3
4
5 6
7
Action Did you perform the On-Board (OBD) System Check? Key ON, DST connected in the System Data mode Clear DTC 686 Start the engine Does DTC 686 re-set? Disconnect ECM connector C001 Using a DVOM check the resistance value between ECM pin 71 and engine ground Is the resistance less than 60 ohms? Remove the power relay from the fuse block Using a DVOM check the resistance value again between ECM pin 71 and engine ground Is the resistance less than 60 ohms?
Replace the power relay Is the replacement complete? Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-686 check for any stored codes. Does the engine operate normally with no stored codes?
188
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4) Intermittent problem Go to Intermittent section Go to Step (5) Go to Step (7)
Go to Step (6) Repair the shorted to ground relay control circuit as necessary. See wiring harness repairs Go to Step _ (8) Go to Step (8) _ System OK
Go to OBD System Check
DTC 687-Relay Coil Short to Power
Conditions for Setting the DTC
Power relay check Check Condition-Key ON Fault Condition-Relay coil shorted to power
Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system. This fault will set if the ECM detects a short circuit to power on the relay control output. Diagnostic Aid Relay coil resistance changes with temperature. The following diagnostic charts have steps to measure relay coil resistance values. When checking the resistance values be sure the relay is at a reasonable temperature, between +20 and +100 degrees F.
189
DTC 687-Relay Coil Short to Power Step 1
2
3 4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? DST connected and in the system data mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between terminals 1 and 2 Is the resistance value less than 60 ohms? Replace the power relay Is the replacement complete? Using a DVOM check for continuity between relay terminals 2 and 3 Do you have continuity between them? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for power between ECM pin 71 and engine ground with the key ON Do you have power? Replace the power relay Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-687 check for any stored codes. Does DTC 687 still re-set? Replace the ECM Is the replacement complete?
190
Value(s) -
System battery voltage
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (4)
Go to Step (9)
_
Go to Step (3)
Go to Step (5)
Repair the short to power. See wiring harness repair. Go to Step (7) Go to Step (8)
Go to Step (6)
Go to Step (9)
_
_ Go to Step (9)
Step
9
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-687 check for any stored codes. Does the engine operate normally with no stored codes?
191
Value(s)
Yes System OK
No Go to OBD System Check
DTC 1111-Fuel Rev Limit
Conditions for Setting the DTC
Fuel Rev Limit Check Condition-Engine Running Fault Condition-Engine rpm greater than set limit MIL-ON during active fault
Circuit Description This fault will set anytime the engine rpm exceeds the specified speed settings in the calibration. This is generally set at 3000 rpms. The MIL command is ON during this active fault Diagnostic Aid Always check for other stored DTC codes before using the following DTC chart for this code set. Repair any existing codes starting with the lowest numerical code first.
192
DTC 1111-Fuel Rev Limit Step 1
2
3
4 5 6 7
8
9
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Key ON, Engine OFF DST in Active Fault Mode Are any other DTC codes present with DTC 1111? Diagnose and repair any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired? Check the service part Number on the ECM to ensure correct calibration is in use Is the service part Number Correct? Replace ECM with the correct service part number Is the replacement complete? Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK? Correct mechanical operation of the throttle. Refer to Engine & Component section Has the mechanical operation of the throttle been corrected? Check engine for large manifold vacuum leaks. Refer to Fuel Systems symptom diagnostics Did you find and correct the vacuum leak?
Go to Step (3)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1111 check for any stored codes. Does the engine operate normally with no stored codes?
System OK
193
No Go to OBD System Check Section Go to Step (4)
Go to Step (4)
-
Go to Step (6)
Go to Step 5
Go to Step (9)
-
Go to Step (8)
Go to Step (7) -
Go to Step (9)
Go to Step (9)
Go to OBD System Check Section Go to OBD System Check
DTC 1112-Spark Rev Limit
Conditions for Setting the DTC
Spark Rev Limit Check Condition-Engine running Fault Condition-Engine rpm greater than set limit MIL-ON during active fault Engine Shut Down
Circuit description This fault will set anytime the engine rpm exceeds the specified speed settings installed in the calibration. This is generally set at 3200 rpms. The MIL command is ON during this active fault and the engine will shut down. Diagnostic Aid Always check for other stored DTC codes before using the following DTC chart for this code set. Repair any existing codes starting with the lowest numerical code first.
194
DTC 1112-Spark Rev Limit Step 1
2
3
4 5 6 7
8
9
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST connected Are any other DTC codes present with DTC 1112? Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been diagnosed and repaired? Check the service part number on the ECM to ensure correct calibration is in use Is the service part number correct? Replace ECM with correct service part number Is the replacement complete? Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK? Correct mechanical operation of the throttle. Refer to Engine & Component section Has the mechanical operation of the throttle been corrected? Check engine for large manifold vacuum leaks. Refer to Fuel Systems section Symptom Diagnostics Did you find and correct the vacuum leak? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1112 check for any stored codes. Does the engine operate normally with no stored codes?
195
Value(s) -
Yes Go to Step (2)
Go to Step (3)
No Go to OBD System Check Section Go to Step (4)
Go to Step (4)
-
Go to Step (6)
Go to Step 5
Go to Step (9)
-
Go to Step (8)
Go to Step (7) -
Go to Step (9)
Go to Step (9)
System OK
Go to OBD System Check Section Go to OBD System Check
DTC 1121 FPP 1 And 2 Redundancy Lost C012
M
FPP 1
K
L
S
FPP 2
J
R
LT GRN/RED DK BLU/ORN BLK/LT GRN
LT GRN/PPL PPL/YEL
LT GRN/BLK
19
9 20
49 10
50
5 volts FPP 1 Signal Sensor Ground 5 volts FPP 2 Signal Sensor Ground ECM
Conditions for Setting the DTC
Foot pedal position sensor 1 and 2 Check Condition-Key ON Fault Condition-FPP1 and FPP 2 redundancy lost MIL-ON Force idle Low rev limit
Circuit Description The foot pedal position sensor uses variable resistors to determine signal voltage based on foot pedal position. Although the voltage outputs are different, the calculated throttle position values should be very close to the same. This fault will set if FPP 1 or FPP 2 positions are 20% greater or 20% less than the expected throttle position target. The MIL command is ON. Forced idle and low rev limit are in effect during this fault limiting full power output. Diagnostic Aid It is very likely that in the event this code sets, other codes will set along with it. Always diagnose and repair codes starting with the lowest numerical value first. It is possible that by correcting the lower code sets first the problem will be corrected. FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
196
DTC-1121 FPP 1 And 2 Redundancy Lost Step 1 2 3 4
5
6
7
Action Did you perform the On-Board (OBD) System Check? Diagnose any other lower numerical value codes that may be present first Did this resolve the problem? Follow the diagnostic chart for DTC 2126 Did the chart resolve the problem? Follow the diagnostic chart for DTC 2121 Did the chart resolve the problem? Inspect FPP and C012 connector pins for damage corrosion or contamination Did you find the problem? Key OFF Disconnect ECM connector C001 Inspect pins 9, 10, 19, 20, 49 and 50 for damage corrosion or contamination. Did you find a problem? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1121 check for any stored codes. Does the engine operate normally with no stored codes?
197
Value(s)
Yes Go to Step (2)
No Go to OBD System Check Go to Step (7) Go to Step (3) Go to Step (7) Go to Step (4) Go to Step (5) Go to Step (7) Correct the Go to Step (6) problem as required. See wiring harness repair. _ Correct the problem as required. See wiring harness repair. Go to OBD System OK System Check
DTC 1151-Closed Loop Multiplier High LPG
Conditions for Setting the DTC
Heated Oxygen Sensor Check Condition-Engine running Fault Condition-Closed Loop multiplier out of range (greater than 35%) MIL-ON
Circuit description The EGO sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation and cannot correctly modify the fuel flow within its limits. Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold. Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition at especially at light load. Fuel Mixer System can be lean due to faulty EPR (Electronic Pressure Regulator) or faulty fuel mixer. Fuel Pressure Low fuel pressure, faulty fuel regulator or contaminated fuel filter can cause fuel the system to run lean Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past the 02 sensor causing a false lean condition. Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean. Ground Problem ECM grounds must be clean, tight and in the proper location.
198
DTC 1151-Closed Loop High LPG Step 1
2
3
4
5
Action Perform the On-Board (OBD) System Check? Are any other DTCs present? Visually and physically check the following items: The air intake duct for being collapsed or restricted The air filter for being plugged System power fuses are good and in the proper location The EGO 1 sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires ECM grounds must be clean and tight. Refer to Engine Electrical Power and Ground Distribution Fuel System Diagnostics. Refer to Fuel System Diagnostics Was a repair made? Diagnose any other DTC codes before proceeding with this chart. Always repair existing codes starting with the lowest numerical code set first. Have any other DTC codes been detected, diagnosed and repaired? Disconnect EGO1 connector C005 Using a DVOM check for voltage between EGO 1 connector pin B and engine ground Key ON (CHECK MUST BE MADE WITHIN 30 SECONDS OR BEFORE POWER RELAY SHUTS DOWN) Do you have voltage? Key OFF Disconnect EGO 1 sensor wire harness connector C005 Disconnect ECM wire harness connector C001 Key ON Using a high impedance DVOM check for continuity between EGO 1 connector signal pin A and engine ground Do you have continuity?
199
Value(s)
Yes Go to Step (3) Go to Step (9)
System voltage
No Go to Step (2) Go to Step (4)
Go to Step (9)
Go to step (4)
Go to Step (5)
Repair the open EGO power circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6)
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
6
7 8
9
Action Using a high impedance DVOM check for continuity between EGO 1 connector signal ground pin C and EGO 1 signal pin A Do you have continuity?
Using a high impedance DVOM check for continuity between EGO 1 heater ground pin D and ECM pin 72 Do you have continuity? Replace EGO 1 sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1151 check for any stored codes. Does the engine operate normally with no stored codes?
200
Value(s)
Yes Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to step (8)
Go to Step (9) System OK
No Go to Step (7)
Repair the open EGO heater ground Go to OBD System Check
DTC 1152-Closed Loop Multiplier Low LPG
Conditions for Setting the DTC Heated Oxygen Sensor Functional Fault-Closed Loop multiplier out of range (at limit of -35%) MIL Disabled Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multiplier exceeds the limits of normal operation. When the multiplier cannot correctly modify the fuel flow within its limits, it is limited at -35%. Diagnostic Aid Fuel System High secondary fuel pressure will cause the system to run rich. A worn fuel mixer, faulty EPR (Electronic Pressure Regulator) may also cause the system to run rich. Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the fuel system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade LPG is used. Air Filter A plugged, damaged or modified air filter may cause the system to run rich.
201
DTC 1152 –Closed Loop Low LPG Step 1
2
3
4
5
6
Action Perform the On-Board (OBD) System Check? Are any other DTCs present? Visually and physically check the following items: The air intake duct for being collapsed or restricted The air filter for being plugged The EGO sensor installed securely and the wire leads not damaged contacting the secondary ignition wires ECM grounds for being clean and tight. Run the fuel system diagnostic checks Was a repair made? Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired? Key OFF Disconnect EGO sensor wire harness connector Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage at the EGO 1 connector C005 signal pin C and engine ground Do you have voltage? Replace EGO sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1152 check for any stored codes. Does the engine operate normally with no stored codes?
202
Value(s)
Yes Go to Step (3) Go to Step (6)
No Go to Step (2) Go to Step (4)
Go to Step (6)
Go to Step (4)
Repair the circuit short to voltage as necessary. Refer to wiring harness repair. Go to Step (6)
Go to Step (5)
System OK
Go to OBD System Check
-
DTC 1161-Adaptive Learn High LPG
Conditions for Setting the DTC
Heated Oxygen Sensor Check Condition-Engine Running Fault Condition-Adaptive multiplier out of range greater than 30% MIL-ON
Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier exceeds the limits of normal operation. Always run the fuel system diagnostic checks before using the following diagnostic chat.
203
Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the exhaust manifold. Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition at especially at light load. Fuel Mixer System can be lean due to faulty EPR (Electronic Pressure Regulator) or faulty fuel mixer. Fuel Pressure Low fuel pressure, faulty fuel regulator or contaminated fuel filter can cause fuel the system to run lean Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past the 02 sensor causing a false lean condition. Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean. Ground Problem ECM grounds must be clean, tight and in the proper location.
204
DTC 1161 Adaptive Learn High LPG Step 1
2
3
4
5
Action Perform the On-Board (OBD) System Check? Are any other DTCs present? Visually and physically check the following items: The air intake duct for being collapsed or restricted The air filter for being plugged System power fuses are good and in the proper location The EGO 1 sensor installed securely and the wire leads not contacting the exhaust manifold or ignition wires ECM grounds must be clean and tight. Refer to Engine Electrical Power and Ground Distribution Fuel System Diagnostics. Refer to Fuel System Diagnostics Was a repair made? Diagnose any other DTC codes before proceeding with this chart. Always repair existing codes starting with the lowest numerical code set first. Have any other DTC codes been detected, diagnosed and repaired? Disconnect EGO1 connector C005 Using a DVOM check for voltage between EGO 1 connector pin B and engine ground Key ON (CHECK MUST BE MADE WITHIN 30 SECONDS OR BEFORE POWER RELAY SHUTS DOWN) Do you have voltage? Key OFF Disconnect EGO 1 sensor wire harness connector C005 Disconnect ECM wire harness connector C001 Key ON Using a high impedance DVOM check for continuity between EGO 1 connector signal pin A and engine ground Do you have continuity?
205
Value(s)
System voltage
Yes Go to Step (3)
No Go to Step (2)
Go to Step (9)
Go to Step (4)
Go to Step (9)
Go to Step (4)
Go to Step (5)
Repair the open EGO power circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6)
Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
6
7 8
9
Action Using a high impedance DVOM check for continuity between EGO 1 connector signal ground pin C and EGO 1 signal pin A Do you have continuity?
Using a high impedance DVOM check for continuity between EGO 1 heater ground pin D and ECM pin 49 Do you have continuity? Replace EGO 1 sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1161 check for any stored codes. Does the engine operate normally with no stored codes?
206
Value(s)
Yes Repair the shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8)
Go to Step (9) System OK
No Go to Step (7)
Repair the open EGO heater ground Go to OBD System Check
DTC 1162-Adaptive Learn Low (LPG)
Conditions for Setting the DTC
Heated Oxygen Sensor Check Condition-Engine running Fault Condition-Adaptive multiplier out of range greater than -30% MIL-ON
Circuit Description The EGO1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier exceeds the limits of normal operation. Always run the fuel system diagnostics before using the following diagnostic chart. Diagnostic Aid Fuel System High secondary fuel pressure will cause the system to run rich. A worn fuel mixer, faulty EPR (Electronic Pressure Regulator) may also cause the system to run rich. Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the fuel system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is used. Air Filter A plugged, damaged or modified air filter may cause the system to run rich.
207
DTC 1162-Adaptive Learn Low LPG Step 1
2
3
4
5
6
Action Perform the On-Board (OBD) System Check? Are any other DTCs present? Visually and physically check the following items: The air intake duct for being collapsed or restricted The air filter for being plugged The EGO sensor is installed securely and the wire leads not damaged or contacting the secondary ignition wires ECM grounds for being clean and tight. Fuel system diagnostic checks Was a repair made? Diagnose any other DTC codes before proceeding with this chart. Have any other DTC codes been detected, diagnosed and repaired? Key OFF Disconnect EGO sensor wire harness connector C005 Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage at EGO 1 connector signal pin A and engine ground Do you have voltage? Replace EGO sensor Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1162 check for any stored codes. Does the engine operate normally with no stored codes?
208
Value(s)
Yes Go to Step (3)
No Go to Step (2)
Go to Step (6)
Go to Step (4)
Go to Step (6)
Go to Step (4)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (5)
Go to Step (6)
-
System OK
Go to OBD System Check
DTC 1165-LPG Catalyst Monitor
Conditions for Setting the DTC • Catalyst Function • Check condition- Engine running • Fault condition- EGO 1 signal = EGO 2 signal for 100 updates • MIL- On during active fault and for 1 second after active fault • Adaptive- Disabled during active fault Circuit Description The ECM uses EGO 1 and EGO 2 sensor signals to diagnose problems with the catalyst muffler. When the signals for EGO 1 & EGO 2 are similar it may indicate a problem with the catalyst. Diagnostic Aids Always diagnose any other troubles, stored along with DTC 420 first. Check for and eliminate any exhaust leaks prior to replacing catalyst muffler. Look for exhaust leaks at the catalyst muffler inlet and tail pipes. Clear this trouble code after repairing exhaust leaks, and recheck for code.
209
DTC1171-EPR Pressure Higher Than Expected
Conditions for Setting the DTC
EPR delivery pressure Check condition-Engine running or cranking MIL-ON during active fault Fault condition-EPR actual pressure greater than 1.5 inches above commanded pressure Adaptive disabled Engine shutdown will occur
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. This code will set in the event the actual pressure is 1.5 inches water pressure higher than the actual commanded pressure. Adaptive learn is disabled and the MIL command is ON during this fault. The engine will shutdown if this fault occurs. Diagnostic Aid Always run the fuel system diagnostic pressure check before proceeding with the following diagnostic chart. High secondary fuel pressure due to a worn or damaged primary or secondary seat may cause this fault to set
210
DTC 1171-EPR Pressure Higher Than Expected Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check? Did you run the fuel pressure diagnostic test in the fuel system diagnostic section with no problems found? Run the EPR pressure test in the fuel system diagnostic section Did the EPR pass the fuel pressure test specifications? Inspect the EPR electrical connector pins C018 for damage, corrosion or contamination. Did you find a problem?
Replace or repair the EPR Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1171 check for any stored codes. Does the engine operate normally with no stored codes?
211
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4) Go to Step (3) Go to Step (4)
Repair the circuit as necessary. Refer to wire harness repair section. Go to Step (6) System OK
Follow the EPR service recommendations from the fuel pressure test chart. Go to Step (5)
_ Go to OBD System Check
DTC1172-EPR Pressure Lower Than Expected
Conditions for Setting the DTC
EPR delivery pressure Check condition-Engine running or cranking MIL-ON during active fault Fault condition-EPR actual pressure less than 1.5 inches below commanded pressure Adaptive disabled Engine shutdown will occur
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. This code will set in the event the actual pressure is 1.0 inches water pressure lower than the actual commanded pressure. Adaptive is disabled and the MIL command is ON during this fault. Engine will shutdown if this fault occurs. Diagnostic Aid Always run the fuel system diagnostic pressure check before proceeding with the following diagnostic chart. Low secondary fuel pressure due to a fuel restriction or faulty regulator may cause this fault.
212
DTC 1172-EPR Pressure Lower Than Expected Step 1
2
3
4
5
6
Action Did you perform the On-Board (OBD) System Check? Did you run the fuel pressure diagnostic test in the fuel system diagnostic section with no problems found? Run the EPR pressure test in the fuel system diagnostic section Did the EPR pass the fuel pressure test specifications? Inspect the EPR electrical connector C018 for damage, corrosion or contamination. Did you find a problem?
Replace or repair the EPR Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1172 check for any stored codes. Does the engine operate normally with no stored codes?
213
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4) Go to Step (3) Go to Step (4)
Repair the circuit as necessary. Refer to wire harness repair section. Go to Step (6) System OK
Follow the EPR service recommendations from the fuel pressure test chart. Go to Step (5)
_ Go to OBD System Check
DTC1173-EPR Communication Lost
Conditions for Setting the DTC
EPR CAN communication Check condition-Engine running or cranking MIL-On during active fault Fault condition-No packets received within 500 ms Adaptive disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. This code will set in the event communication with the ECM is lost. The MIL command is on.
214
DTC 1173-EPR Communication Lost Step 1
2
3
4 5
6
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON DST (Diagnostic Scan Tool) connected in the system data mode Clear DTC1173 Key OFF Key ON, and attempt to start the engine Does DTC1173 re-set? Key OFF Disconnect EPR electrical connector C018 Key ON Using a DVOM check for system power between EPR connector pin 7 and engine ground (Be sure to activate relay control ON using the DST function or check before ECM relay control times out) Do you have power? Check the 10A (F5) fuse Is the fuse open? Replace the F5 fuse Is the replacement complete? Using a DVOM check for system power at power relay terminal 3 (Be sure to activate relay control ON using the DST function or check before ECM relay control times out) Do you have power? Using a DVOM check for continuity between EPR connector pin 6 and engine ground Do you have continuity?
7
215
Yes Go to Step (2)
Go to step (7)
No Go to OBD System Check Section Intermittent problem. Go to Intermittent Problem section in the electrical section of this manual. Go to step (4)
Go to step (5)
Go to step (6)
Go to step (17) Repair the open circuit between power relay pin 3 and EPR pin 7 Go to step (17) Go to step (8)
_
Go to step (3)
System battery voltage
System battery voltage
Repair the power relay circuit as required Go to step (17) Repair the open ground circuit as necessary. Refer to wiring repairs in engine electrical
Step
8
9
10
11
12
13
14
Action Key OFF Disconnect the EPR connector C018 Disconnect the ECM connector C001 Using a DVOM check for continuity between EPR pin 5 and ECM pin 15 Do you have continuity?
Value(s)
Yes Go to step (9)
Using a DVOM check for continuity between EPR pin 2 and ECM pin 14 Do you have continuity?
Go to step (10)
Using a DVOM check for continuity between EPR pin 4 and ECM pin 81 Do you have continuity?
Go to step (11)
Using a DVOM check for continuity between EPR pin 3 and B+ Do you have continuity?
Go to step (12)
Using a DVOM check for continuity between EPR pin 6 and B+ Do you have continuity?
Go to step (13)
Disconnect DST from the DLC connector C014 Using a DVOM check for continuity between engine ground and EPR pin 4 Do you have continuity?
Repair the shorted to ground CAN circuit as necessary. Refer to wiring repairs in engine electrical Go to step (15)
Replace the EPR Is the replacement complete?
216
No Repair the open circuit as necessary. Refer to wiring repairs in engine electrical Repair the open circuit as necessary. Refer to wiring repairs in engine electrical Repair the open circuit as necessary. Refer to wiring repairs in engine electrical Repair the open circuit as necessary. Refer to wiring repairs in engine electrical Repair the open circuit as necessary. Refer to wiring repairs in engine electrical Go to step (14)
_
Step
15
16
17
Action Remove all test equipment and reconnect the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1173 check for any stored codes. Does DTC1173 still re-set? Replace the ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1173 check for any stored codes. Does the engine operate normally with no stored codes?
217
Value(s)
Yes Go to step (16)
No System OK
Go to step (17) System OK
_ Go to OBD System Check
DTC1174-EPR Supply Voltage High
Conditions for Setting the DTC
EPR supply voltage Check condition-Engine running or cranking MIL-ON during active fault Fault condition-internal EPR supply voltage too high Adaptive disabled Closed loop disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the EPR internal supply voltage is too high. Diagnostic Aid This DTC indicates abnormal EPR internal voltages that are not measurable externally. Check the system charging voltage to be sure this DTC and other over voltage DTCs are not present. Repair the charging system if it is found to be out of specification for high charge voltage. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first.
218
DTC 1174-EPR Voltage Supply High Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2) Go to Step (3)
Go to OBD System Check Section Repair the charging system
Go to Step (4)
Go to Step (5)
Go to Step (6)
_
Go to Step (6)
_
System OK
Go to OBD System Check
2
3 4 5
6
DST connected and in the system data mode Engine running Check the system battery voltage. Is the charging voltage within specifications? Using a DVOM compare the system battery voltage to the DST display. Is the voltage reading within 1 volt between the two of them? Replace the EPR Is the replacement complete? Replace the ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1174 check for any stored codes. Does the engine operate normally with no stored codes?
219
1 volt
DTC1175-EPR Supply Voltage Low
Conditions for Setting the DTC
EPR supply voltage Check condition-Engine running or cranking MIL-ON during active fault Fault condition-EPR internal supply voltage low Adaptive disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the internal EPR supply voltage is low. Adaptive is disabled and the MIL command is ON. Diagnostic Aid This DTC indicates abnormal EPR internal voltages that are not measurable externally. Check the system charging voltage to be sure this DTC and other low voltage DTCs are not present. Repair the charging system if it is found to be out of specification for low charge voltage. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first.
220
DTC 1175-EPR Voltage Supply Low Step 1
2
3
Action Did you perform the On-Board (OBD) System Check? DST connected and in the system data mode Engine running Check the system battery voltage. Is the charging voltage within specifications? Key OFF Disconnect the EPR electrical connector C018 Using a DVOM check for power between the EPR connector pin 7 and engine ground. Key ON Record the voltage reading. (Be sure to activate relay control ON using the DST function or check before ECM relay control times out) Using a DVOM check the system battery power at the battery terminals and record the voltage reading. Are the recorded voltage readings within 1 volt of each other? Inspect the EPR connector and F5 fuse holder terminals for damage corrosion or contamination Did you find a problem?
4
5
Check the power relay circuit. Check the power relay connections for damage corrosion or contamination Did you find a problem?
221
Value(s) -
Yes Go to Step (2)
Go to Step (3)
No Go to OBD System Check Section Repair the charging system
Go to Step (6) Go to Step (4)
Correct the Go to Step (5) problem as necessary. See wiring harness repair in the electrical section of this manual Correct the _ problem as necessary. See wiring harness schematic in the electrical section of this manual
Step
6
7
8
9
10
Action Key OFF Disconnect the ECM connector C001 Using a DVOM check the resistance reading between EPR connector pin 6 and ECM connector pin 69 and 81. (Do not forget to subtract any resistance value that may be present in your test cables) Is the resistance reading less than 0.5 ohms? Replace the EPR Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1175 check for any stored codes. Does DTC 1175 still re-set? Replace the ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1175 check for any stored codes. Does the engine operate normally with no stored codes?
222
Value(s) Less than 0.5 ohms
Yes Go to Step (7)
No Repair the poor EPR power ground circuit. See wiring harness repair in the electrical section of this manual Go to Step (8) _ Go to Step (9)
System OK
Go to Step (10) System OK
_ Go to OBD System Check
DTC1176-EPR Internal Actuator Fault
Conditions for Setting the DTC
EPR internal actuator test Check condition-Engine running or cranking MIL-ON during active fault Fault condition-Failed actuator Adaptive disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the ECM detects an internal actuator fault with the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first. In most instances the EPR will need to be replaced in the event of this code set.
223
DTC 1176-EPR Internal Actuator Fault Step 1
2 3
4
5
6
Action Did you perform the On-Board (OBD) System Check? DST connected and in the system data mode. Check for any other current or active DTCs Does the DST show any other codes set? Repair any other DTCs set starting with the lowest DTC number first. Have the other DTCs set been corrected? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature. Observe the MIL. Observe engine performance and driveability After operating the engine within the test parameters of DTC1176 check for any stored codes. Does DTC 1176 still re-set? Replace the EPR Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature. Observe the MIL. Observe engine performance and driveability After operating the engine within the test parameters of DTC1176 check for any stored codes. Does the engine operate normally with no stored codes?
224
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (6) Go to Step (4)
_
Go to Step (5)
System OK
Go to Step (6)
_
System OK
Go to OBD System Check
DTC 1177-EPR internal Circuitry Fault
Conditions for Setting the DTC
EPR internal circuitry test Check condition-Engine running or cranking MIL-ON during active fault Fault conditionAdaptive disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the ECM detects an internal circuitry fault in the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first. In most instances the EPR will need to be replaced in the event of this code set.
225
DTC 1177-EPR Internal Circuitry Failure Step 1
2 3
4
5
6
Action Did you perform the On-Board (OBD) System Check? DST connected and in the system data mode Check for any other current or active DTCs Does the DST show any other codes set? Repair any other DTCs set starting with the lowest DTC number first Have the other DTCs set been corrected? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1177 check for any stored codes. Does DTC 1177 still re-set? Replace the EPR Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1177 check for any stored codes. Does the engine operate normally with no stored codes?
226
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (6) Go to Step (4)
_
Go to Step (5)
System OK
Go to Step (6)
_
System OK
Go to OBD System Check
DTC 1178-EPR Internal Communication Error
Conditions for Setting the DTC
EPR internal communication test Check condition-Engine running or cranking MIL-ON during active fault Fault conditionAdaptive disabled
Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in return the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control. This code will set if the ECM detects an internal communication error in the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest numerical value DTC first. In most instances the EPR will need to be replaced in the event of this code set.
227
DTC 1178-EPR Internal Comm Fault Step 1
2 3
4
5
6
Action Did you perform the On-Board (OBD) System Check? DST connected and in the system data mode. Check for any other current or active DTCs Does the DST show any other codes set? Repair any other DTCs set starting with the lowest DTC number first. Have the other DTCs set been corrected? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature. Observe the MIL. Observe engine performance and driveability After operating the engine within the test parameters of DTC1178 check for any stored codes. Does DTC 1178 still re-set? Replace the EPR Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature. Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC1178 check for any stored codes. Does the engine operate normally with no stored codes?
228
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (6) Go to Step (4)
_
Go to Step (5)
System OK
Go to Step (6)
_
System OK
Go to OBD System Check
DTC 1511- Aux Analog PU1 High Step 1
2
3
4
5
6
Action Did you perform the On Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Did you follow the Diagnostic Aid checks for DTC 1511?
Go to step (3)
Key Off Disconnect the ECM connector C001 Disconnect the vehicle interface connector CO12 Key ON Using a high impedance DVOM check for voltage between ECM pin 46 and engine ground Do you have voltage?
Repair the circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical.
Verify transmission temperature relay and indicator lamp circuit is in proper working order and not shorted to ground. Is the transmission temperature relay and indicator lamp circuit ok?
Go to Step (5)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC 1511 previously set. Observe the MIL Observe engine performance and drive ability After operating the engine within the test parameters of DTC-1511 check for any stored codes. Does the engine operate normally without setting DTC 1511? Replace the ECM Is the replacement complete?
System OK
229
Go to Step (7)
No Go to OBD System Check Section Perform the Diagnostic Aid checks for DTC 1511 Go to Step (4)
Repair the circuit as required. See chassis electrical system section. Go to Step (6)
-
Step
7
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC 1511 previously set. Observe the MIL Observe engine performance and drive ability After operating the engine within the test parameters of DTC-1511 check for any stored codes. Does the engine operate normally with no stored codes?
230
Value(s)
Yes System OK
No Go to OBD System Check
DTC 1512 AUX Analog PU1 Low
Relay CKT #135
CKT #134
C012 H
DK BLU/YEL
46
AUX ANA PU1
Transmission Oil Temperature Lamp CKT #136 Transmission Temperature Switch
CKT #137
Relay Coil Power
ECM
+12 Volt CKT#59A
Conditions for Setting the DTC
Check Condition-Engine running AUX PU1 voltage high Fault Condition- Aux PU1 less than 1.500 volts MIL-On during active fault Power derate level 2
Circuit Description The transmission temperature switch is used to communicate a high temperature condition to the ECM. Transmission damage can occur if the transmission is operated at high temperature. The temperature switch is normally open and should close at 122C and remain closed until the temperature drops to 115C. The fault will set if the AUX Analog PU1 circuit voltage is less than 1.500 volts. Diagnostic Aids The use of the OEM chassis wiring schematic is recommended for the proper repair and diagnosis of components located after the vehicle interface connector C012. It is likely that this code may be accompanied by other DTC codes. Always diagnose and repair the code with the lowest numerical value first.
231
DTC 1512- AUX Analog PU1 Low Step 1
2
3
4
5
6
Action Did you perform the On Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
Did you follow the Diagnostic Aid checks for DTC 1512?
Go to step (3)
Key Off Disconnect the ECM connector C001 Disconnect the vehicle interface connector CO12 Using a high impedance DVOM check for continuity between ECM pin 46 and engine ground Do you have voltage?
Repair the circuit shorted to ground as necessary. Refer to Wiring Repairs in Engine Electrical.
Verify transmission temperature relay and indicator lamp circuit is in proper working order and not shorted to ground. Is the transmission temperature relay and indicator lamp circuit ok?
Go to Step (5)
Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC 1512 previously set. Observe the MIL Observe engine performance and drive ability After operating the engine within the test parameters of DTC-1512 check for any stored codes. Does the engine operate normally without setting DTC 1512? Replace the ECM Is the replacement complete?
System OK
232
Go to Step (7)
No Go to OBD System Check Section Perform the Diagnostic Aid checks for DTC 1512 Go to Step (4)
Repair the circuit as required. See chassis electrical system section. Go to Step (6)
-
Step
7
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature, running the transmission to similar conditions where the DTC 1512 previously set. Observe the MIL Observe engine performance and drive ability After operating the engine within the test parameters of DTC-1512 check for any stored codes. Does the engine operate normally with no stored codes?
233
Value(s)
Yes System OK
No Go to OBD System Check
DTC 1612-RTI 1 Loss
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Adaptive-Disabled for the remainder of the key-ON cycle Engine shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown if this code occurs.
234
DTC 1612-RT 1 Loss Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 1612 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1612 check for any stored codes. Does the engine operate normally with no stored codes?
235
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC 1613-RTI 2 Loss
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Adaptive-Disabled for the remainder of the key-ON cycle Engine shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shut down if this code occurs.
236
DTC 1613-RTI 2 Loss Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 1613 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1613 check for any stored codes. Does the engine operate normally with no stored codes?
237
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC 1614-RTI 3 Loss
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Adaptive-Disabled for the remainder of the key-ON cycle Engine shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown if this code occurs.
238
DTC 1614-RTI 3 Loss Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 1614 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1614 check for any stored codes. Does the engine operate normally with no stored codes?
239
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC 1615-A/D Loss
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Adaptive-Disabled for the remainder of the key-ON cycle Engine shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown if this code occurs.
240
DTC 1615-A/D Loss Step
Action
Value(s)
Yes
No
1
Did you perform the On-Board (OBD) System Check?
-
Go to Step (2)
Go to OBD System Check Section Intermittent problem Go to Intermittent section
2
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 1615 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
Go to Step (3)
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1615 check for any stored codes. Does the engine operate normally with no stored codes?
Go to Step (5)
Go to Step (4)
3
4
5
241
System OK
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to OBD System Check
DTC 1616-Invalid Interrupt
ECM Microprocesso Microprocessor r Ram
RAM Flash
Conditions for Setting the DTC
Engine Control Module Check Condition-Key on Fault Condition-Internal microprocessor error MIL-ON Adaptive-Disabled for the remainder of the key-ON cycle Engine Shutdown will occur
Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and will remain on until the code is cleared using the DST. The engine will shutdown if this code occurs.
242
DTC 1616-Invalid Interrupt Step 1
2
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC 1616 reset with the engine idling? Check ECM power and ground circuits Did the power and ground circuits check OK?
3
4
5
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1616 check for any stored codes. Does the engine operate normally with no stored codes?
243
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (5) System OK
Go to OBD System Check
DTC 1625 - J1939 Shutdown Request
Conditions for Setting the DTC
Fault signal from OEM device Check Condition-Engine running MIL-ON
Circuit description The OEM can connect to the J1939 circuit (CAN circuit) at the customer interface connector 2. The terminals are N and P and continue through the engine wire harness into the GCP header connector. The terminals at the GCP for J1939 are pins 14 and 15. This DTC will set if the OEM device hooked into terminals N and P at the customer interface connector commands the engine to shutdown.
244
DTC 1626-CAN Tx Failure
Conditions for Setting the DTC
CAN Tx Check Condition-Engine running Fault Condition-CAN Tx error 120 packets lost within 1 second MIL-ON
Circuit description The CAN bus (controller area network) is used by the ECM to communicate with other digital devices used throughout the fuel system. Information is sent over the CAN bus in digital information ―packets‖ that contain information for various control functions. This fault will set if the ECM detects 120 packets lost within a one second time period. The MIL command is ON.
245
DTC 1626-CAN Tx Failure Step 1
2
3
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC1626 reset with the engine idling? Check that the ECM power connection C019 is clean, tight and in the proper location. Check that the ECM ground connection C010 is clean, tight and in the proper location. Are the power and ground circuits OK?
Using a DVOM check for continuity between ECM pins 14 and 15 Do you have continuity between them? 4
Using a DVOM check for continuity to engine ground on pins 69 and 81 Do have continuity to engine ground? 5
Using a DVOM check for continuity to battery positive on pins 69 and 81 Do have continuity them? 6
7
Replace the ECM Is the replacement complete?
246
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (5) shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (6) shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (7) shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8) _
Step
8
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1626 check for any stored codes. Does the engine operate normally with no stored codes?
247
Value(s)
Yes System OK
No Go to OBD System Check
DTC 1627-CAN Rx Failure
Conditions for Setting the DTC
CAN Rx Check Condition-Engine running Fault Condition-CAN Rx error 120 packets lost within 1 second MIL-ON
Circuit description The CAN bus (controller area network) is used by the ECM to communicate with other digital devices used throughout the fuel system. Information is sent over the CAN bus in digital information ―packets‖ that contain information for various control functions. This fault will set if the ECM detects 120 packets lost within a one second time period. The MIL command is ON.
248
DTC 1627-CAN Rx Failure Step 1
2
3
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC1627 reset with the engine idling? Check that the ECM power connection C019 is clean, tight and in the proper location. Check that the ECM ground connection C010 is clean, tight and in the proper location. Are the power and ground circuits OK?
Using a DVOM check for continuity between ECM pins 14 and 15 Do you have continuity between them? 4
Using a DVOM check for continuity to engine ground on pin 14. Do have continuity to engine ground? 5
Using a DVOM check for continuity to battery positive on pin 14. Do have continuity between them? 6
7
Replace the ECM Is the replacement complete?
249
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (5) shorted circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (6) shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Repair the Go to Step (7) shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (8) _
Step
8
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1627 check for any stored codes. Does the engine operate normally with no stored codes?
250
Value(s)
Yes System OK
No Go to OBD System Check
DTC 1628-CAN Address Conflict
Conditions for Setting the DTC
CAN Rx Check Condition-Engine running Fault Condition-5 or more address conflict errors MIL-ON
Circuit description The CAN bus (controller area network) is used by the ECM to communicate with other digital devices used throughout the fuel system. Information is sent over the CAN bus in digital information ―packets‖ that contain information for various control functions. Individual devices are assigned network addresses. This fault will set if the ECM detects an address conflict, such as two devices with the same address. This is usually not due to an in field failure and may be the results of ―add on‖ CAN devices
251
DTC 1628-CAN Address Conflict Step 1
2
3
4
5
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Does DTC1628 reset with the engine idling? Key OFF Disconnect one CAN device Clear DTC 1628 Key ON (start engine if possible if not continue cranking for at least 3 seconds) Wait 5 seconds Does DTC 1628 re-set? Has the CAN device been replaced or address conflict resolved? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1628 check for any stored codes. Does the engine operate normally with no stored codes?
252
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Repeat step 3 Contact the until all CAN CAN device devices have manufacturer been discon- for additional nected one at CAN address a time information Go to Step (4) Go to Step (5) _ System OK
Go to OBD System Check
DTC 1644-MIL Control Ground Short
Conditions for setting the DTC
MIL Check Condition-Key ON engine OFF Fault Condition-ECM MIL output shorted to ground MIL Command-ON Circuit Description
The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has a dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTCs that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not illuminate with the vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON. This fault will set if the ECM MIL control is shorted to ground.
253
DTC 1644-MIL Control Ground Short Step 1
2
3
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Key OFF Key ON Does DTC 1644 reset? Key OFF Disconnect the ECM wire harness connector C001 Using a DVOM check for continuity between ECM connector pin 5 and engine ground Do you have continuity? Disconnect vehicle interface connector C012 Using a DVOM check for continuity between ECM connector pin 80 and engine ground Do you have continuity?
4
5
6
Replace the ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1644 check for any stored codes. Does the engine operate normally with no stored codes? 254
Value(s) -
Yes Go to Step (2)
Go to Step (3)
Go to Step (4)
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Intermittent problem Go to Intermittent section
Repair the Repair the shorted to MIL control ground circuit wire short to between the ground beECM connectween the tor and engine vehicle interground. Then face go to step (6) connector and vehicle chassis. Then go to step (6) Go to Step (7) _ System OK
Go to Step (5)
Step
7
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1644 check for any stored codes. Does the engine operate normally with no stored codes?
255
Value(s)
Yes System OK
No Go to OBD System check
DTC 1645-MIL Control Ground Short To Power
Conditions for setting the DTC
MIL check Check Condition-Key ON engine OFF Fault Condition-ECM MIL output shorted to voltage MIL Command-ON Circuit Description
The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has a dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. The MIL also has the ability to flash DTC codes in what is referred to as the blink code mode. It will display DTCs that have been stored due to a possible system malfunction. The following DTC charts in this manual will instruct the technician to perform the OBD system check. This simply means to verify the operation of the MIL. The lamp should illuminate when the key is in the ON position, and the engine is not running. This feature verifies that the lamp is in proper working order. If the lamp does not illuminate with the vehicle key ON and engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the lamp. The ECM completes the circuit to ground to turn the lamp ON. This fault will set if the ECM MIL control is shorted to voltage.
256
DTC 1645-MIL Control Short to Power Step 1
2
3
Action Did you perform the On-Board (OBD) System Check?
Yes Go to Step (2)
Key ON, Engine Running DST (Diagnostic Scan Tool) connected in System Data Mode Clear system fault code Key OFF Key ON Does DTC 1644 reset? Key OFF Disconnect the ECM wire harness connector C001 Using a DVOM check for voltage between ECM connector pin 80 and engine ground Key ON Do you have voltage? Disconnect vehicle interface connector C012 Using a DVOM check for voltage between ECM connector pin 80 and engine ground Do you have voltage?
Go to Step (3)
Replace the ECM Is the replacement complete?
Go to Step (7)
4
5
Value(s) -
257
No Go to OBD System Check Section Intermittent problem Go to Intermittent section
Go to Step (4)
Intermittent problem Go to Intermittent section
Repair the shorted to voltage circuit between the ECM connector and engine ground. Then go to step (6)
Repair the MIL control wire short to voltage between the vehicle interface connector and vehicle chassis. Then go to step (6) _
Step
6
7
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1645 check for any stored codes. Does the engine operate normally with no stored codes? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-1645 check for any stored codes. Does the engine operate normally with no stored codes?
258
Value(s)
Yes System OK
No Go to Step (5)
System OK
Go to OBD System check
DTC 2111-Unable To Reach Lower TPS
Conditions for Setting the DTC
Throttle Position Sensor Check Condition-Cranking or Running Fault Condition-Actual throttle position is 20% greater than the throttle command MIL-ON during active fault Engine shutdown
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if the actual throttle position is 20% greater than the throttle command. During this active fault the MIL command is ON and the engine will shutdown.
259
DTC 2111 Unable To Reach Lower TPS Step 1
2
3
4
5 6
7
8 9 10
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive By Wire) test mode Depress foot pedal until the throttle command is between 63%-68% Is the TPS 1 voltage greater than 2.0 volts? Key OFF Disconnect electronic throttle connector C017 Probe TPS 1 signal pin 6 with a test light connected to battery voltage Key ON Does DST display TPS 1 voltage less than 0.2 volts? Key OFF Disconnect ECM wire harness connector C001 Key ON Using a DVOM check for voltage between throttle connector TPS 1signal pin 6 and engine ground Do you have voltage? Replace ECM Is the replacement complete? Probe sensor ground circuit at ECM connector C001 with a test light connected to battery voltage Does the test light come on? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM signal ground circuit pin 20 Do you have continuity between them? Replace ECM Is the replacement complete? Check throttle for foreign object in bore Did you find a foreign object in the bore? Remove foreign object Is the removal complete?
260
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (6)
Go to Step (4)
Repair the Go to Step (5) circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (13) Go to Step (9) Go to Step (7)
Go to Step (8)
Go to Step (13) Go to Step (10) Go to Step (13)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11) -
Step
11
12
13
Action Inspect the throttle wire harness connector terminals for damage, corrosion or contamination Did you find the problem?
Replace throttle Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2111 check for any stored codes. Does the engine operate normally with no stored codes?
261
Value(s)
Yes Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (13) System OK
No Go to Step (12)
Go to OBD System Check
DTC 2112-Unable To Reach Higher TPS
Conditions for Setting the DTC
Throttle Position Sensor Check Condition-Cranking or Running Fault Condition-Actual throttle position is 20% less than the throttle command MIL-ON during active fault Engine shutdown
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. This fault will set if the actual throttle position is 20% less than the throttle command. The MIL command is ON and the engine will shutdown.
262
DTC 2112-Unable To Reach Higher TPS Step 1
2
3
4 5
6
7
8
9
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in DBW (Drive By Wire) test mode Depress foot pedal until the throttle command is 63%-68% Is the TPS voltage less than 2.0 volts? Key OFF Disconnect electronic throttle connector C017 Probe TPS 1 signal circuit pin 6 with test light connected to battery voltage Key ON Is TPS voltage 4.0 volts or greater? Check throttle bore for foreign object Did you find a problem? Remove the foreign object Has the object been removed? Check the electronic throttle connector terminals for damage corrosion or contamination Did you find a problem?
Replace throttle Is the replacement complete? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM TPS 1 signal pin 5 Do you have continuity between them? Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and engine ground Do you have continuity between them?
263
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (4)
Go to Step (8)
Go to Step (5)
Go to Step (6)
Go to Step (11) Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11) Go to Step (9)
-
Repair the shorted to ground circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Go to Step (7)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (10)
Step 10
11
Action Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2112 check for any stored codes. Does the engine operate normally with no stored codes?
264
Value(s)
Yes Go to Step (11) System OK
No Go to OBD System Check
DTC 2121-FPP 1 Lower Than FPP 2 C012
M
FPP 1
K
L
S
FPP 2
J
R
LT GRN/RED DK BLU/ORN BLK/LT GRN
LT GRN/PPL PPL/YEL
LT GRN/BLK
19
9 20
49 10
50
5 volts FPP 1 Signal Sensor Ground 5 volts FPP 2 Signal Sensor Ground ECM
Conditions for Setting the DTC
Foot pedal position sensor 1 and 2 Check Condition-Key ON Fault Condition-FPP1 sensor higher than FPP 2 MIL-ON Force idle Low rev limit
Circuit Description The foot pedal position sensor uses variable resistors to determine signal voltage based on foot pedal position. Although the voltage outputs are different, the calculated throttle position values should be very close to the same. This fault will set if FPP 1 is 20% or greater than the FPP 2. The MIL command is ON. Forced idle and low rev limit are in effect during this fault limiting full power output. Diagnostic Aid FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
265
DTC 2121 FPP 1 Lower than FPP 2 Step 1
2
3
4
5
6
7
Action Did you perform the On-Board (OBD) System Check? DST (Diagnostic Scan Tool) connected and in the system data mode Clear DTC 2126 Start and run the engine to full operating temperature Depress the foot pedal from idle to the wide open position several times Does DTC 2121 re-set? Key OFF Slowly depress the foot pedal from idle to the wide open position while observing the FPP1 and FPP 2 calculated percentage positions Does the DST display a 20% or more difference between FPP1 and FPP2 calculated positions? Disconnect FPP sensor connector Jump the pins that that lead from the FPP sensor connector to C012 signal pin K and 5 volt supply pin M pin 3 Does the DST show FPP 1 voltage above 0.200 volts? Inspect the FPP and vehicle interface connectors for damage corrosion or contamination Did you find a problem?
Replace the FPP sensor Is the replacement complete? Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between C017 pin 3 and ECM 5 volt pin 19 Do you have continuity?
266
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4) Go to Step (3)
Go to Step (4)
Greater than 0.200 volts
Intermittent problem Go to Intermittent section
Go to Step (5) Go to Step (7)
Repair the Go to Step (6) circuit as required. See wiring harness repair section Go to Step (12) Go to Step (8) Repair the open 5 volt circuit as required. See wiring harness repair section
Step
8
Action Using a DVOM check for continuity between C012 signal pin K and ECM signal pin 9. Do you have continuity?
Using a DVOM check for continuity between ECM connector signal pin 9 and engine ground Do you have continuity? 9
10
11
12
Inspect FPP connector and ECM connector pins for damage corrosion or contamination Did you find a problem?
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2121 check for any stored codes. Does the engine operate normally with no stored codes?
267
Value(s)
Yes Go to Step (9)
Repair the signal shorted to ground circuit as required. See wiring harness repair section Repair the circuit as required. See wiring harness repair section Go to Step (12) System OK
No Repair the open signal circuit as required. See wiring harness repair section Go to Step (10)
Go to Step (11)
Go to OBD System Check
DTC 2122-FPP 1 High Voltage
C012
FPP 1 *
M
*
K
*
L
LT GRN/RED
19
DK BLU/ORN
9
BLK/LT GRN
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
20
5 volts
Signal
Sensor Ground
ECM
Conditions for Setting the DTC
Foot Pedal Position Check Condition-Key On Fault Condition-FPP1 sensor voltage exceeds 4.800 volts MIL-On during active fault Low rev limit Force idle
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. This fault will set if the FPP 1 voltage exceeds 4.800 volts for longer than 0.5 seconds. If the voltage exceeds 4.800 volts the FPP is considered to be out of specification. The MIL command is ON. Forced idle and low rev limit will be in effect during this code set limiting full power output. Diagnostic Aid FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP connection must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete foot pedal sensor assembly must be replaced.
268
DTC 2122 FPP 1 Voltage High Step 1
2
3
4 5
6
7
8
9
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP voltage of 4.800 volts or greater with the foot pedal in the idle position? Slowly increase FPP while observing FPP 1 voltage Does DST FPP voltage ever exceed 4.800 volts?
Greater than 4.800 volts
Disconnect the FPP sensor connector Does the DST now show FPP 1 voltage below 0.200 volts? Replace FPP sensor Is the replacement complete? Key OFF Disconnect ECM connector C001 Disconnect vehicle interface connector C012 Using a DVOM check continuity between connector C012 pin L and ECM sensor ground pin 20 Do you have continuity? Key ON Using a DVOM check for voltage between the FPP connector pin K and engine ground Do you have voltage? Inspect ECM and FPP connectors for damage corrosion or contamination Did you find a problem?
0.200 volts or less
Replace ECM Is the replacement complete?
269
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (3)
Go to step (4)
Go to step (5) Go to step (10) Go to step (7)
No voltage
Repair the signal shorted to voltage circuit Repair the circuit as required. See wire harness repair section Go to step (10)
Intermittent problem Go to Intermittent section Go to step (6) Repair the open ground circuit as required
Go to step (8)
Go to step (9)
-
Step
10
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2122 check for any stored codes. Does the engine operate normally with no stored codes?
270
Value(s)
Yes System OK
No Go to OBD System Check
DTC 2123-FPP 1 Low Voltage
C012
FPP 1 *
M
*
K
*
L
LT GRN/RED
19
DK BLU/ORN
9
BLK/LT GRN
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
20
5 volts
Signal
Sensor Ground
ECM
Conditions for Setting the DTC
Foot Pedal Position Check Condition-Key On Fault Condition-FPP sensor voltage less than 0.200 MIL-On during active Low rev limit Force idle
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. This fault will set if the FPP 1 voltage is less than 0.200 volts at any operating condition while the key is on. If the voltage drops below 0.200 volts the FPP is considered to be out of specification. The MIL command is ON. Forced idle and low rev limit will be in effect during this code set limiting full power output. Diagnostic Aid FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP connection must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete foot pedal sensor assembly must be replaced.
271
DTC 2123 FPP 1 Voltage Low Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP 1 voltage of 0.200 volts or less with the foot pedal in the idle position? Slowly increase FPP while observing the FPP 1 voltage Does the DST ever display FPP voltage below 0.200 volts?
0.200 volts or less
Disconnect the FPP sensor connector Jump the FPP sensor pins at the FPP 1 connector that lead to C012 5 volt pin M and signal pin K Does the DST now show FPP 1 voltage above 0.200 volts? Inspect FPP 1 and C012 connectors for damage corrosion or contamination Did you find a problem?
Greater than 0.200 volts
Replace FPP 1 sensor Is the replacement complete? Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity between ECM 5 volt pin 19 and FPP connector pin that leads to C012 pin M Do you have continuity? Using a DVOM check for continuity between ECM signal pin 9 and FPP connector pin that leads to C012 pin K Do you have continuity?
272
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (3)
Go to step (4)
Go to step (5)
Repair the circuit as required. See wiring harness repair section Go to step (12) Go to step (8)
Go to step (9)
Intermittent problem Go to Intermittent section Go to step (7)
Go to step (6)
Repair the open circuit as required. See wiring harness repair section Repair the open circuit as required. See wiring harness repair section
Step
9
10
11
12
Action Key ON Using a DVOM check for continuity between ECM connector signal pin 9 and engine ground Do you have continuity?
Inspect FPP1, C012 and ECM connectors for damage corrosion or contamination Did you find a problem?
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2123 check for any stored codes. Does the engine operate normally with no stored codes?
273
Value(s)
Yes Repair the signal shorted to ground circuit as required. See wiring harness repair section Repair the circuit as required. See wiring harness repair section Go to step 12
No Go to step (10)
System OK
Go to OBD System Check
Go to step (11)
-
DTC 2126-FPP 1 Higher Than FPP 2 C012
M
FPP 1
K
L
S
FPP 2
J
R
LT GRN/RED DK BLU/ORN BLK/LT GRN
LT GRN/PPL PPL/YEL
LT GRN/BLK
19
9 20
49 10
50
5 volts FPP 1 Signal Sensor Ground 5 volts FPP 2 Signal Sensor Ground ECM
Conditions for Setting the DTC
Foot pedal position sensor 1 and 2 Check Condition-Key ON Fault Condition-FPP 1 20% higher than FPP 2 MIL-ON Force idle Low rev limit
Circuit Description The foot pedal position sensor uses variable resistors to determine signal voltage based on foot pedal position. Although the voltage outputs are different, the calculated throttle position values should be very close to the same. This fault will set if FPP 1 is 20% or more higher that FPP 2. The MIL command is ON. Forced idle and low rev limit are in effect during this fault limiting full power output. Diagnostic Aid FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
274
DTC 2126 FPP 1 Higher Than FPP 2 Step 1
2
3
4 5
6
7
8
9
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (4) Go to Step (3)
DST (Diagnostic Scan Tool) connected in System Data Mode Clear DTC 2126 Start the engine and run to full operating temperature. Depress the foot pedal from idle to wide open throttle several times. Does DTC 2126 re-set? Key OFF Go to Step (4) Intermittent Slowly depress the foot pedal from idle to the problem wide open position while observing the FPP1 and Go to InterFPP 2 calculated percentage positions mittent Does the DST display a 20% or more difference section between FPP1 and FPP2 calculated positions? Disconnect FPP sensor connector Below 0.200 Go to Step (5) Go to Step (6) Does the DST now show FPP 1 voltage below volts 0.200 volts? Replace the FPP sensor Go to Step Is the replacement complete? (10) Key OFF Go to Step (7) Repair the Disconnect ECM connector C001 open ground Disconnect vehicle interface connector C012 circuit as reUsing a DVOM check continuity between the quired interface connector pin L and ECM sensor ground pin 20 Do you have continuity? Key ON No voltage Repair the Go to Step (8) Using a DVOM check for voltage between the signal shorted FPP connector that leads to the vehicle interface to voltage connector signal pin K and engine ground Do you have voltage? Inspect ECM and FPP connectors for damage Repair the Go to Step (9) corrosion or contamination circuit as reDid you find a problem? quired. See wire harness repair section Replace ECM Go to Step Is the replacement complete? (10)
275
Step
10
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2126 check for any stored codes. Does the engine operate normally with no stored codes?
276
Value(s)
Yes System OK
No Go to OBD System Check
DTC 2127-FPP 2 Low Voltage
FPP 2
C012
*
S
*
J
*
R
LT GRN/PPL
PPL/YEL
LT GRN/BLK
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
49 10
50
5 volts
FPP 2 Signal
Sensor Ground
ECM
Conditions for Setting the DTC
Foot Pedal Position Check Condition-Key On Fault Condition-FPP sensor voltage less than 0.400 MIL-On Low Rev Limit Force Idle
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position. This fault will set if the FPP 2 voltage is less than 0.400 volts at any operating condition while the key is on. If the voltage drops below 0.400 volts the FPP is considered to be out of specification. The MIL command is ON. Low rev limit and forced idle will be effect during this fault limiting power output. Diagnostic Aid FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
277
DTC 2127 FPP 2 Voltage Low Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP 2 voltage of less than 0.400 volts with the foot pedal in the idle position? Slowly increase the FPP while observing the FPP 2 voltage Does the DST ever display FPP voltage below 0.400 volts?
Less than 0.400 volts
Disconnect the FPP sensor connector Jump the pins from the FPP sensor connector that leads to C012 signal pin J and 5 volt supply pin S Does the DST now show FPP 1 voltage above 0.400 volts? Inspect the FPP and C012 connectors for damage corrosion or contamination Did you find a problem?
Greater than 0.400 volts
Replace FPP sensor Is the replacement complete? Key OFF Disconnect ECM connector C001 Disconnect the vehicle interface connector C012 Using a DVOM check for continuity between C012 pin S and ECM 5 volt pin 49 Do you have continuity? Using a DVOM check for continuity between C012 signal pin J and ECM signal pin 10 Do you have continuity?
278
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (3)
Go to step (4)
Go to step (5)
Repair the circuit as required. See wiring harness repair section Go to step (12) Go to step (8)
Go to step (9)
Intermittent problem Go to Intermittent section Go to step (7)
Go to step (6)
Repair the open 5 volt circuit as required. See wiring harness repair section Repair the open signal circuit as required. See wiring harness repair section
Step
Action Using a DVOM check for continuity between ECM connector signal pin 10 and engine ground Do you have continuity?
9
10
11
12
Inspect FPP connector C012 and ECM connector pins for damage corrosion or contamination Did you find a problem?
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2127 check for any stored codes. Does the engine operate normally with no stored codes?
279
Value(s)
Yes Repair the signal shorted to ground circuit as required. See wiring harness repair section Repair the circuit as required. See wiring harness repair section Go to step 12
No Go to step (10)
System OK
Go to OBD System Check
Go to step (11)
-
DTC 2128-FPP 2 High Voltage
FPP 2
C012
*
S
*
J
*
R
LT GRN/PPL
PPL/YEL
LT GRN/BLK
*Check OEM chassis wiring diagram for specific pin numbers and wire colors
49 10
50
5 volts
FPP 2 Signal
Sensor Ground
ECM
Conditions for Setting the DTC
Foot pedal position sensor 2 Check Condition-Key On Fault Condition-FPP2 sensor voltage exceeds 4.800 volts MIL-On Forced idle Low rev limit
Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on foot pedal position. This fault will set if the FPP 2 voltage exceeds 4.800 volts at any operating condition while the key is on. If the voltage exceeds 4.800 volts the FPP is considered to be out of specification. The MIL command is ON. Forced idle and low rev limit will be in effect limiting power output during this fault. Diagnostic Aid FPP sensors are OEM specific and vary in configuration. The exact wire color and pin numbers for the FPP must be verified in the OEM chassis wiring schematic. The FPP sensor used in this system provides two sensors in one packaged assembly. FPP1 and FPP 2 are not serviceable individually, and in the event of a failure the complete FPP assembly must be replaced.
280
DTC 2128 FPP 2 Voltage High Step 1
2
3
4 5
6
7
8
9
Action Did you perform the On-Board (OBD) System Check?
Value(s) -
Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display FPP voltage of 4.800 volts or greater with the foot pedal in the idle position? Slowly increase FPP while observing FPP 2 voltage Does DST FPP voltage ever exceed 4.800 volts?
4.800 volts or greater
Disconnect the FPP sensor connector Does the DST now show FPP 2 voltage below 0.200 volts? Replace FPP sensor Is the replacement complete? Key OFF Disconnect ECM connector C001 Disconnect vehicle interface connector C012 Using a DVOM check continuity between connector C012 pin R and ECM sensor ground pin 50 Do you have continuity? Key ON Using a DVOM check for voltage between the FPP connector pin J and engine ground Do you have voltage? Inspect ECM and FPP connectors and pins for damage corrosion or contamination Did you find a problem?
Below 0.200 volts
Replace ECM Is the replacement complete?
281
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Go to Step (3)
Go to step (4)
Go to step (5) Go to step (10) Go to step (7)
No voltage
Repair the signal shorted to voltage circuit Repair the circuit as required. See wire harness repair section Go to step (10)
Intermittent problem Go to Intermittent section Go to step (6) Repair the open ground circuit as required
Go to step (8)
Go to step (9)
-
Step
10
Action Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2128 check for any stored codes. Does the engine operate normally with no stored codes?
282
Value(s)
Yes System OK
No Go to OBD System Check
DTC 2135: TPS1/2 simultaneous voltages out-of-range
Conditions for Setting the DTC
Throttle Position Sensor 1 & 2 Check Condition-Key ON Fault Condition-TPS 1 20% higher than TPS2 MIL-ON for remainder of key on cycle Engine shutdown
Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to determine signal voltage based on throttle plate position. TPS 1 will read lower voltage when closed and TPS 2 will read higher voltage when closed. The TPS 1 and TPS 2 percentages are calculated from these voltages. Although the voltages are different, the calculated values for the throttle position percentages should be very close to the same. The TPS values are used by the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced. This fault will set if TPS 1 is 20% (or more) higher than TPS 2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit. The MIL command is ON and the engine will shutdown.
283
DTC 2135: TPS1/2 simultaneous voltages out-of-range Step 1
2
3
4
5
6
7
8
Action Did you perform the On-Board (OBD) System Check? Key ON, Engine OFF DST (Diagnostic Scan Tool) connected in System Data Mode Does the DST display more than a 20% difference between TPS 1 and TPS 2? Key OFF Disconnect electronic throttle connector C017 Key ON Change DST mode to DBW (drive by wire) test mode Is the voltage for TPS 1 less than 0.1 volts? Key OFF Disconnect ECM wiring harness connector C001 Key ON Using a DVOM check for voltage between ECM connector TPS 1 signal pin 5 and engine ground Do you have voltage?
Jump TPS 1 signal pin 6 to the 5 volt reference pin 3 at connector C017 Does DST display TPS 1 voltage over 4.900 volts? Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found?
Replace the electronic Throttle Is the replacement complete? Key OFF Disconnect ECM wire harness connector C001 Using a DVOM check for continuity between throttle connector TPS 1 signal pin 6 and ECM connector TPS 1 signal pin 5 Do you have continuity between them?
284
Value(s) -
Yes Go to Step (2)
No Go to OBD System Check Section Go to Step (3) Intermittent problem Go to Intermittent section Go to Step (5)
Go to Step (4)
Repair the Go to Step (9) TPS 1 circuit shorted to voltage as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (6) Go to Step (8)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (12) Go to Step (9)
Go to Step (7)
Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical.
Step
9
10
11
12
Action Using a DVOM check for continuity between throttle connector signal ground pin 2 and ECM connector signal ground pin 3 Do you have continuity between them?
Inspect ECM connector terminals for damage corrosion or contamination. Any problems found?
Replace ECM Is the replacement complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-221 check for any stored codes. Does the engine operate normally with no stored codes?
285
Value(s)
Yes Go to Step (10)
Repair the circuit as necessary. Refer to Wiring Repairs in Engine Electrical Go to Step (12) System OK
No Repair the open circuit as necessary. Refer to Wiring Repairs in Engine Electrical. Go to Step (11)
Go to OBD System Check
DTC 2229-BP High Pressure
Conditions for Setting the DTC
Barometric Pressure Check Condition-Key ON Fault Condition-BP greater than 16 psia MIL-ON for active fault Adaptive-Disabled
Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of the normal range.
286
DTC 2229-BP High Pressure Step 1
2
3
4
Action Did you perform the On-Board (OBD) System Check? Key ON DST (Diagnostic Scan Tool) connected in System Data Mode Does DST display MAP pressure of 16 psia or greater? Replace TMAP sensor. Is the repair complete? Remove all test equipment except the DST. Connect any disconnected components, fuses, etc. Using the DST clear DTC information from the ECM. Turn the ignition OFF and wait 30 seconds. Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test parameters of DTC-2229 check for any stored codes. Does the engine operate normally with no stored codes?
287
Value(s) -
Yes Go to Step (2)
Go to Step (3)
Go to Step 4 System OK
No Go to OBD System Check Section Intermittent problem Go to Intermittent section Go to OBD System Check
Definitions
289
Air Valve Vacuum (AVV): The vacuum signal taken from below the air valve assembly and above the throttle butterfly valve. ADP: Adaptive Digital Processor. Air/Fuel Ratio: The amount or balance of air and fuel in the air fuel mixture that enters the engine. Analog Voltmeter: A meter that uses a mechanical needle to point to a value on a scale of numbers. It is usually of the low impedance type and used to measure voltage and resistance. Aromatics: Pertaining to or containing the sixcarbon ring characteristic of the benzene series. Found in many petroleum distillates. Backfire: Combustion of the air/fuel mixture in the intake or exhaust manifolds. A backfire can occur if the intake or exhaust valves are open when there is a mis-timed ignition spark. Benzene: An aromatic (C6H6). Sometimes blended with gasoline to improve anti-knock value. Benzene is toxic and suspected of causing cancer. Bi-Fueled: A vehicle equipped to run on two fuels. Blow-By: Gases formed by the combustion of fuel and air, which ordinarily should exert pressure only against the piston crown and first compression ring. When rings do not seal, these gases escape or ―blow by‖ the side of the piston into the crankcase. BTU: British Thermal Unit. A measurement of the amount of heat required to raise the temperature of 1lb. of water 1 degree F. Butane: An odorless, colorless gas, C4H10 found in natural gas and petroleum. One of the five LP gases. CAFE: Corporate Average Fuel Economy. CARB: California Air Resources Board. Carbon Monoxide (CO): A chemical compound of a highly toxic gas that is both odorless and colorless. Carburetor: An apparatus for supplying an internal-combustion engine a mixture of vaporized fuel and air. Cathode Ray Tube: A vacuum tube in which cathode rays usually in the form of a slender beam are projected on a fluorescent screen and produce a luminous spot. Circuit: A path of conductors through which electricity flows. Closed Loop Operation: Applies to systems utilizing an oxygen sensor. In this mode of operation, the system uses oxygen sensor information to determine air/fuel ratio. Adjustments are made accordingly and checked by comparing the new oxygen sensor to previous signals. No stored information is used.
CNG: Compressed Natural Gas. CKP: Crankshaft Position Sensor CMP: Camshaft Position Sensor Conductor: A material, normally metallic, that permits easy passage of electricity. Contaminants: Impurities or foreign material present in fuel. Control Module: One of several informal names for a solid state microcomputer which monitors engine conditions and controls certain engine functions; i.e. air/fuel ratio, injection and ignition time, etc. The formal name and the one used throughout this manual is ECM, or Engine Control Module. Converter: A LPG fuel system component containing varying stages of fuel pressure regulation combined with a vaporizer. Cryogen: A refrigerant used to obtain very low temperatures. Current: The volume or flow of electrons through a conductor. Measured in amperes or amps. DBW: Drive By Wire Dedicated Fuel System: A motor fuel system designed to operate on only one fuel type. Diaphragm: A thin, flexible membrane that separates two chambers. When the pressure in one chamber is lower than in the other chamber, the diaphragm will move toward the side with the low pressure. Diaphragm Port: The external port located at the fuel inlet assembly and connected to the vacuum chamber above the air valve diaphragm. DLC: Data Link Connector. DTC: Diagnostic Trouble Code DST: Diagnostic Scan Tool. DVOM: Digital Volt/ohm Meter. A meter that uses a numerical display in place of a gauge and is usually of the high impedance type. ECT: Engine Coolant Temperature. ECM: Electronic Control Module ECOM: A DLC cable supporting CAN and serial communication with an ECM. EFI: Electronic Fuel Injection. A fuel injection system, which uses a microcomputer (ECM) to determine and control the amount of fuel, required by, and injected into, a particular engine. EGO: Exhaust Gas Oxygen, used to describe a sensor. Also known as ―HEGO‖ (Heat Exhaust Gas Oxygen) sensor, ―O2‖ or ―Oxygen sensor. EGR: Exhaust Gas Recirculation. EPA: Environmental Protection Agency: A regulating agency of the Federal government which, among other duties, establishes and enforces automotive emissions standards.
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Ethanol: Grain alcohol (C2H5OH), generally produced by fermenting starch or sugar. Evaporative Emissions Controls: An automotive emission control system designed to reduce hydrocarbon emissions by trapping evaporated fuel vapors from the fuel system. Excess Flow Valve: A check valve that is caused to close by the fuel when the flow exceeds a predetermined rate. FTV: Fuel Trim Valve. FFV: Flexible Fuel Vehicle. Firing Line: The portion of an oscilloscope pattern that represents the total amount of voltage being expended through the secondary circuit. FMVSS: Federal Motor Vehicle Safety Standards. FPP: Foot Pedal Position Sensor Fuel Injector: a spring loaded, electromagnetic valve which delivers fuel into the intake manifold, in response to an electrical input from the control module. Fuel Lock: A solenoid-controlled valve located in the fuel line to stop the flow when the engine stops or the ignition switch is off. Gasohol: 10 percent ethanol, 90 percent gasoline. Often referred to as E-10. Gasoline: A motor vehicle fuel that is a complex blend of hydrocarbons and additives. Typical octane level is 89. GCP: Spectrum III (90-pin) ECM. Greenhouse Effect: A scientific theory suggesting that carbon dioxide from the burning of fossil fuels is causing the atmosphere to trap heat and cause global warming. HC: Hydrocarbon. An organic chemical compound. HD 10: A fuel of not less than 80% liquid volume propane and not more than 10% liquid volume propylene. HD 5: A fuel of not less than 90% liquid volume propane and not more than 5% liquid volume propylene. HDV: Heavy Duty Vehicle. Heavy Ends: A term used to describe the build up of wax-like impurities that fall out of LPG when vaporized. HEGO: Heated Exhaust Gas Oxygen, used to describe a sensor. Also known as ―EGO‖ (Exhaust Gas Oxygen sensor), ―O2‖ or ―Oxygen sensor. Hg: Chemical symbol for the element mercury. Used in reference to a measure of vacuum (inches of Hg). Histogram: The graphical version of a table which shows what proportion of values fall into specific categories over a specific period of time.
Hydrocarbon: A chemical compound made up of hydrogen and carbon (HC). Gasoline and almost all other fuels are hydrocarbons. Hydrostatic Relief Valve: A pressure relief device installed in the liquid LPG hose on a LPG fuel system. IAT: Intake Air Temperature Ideal Mixture: The air/fuel ratio at which the best compromise of engine performance to exhaust emissions is obtained. Typically 14.7:1. Ignition Reserve: The difference between available voltage and the required voltage. ILEV: Inherently Low Emission Vehicle. Impedance: A form of opposition of AC electrical current flow (resistance) measured in ohms. Insulation: A nonconductive material used to cover wires in electrical circuits to prevent the leakage of electricity and to protect the wire from corrosion. Intercept: An electrical term for a type of splice where the original circuit is interrupted and redirected through another circuit. Knock: Sound produced when an engine‘s air/fuel mixture is ignited by something other than the spark plug, such as a hot spot in the combustion chamber. Also caused by a fuel with an octane rating that is too low and/or incorrect ignition timing. Also called detonation or ping. Lambda Sensor: A feedback device, usually located in the exhaust manifold, which detects the amount of oxygen present in exhaust gases in relation to the surrounding atmosphere. (See HEGO). LDV: Light Duty Vehicle. Lean Mixture: An air to fuel ratio above the stoichiometric ratio; too much air. LEV: Low Emission Vehicle. Limp-in or Limp Home: A mode where the ECM or a component has failed, but the vehicle remains operational although the engine may operate minimally. This term may also describe the drivability characteristics of a failed computer system. Liquid Petroleum Gas (LPG): A fuel commonly known as propane consisting mostly of propane (C3H8), derived from the liquid components of natural gas stripped out before the gas enters the pipeline, and the lightest hydrocarbons produced during petroleum refining. Octane level of LPG is 107. LPG: Liquified Petroleum Gas. M85: A blend of gasoline and methanol consisting of 85% methanol and 15% gasoline. Measurements of Pressure: 1 PSI=2.06‖ Hg
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(mercury) = 27.72‖ H2O (water column). At sea level atmospheric pressure is 29.92‖ Hg. Methanol: Known as wood alcohol (CH3OH), a light, volatile, flammable alcohol commonly made from natural gas. MIL: Malfunction Indicator Lamp. Misfire: Failure of the air/fuel mixture to ignite during the power stroke. Mixer: Fuel introduction device that does not include a throttle plate. MFI: Multiport Fuel Injection. A fuel injection system that uses one injector per cylinder mounted on the engine to spray fuel near the intake valve area of combustion chamber. MSV: Manual Shut-Off Valve. Refers to the manually operated valve on the LPG tank. MTBE: Methyl Tertiary Butyl Ether. Oxygenate add to gasoline to reduce harmful emissions and to improve the octane rating. Multi-fuel System: A motor fuel system designed to operate on two different fuels, such as LPG and gasoline. Natural Gas: A gas formed naturally from buried organic material, composed of a mixture of hydrocarbons, with methane (CH4) being the dominant component. NGV: Natural Gas Vehicle. NOX: See Oxides of Nitrogen. OBD: On Board Diagnostic Octane Rating: The measurement of the antiknock value of a motor fuel. OEM: Original Equipment Manufacturer, the vehicle manufacturer. Open-Loop: An operational mode during which control module memory information is used to determine air/fuel ratio, injection timing, etc., as opposed to actual oxygen sensor input. Orifice: A port or passage with a calibrated opening designed to control or limit the amount of flow through it. Oscilloscope: An instrument that converts voltage and frequency readings into traces on a cathode ray tube (also see Cathode Ray Tube). Oxides of Nitrogen: Chemical compounds of nitrogen bonded to various amounts of oxygen (NOX). A chief smog forming-agent. Oxygen Sensor: An automotive fuel system that produces a signal in accordance with the oxygen content of the exhaust gas. (See Lambda Sensor). Oxygenate: Oxygenates (such as MTBE, ethanol and methanol) added to gasoline to increase the oxygen content and therefore reduce exhaust emissions.
Ozone: A radical oxygen module (O3) that is found in the upper atmosphere and filters out ultraviolet radiation from the sun. Ground level ozone is formed by NOX, during the formation of photochemical smog. Particulates: Microscopic pieces of solid or liquid substances such as lead and carbon that are discharged into the atmosphere by internal combustion engines. Positive Crankcase Ventilation (PCV): An automotive emission control system designed to reduce hydrocarbon emissions by routing crankcase fumes into the intake manifold rather than to the atmosphere. Power Derate: A mode of reduced engine power output for the purposes of protecting engine components during a failure or malfunction. Pressure Differential: The differential between atmospheric pressure and intake manifold (referred to as vacuum) pressure. Pressure Regulator: A device to control the pressure of fuel delivered to the fuel injector(s). Primary Circuit: The low-voltage or input side of the ignition coil. Propane: An odorless and colorless gas, C3H8, found in natural gas and petroleum. Psia: pounds per square inch absolute PTV: Pressure Trim Valve Reactivity: Refers to the tendency of an HC in the presence of NOX and sunlight to cause a smogforming reaction. The lighter the HC, the lower reactivity tends to be. Regulator: An assembly used to reduce and control the pressure of a liquid or vapor. Resistance: The opposition to the flow of current in an electrical circuit. Measured in ohms. Rest Pressure: Fuel pressure maintained within the system after engine shutdown. Rich Mixture: An air to fuel ratio below the stoichiometric ratio; too much fuel. SAE: Society of Automotive Engineers. Secondary Circuit: The high-voltage output side of the ignition coil. SEFI or SFI: Sequential Electronic Fuel Injection or Sequential Fuel Injection. Sensors: Devices that provide the control module with engine information as needed to properly control engine function.
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Spark Line: The portion of an oscilloscope pattern that represents the time during which the air/fuel mixture is being burned in the combustion chamber. Splice: An electrical term for the joining of two or more conductors at a single point. Stoichiometric Ratio: An ideal fuel/air ratio for combustion in which all of the fuel and most of the oxygen will be burned. Sulfur Oxides: Chemical compounds where sulfur is bonded to oxygen produced by the combustion of gasoline or any other fuel that contains sulfur. As sulfur oxides combine with water in the atmosphere to form sulfuric acid. System Pressure: The fuel pressure maintained in the system during normal engine operation. Tap: An electrical term for a type of splice where the original circuit is not interrupted. TBI: Throttle Body Injection. Any of several injection systems that have the fuel injector(s) mounted in a centrally located throttle body. Throttle Body: Controls engine RPM by adjusting the engine manifold vacuum to the mixer. Consists of a housing shaft, throttle liner and butterfly valve. TLEV: Transitional Low Emission Vehicle. TMAP: Combined Air Inlet and Manifold Pressure Sensor. Toluene: A liquid aromatic hydrocarbon C7H8. TPS: Throttle Position Sensor.
TSB: Technical Service Bulletin. ULEV: Ultra Low Emission Vehicle. USB: Universal Serial Bus. A plug or interface supplied on most personal computers. Vaporization: A process in which liquid changes states into gas. Venturi Air Valve Vacuum (VAVV): An amplified air valve vacuum signal coming from the venturi area of the mixer, directly exposed to airflow before the addition of vaporized LPG. Volt/ohmmeter (VOM): A combination meter used to measure voltage and resistance in an electrical circuit. Available in both analog and digital types. May also referred to as AVOM and DVOM. Voltage: The electrical pressure that causes current to flow in a circuit. Measured in volts. Voltage Drop: A lowering of the voltage in a circuit when resistance or electrical load is added. Voltmeter: A meter that uses a needle to point to a value on a scale of numbers usually of the low impedance type; used to measure voltage and resistance. VSS: Vehicle Speed Sensor Xylene: C6H4 (CH3)2. Any of three toxic, flammable, and oily isomeric aromatic hydrocarbons that are dimethyl homologues of benzene and usually obtained from petroleum or natural gas distillates. ZEV: Zero Emission Vehicle.
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Parts Illustration (AT87A-30231-UP, AT88A-30231-UP, AT89A-30231-UP)
Wiring Schematic
SCHEMATIC(S) INSTERTION
Schematic(s) Name/Number Insert copy of oversized schematic Cat: 99789-84133s
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Electrical System Schematic Chassis (2007-01~up)
CRANKSHAFT POSITION SENSOR