MICROPROCESSOR
SPARK TIMING SYSTEM
(MSTS)
LATE MODEL
GM 3.0L AND 4.3L LPG FUEL ENGINES
PART NO. 1473385 2200 SRM 765
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Microprocessor Spark Timing System (MSTS) Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
What MSTS Does ........................................................................................................................................... 2
How MSTS Begins Operation ....................................................................................................................... 2
Operation ............................................................................................................................................................ 3
Distributor ..................................................................................................................................................... 3
Ignition Coil ................................................................................................................................................... 3
Ignition Module.............................................................................................................................................. 3
When Engine Is Being Started ..................................................................................................................... 4
When Engine Is Running .............................................................................................................................. 5
Manifold Absolute Pressure (MAP) Sensor .................................................................................................. 6
Engine Coolant Temperature (ECT) Sensor................................................................................................. 6
MSTS Module Corrections ............................................................................................................................ 7
Troubleshooting .................................................................................................................................................. 8
General ........................................................................................................................................................... 8
Tools and Test Equipment ............................................................................................................................. 10
MSTS .............................................................................................................................................................. 11
Troubleshooting Procedure............................................................................................................................ 11
Where to Start ........................................................................................................................................... 11
Visual/Physical Inspection ........................................................................................................................ 11
Knowledge/Tools Required ........................................................................................................................ 11
Damage from Static Discharge (Static Electricity) ................................................................................. 11
Troubleshooting Information ........................................................................................................................ 12
Malfunction Indicator Lamp (MIL) .......................................................................................................... 12
Connecting CodeMate Tester .................................................................................................................... 12
Reading Diagnostic Trouble Codes (DTC) ................................................................................................ 13
Clearing Diagnostic Trouble Codes (DTC’s) ............................................................................................. 14
On-Board Diagnostic (OBD) System Check ................................................................................................. 14
Test Description ......................................................................................................................................... 14
No Malfunction Indicator Lamp........................................................................................................................ 16
Circuit Description ........................................................................................................................................ 16
Test Description ............................................................................................................................................. 16
No DTC-12, Malfunction Indicator Lamp ON .................................................................................................. 18
Circuit Description ........................................................................................................................................ 18
Test Description ............................................................................................................................................. 18
Starter Rotates Engine, Engine Does Not Run ................................................................................................ 19
Test Description ............................................................................................................................................. 19
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicated).................................................. 23
Circuit Description ........................................................................................................................................ 23
Test Description ............................................................................................................................................. 23
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature Indicated) .................................... 25
Circuit Description ........................................................................................................................................ 25
Test Description ............................................................................................................................................. 25
DTC-34 Manifold Absolute Pressure (MAP) Sensor ........................................................................................ 27
Circuit Description ........................................................................................................................................ 27
Test Description ............................................................................................................................................. 27
DTC-41 Electronic Spark Timing (EST) Open Circuit..................................................................................... 30
Circuit Description ........................................................................................................................................ 30
Test Description ............................................................................................................................................. 30
DTC-42 Electronic Spark Timing (EST) Grounded Circuit ............................................................................. 32
Circuit Description ........................................................................................................................................ 32
©2002 HYSTER COMPANY i
Table of Contents Microprocessor Spark Timing System (MSTS)
TABLE OF CONTENTS (Continued)
Test Description ............................................................................................................................................. 32
DTC-51 MSTS Failure ....................................................................................................................................... 34
Circuit Description ........................................................................................................................................ 34
Distributor Repair.............................................................................................................................................. 34
Remove ........................................................................................................................................................... 34
Disassemble ................................................................................................................................................... 35
Inspect ............................................................................................................................................................ 35
Assemble ........................................................................................................................................................ 35
Install ............................................................................................................................................................. 36
Ignition Timing .............................................................................................................................................. 36
Ignition Module Repair ...................................................................................................................................... 37
Test For Fault ................................................................................................................................................ 37
Replace ........................................................................................................................................................... 38
Sensing Coil Repair ........................................................................................................................................... 38
Test For Fault ................................................................................................................................................ 38
Replace ........................................................................................................................................................... 38
Ignition Coil Repair ........................................................................................................................................... 39
Test For Fault ................................................................................................................................................ 39
Remove ........................................................................................................................................................... 39
Install ............................................................................................................................................................. 39
MSTS Module Repair......................................................................................................................................... 40
Remove ........................................................................................................................................................... 40
Install ............................................................................................................................................................. 40
ECT Sensor Replacement .................................................................................................................................. 40
MAP Sensor Replacement ................................................................................................................................. 41
This section is for the following models:
GM 3.0L and 4.3L LPG Fuel Engines
ii
2200 SRM 765 General
General
This section describes the operation of the Micropro-
cessor Spark Timing System (MSTS). The MSTS ig-
nition system is used on engines that use an LPG fuel
system. The description, operation, troubleshooting,
and repair of the MSTS is identical for both the GM
3.0L and 4.3L engines. Illustrations in this man-
ual show the MSTS in the 3.0L engine only. Repairs
and Troubleshooting procedures are also in this sec-
tion. Typical installation of the MSTS is shown in
Figure 1.
1. ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
2. DISTRIBUTOR
3. MSTS MODULE
4. TACHOMETER CONNECTOR
5. IGNITION COIL
6. MAP SENSOR
Figure 1. MSTS Arrangement in Engine Compartment (Typical)
1
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HYSTER Challenger H40XL, H50XL, H60XL, H2.00XL, H2.50XL, H3.00XL Forklift Service Repair Manual & Parts Manual (B177)
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Description
This is a comprehensive Service Repair Manual & Parts manual for the HYSTER CHALLENGER H40XL, H50XL, H60XL, H2.00XL, H2.50XL, H3.00XL FORKLIFT.
Models Covered:
- HYSTER CHALLENGER H40XL (B177) FORKLIFT
- HYSTER CHALLENGER H50XL (B177) FORKLIFT
- HYSTER CHALLENGER H60XL (B177) FORKLIFT
- HYSTER CHALLENGER H2.00XL (B177) FORKLIFT
- HYSTER CHALLENGER H2.50XL (B177) FORKLIFT
- HYSTER CHALLENGER H3.00XL (B177) FORKLIFT
This Service Manual contains essential information, specs, diagrams, real photo illustrations, and schemes for complete step-by-step operations on repair, servicing, technical maintenance, and troubleshooting procedures for your machine. It provides all the necessary information for repairing your machine, enabling you to identify issues and understand how to repair and maintain your machine without professional service. All pages are printable, allowing you to have the required information with you in the garage or workshop.
The Parts manual contains all the information required for proper parts replacement on your HYSTER CHALLENGER H40XL, H50XL, H60XL, H2.00XL, H2.50XL, H3.00XL FORKLIFT. It includes illustrations, part numbers, and step-by-step instructions with highly detailed exploded pictures and diagrams to ensure the correct and efficient completion of the required job.
Table of Contents:
- FRAME
- GM ENGINE
- MAZDA M4-121G ENGINE
- ISUZU C240 (2.4L) ENGINE
- COOLING SYSTEM
- ROCHESTER CARBURETOR (GM ENG)
- LPG FUEL SYSTEM
- GASOLINE CARBURETOR (MAZDA)
- SINGLE-SPEED PS TRANS - DESCR / OPER (T41,T42,T43)
- SINGLE-SPEED PS TRANS - REPAIR (T41,T42,T43)
- DRIVE AXLE
- STEERING AXLE
- STEERING CONTROL UNIT
- STEERING SYSTEM
- BRAKE SYSTEM
- HYDRAULIC SYSTEM and GEAR PUMP
- HYDRAULIC PUMP DRIVE ASSEMBLY
- MAIN CONTROL VALVE
- TILT CYLINDERS
- ALTERNATOR
- STARTER
- ELECTRICAL SYSTEM (MAZDA)
- ELECTRICAL SYSTEM (ISUZU)
- INSTRUMENT PANEL INDICATORS and SENDERS
- MSTS - GM LPG (EARLY CONTROL MODULES)
- MSTS - GM LPG (LATER CONTROL MODULES)
- LIFT CYLINDERS
- VISTA MASTS - DESCRIPTION
- VISTA MASTS - REPAIR
- CAPACITIES and SPECIFICATIONS
- INCH (SAE) and METRIC FASTENERS
- PERIODIC MAINTENANCE
- DIAGRAMS
Additionally, it includes a Parts Manual for the HYSTER CHALLENGER H40XL, H50XL, H60XL, H2.00XL, H2.50XL, H3.00XL FORKLIFT.
Model Specification: HYSTER CHALLENGER H40XL, H50XL, H60XL, H2.00XL, H2.50XL, H3.00XL FORKLIFT
Language: English
File Format: PDF
Requirements: Adobe Reader & Win
Compatible: All Versions of Windows & Mac, APP ISO, Iphone, Ipad, Ipod, Android etc
This quality manual is 100% complete and intact, with no missing/corrupt pages/sections. The file is bookmarked and searchable, making it easy to find what you need. Detailed illustrations, exploded diagrams, drawings, and photos guide you through every service repair procedure. The manual can be viewed on any computer, zoomed, and printed. It comes in PDF format, compatible with all PC-based Windows operating systems and Mac. It can be saved to your hard drive and burned to CD-ROM. Instant access means there are no shipping costs or waiting for a CD or paper manual to arrive in the mail. You will receive this manual today via instant download on completion of payment via our secure payment processor. We accept all major credit/debit cards and PayPal. You can do the repairs yourself and save money.
