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CONTROL
GM V-6 4.3L
DESCRIPTION AND OPERATION
H3.50-5.50XM (H70-120XM) [K005]
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 Maintenance 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!
Table of Contents
TABLE OF CONTENTS
General ...............................................................................................................................................................
Description and Operation ................................................................................................................................
General ...........................................................................................................................................................
ECM (Electronic Control Module) ................................................................................................................
Diagnostic Connector ................................................................................................................................
How ECM Begins Operation.....................................................................................................................
Electronic Engine Control .............................................................................................................................
What ECM Does ........................................................................................................................................
Pulse Generator, EST Distributor ............................................................................................................
EST Module ...............................................................................................................................................
When Engine is Being Started .................................................................................................................
When Engine is Running ..........................................................................................................................
Electronic Control Module (ECM) With EST Distributor, Corrections ..................................................
Fuel Control ...................................................................................................................................................
Injection Throttle Body .................................................................................................................................
Fuel Injectors.............................................................................................................................................
Fuel Pressure Regulator ...........................................................................................................................
Governor Throttle Body Assembly................................................................................................................
Throttle Position Sensor (TPS) .................................................................................................................
Idle Air Control..........................................................................................................................................
Vacuum Ports.............................................................................................................................................
Fuel Pump .................................................................................................................................................
ECM Sensors and Controllers.......................................................................................................................
Manifold Absolute Pressure (MAP) ..........................................................................................................
Coolant Temperature Sensor (CTS) .........................................................................................................
1
1
1
1
1
3
3
3
5
5
6
7
7
8
9
9
9
10
11
11
12
12
13
13
13
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
NOTE: Engines that have an LPG fuel system use
the carbureted engine management system (CEMS).
They do not have an electronically controlled fuel injection system.
1. ECM
2. J1 CONNECTOR
3. J2 CONNECTOR
Figure 1. ECM
Each ECM has a specific program for the model of
lift truck in which it is installed. A replacement
ECM must have the same part number so that the
lift truck will operate correctly.
Diagnostic Connector
The diagnostic connector is connected through a
wiring harness to the ECM. The connector is an
important link for troubleshooting the operation of
the ECM and the electronic engine control system.
The diagnostic connector is found in the engine compartment. See Figure 2. The use of the diagnostic
connector is described in the Electronic Engine
Control Troubleshooting and Repairs 2200
SRM 767 section for these engines.
A. TOP VIEW
1.
2.
3.
4.
9.
10.
11.
12.
13.
14.
15.
16.
5.
6.
7.
8.
IGNITION COIL
EST DISTRIBUTOR
OIL PRESSURE SENDER
FUEL PRESSURE REGULATOR
FUEL STACK
FUEL INJECTORS
IDLE AIR CONTROL (IAC) VALVE
WATER TEMPERATURE SENDER
7.
8.
9.
10.
11.
12.
1.
2.
3.
4.
5.
6.
7.
8.
CAP
ROTOR
SHAFT/TIMER
RETAINER
SHIELD
COIL
POLE PIECE
EST MODULE
EST Module
The EST module is a solid-state electronic device that
operates like a fast switch, except that it does not
have any moving or mechanical parts. See Figure 6.
Small electrical pulses from the sensing coil of the
pulse generator go to the EST module.
9.
10.
11.
12.
13.
14.
15.
ALIGNMENT PIN
HOUSING
WASHER
SEAL
DRIVE GEAR
ROLL PIN
GASKET
The other two wires between the ECM and the distributor control the Electronic Spark Timing and are
called EST and BYPASS.
1.
2.
3.
4.
EST MODULE
ELECTRONIC RELAY
SQUARE WAVE GENERATOR
SENSING COIL
5.
6.
7.
8.
1.
2.
3.
4.
EST MODULE
ELECTRONIC RELAY
SQUARE WAVE GENERATOR
SENSING COIL
5.
6.
7.
8.
FUEL CONTROL
The components of the fuel system are shown in Figure 8.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ADAPTER
GASKET
INJECTOR THROTTLE BODY
FUEL PRESSURE REGULATOR
GASKET
THROTTLE POSITION SENSOR
GOVERNOR MOTOR
MAP VACUUM PORT
PCV VACUUM PORT
GOVERNOR THROTTLE BODY
Figure 8. Fuel System Components
Fuel Injectors
The fuel injectors are solenoids controlled by the
ECM. The ECM energizes a solenoid which lifts a
normally closed ball valve from its seat. The fuel is
under a constant pressure and is injected in a cone
spray pattern into the bore of the throttle body above
the throttle plate. The fuel which is not used by the
fuel injector flows through the pressure regulator
and returns to the fuel tank.
10
1.
2.
3.
4.
5.
6.
7.
8.
9.
SPACER
THROTTLE POSITION SENSOR
RETAINER
CAPSCREW (2)
pintle valve to control the idle air system. See Figure 11. The shaft of the pintle valve moves through
256 steps. The step motor moves the pintle one step
for each count that it receives from the ECM. Each
voltage pulse from the ECM to move the pintle valve
is a count.
When the throttle shaft rotates to open the throttle plates, this rotation turns a potentiometer in the
throttle position sensor. This rotation of the potentiometer causes a variation in the voltage signal to
the ECM. The reference voltage is approximately 4.5
volts at full open throttle and 0.5 volts at engine idle.
1. LINEAR DC STEP
MOTOR
2. PINTLE VALVE
3. O-RING
11
This movement of the pintle valve controls the airflow around the throttle plates. This airflow controls the engine idle speed at all operating temperatures. A minimum idle is set at the factory with a
setscrew. This minimum setting is for engine idle at
sea level and normal operating conditions. A heavier
load from the alternator, hydraulic pumps, and other
accessories will cause the ECM to set a higher number of counts on the pintle valve.
The number of counts that indicates position of the
pintle valve can be seen when a scan tool is connected
for troubleshooting.
When the engine speed increases toward approximately 2500 rpm, the ECM sends signals to the governor control module to energize the governor motor.
The governor control lever moves from its parked position to control the opening of the throttle plates.
If the engine load increases and the engine rpm decreases, the governor motor opens the throttle plates
further. If the governor system is not operating correctly, the ECM will stop fuel to the engine at engine
speeds greater than 2900 rpm.
Vacuum Ports
The governor throttle body has two vacuum ports on
the side of the assembly body. See Figure 8. These
vacuum ports provide a source of vacuum for the
MAP sensor and PCV valve that need a vacuum
source to operate.
Fuel Pump
The fuel injection system must have a constant fuel
pressure to operate correctly (see Figure 12). A check
for the correct fuel pressure is often the first test
when troubleshooting a fuel injection system. A test
port is installed in the injector throttle body for this
purpose.
A small turbine pump connected to an electric motor
is installed in the fuel tank below the liquid level. See
Figure 12. The fuel pressure regulator on the throttle
body keeps the fuel pressure at a constant 69 kPa
(10 psi). Fuel that is not used by the throttle body is
returned to the fuel tank. Baffles are installed in the
fuel tank to make sure that fuel is always available
to the fuel pump during normal operation of the lift
truck.
12
1. FUEL SENDER
CONNECTOR
2. FUEL PUMP
CONNECTOR
3. FUEL INLET WITH
SHUTOFF VALVE
4. FUEL OUTLET
WITH SHUTOFF
VALVE
5. FUEL PUMP
1. SENSOR
2. ELECTRICAL
CONNECTOR
The Coolant Temperature Sensor (CTS) uses a thermistor to control the signal voltage to the ECM. The
ECM applies a 5-volt reference voltage to the CTS.
The measured voltage will be high when the engine
coolant is cold. The measured voltage will be lower
when the engine coolant is at operating temperature.
The ECM will adjust the range of the air and fuel ratio between 1.5:1 at 36 C ( 33 F) to 14.7:1 at 94 C
(201 F) from the CTS signal. The ECM will also adjust the ignition timing for more spark advance when
the engine coolant is cold and less spark advance
when the engine coolant is hot. An engine at operating temperature normally needs less spark advance.
13
NOTES
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TECHNICAL PUBLICATIONS
2200 SRM 766