Maintenance

HIGH ENERGY
IGNITION (HEI) SYSTEM
GM ENGINES
GC/GLC70-120LG/MG [B818];
GC/GLC70-120LJ/MJ [C818];
GP/GLP70-110LG/MG [B813];
GP/GLP35-45LJ/MJ (GP/GLP70-120LJ/MJ) [C813];
GP/GLP60-70CA (GP/GLP135-155CA) [A878];
GLP20-30RF/TF (GP/GLP40-65RG/TG/ZG) [A875];
GLP165-280DA [A876];
GLP300-360EA [A877];
GC/GLC135-155CA [A879];
GC/GLC040-065RG/TG/ZG [E187]

PART NO. 524153914 2200 YRM 107

 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 YALE 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 hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
High Energy Ignition (HEI) System Table of Contents

TABLE OF CONTENTS

Description .......................................................................................................................................................... 1
Distributor Repair................................................................................................................................................. 3
Remove ........................................................................................................................................................... 3
Disassemble.................................................................................................................................................... 3
Assemble ........................................................................................................................................................ 9
Install, If Crankshaft WAS NOT Rotated when Distributor was Removed....................................................... 10
Install, If Crankshaft WAS Rotated when Distributor was Removed ............................................................... 10
Ignition Coil Replacement.................................................................................................................................... 12
Some Four- and Six-Cylinder Models ............................................................................................................. 12
Remove....................................................................................................................................................... 12
Install .......................................................................................................................................................... 12
V8, Some Four- and Six-Cylinder Models ....................................................................................................... 13
Remove....................................................................................................................................................... 13
Install .......................................................................................................................................................... 13
Electronic Module Replacement.......................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Install............................................................................................................................................................... 14
Sensing Coil Replacement .................................................................................................................................. 16
Remove ........................................................................................................................................................... 16
Install............................................................................................................................................................... 16
Spark Plugs Replacement ................................................................................................................................... 16
Remove ........................................................................................................................................................... 16
Install............................................................................................................................................................... 17
Visual Check........................................................................................................................................................ 17
High Voltage Wires Check ................................................................................................................................... 17
Ignition Coil Check............................................................................................................................................... 18
Coil in Distributor Cap Design ......................................................................................................................... 18
Separate Coil Design ...................................................................................................................................... 18
Sensing Coil, Check ........................................................................................................................................ 19
Electronic Module Check..................................................................................................................................... 19
Ignition Timing Adjustment .................................................................................................................................. 20
GM V8-366 (6-liter) Ignition System Check ......................................................................................................... 21
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and Idle Speed Adjustment ................................. 21
Specifications ...................................................................................................................................................... 21
Troubleshooting ................................................................................................................................................... 22

This section is for the following models:

GC/GLC70-120LG/MG [B818];
GC/GLC70-120LJ/MJ [C818];
GP/GLP70-110LG/MG [B813];
GP/GLP35-45LJ/MJ (GP/GLP70-120LJ/MJ) [C813];
GP/GLP60-70CA (GP/GLP135-155CA) [A878];
GLP20-30RF/TF (GP/GLP40-65RG/TG/ZG) [A875];
GLP165-280DA [A876];
GLP300-360EA [A877];
GC/GLC135-155CA [A879];
GC/GLC040-065RG/TG/ZG [E187]

©2008 Yale Materials Handling Corp. i

2200 YRM 107 Description

Description
This section has a description and the service proce- ignition coil. The flow of current generates a magnetic
dures for the High Energy Ignition (HEI) system for Gen- field around both windings. When the sensing coil
eral Motors engines. See Figure 1. removes the voltage signal, the electronic module
deactivates OFF. Current stops flowing in the primary
The High Energy Ignition (HEI) system generates the winding. The magnetic field decreases quickly. This
spark which starts combustion. The main parts of the changing magnetic field generates a high voltage in
system are: the battery, key switch, distributor, ignition the secondary winding.
coil, spark plugs, and the wires. If the engine is start-
ing or running, current flows from the battery to the key
switch, primary winding of the ignition coil, electronic
module and returns to the battery. A magnetic field
is generated in the primary winding of the coil when
current flows through it. The pole piece and sensing
coil sends a signal to the electronic module to interrupt
primary current. When the current flow in the primary
windings are interrupted, the decreasing magnetic field
generates a high voltage in the secondary windings of
the coil.

The distributor rotor applies the secondary (high) volt-

age to the correct spark plug at the correct time. The
secondary voltage is applied to the rotor. The rotor
transfers this high voltage to one of the terminals in
the distributor cap. When the high voltage is applied
through the high voltage wire to the spark plug, the
spark in the spark plug starts combustion in the cylin-
der.

The parts that generate the voltage signal for the elec-
tronic module are shown in Figure 2. The timer core of
the distributor shaft has a tooth for each cylinder in the
engine. The pole piece also has a tooth for each cylin-
der. A permanent magnet is fastened under the pole
piece. A sensing coil is put in the center of the mag-
net and pole piece. When the teeth are aligned, the
magnetic field from the permanent magnet will have a
path. The magnetic field generates a voltage signal in
the sensing coil. When the teeth are not aligned, the
magnetic path is removed. This disables the magnetic
field and the voltage signal.
1. BATTERY 5. ROTOR
The electronic module is an electronic switch which 2. TIMER CORE 6. DISTRIBUTOR CAP
controls the current in the primary of the ignition 3. POLE 7. ELECTRONIC
PIECE/SENSING MODULE
coil. The basic circuit is shown in Figure 3. When COIL 8. IGNITION COIL
the electronic module receives a voltage signal from 4. SPARK PLUG 9. KEY SWITCH
the sensing coil, the electronic module activates ON.
Current now flows through the primary winding of the Figure 1. HEI System

1
Description 2200 YRM 107

A. TEETH ALIGNED B. TEETH NOT

ALIGNED
1. TIMER CORE
2. POLE PIECE
3. PERMANENT MAGNET
4. SENSING COIL

Figure 2. Voltage Signal A. MODULE "ON" B. MODULE "OFF"

1. ELECTRONIC MODULE
2. BATTERY
3. PRIMARY (IGNITION COIL)
4. SECONDARY (IGNITION COIL)

Figure 3. Electronic Module Operation

2
2200 YRM 107 Distributor Repair

Distributor Repair
REMOVE 3. If needed, remove electronic module as follows:

a. Distributors shown in Figure 4, Figure 5, and

WARNING Figure 6: Remove two screws which fasten
Do not disconnect the spark plug wires when the electronic module to housing. Move electronic
engine is running. The high voltage can cause elec- module to a position where connector can be
tric shock. removed from B and C terminals. Remove con-
nector from electronic module. Carefully dis-
1. Disconnect wire from negative terminal of battery.
connect wires from W and G terminals. Re-
2. Disconnect primary wiring connector to distributor. move electronic module. If installed, remove
Some distributors have the primary wiring con- screw from capacitor. Disconnect capacitor
nected to the coil and others are connected to the from wire connector. Remove capacitor.
distributor.
b. Distributors shown in Figure 7: Remove three
NOTE: Some four- and six-cylinder models have two screws that fasten electronic module, wiring
latch screws. Some four- and six-cylinder models and harness, and capacitor to housing. Disconnect
all V8 models have four latch screws. connector for the green and white wire from the
electronic module. Remove electronic module,
3. Unlock latch screws that fasten the cap to the hous- wiring harness, and capacitor from the hous-
ing. Remove cap and put it away from the distribu- ing.
tor.
4. Make a mark on gear and shaft which can be
aligned during assembly.
CAUTION
Do not rotate the engine after making the alignment
marks. CAUTION
Do not damage the shaft when removing the gear.
4. Make a mark on distributor housing which aligns Hold the gear on a block of wood while removing
with rotor. Make a double mark on housing and the pin.
engine to use during assembly.
5. Remove pin from gear. Remove gear, shim, and
5. Remove capscrew and clamp that fastens distribu- thrust washer if used.
tor to engine. Clean area around base of distributor.

6. Lift distributor from engine. CAUTION

Make sure the roll pin area of the shaft is smooth
DISASSEMBLE before removing the shaft.

1. Remove distributor from engine according to the 6. Remove shaft assembly from housing.
above procedure.

2. If installed, remove two screws that fasten rotor to CAUTION

shaft assembly. Remove rotor. Do not disassemble the pole piece/sensing coil. If
damaged, replace as a unit.
CAUTION 7. Remove snap ring/retainer from top of sleeve in
Do not clean the lubricant from the electronic mod- center of housing. Remove pole piece/sensing coil
ule or the area where it is fastened. and shield, if installed from the sleeve.

3
Distributor Repair 2200 YRM 107

Figure 4. GM-V8, Some Models

4
2200 YRM 107 Distributor Repair

Legend for Figure 4

A. DESIGN 1 B. DESIGN 2
1. PIN 14. SNAP RING
2. DRIVE GEAR 15. ELECTRONIC MODULE
3. SHIM 16. IGNITION COIL
4. THRUST WASHER 17. SEAL
5. O-RING 18. SPRING
6. WIRING HARNESS 19. WIRE RETAINER
7. HOUSING 20. COIL COVER
8. WIRE RETAINER 21. CAP
9. FELT WASHER 22. ROTOR
10. SHIM 23. CENTRIFUGAL MECHANISM
11. CAPACITOR 24. TIMER CORE
12. SPACER RETAINER 25. SHAFT
13. POLE PIECE/SENSING COIL

CAUTION WARNING
Do not remove the bushing from the center of the Compressed air can move particles so they cause
housing. injury to the user or to other personnel. Make sure
the path of the compressed air is away from all per-
8. If needed, remove spacer retainer from housing. sonnel. Wear protective goggles or a face shield to
Remove other parts as follows: prevent injury to the eyes.
a. On distributors shown in Figure 4 and Figure 5,
remove shim, felt washer, and wire retainer CAUTION
from housing. Remove wiring from housing. Do not use solvents with an oil base to clean elec-
trical parts.
b. On distributors shown in Figure 7, remove plas-
tic retainer that seals the grease. 9. Wash housing, shaft assembly, and gear in solvent.
Dry parts with compressed air.
WARNING 10. Check all parts for damage. Replace damaged
Cleaning solvents can be flammable and toxic, and parts with new parts.
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.

5
Distributor Repair 2200 YRM 107

1. PIN 10. POLE PIECE/SENSING COIL

2. DRIVE GEAR 11. SNAP RING
3. O-RING 12. ELECTRONIC MODULE
4. WIRING HARNESS 13. CAP (FOUR-CYLINDER SHOWN)
5. HOUSING 14. ROTOR
6. WIRE RETAINER 15. TIMER CORE
7. FELT WASHER 16. SHAFT
8. SHIM 17. CENTRIFUGAL MECHANISM
9. CAPACITOR

Figure 5. GM Four-Cylinder and Six-Cylinder Models with Separate Coil

6
2200 YRM 107 Distributor Repair

1. SCREW 11. PIN

2. DISTRIBUTOR CAP 12. HOUSING
3. ROTOR 13. THRUST WASHER
4. SHAFT ASSEMBLY 14. SHIM
5. RETAINER 15. GEAR
6. SHIELD 16. PIN
7. SENSING COIL 17. GASKET
8. POLE (STATIONARY) 18. CLAMP
9. BOLT 19. BOLT
10. ELECTRONIC MODULE

Figure 6. GM V6 Models

7
Distributor Repair 2200 YRM 107

1. SCREW 15. GEAR

2. BRACKET 16. PIN
3. CAPACITOR 17. SHAFT ASSEMBLY
4. SCREW 18. ROTOR
5. WIRING HARNESS 19. SCREW
6. ELECTRONIC MODULE 20. DISTRIBUTOR CAP (V8 SHOWN)
7. SNAP RING 21. RESISTOR BRUSH AND SPRING
8. POLE PIECE/SENSING COIL 22. SEAL
9. SCREW 23. IGNITION COIL
10. SPACER RETAINER* 24. SCREW
11. GREASE SEAL 25. COVER
12. HOUSING 26. SCREW
13. THRUST WASHER* 27. VACUUM ADVANCE UNIT
14. SHIM*

*V8 ONLY

Figure 7. HEI, Some Models with Coil as Part of Distributor

8
2200 YRM 107 Distributor Repair

ASSEMBLE
CAUTION
1. Fill lubrication reservoir with correct lubricant. In- Make sure to put silicone grease (Yale Part No.
stall parts as follows: 504223239) between the module and the fastening
plate.
CAUTION 5. Install electronic module as described in the follow-
On four- and six-cylinder distributors shown in Fig- ing procedures:
ure 5, make sure the brown wire has a circle shape.
a. Distributors shown in Figure 4, Figure 5, and
a. On distributors shown in Figure 4, Figure 5, Figure 6, if used, install capacitor, but do not
and Figure 6, install wiring in correct position in tighten screw. Connect wire connector to B and
housing. Install wire retainer, felt washer, and C terminals on electronic module. Apply sil-
shim in housing. icone grease to bottom of electronic module.
Fasten electronic module to housing with two
b. On distributors shown in Figure 7, install plastic
screws. Make sure screws are tight. Put wiring
retainer on top of lubrication reservoir.
grommet in the notch in the housing. Connect
2. If removed, install spacer retainer and screws. pink wire to capacitor terminal. If a black wire
Install pole piece/sensing coil and shield if used. is used, connect it to screw that fastens capac-
Make sure hole in arm of pole piece connects to itor. Tighten screw. Connect white wire from
pin of retainer. Install snap ring/retainer on top of sensing coil to W terminal on electronic mod-
sleeve. Make sure ring fits in groove. ule. Connect green wire from sensing coil to G
terminal on electronic module.
3. Install distributor shaft. Slowly rotate shaft. Check
for equal clearance between pole piece and timer b. Distributors shown in Figure 7, connect wiring
teeth of shaft. If wrong, loosen three screws fasten- connector to electronic module. Connect ca-
ing pole piece. Move pole piece until it is in center. pacitor to wiring connector. Apply silicone
Tighten three screws. grease to bottom of electronic module. Put
wiring connector assembly into correct position
4. Install gear with teeth toward housing as follows: in housing. Make sure wiring grommet fits
into notch. Install three fastening screws and
a. Install thrust washer and then shim, if used. tighten. Install connector for green and white
Align marks and slide gear on shaft. wires to electronic module.

CAUTION CAUTION
Put a block under the gear to prevent damage when The notch on the rotor must fit into the tooth of the
installing the gear pin. centrifugal mechanism.

b. Align hole in gear with hole in shaft. Install pin 6. Install rotor and two screws to shaft assembly.
to lock gear to shaft. Tighten screws.

9
Distributor Repair 2200 YRM 107

INSTALL, IF CRANKSHAFT WAS NOT INSTALL, IF CRANKSHAFT WAS ROTATED

ROTATED WHEN DISTRIBUTOR WAS WHEN DISTRIBUTOR WAS REMOVED
REMOVED
1. Find ignition position of the number one cylinder as
1. Turn rotor 1/8 turn to the left, past the mark put on follows:
the housing during removal.
a. Remove valve cover (left valve cover on V8
NOTE: If needed, turn rotor until gears align correctly. 350).
The rotor must align with the mark on the housing after
b. Rotate crankshaft until inlet valve closes.
installation.
c. Rotate crankshaft 1/3 turn more. Stop crank-
2. Push distributor into position in block. Turn housing
shaft when timing mark on pulley aligns with
until the double mark on the housing aligns with the
TDC mark.
marks on the engine.
2. Hold distributor just above the installation position.
3. Install distributor clamp and capscrew.
Rotate distributor rotor until it is aligned with number
one terminal.
CAUTION
The tooth on the bottom of the cap must fit into the NOTE: If needed, turn rotor until gears align correctly.
notch in the housing. If needed, rotate oil pump driveshaft with a screwdriver
so distributor shaft aligns with oil pump drive. The rotor
4. Put distributor cap on housing. Lock cap to housing must align with the number one terminal of the distrib-
with four latch screws. The early four- and six-cylin- utor cap. (See Figure 8.)
der distributors use only two latch screws.
3. Push distributor into position in block. Turn housing
5. Connect primary wiring harness to distributor. until double mark on housing aligns with marks on
engine.
a. Some four- and six-cylinder models, connect
connector to coil. 4. Install distributor clamp and capscrew.

b. V8 350 and some four- and six-cylinder models,

connect connector at side of distributor. CAUTION
The tooth on the bottom of the distributor cap must
6. If removed, connect battery wire to negative termi- fit into the notch in the housing or the alignment will
nal of battery. Tighten nut on capscrew. not be correct.

7. Adjust ignition timing according to the procedure in 5. Put distributor cap in position on housing. Lock cap
Ignition Timing Adjustment. to housing with latch screws.

6. Connect primary wiring harness to distributor. (See

Figure 4, Figure 5, Figure 6, and Figure 7.)

7. Adjust ignition timing according to the procedure in

Ignition Timing Adjustment.

10
2200 YRM 107 Distributor Repair

A. FIRING ORDER 1-3-4-2 C. FIRING ORDER 1-8-4-3-6-5-7-2

B. FIRING ORDER 1-5-3-6-2-4 D. FIRING ORDER 1-6-5-4-3-2
1. FOUR CYLINDER 3. V8
2. SIX CYLINDER 4. V6

Figure 8. Firing Order

11
Ignition Coil Replacement 2200 YRM 107

Ignition Coil Replacement

SOME FOUR- AND SIX-CYLINDER Install
MODELS
NOTE: It is normal for a new coil to be loose in the
Remove frame.

1. Disconnect wire from negative terminal of battery. 1. Turn coil so terminals are on top. See Figure 9 and
Figure 10. Put coil frame on studs that fasten coil
2. Disconnect secondary wire from coil. See Figure 9 to engine. Install and tighten nuts.
and Figure 10.
2. Connect primary wiring harness to coil. Push con-
3. Remove dust cover from primary wiring. nector until latches lock.

4. Disconnect primary wiring harness from coil. 3. Install dust cover over primary wiring connector.

5. Remove nuts from studs that fasten coil to block. 4. Connect secondary wire to coil. Push connector
until latches lock.

5. If removed, connect battery wire to negative termi-

nal of battery. Tighten nut on capscrew.

1. SECONDARY TERMINAL
2. TACHOMETER TERMINAL
3. PRIMARY TERMINAL
4. FRAME
5. BATTERY TERMINAL

Figure 9. Some Four- and Six-Cylinder Models

Ignition Coil
1. SECONDARY TERMINAL
2. TACHOMETER TERMINAL
3. PRIMARY TERMINAL
4. FRAME
5. BATTERY TERMINAL

Figure 10. GM V6 Models Ignition Coil

12
2200 YRM 107 Ignition Coil Replacement

V8, SOME FOUR- AND SIX-CYLINDER 4. Align terminal(s) of ground wire(s) to hole in coil
MODELS frame. Install four screws in frame of coil. Tighten
screws.
Remove
1. Disconnect wire from negative terminal of battery.

2. Unlock holder for secondary wires. See Figure 11.

Remove secondary wires by carefully pulling on
holder.

3. Disconnect wiring harness for primary wires from

side of distributor.

4. Unlock four latch screws that fasten cap to housing.

Remove distributor cap from distributor.

NOTE: Some V8-350 models used three screws to

fasten the cover. Some V8-350, four- and six-cylinder
models use two screws to fasten cover.

5. Remove screws that hold coil cover to distributor

cap. Remove cover.

CAUTION
Do not damage the ground wires.

6. Remove four screws that hold coil to distributor cap.

Loosen terminals of primary wires by pushing from
connector side of cap. Carefully remove coil and
primary wires.

7. Check rubber seal, spring, and resistor brush in cap

for damage. Check cap for cracks or other damage.
Replace parts that are damaged.

Install
NOTE: On some distributor models, the ground wire
must be installed before the coil is installed.

1. If the ground wire was removed, install wire into

position.
A. DESIGN 1 C. DESIGN 3
2. Install resistor brush, spring, and rubber seal in cap. B. DESIGN 2
See Figure 11. 1. TACHOMETER TERMINAL
2. PRIMARY WIRE
NOTE: If the coil is new, make sure the part number is 3. GROUND WIRE
correct. 4. BATTERY TERMINAL
3. Put coil in correct position in cap. Push terminals of Figure 11. V8 and Some Four- and Six-Cylinder
primary wires into connector on side of cap. Models Ignition Coil

13
Electronic Module Replacement 2200 YRM 107

6. Put distributor cap in position on housing. Lock cap

CAUTION to housing with four latch screws.
Some V8 units use three screws to fasten the cover.
Some V8, four- and six-cylinder models use two 7. Connect wiring harness for primary wires to side of
screws to fasten the cover. distributor. Make sure connector is locked together.

5. Install coil cover and fastening screws. Tighten 8. Connect secondary wires and holder to cap. Make
screws. sure holder is locked to cap.

9. If removed, connect battery wire to negative termi-

CAUTION nal of battery. Tighten nut on capscrew.
The tooth on the bottom of the distributor cap must
fit into the notch in the housing or the alignment will
not be correct.

Electronic Module Replacement

REMOVE electronic module. Remove electronic mod-
ule, wire connector, and capacitor from hous-
1. Disconnect wire from negative terminal of battery. ing. Disconnect electronic module from con-
See Figure 12. nector.
2. Disconnect primary wiring harness to distributor.
INSTALL
(See Figure 4, Figure 5, Figure 6, and Figure 7.)

3. Unlock latch screws that fasten cap to housing. Re- CAUTION

move cap. Apply silicone grease (Yale Part No. 504223239)
between the electronic module and the fastening
4. If used, remove two screws that fasten rotor to shaft
plate.
assembly. Remove rotor.
1. The following procedure is for installation of the
5. Remove electronic module as follows:
electronic module:
a. Distributors shown in Figure 4, Figure 5, and
a. Distributors shown in Figure 4, Figure 5, and
Figure 6: Remove two screws which fasten
Figure 6: Connect wire connector to B and C
electronic module to housing. Move electronic
terminals on electronic module. Apply silicone
module so connector can be removed from B
grease to bottom of electronic module. Fasten
and C terminals. Remove connector from elec-
electronic module to housing with two screws.
tronic module. Carefully disconnect other wires
Make sure screws are tight. Put wiring grom-
from W and G terminals. Remove electronic
met in notch in housing. Connect pink wire
module from housing.
to capacitor terminal. If a black wire is used,
b. Distributors shown in Figure 7: Remove three connect it to screw that fastens the capacitor.
screws that fasten electronic module, wiring Tighten screw. Connect white wire from sens-
harness, and capacitor to housing. Disconnect ing coil to W terminal on electronic module.
connector for the green and white wire from the Connect green wire from sensing coil to G ter-
minal on electronic module.

14
2200 YRM 107 Electronic Module Replacement

b. Distributors shown in Figure 7: Connect wiring

connector to electronic module. Connect ca-
pacitor to wiring connector. Apply silicone
grease to bottom of electronic module. Put
wiring connector assembly into correct position
in housing. Make sure wiring grommet fits
into notch. Install three fastening screws and
tighten screws. Install connector for the green
and white wires to the electronic module.

CAUTION
The notch on the rotor must fit into the tooth of the
centrifugal mechanism.

2. Install rotor and two screws to shaft assembly.

CAUTION
The tooth on the bottom of the distributor cap must
fit into the notch in the housing or the alignment will
not be correct.

3. Put distributor cap in position on housing. Lock cap

to housing with latch screws.

4. Connect primary wiring harness to distributor.

5. If removed, connect battery wire to negative termi-

nal of battery. Tighten nut on capscrew.

1. WIRING HARNESS
2. CAPACITOR
3. SENSING COIL WIRES
4. ELECTRONIC MODULE

Figure 12. Electronic Module Installation

15
Spark Plugs Replacement 2200 YRM 107

Sensing Coil Replacement

REMOVE
1. Remove distributor from engine. See the procedure
for your lift truck for Distributor Repair, Remove.

CAUTION
Do not disassemble the sensing coil/pole piece.
Disassembly can change the polarity of the coil. If
damaged, replace the sensing coil/pole piece with
a new assembly.

2. Disassemble distributor. See the procedure for Dis-

tributor Repair, Disassemble for your lift truck. See
Figure 13.

INSTALL
1. Assemble distributor. See the procedure for Distrib-
1. MAGNET 3. POSITION ARM
utor Repair, Assemble. 2. POLE PIECE 4. SENSING COIL
2. Install distributor to engine. See the procedures for Figure 13. Pole Piece and Sensing Coil
Distributor Repair, Install, If Crankshaft WAS NOT
Rotated when Distributor was Removed and Dis-
tributor Repair, Install, If Crankshaft WAS Rotated
when Distributor was Removed.

Spark Plugs Replacement

REMOVE the path of the compressed air is away from all per-
sonnel. Wear protective goggles or a face shield to
WARNING prevent injury to the eyes.
Do not remove the wires to the spark plugs with the 2. Clean area around spark plug with compressed air.
engine running. The high voltage can cause electric
shock.
CAUTION
CAUTION Use a deep socket for removing the spark plug.
Make sure the insulator is not damaged.
Do not pull on the wires. The core can separate and
cause ignition problems. 3. Remove spark plugs. If used, remove gaskets.
1. Disconnect wires by pulling on terminal cover. Turn 4. Inspect spark plugs for normal operation. If dam-
cover to loosen it from spark plug. aged, replace plugs.

WARNING
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure

16
2200 YRM 107 High Voltage Wires Check

INSTALL 3. Install spark plugs and if used, gaskets.

1. Clean thread area where spark plugs screw into

cylinder head. Make sure seat area is clean. CAUTION
Do not tighten the spark plugs to more than the
2. Check clearance between electrodes. Bend side specification.
electrode to get correct clearance.
4. Tighten plugs to correct torque.
CAUTION 5. Connect wires to spark plugs. Push wire terminal
Do not use a gasket if the spark plug has a tapered until wire locks to plug.
seat.

Visual Check
Remove the distributor cap. Inspect the rotor and the
WARNING inside of the cap for dust and carbon deposits. Clean
Compressed air can move particles so they cause the dust from the parts with compressed air. Inspect
injury to the user or to other personnel. Make sure the rotor and cap for damage. If parts are damaged,
the path of the compressed air is away from all per- replace with new parts. Remove the rotor. Inspect the
sonnel. Wear protective goggles or a face shield to pivot area of the centrifugal weights. If the pivot has a
prevent injury to the eyes. rust condition, put one drop of oil on the pivot. If the
pivot is damaged, replace the damaged parts with new
The HEI distributor will operate for a long time without
parts.
causing problems. A visual inspection of the distributor
when the spark plugs are changed is a good check.

High Voltage Wires Check

The high voltage wires must be handled very carefully. 3. Move high voltage wire a little while looking at ohm-
Do not pull on the wires. The core can separate and meter. If the ohmmeter indicates more than 2500
cause ignition problems. If the wires are causing a prob- ohms, replace wire with a new part. If the ohm-
lem, do the following checks: meter indication changes from infinity to any value,
replace wire with a new part.
WARNING
Do not remove the high voltage wires with the en- CAUTION
gine running. The high voltage can cause electric Make sure the new wires have a diameter of 8 mm
shock. and have silicone insulation.

1. Disconnect each wire by pulling on terminal cover. 4. Check wire without moving it. Replace wire with
Turn cover to loosen wire. a new part if the meter indications are not within
specifications.
2. Connect wires from an ohmmeter to high voltage
wire. Set ohmmeter to a high scale.

17
Ignition Coil Check 2200 YRM 107

Ignition Coil Check

COIL IN DISTRIBUTOR CAP DESIGN SEPARATE COIL DESIGN
1. Disconnect wire from negative terminal of battery. 1. Disconnect wire from negative terminal of battery.

2. Disconnect primary wiring connector to distributor. 2. Disconnect secondary wire from coil.

3. Unlock four screws that fasten cap to housing. 3. Remove dust cover from primary wiring.
Carefully remove cap and turn it to the position
shown in Figure 14. 4. Disconnect primary wiring harness from coil.

5. Set ohmmeter to the high scale. Connect ohmme-

ter as shown in step 1 of Figure 15. If the meter
indication is less than infinity, install new coil and
repeat Step 5.

Figure 14. Ignition Coil Checks, V8 and Some

Four- and Six-Cylinder Engines

4. Set ohmmeter to the low scale. Connect ohmmeter Figure 15. Ignition Coil Checks, Some Four- and
as shown in step 1 of Figure 14. The normal indica- Six-Cylinder Engines
tion is less than 2 ohms. Replace coil if indication
is infinity and repeat Step 4. 6. Set ohmmeter to the low scale. Connect ohmmeter
as shown in step 2 of Figure 15. If it does not in-
5. Set ohmmeter to the high scale. Connect ohmme- dicate zero to one ohm, install new coil and repeat
ter as shown in steps A and B of step 2 of Figure 14. Step 5 and Step 6.
Install a new coil if both the indications are infinity
and repeat Step 4 and Step 5. A resistance indica- 7. Set ohmmeter to the middle scale. Connect ohm-
tion one way and an infinity indication the other way meter as shown in step 3 of Figure 15. If the me-
is normal. ter indication is infinity, install new coil and repeat
Step 5 and Step 7.

18
2200 YRM 107 Electronic Module Check

SENSING COIL, CHECK

1. Disconnect wire from negative terminal of battery.

2. Disconnect primary wiring connector to distributor.

3. Unlock latch screws that fasten cap to housing.

Carefully remove cap and put it away from distrib-
utor.

NOTE: Some models use separate terminals. Some

models use a double terminal.

4. Disconnect white and green wires from electronic

module.

5. Set ohmmeter to a middle scale. Connect ohmme-

ter as shown in step 1 of Figure 16. If the ohmme-
ter indicates less than 500 ohms or more than 1500
ohms, install new part and Step 5.

6. Set ohmmeter to a high scale. Connect ohmmeter

as shown in step 2 of Figure 16. Do step 2 for 1. GREEN WIRE 3. HOUSING
each wire. If the meter indication is less than infinity, 2. WHITE WIRE
install new coil and repeat Step 5 and Step 6.
Figure 16. Sensing Coil Checks

Electronic Module Check

The electronic module can be tested only with a special tool. Use the procedure given by the manufacturer to test
the electronic module. If needed, get tool number J-24642 from the Kent-Moore Tool Division, Jackson, Michigan.

19
Ignition Timing Adjustment 2200 YRM 107

Ignition Timing Adjustment

1. If equipped with vacuum advance, disconnect vac- NOTE: Do not use a dwell meter to check the cam an-
uum line at distributor and put a plug in the line. gle. The cam angle is set by the electronic module.

CAUTION
Not all tachometers will give the correct indication
of speed when connected to the HEI system. Check
with the manufacturer of the tachometer to make
sure it will work with HEI.

2. Connect tachometer to tachometer terminal.

a. Some four- and six-cylinder engines, connect

at the ignition coil. See Figure 9.

b. V8-350, some four- and six-cylinder engines,

connect at the distributor.(See Figure 11 and
GM V8-366 (6-liter) Ignition System Check.)

CAUTION
Not all timing lights will give the correct indication
when connected to the HEI system. Check with the
manufacturer of the timing light to make sure it will
work with HEI.

3. Connect timing light to spark plug wire that goes

to number one cylinder. Make other connections
described by the manufacturer.

WARNING
Do not touch moving parts (fan, belt, shafts, pul-
leys). A. BEFORE B. AFTER
4. Start engine and run at correct speed. Hold timing 1. FOUR AND SIX 2. V8-350
light so it illuminates timing plate and the mark on CYLINDER
crankshaft pulley. See Figure 17. Check for correct
Figure 17. Timing Marks
timing. If timing is not correct, loosen clamp that
holds distributor housing. Rotate housing right or
left to get correct timing. Tighten clamp when timing
is correct. Connect vacuum line to distributor.

20
2200 YRM 107 Specifications

GM V8-366 (6-liter) Ignition System Check

Check spark plugs. Replace worn spark plugs and dis-
tributor contacts. The correct spark plug gap is 0.89 to
1.1 mm (0.035 to 0.043 in.).

Check ignition timing. See Figure 18. Adjust timing

according to specifications.

1. CRANKSHAFT 2. TIMING TAB

DAMPER

Figure 18. GM V8 Timing Marks

GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition

Timing and Idle Speed Adjustment
For ingnition timing and idle speed adjustment for the For ingnition timing and idle speed adjustment for the
GM V6 (4.3-liter) with EPIC LPG System, see Carbu- GM V6 (4.3-liter) on lift trucks equipped with MSTS,
reted Engine Management System Open Loop Car- see MSTS GM V6-4.3L (Later Control Modules) Mi-
bureted Engine Management System (CEMS) 2200 croprocessor Spark Timing System (MSTS), Late
YRM 744. Model 2200 YRM 765

Specifications
Item Specifications
Spark Plugs See Parts Manual
Electrode gap ............................................................. 0.89 to 1.1 mm (0.035 to 0.045 in.)
Torque
Gasket type............................................................ 35 to 40 N•m (26 to 30 lbf ft)
Tapered seat .......................................................... 14 to 27 N•m (10 to 20 lbf ft)
Firing Order
Four cylinder............................................................... 1-3-4-2
Six cylinder (in-line).................................................... 1-5-3-6-2-4
V-6.............................................................................. 1-6-5-4-3-2
V-8.............................................................................. 1-8-4-3-6-5-7-2

21
Troubleshooting 2200 YRM 107

Item Specifications
Ignition Timing
4 cylinder.................................................................... 8 BTDC @ 600 rpm
6 cylinder (in-line)....................................................... 8 BTDC @ 600 rpm
V-6.............................................................................. 0 BTDC @ 650 rpm
V8-350........................................................................ 6 BTDC @ 600 rpm (gasoline fuel)
V8-366........................................................................ 10 BTDC @ 650 rpm (LPG fuel)
6 to 8 BTDC @ 725 to 750 rpm (LPG fuel)
Module Grease ............................................................... Silicone Grease, Part No. 504223239
Sensing Coil Resistance................................................. 500 to 1500 Ohms
High Voltage Wire Resistance
0 to 381 mm (0 to 15 in.) ............................................ 3000 to 10,000 Ohms
381 to 635 mm (15 to 20 in.) ...................................... 4000 to 15,000 Ohms
635 to 890 mm (25 to 35 in.) ...................................... 6000 to 20,000 Ohms

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The engine will not start. Open circuit between the battery and Repair or replace cable from battery to
the distributor. distributor.

Moisture or dirt in the distributor cap. Clean and dry distributor cap.

New spark plugs are needed. Replace spark plugs. See Spark Plugs
Replacement.

High voltage wires are damaged. Perform high voltage wire checks. See
High Voltage Wires Check.

Open circuit between the distributor Perform Ignition Coil Check and re-
connector and the ignition coil. pair as required. See Ignition Coil
Check and Ignition Coil Replacement.

Open circuit in the ignition coil. Replace ignition coil. See Ignition Coil
Replacement.

Open circuit in the sensing coil. Replace Sensing Coil. See Sensing
Coil Replacement.

The electronic module is damaged. Replace electronic module. See Elec-

tronic Module Replacement.

22
2200 YRM 107 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Engine does not run correctly. Ignition timing is not correct. Perform proper timing procedures.
See Ignition Timing Adjustment.

New spark plugs are needed. Replace spark plugs. See Spark Plugs
Replacement.

High voltage wires are damaged. Perform high voltage wire checks. See
High Voltage Wires Check.

Moisture or dirt in the distributor cap. Clean and dry distributor cap.

Distributor cap is damaged. Replace distributor cap.

Centrifugal mechanism is damaged. Replace centrifugal mechanism. See

Distributor Repair.

Ignition coil is damaged. Replace ignition coil. See Ignition Coil

Replacement.

Sensing coil is damaged. Replace Sensing Coil. See Sensing

Coil Replacement.

The electronic module is damaged. Replace electronic module. See Elec-

tronic Module Replacement.

23
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 Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

2200 YRM 107 3/08 (11/03)(3/03)(3/02)(12/01) Printed in the United Kingdom