Hyster C187 (S60XL) Forklift Service Manual

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 ignition 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 manual show the MSTS in the 3.0L engine only. Repairs and Troubleshooting procedures are also in this section. 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

Hyster C187 (S60XL) Forklift Service Manual

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