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Old 10-08-2018, 07:04 PM
coltnovice coltnovice is offline
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Default Fault Code 537 Throttle Unable to Open

Ford LRG 425 2.5L EFI. The engine cranks but will not start. Before I replace the electronic throttle body, I am asking if there are other problems that can cause this code? I hate to pay $300 for a new one and then find out that it was something else.
I have removed the throttle body, cleaned it, tested the motor, and reinstalled with the same result.

I am told that this is the same engine in a '99-'00 Ranger. This engine is in a Genie Lift Boom.

Last edited by coltnovice; 10-08-2018 at 07:07 PM.
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Old 10-09-2018, 05:46 AM
tomw0 tomw0 is offline
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Default Re: Fault Code 537 Throttle Unable to Open

Have you looked at the Throttle Position Sensor? If the sensor has 'dropout', or bad spots (likely from wear) it may be reporting the throttle is not open when it actually is.
A quick goog for 'ford lrg 425 troubleshooting' got me to a Genie S-65 engine startup problem at this site:
https://www.heavyequipmentforums.com...problem.25429/

Not that this is your problem, but you might want to give a little more specs to narrow it down. EFI, but is it the Bosch mentioned or a FoMoCo EEC system? Is it OBD-II compliant or totally industrial?
tom
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Old 10-16-2018, 05:31 PM
coltnovice coltnovice is offline
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Default Re: Fault Code 537 Throttle Unable to Open

Totally industrial. Cannot connect scanner.
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Old 10-17-2018, 08:26 AM
tomw0 tomw0 is offline
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Default Re: Fault Code 537 Throttle Unable to Open

Unless Genie supplied instructions, trouble shooting a system with no documentation will be difficult. I know nothing about the engine control system used, but would think that a signal is being sent from the hand controls to a 'governor' of some sort that knows the hydraulic load will increase in about 2ms when the operator pulls on the 'boom lift' lever. A signal should be sent to the throttle body to "Open up a bit, George, we's gonna have a load soonly."

If you can see the signal(VOM) to the throttle body, and the TB does not respond, then you likely need a new one. If you do NOT see the signal(OPEN! throttle), then you have to check the wiring and the 'controller' that is generating(supposed to) the signal for the throttle to open.
There's a youtube by PHAD(Pine Hollow Auto Diagnostic) where he works on a Lima 2.3 used in a lift boom somewhere in Illinois. Techs butchered the wiring, and he was able to make it work again. If you follow his trouble shooting, you may be able to fix your machine.
I would find out which system was being used, Bosch, or Ford EEC(guessing from the original link I posted a few up from this one), and if a USA throttle body is used, check in a boneyard to see if one from another FoMoCo engine would work. I think Ford started using electrical throttle control in 08 or 09, but don't bet more than one donut.
If you can signal the TB to open and close, manually, then it should work, and the problem is likely in the control system. If it will not respond, then likely the TB is defunct. Most seem to use stepper motors to position the throttle plate at a specific position, and expect 'feedback' signal from same to indicate that the plate has moved as specified. If the feedback is not getting to the controller, then the TB is assumed to be bad. Check the feedback circuit also. Some 'count' pulses, some use a variable resistor POT. I know nothing...
tom
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