Hyster Forklift Trucks F007 (H170-280HD & H8.00-12.00XM Europe) Repair Service Manual
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Complete service repair manual for Hyster F007 (H170-280HD & H8.00-12.00XM Europe) Forklift Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F007 (H170-280HD & H8.00-12.00XM Europe) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Hyster F007 (H170-280HD & H8.00-12.00XM Europe) Service Manual.pdf
Total Pages: 1，363 + 1,452 pages
File Format: PDF
Language: English
F007 (H170-280HD)...2
1455747-0600SRM0705-(03-2006)-US-EN...4
toc...4
Perkins Diesel Engines...4
Safety Precautions Maintenance and Repair...5
General...12
General Safety Rules...12
Description...13
Engine Serial Number Codes...16
Engine Data...16
Engine Removal and Installation...18
Lift Engine...18
Cylinder Head Assembly Repair...18
Valve Cover...18
Remove...18
Install...19
Rocker Arm Assembly...19
Remove...19
Install...19
Disassemble...19
Inspect...20
Assemble...20
Valve Clearance Adjustments...20
Four-Cylinder Engines...21
Six-Cylinder Engines...21
Valve Springs...21
Cylinder Head Assembly...23
Remove...23
Install...25
Valves and Valve Springs...29
Remove...29
Inspect...29
Install...30
Valve Guides...30
Inspect...30
Remove...31
Install...31
Cylinder Head and Valve Seats...31
Inspect...31
Repair...31
New Valve Seats, Install...31
Piston and Connecting Rod Assemblies Repair...33
Rod Bearings...33
Remove...34
Install...34
Piston and Connecting Rod Assembly...35
Service Note...35
Remove...35
Install...36
Piston Rings...37
Remove...37
Inspect...37
Install...37
Piston and Connecting Rod...38
Disassemble...38
Inspect...39
How to Select Correct Replacements...39
Install...40
Piston Cooling Jets...40
Remove...40
Install...41
Crankshaft Assembly Repair...41
General...41
Crankshaft Pulley...42
Engine AR, Remove...42
Engines YG and YH, Remove...42
Inspect...43
Engine AR, Install...43
Engines YG and YH, Install...43
Rear Oil Seal...44
Replace...44
Main Bearings...45
Remove...45
Inspect...46
Install...46
Thrust Washers...46
Crankshaft Axial Movement, Check...46
Remove...47
Install...47
Crankshaft...48
Remove...48
Inspect...48
Install...48
Flywheel...50
Remove...50
Ring Gear, Replace...50
Install...50
Flywheel Housing...51
Remove...51
Install...51
Timing Case and Timing Gears Repair...52
General...52
Timing Case Cover...52
Remove...52
Install...53
Front Oil Seal...53
Remove...53
Install...53
Crankshaft Pulley Wear Sleeve...54
Install...54
Idler Gear and Hub...54
Remove...54
Install...55
Air Compressor Drive, Bendix...56
Disassemble...56
Assemble...57
Fuel Injection Pump Gear...57
Remove...58
Install...58
Camshaft Gear...59
Remove...59
Install...59
Crankshaft Gear...60
Remove...60
Install...60
Timing Case...60
Remove...60
Install...61
Camshaft and Tappets...62
Remove...62
Install...62
Cylinder Block Assembly Repair...63
Description...63
Cylinder Block...63
Disassemble...63
Inspect...64
Assemble...64
Cylinder Bore (Four-Cylinder Engines)...65
Cylinder Liner (Six-Cylinder Engines)...65
Inspect...65
Cylinder Liner Condition, Check...65
Remove...66
Service Liner, Install...67
Partially Finished Liner, Install...68
Engine Timing...69
Description...69
How to Set Number One Piston to TDC on Compression Stroke...70
How to Set Number One Piston to TDC on Compression Stroke (Alter...71
Valve Timing, Check...71
Fuel Injection Pump Timing, Check...72
Turbocharger - Engine YH Repair...73
General...73
Remove...73
Install...73
Impeller and Compressor Housing, Clean...74
Lubrication System Repair...75
General...75
Oil Filter, Replace...75
Filter Head...76
Remove and Install...76
Oil Sump...76
Remove...76
Install...77
Oil Pump...77
Remove...77
Inspect...77
Install...78
Relief Valve...78
Remove...78
Disassemble...79
Inspect...79
Assemble...79
Install...80
Idler Gear Shaft, Replace...80
Remove...80
Remove (Alternative)...80
Install...81
Install (Alternative)...81
Install (Alternative for Four-Cylinder Engines Only)...82
Fuel System Repair...82
Description...82
Fuel Injection Pump...83
Remove...83
Install...84
Check and Adjust...85
Fuel System Air Removal...85
Fuel Filter, Replace...86
Canister Type...87
Quick Release Canister Type...87
Fuel Injectors...88
Remove...88
Inspect...89
Install...89
Fuel Pump...90
Remove...90
Disassemble...90
Assemble...90
Install...91
Test...91
Cooling System Repair...92
General...92
Thermostat...92
Remove...92
Install...92
Test...93
Coolant Pump...93
Remove...93
Disassemble...93
Assemble...95
Install...97
Fan and Fan Drive...98
Remove...98
Install...98
Oil Cooler (Six-Cylinder Engines)...99
Remove...99
Disassemble and Assemble...99
Install...99
Oil Cooler Bypass Valve...99
Electrical Equipment Repair...100
Drive Belts...100
Adjustment...100
Remove...101
Install...101
Alternator...101
Remove...101
Install...101
Starter Motor...101
Remove...101
Install...101
Cold Start Aid...101
Air Compressor - Engines YG and YH...102
General...102
Repair...102
Remove...102
Install...102
Rotary Exhauster Replacement...104
Remove...104
Clean...104
Install...104
Engine Specifications...105
Cylinder Head Assembly...105
Piston and Connecting Rods...108
Crankshaft Assembly...111
Crankshaft Overhaul...113
Timing Case and Drive Assembly...115
Engine Block Assembly...116
Turbocharger...119
Lubrication System...119
Fuel System...120
Cooling System...122
Flywheel and Housing...122
Electrical Equipment...123
Torque Specifications...123
Cylinder Head Assembly...123
Piston and Connecting Rod Assemblies...123
Crankshaft Assembly...123
Timing Case and Drive Assembly...124
Turbocharger...124
Lubrication System...124
Fuel System...124
Cooling System...124
Flywheel...124
Auxiliary Equipment...124
Special Torque Specifications...125
Flywheel and Housing...125
Turbocharger...125
Electrical Equipment...125
Auxiliary Equipment...125
Special Tools*...126
Troubleshooting...131
tables...4
Table 1. Cylinder Head...105
Table 2. Valve Guides...105
Table 3. Inlet Valves...105
Table 4. Exhaust Valves...106
Table 5. Valve Springs...108
Table 6. Tappets...108
Table 7. Rocker Arm Shaft...108
Table 8. Rocker Arms and Bushings...108
Table 9. Pistons (Engine AR)...108
Table 10. Pistons (Engines YG and YH)...108
Table 11. Piston Rings (Engine AR)...109
Table 12. Piston Rings (Engines YG and YH)...109
Table 13. Piston Pins...110
Table 14. Connecting Rods...110
Table 15. Small End Bushings...110
Table 16. Connecting Rod Bearings (Engines AR and YG)...110
Table 17. Connecting Rod Bearings (Engine YH)...110
Table 18. Piston Cooling Jets...111
Table 19. Crankshaft...111
Table 20. Main Bearings...112
Table 21. Crankshaft Thrust Washers...112
Table 22. Crankshaft Heat Treatment...112
Table 23. Crankshaft Overhaul Specifications...113
Table 24. Maximum Variation (Run-out)...115
Table 25. Camshaft...115
Table 26. Camshaft Thrust Washer...115
Table 27. Camshaft Gear...115
Table 28. Gear for Fuel Injection Pump...116
Table 29. Crankshaft Gear...116
Table 30. Idler Gear and Hub...116
Table 31. Cylinder Block (Engine AR)...116
Table 32. Cylinder Bore Specifications...117
Table 33. Cylinder Block (Engines YG and YH)...118
Table 34. Cylinder Liners (Engines YG and YH)...118
Table 35. Cylinder Liner Specifications (Partially Finished)...118
Table 36. Oil Pump (Engine AR)...119
Table 37. Oil Pump (Engines YG and YH)...119
Table 38. Idler Gear for Oil Pump...120
Table 39. Relief Valve...120
Table 40. Oil Filter...120
Table 41. Lucas Fuel Injection Pump...120
Table 42. Fuel Injector Codes...121
Table 43. Fuel Pump (Engine AR)...122
Table 44. Fuel Pump (Engines YG and YH)...122
Table 45. Fuel Filter...122
Table 46. Coolant Pump...122
Table 47. Thermostat...122
Table 48. Fan Drive Housing...122
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic...123
Table 50. Alternator...123
Table 51. Starter Motor...123
Table 52. Cold Start Aid...123
Table 53. List of Possible Causes...131
1493991-1300SRM0930-(02-2001)-US-EN...136
toc...136
Three-Speed Powershift Transmission...136
Safety Precautions Maintenance and Repair...137
General...140
Mechanical Description...140
General...140
Torque Converter...144
Description...144
Operation...144
Clutch Assemblies...145
Description...145
Operation...145
Forward and First-Speed Clutch Assembly...146
Reverse and Second-Speed Shaft, First and Second Gear Shaft...146
Third-Speed Shaft...146
Output Shaft...146
Hydraulic Operation...148
Sump, Filter and Pump...148
Transmission Control Valve...148
Solenoid Valves...148
Inching Spool...149
Direction Spools...149
Range Spool...149
Modulator Valve...150
Operation...150
Modulator Operation...151
Transmission Control System...154
Monotrol Pedal...154
Control Lever...155
Hydraulic Circuits...156
Cooling and Lubrication...156
Neutral...156
Forward-First...156
Reverse-First...159
From First to Second Speed...160
From Second to Third Speed...161
Inching...162
1493992-1300SRM0931-(02-2001)-US-EN...166
toc...166
Three-Speed Powershift Transmission...166
Safety Precautions Maintenance and Repair...167
General...170
Transmission Repair...173
Remove...173
Disassemble...175
Torque Converter Housing and Pump Gears...175
Transmission Cover, Remove...176
Clutch Assemblies, Remove...178
Forward and Low-Speed Clutches...179
Forward Clutch, Disassemble...179
First-Speed Clutch, Disassemble...181
Reverse and Second-Speed Clutches, Disassemble...181
Second-Speed Clutch, Disassemble...181
Reverse Clutch, Disassemble...183
Third-Speed Clutch, Disassemble...183
Output Gears, Disassemble...185
Clean...185
Inspect...185
Assemble...187
Output Gears, Assemble...187
Third-Speed Clutch, Assemble...187
Reverse and Second-Speed Clutches, Assemble...187
Second-Speed Clutch, Assemble...187
Reverse Clutch, Assemble...190
Forward and First-Speed Clutches, Assemble...190
Forward Clutch, Assemble...190
First-Speed Clutch, Assemble...192
Clutch Assemblies, Install...192
Input Shaft and Forward Clutch Hub, Install...193
Transmission Cover, Install...194
Torque Converter Housing...196
Install...198
Control Valve Repair...200
Remove...200
Disassemble and Assemble...201
Clean and Inspect...201
Install...201
Modulator Valve Repair...203
Remove...203
Disassemble...203
Clean and Inspect...203
Install...203
Transmission Pump Repair...205
Remove...205
Disassemble...205
Clean and Inspect...205
Assemble...205
Install...205
Monotrol Pedal Repair...207
Remove and Disassemble...207
Assemble and Install...207
Inching/Brake Pedal Linkage Adjustment...209
Stall Test...210
Transmission Oil Pressure Check...211
Troubleshooting...213
tables...166
Table 1. Transmission Pressures...212
1493993-1300SRM0932-(12-2004)-US-EN...218
toc...218
Autoshift Transmission Controller...218
Safety Precautions Maintenance and Repair...219
General...222
Autoshift Control Module...222
Transmission Shift Control Valve...222
Autoshift Functions...223
System Interaction With Operator Display...223
Error Code Descriptions...223
System Audible Alarm...223
Park Brake Interlock...225
System Reset/Override...225
System Degraded Operating Mode...225
System Failure Mode...225
Transmission Oil High-Temperature Fault...225
Loss of Transmission Oil Pressure Fault...225
Controller Bypass...226
Automatic/Manual Shift Mode...226
Automatic Transmission Shifting...226
Manual Transmission Shifting...227
Direction Change...227
Direction Change Inhibit...227
Downshift Inhibit...228
Driveshaft Engagement Inhibit...228
Lift Height Transmission Interrupt (Optional)...228
Engine Dethrottle (Optional)...229
Autoshift Hardware...229
Autoshift Lever...229
Speed Sensors...230
Transmission System Monitor Diagnostics...231
Controller Parameter Adjustment Software User Interface...231
User Interface Description...231
Components Required to Communicate With Controller...231
Userlink Installation Instructions...231
Start Procedures...231
Controller Product Codes...231
Main Menu Description...232
Language Selection...232
Help Menu...232
PC Serial Communication Port...233
Monitor Screen...233
Event Log...233
Parameter Adjustment...234
Current Parameters...234
Load Parameters...235
Restore Factory Parameters...235
Load Controller Software from File...235
Exit Menu...235
Controller Connector Pin-Out Tables...237
tables...218
Table 1. Error Code Descriptions...224
Table 2. Automatic Transmission Upshift...226
Table 3. Automatic Transmission Downshift...227
Table 4. Event Log Descriptions and Values...234
Table 5. Parameter Descriptions and Values...235
Table 6. J2 Controller Connector (Black)...237
Table 7. J1 Controller Connector (Blue)...238
1494123-0100SRM0927-(01-2006)-US-EN...242
toc...242
Frame...242
Safety Precautions Maintenance and Repair...243
General...246
Description...246
Counterweight Repair...246
Remove...246
Install...248
Fenders...248
Remove...248
Install...248
Side Counterweights H13.00-16.00XM (H300-360HD)...248
Side Counterweight, Replace...248
Hood and Air Cleaner Repair...249
Remove...249
Install...251
Hydraulic Tank Repair...251
Remove...251
Repairs, All Units...252
Small Leaks...252
Large Leaks...253
Clean...253
Steam Method...253
Chemical Solution Method...254
Other Methods of Preparation for Repair...254
Install...254
Fuel Tank Repair...255
Remove...255
Repairs...255
Install...255
Cooling System and Radiator Repair...257
Remove...257
Install...258
Engine and Transmission Repair...259
Hyster T-50 Transmission, Remove...259
Hyster T-50 Transmission, Install...260
TE-10 Transmission...261
Remove...261
Install...264
Label Replacement...266
1494139-0100SRM0935-(09-2004)-US-EN...274
toc...274
Operators Cab...274
Safety Precautions Maintenance and Repair...275
General...278
Cab Repair...279
Rear Cab Assembly...279
Bottom Cab Assembly...280
Raising and Lowering Cab...280
Raise Cab...280
Lower Cab...281
Cab Repair...281
Remove...281
Install...282
Oil Filling for Tilt System...283
Inching and Brake Pedals...283
Pedal Adjustment...283
Inching Cable Adjustment...283
Throttle Cable Adjustment...284
Cable Alignment...285
Engine Side...285
Pedal Housing Side...285
Throttle Pedal Sensor...285
Check...285
Adjust...285
Seat Assembly Removal...286
Power Assist Armrest...287
Adjust...287
Steering Column Repair...287
Remove...287
Install...287
Window Wipers Replacement...288
Window Wiper Assembly, Replace...288
Front Window Wiper Motor Assembly, Replace...289
Rear Window Wiper Motor Assembly, Replace...289
Top Window Wiper Motor Assembly, Replace...289
Window Washer Motors and Pumps...290
Window Wiper and Washer Operating Switches...290
Window Replacement...290
Front Window, Replace...291
Rear Window, Replace...291
Top Window, Replace...291
Door Window, Replace...292
Heater and Air Conditioning Assembly...293
Heater Parts, Replace...293
Heat Control Knob/Switches...294
Heat Control Knob/Cable...294
Adjust...294
Air Control Knob/Cable...295
Adjust...295
Air Filter, Replace...295
Air Conditioning Condenser Fan(s), Standard...295
Remove...295
Install...296
Air Conditioning Condenser Fan(s), Tropical...296
Remove...296
Install...296
Instruments, Switches, and Controls...296
Switches...296
Controls...297
Fuses and Relays...298
Fuse Panel...298
Fuses...298
Relays...299
Label Replacement...300
Electrical Schematics...300
1494140-1600SRM0936-(03-2007)-US-EN...304
toc...304
Steering System...304
Safety Precautions Maintenance and Repair...305
General...308
Description...308
Steering Wheel and Column Assembly...310
General...310
Steering Wheel and Horn...310
Remove...310
Install...310
Steering Control Unit Repair...312
General...312
Description...312
Operation...312
Remove...313
Disassemble...313
Clean...316
Assemble and Install...316
Steering System Air Removal...322
Steering Relief Pressure Check...323
Troubleshooting...323
1494141-1800SRM0937-(03-2007)-US-EN...328
toc...328
Dry Brake System...328
Safety Precautions Maintenance and Repair...329
General...332
Description...332
Operation...333
Service Brakes...333
Parking Brake...335
Air Tank Repair...336
Relief Valve...336
Drain Valve...336
Brake Pedal Valve Repair...337
Remove...337
Disassemble, Inspect, and Assemble...337
Install...337
Air Chambers Repair...338
Remove...338
Disassemble...338
Inspect...339
Assemble...340
Install...340
Actuator Arms Repair...340
Remove...340
Inspect...341
Install...341
Brake Assemblies Repair...342
Brake Shoe, Remove...342
Camshaft, Remove...344
Clean...344
Inspect...345
Camshaft, Install...345
Brake Shoe, Install...346
Air Dryer...347
Description...347
Cartridge...347
Remove...347
Install...347
Filter...347
Remove...347
Install...347
Quick-Release Valve...349
Governor Check and Adjustment for Air Compressor...349
Brake Shoes Adjustment...350
Specifications...351
Troubleshooting...351
Service Brakes...351
Service Brakes, Park Function ...354
tables...328
Table 1. Air Chambers Operation...335
1494142-1900SRM0938-(03-2007)-US-EN...358
toc...358
Hydraulic System...358
Safety Precautions Maintenance and Repair...359
General...362
Description and Operation...362
Hydraulic Tank...362
Hydraulic Pump...363
Steering Priority Flow Valve...363
Pilot Valve...364
Main Control Valve...366
Unloader Valve...367
Hydraulic Operation...368
Checks and Adjustments...371
Quick Disconnect Fittings...371
Steering Priority Flow Valve...371
Steering Relief Pressure...371
Modulator Valve...372
Pilot Valve and Pressure Reducing Valve...372
Accumulator...373
Filter...373
Main Control Valve...373
Relief Pressure Check...373
Check Valves...374
Unloader Valve...374
Hydraulic Pump Repair...375
Remove...375
Disassemble...375
Clean and Inspect...375
Assemble...376
Install...377
Pilot Accumulator Replacement ...377
Remove...377
Install...377
Pilot Valve Repair...378
Remove...378
Disassemble...379
Clean and Inspect...379
Assemble...379
Install...379
Control Levers and Joystick Repair...380
Remove...380
Install...380
Calibration and Diagnostics...381
General...381
Description...381
Lever and Joystick Calibration...381
Flow Adjustment...381
Dead Band Value Setting...382
Lowering Delay...383
PWM and I/O Module Readouts...383
Function Disable...384
General Startup...384
Minimum system requirements...384
Install the Hydraulic Controls Program...384
DelayTimeFile (Reset)...384
Select the Processor Speed...385
Hydraulic Controls Program...385
Calibration...387
Joystick/Lever Calibration...387
Levers...387
Joystick...387
Valve Flow Adjustment...388
Diagnostics...388
Calibration System Shutdown...388
LED Diagnostics...389
Electrical Connections...392
Specifications...396
tables...358
Table 1. Main Control Valve Port Settings...364
Table 2. Processor Speed Settings...384
Table 3. PWM Board LED Error Codes...389
Table 4. Altering PT FLT I/O Board LED's (Old Logic)...390
Table 5. Altering PT FLT I/O Board LED's (New Logic)...390
Table 6. Fixed PT Logic I/O Boards LED's...391
Table 7. ECH...391
Table 8. PWM Driver Module...392
Table 9. Input/Output Module 1...393
Table 10. Input/Output Module 2...394
Table 11. Altering PT FLT...395
Table 12. Fixed PT FLT...395
Table 13. ECH...396
1494143-2200SRM0939-(12-2004)-US-EN...400
toc...400
Instrument Panel Indicators and Senders...400
Safety Precautions Maintenance and Repair...401
General...404
Description...404
General...404
Instrument Panel Meters, Indicators, and LCD Display...404
Error Code Display, Transmission...411
Error Code Display, Engine...412
Connector...413
Seat Switch Logic...413
Central Warning Light Output...415
Buzzer Output...415
Engine Shutdown Output...415
Instrument Panel Component Replacement...418
Instrument Panel...418
Remove...418
Light...419
Replace...419
Sender Replacement...419
Fuel Level Sender...419
Transmission Pressure and Temperature Sender, Tier 1...420
Pressure Sender, Tier 2...421
Temperature Sender, Tier 2...421
Low Coolant Sender...421
Vacuum Switch...421
Crankshaft Position Sensor...422
Specifications...422
Troubleshooting...424
tables...400
Table 1. Instrument Panel and Indicators...405
Table 2. Engine Error Code Descriptions...413
Table 3. Pin Description...414
Table 4. Sender Description...415
1494144-8000SRM0934-(08-2001)-US-EN...428
toc...428
Periodic Maintenance...428
Safety Precautions Maintenance and Repair...429
General...432
How to Move Disabled Lift Truck...432
How to Tow Lift Truck...432
How to Put Lift Truck on Blocks...433
How to Raise Drive Tires...433
How to Raise Steering Tires...433
Maintenance Schedule...434
Maintenance Procedures Every 8 Hours or Daily...443
How to Make Checks with Engine Stopped...443
Tires and Wheels...444
Forks...445
Adjust...445
Remove...445
Install...445
Forks, Mast, and Lift Chains, Inspect...445
Safety Labels...446
Operator Restraint System...446
Steering Column Latch...447
Drive Belts...447
Cooling System...447
Fuel, Oil, or Coolant Leaks, Check...448
Cab Hydraulic System...448
Hydraulic System...448
Engine Oil...449
Fuel System...449
Primary Fuel Filter...450
Battery...450
Air Filter...450
How to Make Checks with Engine Running...450
Gauges, Lights, Horn, and Fuses...450
Control Levers and Pedals...451
Transmission Oil...451
Lift System Operation...452
Brakes...452
Steering System...453
Maintenance Procedures Every 250 Hours or Every 2 Months...453
Engine Oil and Filter - Cummins Engine...453
Empty Container Handler...453
Maintenance Procedures Every 500 Hours or Every 2 Months...453
Lift Chains...453
Lubrication...453
Adjust...453
Drive Shaft...454
Steering Axle...454
Wheel Nuts...454
Shafts for Brake Actuators...454
Drive Axle and Differential...454
Hydraulic Tank Breather...455
Air Filter, Engine, and Air Compressor...455
Cabin Air Filter, Heater...455
Engine Oil and Filter - Perkins Engine...455
Drive Belts...455
Mast...455
General Lubrication...457
Forks Wear and Damage Check...457
Lift Chains Wear Check...457
Fuel System...457
Idle Speed...457
Governor Speed (Diesel)...457
Maintenance Procedures Every 1000 Hours or 6 Months...459
Transmission Oil and Filter, Change...459
Final Fuel Filters, Diesel...459
Diesel Fuel System Air Removal...459
Fuel Injection Pump Without Vent Tube...460
Fuel Injection Pump Timing...460
Valve Adjustment...460
Maintenance Procedures Every 2000 Hours or Yearly...462
Hydraulic System...462
Hydraulic Oil Filter, Change...462
Hydraulic Oil, Change...462
Differential and Drive Axle...462
Wheel Bearings...462
Steer Wheels...462
Drive Wheels...462
Service Brakes...463
Cleaning Procedures (Dry Brake Axle)...463
Safety Procedures When Working Near Mast...463
Fuel Injectors Check...464
Lift and Tilt System Leak Check...465
Lift System...465
Tilt System...465
Welding Repairs...466
Wheel and Tire Replacement...467
Remove Wheels from Lift Truck...467
Pneumatic Tires...467
Remove Tire from Wheel...467
Remove Tire from Three- and Four-Piece Wheel...468
Install Tire on Wheel...469
Install Three- or Four-Piece Wheel in Tire...469
Add Air to Tires...470
Solid Rubber Tires...471
Remove Tire from Wheel...471
Install Tire on Wheel...472
Wheels, Install...474
tables...428
Table 1. Maintenance Schedule...435
Table 2. Maintenance Schedule (Empty Container Handler Model 553...440
Table 3. Maintenance Schedule (Empty Container Handler Model 555...441
Table 4. Maintenance Schedule (Empty Container Handler Model 558...442
Table 5. Allowable Mast Movement from Internal Leakage...466
1494145-8000SRM0940-(03-2008)-US-EN...478
toc...478
Capacities and Specifications...478
Safety Precautions Maintenance and Repair...479
Lift Truck Weights...482
Capacities...482
Engine Specifications...483
Perkins Diesel...483
Cummins Diesel/LPG...484
Hydraulic System...485
Electrical System...486
Tire Sizes...486
Mast Speeds...486
Perkins Diesel...486
Cummins Diesel/LPG...487
Torque Specifications, Cummins Diesel...488
Lubrication System...488
Torque Specifications, Perkins Diesel...488
Engine...488
Cylinder Head Assembly...488
Piston and Connecting Rod Assemblies...488
Crankshaft Assembly...488
Timing Case and Drive Assembly...489
Turbocharger...489
Lubrication System...489
Fuel System...489
Cooling System...489
Flywheel and Housing...489
Aspiration System...490
Electrical Equipment...490
Auxiliary Equipment...490
Torque Specifications - Perkins, Tier 2...490
Cylinder Head Assembly...490
Piston and Connecting Rod Assemblies...490
Crankshaft Assembly...490
Timing Case and Drive Assembly...490
Turbocharger...491
Lubrication System...491
Fuel System...491
Cooling System...491
Flywheel...491
Auxiliary Equipment...491
Torque Specifications, General...492
Transmission...492
Driveline and Axle...492
Differential...492
Brakes - Wet...492
Brakes - Dry...492
Steering...492
Hydraulic System...493
Mast...493
Carriage...493
Tilt Cylinders...493
Frame...493
Wiper Arms, Front...493
Hyster T-50 Transmission Pressures (Powershift and Automatic)...494
TE-10 Transmission Specifications...495
Electrical...495
Hydraulic Cooler Lines...495
Torque Specifications for Lubricated or Plated Screw Threads...496
tables...478
Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp...495
Table 2. Grade 5...496
Table 3. Grade 8...496
Table 4. Grades 8.8, 10.9, and 12.9...496
Table 5. O-ring Port Plug Torque Chart...497
Table 6. Pipe Plug Torque Chart...497
1494146-8000SRM0941-(01-2006)-US-EN...500
toc...500
Diagrams...500
Safety Precautions Maintenance and Repair...501
General...504
Description...504
1494953-1400SRM0944-(03-2007)-US-EN...562
toc...562
Planetary Drive Axle...562
Safety Precautions Maintenance and Repair...563
General...566
Description...566
Operation...568
Identification...568
Removal...569
Disassembly...569
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...569
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...571
Wheel End...573
Spindle and Piston Housing...574
Cleaning...575
Clean Ground or Polished Parts...575
Clean Parts With Rough Finish...575
Clean Axle Assemblies...575
Drying Cleaned Parts...575
Corrosion Prevention...575
Parts Inspection...576
Tapered Roller Bearings...576
Bevel Pinion and Ring Gear Sets...577
Main Differential Assembly...577
Axle Shafts...577
Yoke...577
Brakes...577
Repair or Replace Parts...577
Repair Welding...577
Apply Silicone Gasket Material...578
Assembly...578
Spindle and Piston Housing to Axle Housing...578
Wet Disc Brakes...579
Adjust Wheel Bearing Preload...580
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...581
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...582
Planetary Spider Assembly...582
Installation...583
Fill Wet Disc Brakes With Hydraulic Fluid...583
Torque Specifications...584
Lubrication Specification...585
1494955-2000SRM0943-(03-2007)-US-EN...588
toc...588
Main Control Valve...588
Safety Precautions Maintenance and Repair...589
General...592
Description...592
Operation...595
Lift Section...595
Tilt/Auxiliary Section...595
Relief Valves...595
Unloader Valve...595
Main Control Valve Repair...598
Remove...598
Disassemble...598
Auxiliary Side...598
Lift Side...598
Clean and Inspect...601
Assemble...601
Auxiliary Side...601
Lift Side...601
Install...601
Pressure Relief Valve Check and Adjustment...602
Check and Adjust...602
Replace...602
Specifications...603
Troubleshooting...603
1498445-1400SRM0945-(03-2007)-US-EN...608
toc...608
Planetary Drive Axle...608
Safety Precautions Maintenance and Repair...609
General...612
Description...612
Operation...614
Identification...614
Removal...615
Disassembly...615
Brake Drum...615
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...616
Dry Brakes...618
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...618
Spindle and Brake Spider...620
Cleaning...621
Ground or Polished Parts...621
Parts With Rough Finish...621
Axle Assemblies...621
Drying Cleaned Parts...621
Corrosion Prevention...621
Parts Inspection...622
Tapered Roller Bearings...622
Bevel Pinion and Ring Gear Sets...623
Main Differential Assembly...623
Axle Shafts...623
Yoke...623
Brakes...623
Repair or Replace Parts...623
Repair Welding...623
Apply Silicone Gasket Material...624
Assembly...624
Spindle, Brake Spider, and Brake...624
Wheel End...625
Adjust Wheel Bearing Preload...626
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...627
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...628
Planetary Spider Assembly...628
Installation...629
Torque Specifications...630
Lubrication Specification...631
1498450-1800SRM0951-(03-2007)-US-EN...634
toc...634
Wet Brake System...634
Safety Precautions Maintenance and Repair...635
General...638
Description and Operation...638
Service Brakes...638
Parking Brake...638
Oil Cooler Circuit...638
Pressure Switch Replacement...642
Accumulators Replacement...642
Brake Treadle Valve Repair...642
Remove and Disassemble...642
Clean and Inspect...643
Assemble and Install...643
Parking Brake Valve Repair...643
Remove...643
Clean and Inspect...643
Repair...643
Install...643
Parking Brake Caliper Repair...644
Remove...644
Disassemble...646
Inspect...646
Install...646
Adjust...646
Brake Pad Repair...647
Inspect...647
Remove...647
Install...647
Seals Repair...647
Remove...647
Install...648
Service Brake Repair...648
Remove and Disassemble...648
Drain Lubricating Oil...648
Drain Coolant Oil...655
Disconnect Brake Lines...655
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14...655
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...656
Brake Disc Housing Assembly Wheel End...657
Brake Piston Housing...658
Brake Piston Housing and Wheel Spindle...659
Inspect...659
Clean...661
Assemble...662
Wheel Spindle...662
Brake Piston Housing...662
Piston Assembly...664
Brake Disc Housing...664
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub...666
Check for Correct Installation of Duo-Cone Seal...667
Wheel Hub to Brake Disc Housing...668
Adjust...669
Fill Brake System With Coolant Oil...669
System Air Removal...670
Adjust Brake With New Disc Pack...670
Coolant Change Intervals...671
Coolant Draining and Filling...671
Specifications...673
Minimum Brake Disc Thickness...676
Hydraulic Fluid for Brake Actuation...676
Brake Coolant Specifications...676
Coolant Change Intervals...676
Hydraulic Fluid Specifications...676
Troubleshooting...676
Brake Does Not Apply...676
Brake Does Not Release...677
Brake Performance...677
Brake Leaks Actuation Fluid...678
Brake Cooling Fluid Leakage...679
Brake Noise and Vibration...679
Brake Overheats...679
tables...634
Table 1. Brake Pad Adjustment...646
Table 2. Minimum Brake Disc Thickness...660
Table 3. Formed Seal Wear Chart...660
1503241-5000SRM0969-(10-2007)-US-EN...684
toc...684
Empty Container Handling Attachment...684
Safety Precautions Maintenance and Repair...685
General...688
Description...688
Operation...694
General...694
Selector Valves...694
Sideshift Circuit...694
Extend and Retract Circuit...694
Twist Lock Circuit and Control...695
Model 553 - Horizontally Mounted...695
Model 558 - Vertically Mounted...695
Lifting Hooks...695
Model 555...695
Indicator Lights and LEDs...695
Lift Interrupt and Override...696
Overlowering Interrupt and Override...696
Carriage and Attachment Repair...696
Remove...696
Attachment Without Carriage Repair...697
Remove...697
Sideshift Cylinders Repair...698
Remove...698
Disassemble...698
Assemble...698
Extension Cylinders Repair...699
Remove...699
Disassemble...699
Clean and Inspect...699
Assemble...699
Install...699
Vertical End Beams Repair...701
Remove...701
Install...701
Hose Replacement in End Beams...701
Twist Locks Repair for Model 553...702
Remove...702
Disassemble...702
Clean and Inspect...702
Assemble...702
Hooks Replacement for Model 555...703
Inspect...703
Remove...703
Install...703
Twist Locks Repair for Model 558...704
Disassemble...704
Clean and Inspect...704
Assemble...704
Bleed the System...705
Valve Assembly...705
Slide Pad Replacement...706
Adjustments...706
Twist Lock Angle Adjustment...706
Model 558 Only...706
LOCKED/NOT LOCKED Sensors Adjustment...707
Model 553...707
Model 558...707
Seated Sensor Adjustment...707
Model 553...707
Model 558...707
Overlowering Protection Sensor Adjustment (Models 553 and 558)...707
Torque Chart...708
Maintenance...708
Additional Attachment Maintenance...710
Interface Boxes...711
Model 555...711
Models 553 and 558...711
Troubleshooting...713
tables...684
Table 1. Torque Chart...708
Table 2. Inspect and Adjust (See Figure 14 )...709
Table 3. Lubricate (See Figure 14 )...710
Table 4. Replace (See Figure 14 )...710
1538764-8000SRM1066-(09-2005)-US-EN...730
toc...730
Periodic Maintenance...730
Safety Precautions Maintenance and Repair...731
General...734
How to Move Disabled Lift Truck...734
How to Tow Lift Truck...734
How to Put Lift Truck on Blocks...735
How to Raise Drive Tires...735
How to Raise Steering Tires...735
Maintenance Schedule...737
Empty Container Attachment Maintenance...743
Maintenance Procedures Every 8 Hours or Daily...745
How to Make Checks With Engine Stopped...745
Hydraulic System Oil...745
Engine Oil...745
Cooling System...746
Fuel System...747
Water Separator/Fuel Filter...747
Fuel, Oil, or Coolant Leaks, Check...747
Cab Hydraulic System...747
Drive Belts...748
Battery...748
Air Filters...748
Forks...748
Adjust...748
Remove...748
Install...748
Forks, Mast, and Lift Chains, Inspect...749
Tires and Wheels...750
Operator Restraint System...750
Steering Column Latch...751
Safety Labels...751
How to Make Checks With Engine Running...752
Gauges, Lights, Horn and Fuses...752
Control Levers and Pedals...754
Transmission Oil...754
Lift System Operation...754
Brakes...754
Steering System...754
Attachments...754
Maintenance Procedures Every 250 Hours or Every 2 Months...755
Empty Container Handler...755
Maintenance Procedures Every 500 Hours or Every 3 Months...755
Lift Chains...755
Lubrication...755
Adjust...755
Drive Shaft...756
Steering Axle...756
Wheel Nuts...756
Shafts for Brake Actuators...756
Drive Axle and Differential...756
Hydraulic Tank Breather...756
Air Filter, Engine, and Air Compressor...756
Cabin Air Filter, Heater...756
Engine Oil and Filter...756
Drive Belts...757
Mast...757
General Lubrication...758
Fork Wear and Damage Check...758
Lift Chains Wear Check...759
Maintenance Procedures Every 1000 Hours or 6 Months...759
Transmission Oil and Filter, Change...759
Fuel Filter...760
Diesel Fuel System Air Removal...760
Fuel Injection Pump Without Vent Tube...760
Fuel Injection Pump Timing...761
Valve Adjustment...761
Pilot Accumulator Pressure Charge Check...762
Maintenance Procedures Every 2000 Hours or Yearly...762
Hydraulic System...762
Hydraulic Oil Filter, Change...762
Hydraulic Oil, Change...762
Differential and Drive Axle...763
Wheel Bearings...763
Steer Wheels...763
Drive Wheels...764
Service Brakes...764
Cleaning Procedures (Dry Brake Axle)...764
Safety Procedures When Working Near Mast...764
Fuel Injectors Check...766
Perkins...766
Lift and Tilt System Leak Check...766
Lift System...766
Tilt System...766
Welding Repairs...767
Wheel and Tire Replacement...768
Remove Wheels From Lift Truck...768
Pneumatic Tires...768
Remove Tire From Wheel...768
Remove Tire From Three- and Four-Piece Wheel...769
Install Tire on Wheel...770
Install Three- or Four-Piece Wheel in Tire...770
Add Air to Tires...771
Solid Rubber Tires...772
Remove Tire From Wheel...772
Install Tire on Wheel...773
Wheels, Install...775
tables...730
Table 1. Daily Inspections − Condition Check...737
Table 2. Daily Inspections − Fluid Level Check...738
Table 3. Daily Inspections − Checks With the Engine Running...738
Table 4. First Inspection After First 100 Hours of Operation...739
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...740
Table 6. Periodic Maintenance Schedule − Lubricate...741
Table 7. Periodic Maintenance Schedule − Change...741
Table 8. Empty Container Attachment Maintenance − Inspect and ...744
Table 9. Empty Container Attachment Maintenance − Lubricate...744
Table 10. Allowable Mast Movement from Internal Leakage...767
1541323-0600SRM1068-(05-2004)-US-EN...778
toc...778
Perkins Tier 2 Diesel Engines...778
Safety Precautions Maintenance and Repair...779
General...786
General Safety Rules...786
Description...787
Engine Serial Number Codes...789
Engine Data...789
Engine Removal and Installation...790
Cylinder Head Assembly Repair...790
Valve Cover...790
Remove...790
Install...791
Rocker Arm Assembly...791
Remove...791
Disassemble...791
Inspect...791
Assemble...791
Install...791
Valve Clearance Adjustments...792
Valve Springs...793
Cylinder Head Assembly...794
Remove...794
Install...796
Valves and Valve Springs...799
Remove...799
Inspect...799
Install...800
Valve Guides...800
Inspect...800
Remove...800
Install...800
Cylinder Head and Valve Seats...801
Inspect...801
Repair...802
New Valve Seats, Install...802
Piston and Connecting Rod Assemblies Repair...802
Rod Bearings...803
Remove...803
Install...803
Piston and Connecting Rod Assembly...804
Service Note...804
Remove...804
Install...805
Piston Rings...806
Remove...806
Inspect...806
Install...807
Piston and Connecting Rod...807
Disassemble...807
Inspect...807
How to Select Correct Replacements...808
Install...809
Piston Cooling Jets...809
Remove...809
Install...810
Crankshaft Assembly Repair...810
General...810
Crankshaft Pulley...811
Remove...811
Inspect...811
Install...811
Rear Oil Seal...812
Remove...812
Install...812
Main Bearings...813
Remove...813
Inspect...814
Install...814
Thrust Washers...814
Crankshaft Axial Movement, Check...814
Remove...815
Install...815
Crankshaft...816
Remove...816
Inspect...816
Install...817
Flywheel...818
Remove...818
Ring Gear, Replace...818
Install...818
Flywheel Housing...819
Remove...819
Install...819
Timing Case and Timing Gears Repair...820
General...820
Timing Case Cover...820
Remove...820
Install...821
Front Oil Seal...821
Remove...821
Install...821
Crankshaft Pulley Wear Sleeve...822
Install...822
Idler Gear and Hub...822
Remove...822
Install...823
Air Compressor Drive, Bendix...824
Disassemble...824
Assemble...824
Fuel Injection Pump Gear...825
Remove...825
Install...826
Camshaft Gear...826
Remove...826
Install...827
Crankshaft Gear...827
Remove...827
Install...828
Timing Case...828
Remove...828
Install...828
Camshaft and Tappets...829
Remove...829
Install...830
Cylinder Block Assembly Repair...830
Description...830
Cylinder Block...830
Disassemble...830
Inspect...831
Assemble...831
Cylinder Liner...832
Inspect...832
Cylinder Liner Condition, Check...832
Remove...833
Service Liner, Install...834
Partially Finished Liner, Install...835
Engine Timing...836
Description...836
How to Set Number One Piston to TDC on Compression Stroke...837
How to Set Number One Piston to TDC on Compression Stroke (Alter...838
How to Set Number One Piston to 4° After TDC on Compression Stro...839
Valve Timing, Check...840
Fuel Injection Pump Timing, Check...841
Turbocharger...841
General...841
Remove...841
Install...842
Impeller and Compressor Housing, Clean...842
Waste-Gate Valve Check...843
Closed Circuit Breather System (CCB)...844
CCB Assembly, Remove...844
Closed Circuit Drain Valve, Remove...844
CCB Assembly, Install...844
Closed Circuit Drain Valve, Install...844
Lubrication System Repair...845
General...845
Oil Filter, Replace...845
Oil Filter Head...845
Remove...845
Install...845
Oil Filter Head Bypass Valve...846
Remove and Install...846
Oil Sump...846
Remove...846
Install...846
Oil Pump...847
Remove...847
Inspect...847
Install...848
Relief Valve...849
Remove...849
Disassemble...849
Inspect...849
Assemble...849
Install...849
Idler Gear Shaft, Replace...849
Remove...850
Remove (Alternative)...850
Install...851
Install (Alternative)...851
Fuel System Repair...852
Description...852
Fuel Injection Pump...854
Remove...854
Install...856
Fuel System Air Removal...857
Fuel Filter, Replace...859
Fuel Injectors...859
Remove...860
Inspect...860
Install...860
Fuel Lift Pump...861
Remove...861
Disassemble...861
Assemble...861
Install...862
Test...862
Cooling System Repair...863
General...863
Thermostat...863
Remove...863
Install...864
Test...864
Coolant Pump...864
Remove...864
Disassemble...865
Assemble...867
Install...869
Fan and Fan Drive...870
Remove...870
Install...870
Oil Cooler...870
Remove...870
Disassemble and Assemble...871
Install...871
Electrical Equipment Repair...872
Drive Belts...872
Alternator...872
Remove...872
Install...872
Electronic Control Module (ECM)...873
Remove...873
Inspect...873
Install...873
Voltage Load and Protection Module (VLPM)...874
Remove...874
Install...874
Engine Speed and Timing Sensor...874
Remove...874
Install...875
Pressure Sensors (Engine Oil and Air Intake)...875
Remove...875
Install...876
Temperature Sensor...876
Remove...876
Install...877
Starter Motor...877
Remove...877
Install...877
Cold Start Aid...877
Air Compressor...877
General...877
Repair...878
Remove...878
Install...878
Rotary Exhauster Replacement...879
Remove...879
Clean...879
Install...879
Engine Specifications...880
Cylinder Head Assembly...880
Piston and Connecting Rods...883
Crankshaft Assembly...884
Crankshaft Overhaul...885
Timing Case and Drive Assembly...887
Engine Block Assembly...888
Turbocharger...889
Lubrication System...890
Cooling System...892
Flywheel and Housing...892
Electrical Equipment...892
Torque Specifications...893
Cylinder Head Assembly...893
Piston and Connecting Rod Assemblies...893
Crankshaft Assembly...893
Timing Case and Drive Assembly...893
Turbocharger...893
Lubrication System...893
Fuel System...893
Cooling System...894
Flywheel...894
Auxiliary Equipment...894
Special Torque Specifications...894
Flywheel and Housing...894
Electrical Equipment...894
Auxiliary Equipment...894
Special Tools...895
Troubleshooting...900
Turbocharger Troubleshooting...902
tables...778
Table 1. Cylinder Head...880
Table 2. Valve Guides...880
Table 3. Inlet Valves...881
Table 4. Exhaust Valves...881
Table 5. Valve Springs...882
Table 6. Tappets...882
Table 7. Rocker Arm Shaft...882
Table 8. Rocker Arms and Bushings...882
Table 9. Pistons...883
Table 10. Piston Rings...883
Table 11. Piston Pins...883
Table 12. Connecting Rods...883
Table 13. Small End Bushings...884
Table 14. Connecting Rod Bearings...884
Table 15. Piston Cooling Jets...884
Table 16. Crankshaft...884
Table 17. Main Bearings...885
Table 18. Crankshaft Thrust Washers...885
Table 19. Crankshaft Heat Treatment...885
Table 20. Crankshaft Overhaul Specifications...885
Table 21. Maximum Variation (Run-Out)...887
Table 22. Camshaft...887
Table 23. Camshaft Thrust Washer...887
Table 24. Camshaft Gear...887
Table 25. Gear for Fuel Injection Pump...887
Table 26. Crankshaft Gear...888
Table 27. Idler Gear and Hub...888
Table 28. Cylinder Block...888
Table 29. Cylinder Liners...888
Table 30. Cylinder Liner Specifications (Partially Finished)...889
Table 31. Oil Pump...890
Table 32. Idler Gear for Oil Pump...890
Table 33. Relief Valve...890
Table 34. Oil Filter...890
Table 35. Bosch Fuel Injection Pump...890
Table 36. Fuel Injector Codes...891
Table 37. Fuel Pump...892
Table 38. Fuel Filter...892
Table 39. Coolant Pump...892
Table 40. Thermostat...892
Table 41. Fan Drive Housing...892
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic...892
Table 43. Alternator...892
Table 44. Starter Motor...892
Table 45. Cold Start Aid...892
Table 46. List of Possible Causes...900
Table 47. List of Possible Causes...902
1553599-4000SRM1062-(03-2007)-US-EN...906
toc...906
Masts and Carriages...906
Safety Precautions Maintenance and Repair...907
General...910
Description...910
Operation...911
Two-Stage Mast...911
Three-Stage Mast...912
Safety Procedures When Working Near Mast...913
Forks Repair...916
Remove...916
Inspect and Adjust...916
Install...916
Carriage Repair...917
Description...917
Three Function...917
Four to Six Function...917
Remove...917
Disassemble...918
Clean and Inspect...920
Assemble...920
Install...920
Sideshift Cylinder Repair...921
Remove...921
Disassemble...921
Clean and Inspect...921
Assemble...921
Install...921
Fork Positioner Cylinders Repair...925
Remove...925
Disassemble...925
Clean and Inspect...925
Assemble...925
Install...925
Directional Control Valve Repair...932
Remove...932
Disassemble...932
Clean and Inspect...932
Assemble...933
Install...933
Mast Repair...933
Two- and Three-Stage Mast...933
Remove...933
Disassemble...938
Clean and Inspect...940
Assemble...941
Install...942
Three-Stage Mast (Four Cylinders)...942
Remove...942
Disassemble...944
Clean and Inspect...946
Assemble...946
Install...946
Fork Carriage Chains...948
Adjust...948
Bearing Rollers...950
Description...950
Lubrication...950
Clearance...950
Remove and Disassemble...950
Assemble...951
Mast Profile...951
Lift Cylinders Description...951
Piston-Type Cylinders...951
Displacement-Type Cylinders...951
Lift Cylinders Repair...952
Remove...952
Disassemble...954
Clean and Inspect...954
Assemble...954
Install...955
Mast Operation Check...955
Lift and Tilt System Leak Checks...956
Lift System...956
Tilt System...956
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...957
Lift Chain Adjustments...957
Mast Adjustments...958
Bearing Blocks, Two-Stage Masts...958
Wear Plates...958
Carriage Adjustment...958
Troubleshooting...960
tables...906
Table 1. Allowable Mast Movement from Internal Leakage...956
1553764-0600SRM1072-(06-2005)-US-EN...964
toc...964
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...964
Safety Precautions Maintenance and Repair...965
Electronic Troubleshooting...988
System Operation...988
Electronic Controls...988
Engine Governor...989
Timing Considerations...989
Fuel Injection...989
Diagnostic Codes...989
Diagnostic Fault Codes...989
Diagnostic Event Codes...989
Programmable Parameters...990
Passwords...990
Electronic Service Tools...990
Electronic Service Tool (EST)...990
Connecting the Electronic Service Tool and the Communication Ada...990
Support for the Electronic Service Tool...991
Optional Service Tools...991
Diagnostic Codes...991
Diagnostic Fault Code Access Via Indicator Lamps...995
Replacing the ECM...996
Self Diagnostics...997
Glossary...998
Sensors and Electrical Connectors...1001
Engine Wiring Information...1004
Harness Wire Identification...1007
Diagnostic Code Reader...1007
General...1007
Reference Documents...1007
Abbreviations...1007
Environmental Specification...1007
Hardware...1008
Connection Cable...1009
Software...1009
Engine Communication...1009
User Controls...1009
Power Supply...1009
Display Screen...1010
Operation Controls...1010
Audible Warning...1010
Operation Instructions...1010
How to Connect the Diagnostic Code Reader to the Engine...1010
How to Turn ON the Diagnostic Code Reader...1010
How to use the Display Screen...1010
How to Operate the Diagnostic Code Reader...1011
Main Menu...1011
Active Codes...1011
Inactive Codes...1012
How to Clear Codes...1012
Status Lamp...1012
Data List...1013
Diagnostics...1013
Programming Parameters...1014
Passwords...1014
Factory Passwords...1014
Customer Passwords...1015
Flash Programming...1015
Flash Programming a Personality Module...1015
WinFlash Error Messages...1015
System Configuration Parameters...1016
Full Load Setting...1016
Full Torque Setting...1016
Rating Interlock...1016
Engine Serial Number...1016
ECM Software Release Date...1016
Troubleshooting Without a Diagnostic Code...1017
Alternator Noise (Noisy Operation)...1017
Probable Causes...1017
Recommended Actions...1017
Alternator Drive Belts...1017
Alternator Drive Pulley...1017
Alternator Bearings...1017
Alternator Will Not Charge (Charging Problem)...1017
Probable Causes...1017
Recommended Actions...1017
Alternator Drive Belts...1017
Charging Circuit...1017
Alternator or Regulator...1017
Battery...1017
Probable Causes...1017
Recommended Actions...1017
Faulty Battery...1017
Auxiliary Device...1017
Cannot Reach Top Engine RPM...1018
Probable Causes...1018
Recommended Actions...1018
Diagnostic Codes...1018
Fuel Supply...1018
Air Intake and Exhaust System...1018
Individual Malfunctioning Cylinders...1018
Valve Lash...1018
Check for Low Compression...1018
Check the Fuel Injection Nozzles...1019
Check the Turbocharger...1019
ECM Parameters...1019
Check the Signal for the Throttle Position Sensor...1019
Coolant in Engine Oil...1019
Probable Causes...1019
Recommended Actions...1019
Engine Oil Cooler Core...1019
Cylinder Head Gasket...1019
Cylinder Head...1020
Cylinder Block...1020
Coolant Temperature Is Too High...1020
Probable Causes...1020
Recommended Actions...1020
Radiator Fins...1020
Coolant Level...1020
Radiator Cap and/or Pressure Relief Valve...1020
Combustion Gases in the Cooling System...1020
Water Temperature Regulator...1020
Restriction in the Coolant System...1020
Coolant Temperature Gauge...1020
Coolant Pump...1020
Excessive Load on the System...1021
ECM Will Not Accept Factory Passwords...1021
Probable Causes...1021
Recommended Actions...1021
ECM Will Not Communicate With Other Systems or Display Modules...1021
Probable Causes...1021
Recommended Actions...1021
Electronic Service Tool Will Not Communicate With ECM...1021
Probable Causes...1021
Recommended Actions...1021
Engine Cranks but Will Not Start...1022
Probable Causes...1022
Recommended Actions...1022
Diagnostic Codes...1022
Visual Checks...1022
Crank Without Injection...1022
Starting Motor Solenoid or Starting Circuit...1022
Valve Lash...1022
Fuel Injection Nozzles...1023
Air Inlet Heater Starting Aid...1023
Air Intake and Exhaust System...1023
Low Compression...1023
Fuel Supply...1023
Engine Has Early Wear...1023
Probable Causes...1023
Recommended Actions...1023
Dirt in Engine Oil...1023
Leaks in Air Intake System...1023
Low Oil Pressure...1024
Engine Misfires, Runs Rough or Is Unstable...1024
Probable Causes...1024
Recommended Actions...1024
Logged Codes...1024
Fuel Supply...1024
Air Intake and Exhaust System...1024
Individual Malfunctioning Cylinders...1024
Valve Lash...1024
Check for Low Compression...1025
Check the Fuel Injection Nozzles...1025
Check the Air Inlet Heater Starting Aid...1025
Check the Engine Speed/Timing Sensors...1025
Check the Signal for the Throttle Position Sensor...1025
Check the Fuel Injection Pump...1025
Engine Oil in Cooling System...1025
Probable Causes...1025
Recommended Actions...1026
Engine Oil Cooler Core...1026
Cylinder Head Gasket...1026
Cylinder Head...1026
Engine Speed Does Not Change...1026
Probable Causes...1026
Recommended Repairs...1026
Diagnostic Codes...1026
Engine Stalls at Low RPM...1026
Probable Causes...1026
Recommended Actions...1026
Diagnostic Codes...1026
Fuel Injection Nozzles...1026
Fuel Supply...1027
Accessory Equipment...1027
Power Mode Control...1027
Engine Vibration...1027
Probable Causes...1027
Recommended Actions...1027
Engine Supports...1027
Malfunctioning Individual Cylinder...1027
Valve Lash...1027
Check for Low Compression (cylinder pressure)...1027
Check the Fuel Injection Nozzles...1028
Turbocharger...1028
Engine Will Not Crank...1028
Probable Causes...1028
Recommended Repairs...1028
Machine Security System...1028
Battery Cables and/or Batteries...1028
Starting Motor Solenoid or Starting Circuit...1028
Starting Motor and/or Flywheel Ring Gear...1028
Electrical Power Supply...1029
Internal Engine Problem...1029
Excessive Black Smoke...1029
Probable Causes...1029
Recommended Actions...1029
Air Intake System or Exhaust System...1029
Individual Malfunctioning Cylinder...1029
Valve Lash...1029
Low Compression (cylinder pressure)...1029
Check the Fuel Injection Nozzles...1029
Check the Turbocharger...1030
Broken 5-Volt Supply Wire...1030
Verifying the ECM Software...1030
Excessive Engine Oil Consumption...1030
Probable Causes...1030
Recommended Actions...1030
Oil Level...1030
Engine Crankcase Breather...1030
Air Intake and Exhaust System...1030
Turbocharger...1030
Low Compression (cylinder pressure)...1031
Excessive Valve Lash...1031
Probable Causes...1031
Recommended Actions...1031
Lubrication...1031
Valve Lash...1031
Valve Train Components...1031
Excessive White Smoke...1031
Probable Causes...1031
Recommended Actions...1032
Fuel Supply...1032
Individual Malfunctioning Cylinder...1032
Valve Lash...1032
Low Compression (cylinder pressure)...1032
Air Inlet Heater Starting Aid...1032
Fuel Injection Nozzles...1032
Coolant Temperature Sensor Circuit...1032
Engine Pressure Sensors...1032
Intake Air Temperature Is Too High...1033
Probable Causes...1033
Recommended Repairs...1033
High Ambient Air Temperature...1033
Coolant Temperature...1033
Check for High Intake Air Restriction and/or High Altitude...1033
Intake Air Restriction...1033
High Altitude...1033
Check the Intake Manifold Air Temperature Sensor and/or the Circ...1033
Check for Sufficient Coolant Flow Through the Aftercooler (if eq...1033
Check for Sufficient Flow of Air Through the Aftercooler (if equ...1033
Intermittent Engine Shutdown...1033
Probable Causes...1033
Recommended Actions...1033
Logged Codes...1033
Fuel Supply...1034
Engine Protection Device...1034
Electrical Connectors...1034
Intermittent Low Power or Power Cutout...1034
Probable Causes...1034
Recommended Repairs...1034
Diagnostic Codes...1035
Electrical Connectors...1035
Fuel Supply...1035
Check the Intake Manifold Pressure...1035
Air Intake and Exhaust System...1035
Individual Malfunctioning Cylinders...1035
Valve Lash...1036
Check for Low Compression...1036
Check the Fuel Injection Nozzles...1036
Check the Turbocharger...1036
ECM Parameters...1036
Electronic System Problem...1036
Low Engine Oil Pressure...1037
Probable Causes...1037
Recommended Actions...1037
Engine Oil Level...1037
Engine Oil Pressure Gauge...1037
Engine Oil Bypass Valves...1037
Piston Cooling Jets ...1037
Engine Oil Suction Tube...1037
Engine Oil Pump...1037
Bearing Clearance...1037
Low Power/Poor or No Response to Throttle...1037
Probable Causes...1037
Recommended Actions...1038
Diagnostic Codes...1038
Fuel Supply...1038
Air Intake and Exhaust System...1038
Individual Malfunctioning Cylinders...1038
Valve Lash...1038
Check for Low Compression...1038
Check the Fuel Injection Nozzles...1039
Check the Turbocharger...1039
ECM Parameters...1039
Electronic System Problem...1039
Mechanical Noise (Knock) in Engine...1039
Probable Causes...1039
Recommended Actions...1040
Accessory Equipment...1040
Valve Train Components...1040
Connecting Rod and Main Bearings...1040
Noise Coming from Cylinder...1040
Probable Causes...1040
Recommended Actions...1040
Fuel Quality...1040
Fuel Injection Nozzles...1040
Valve Lash...1040
Poor Acceleration or Response...1040
Probable Causes...1040
Recommended Repairs...1040
Diagnostic Codes...1040
Fuel Supply...1040
Individual Malfunctioning Cylinder...1041
Valve Lash...1041
Check for Low Compression...1041
Check the Fuel Injection Nozzles...1041
Check the Turbocharger...1041
ECM Parameters...1041
Check Intake Manifold Pressure...1042
Troubleshooting With a Diagnostic Code...1042
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal...1042
Conditions Which Generate This Code...1042
System Response...1042
Possible Performance Effect...1042
Troubleshooting...1042
Results...1042
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent...1042
Conditions Which Generate This Code...1042
System Response...1042
Possible Performance Effect...1042
Troubleshooting...1042
Test Step 1...1042
Results...1042
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted...1042
Conditions Which Generate This Code...1042
System Response...1042
Possible Performance Effect...1043
CID 0091 FMI 04 Throttle Position Sensor Shorted Low...1043
Conditions Which Generate This Code...1043
System Response...1043
Possible Performance Effect...1043
Troubleshooting...1043
Results...1043
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal...1043
Conditions Which Generate This Code...1043
System Response...1043
Troubleshooting...1043
Results...1043
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...1043
Conditions Which Generate This Code...1043
Possible Performance Effect...1043
Troubleshooting...1043
Results...1043
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short...1043
Conditions Which Generate This Code...1043
System Response...1044
Troubleshooting...1044
Results...1044
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...1044
Conditions Which Generate This Code...1044
System Response...1044
Troubleshooting...1044
Results...1044
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci...1044
Conditions Which Generate This Code...1044
System Response...1044
Possible Performance Effect...1044
Results...1044
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or...1044
Conditions Which Generate This Code...1044
System Response...1044
Possible Performance Effect...1045
Results...1045
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...1045
Conditions Which Generate This Code...1045
System Response...1045
Possible Performance Effect...1045
Results...1045
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope...1045
Conditions Which Generate This Code...1045
System Response...1045
Results...1045
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ...1045
Conditions Which Generate This Code...1045
System Response...1045
Possible Performance Effect...1046
Troubleshooting...1046
Results...1046
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low...1046
Conditions Which Generate This Code...1046
System Response...1046
Possible Performance Effect...1046
Troubleshooting...1046
Results...1046
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o...1046
Conditions Which Generate This Code...1046
System Response...1046
Possible Performance Effect...1046
Troubleshooting...1046
Results...1046
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...1046
Conditions Which Generate This Code...1046
System Response...1046
Possible Performance Effect...1046
Troubleshooting...1047
Results...1047
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...1047
Conditions Which Generate This Code...1047
System Response...1047
Possible Performance Effect...1047
Troubleshooting...1047
Results...1047
CID 0247 FMI 09 J1939 Datalink, Abnormal Update...1047
Conditions Which Generate This Code...1047
System Response...1047
Results...1047
CID 0253 FMI 02 Incorrect ECM Software...1047
Conditions Which Generate This Code...1047
System Response...1047
Possible Performance Effect...1047
Troubleshooting...1048
Expected Result...1048
Results...1048
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal...1048
Conditions Which Generate This Code...1048
System Response...1048
Possible Performance Effect...1048
Troubleshooting...1048
Results...1048
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal...1048
Conditions Which Generate This Code...1048
System Response...1048
Possible Performance Effect...1048
Troubleshooting...1048
Results...1048
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs...1048
Conditions Which Generate This Code...1048
System Response...1048
Possible Performance Effect...1048
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig...1049
Conditions Which Generate This Code...1049
System Response...1049
Possible Performance Effect...1049
Results...1049
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...1049
Conditions Which Generate This Code...1049
System Response...1049
Possible Performance Effect...1049
Results...1049
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa...1049
Conditions Which Generate This Code...1049
System Response...1049
Possible Performance Effect...1049
Test Step 1...1049
Results...1049
Test Step 2...1049
Results...1050
CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm...1050
Conditions Which Generate This Code...1050
System Response...1050
Possible Performance Effect...1050
Results...1050
CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S...1050
Conditions Which Generate This Code...1050
System Response...1050
Possible Performance Effect...1050
Troubleshooting...1050
Results...1050
CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low...1050
Conditions Which Generate This Code...1050
System Response...1050
Possible Performance Effect...1050
Troubleshooting...1050
Results...1050
CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal...1051
Conditions Which Generate This Code...1051
System Response...1051
Possible Performance Effect...1051
Results...1051
CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio...1051
Conditions Which Generate This Code...1051
System Response...1051
Possible Performance Effect...1051
Results...1051
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off...1051
Conditions Which Generate This Code...1051
System Response...1051
Possible Performance Effect...1051
Results...1051
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ...1051
Conditions Which Generate This Code...1051
System Response...1051
Possible Performance Effect...1052
Test Step 1...1052
Results...1052
Test Step 2...1052
Results...1052
CID 1684 FMI 02 Fuel Injection Pump, Software Failure...1052
Conditions Which Generate This Code...1052
System Response...1052
Possible Performance Effect...1052
Troubleshooting...1052
Results...1052
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault...1052
Conditions Which Generate This Code...1052
System Response...1052
Possible Performance Effect...1052
Troubleshooting...1052
Results...1052
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...1053
Conditions Which Generate This Code...1053
System Response...1053
Possible Performance Effect...1053
Troubleshooting...1053
Results...1053
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width...1053
Conditions Which Generate This Code...1053
Troubleshooting...1053
Results...1053
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault...1053
Conditions Which Generate This Code...1053
System Response...1053
Possible Performance Effect...1053
Troubleshooting...1053
Results...1053
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...1053
Conditions Which Generate This Code...1053
System Response...1054
Possible Performance Effect...1054
Troubleshooting...1054
Test Step 1...1054
Results...1054
Test Step 2...1054
Results...1054
Test Step 3...1054
Results...1054
Test Step 4...1054
Expected Result...1054
Results...1054
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault...1054
Conditions Which Generate This Code...1054
System Response...1054
Possible Performance Effect...1054
Troubleshooting...1054
Expected Result...1055
Results...1055
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error...1055
Conditions Which Generate This Code...1055
System Response...1055
Troubleshooting...1055
Test Step 1...1055
Results...1055
Test Step 2...1055
Results...1055
Test Step 3...1055
Results...1055
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault...1055
Conditions Which Generate This Code...1055
System Response...1055
Possible Performance Effect...1056
Troubleshooting...1056
Test Step 1...1056
Results...1056
Test Step 2...1056
Results...1056
CID 1684 FMI 14 Fuel Injection Pump, No Communications...1056
Conditions Which Generate This Code...1056
System Response...1056
Troubleshooting...1056
Test Step 1...1056
Results...1056
Test Step 2...1056
Results...1056
Test Step 3...1056
Results...1056
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali...1056
Conditions Which Generate This Code...1056
System Response...1056
Possible Performance Effect...1057
Troubleshooting...1057
Results...1057
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali...1057
Conditions Which Generate This Code...1057
System Response...1057
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S...1057
Conditions Which Generate This Code...1057
System Response...1057
Troubleshooting With an Event Code...1057
Event Codes...1057
Programmable Engine Parameters...1057
E015 High Engine Coolant Temperature Derate...1057
Conditions Which Generate This Code...1057
System Response...1057
Possible Performance Effect...1057
Troubleshooting...1057
Results...1057
E016 High Engine Coolant Temperature Shutdown...1058
Conditions Which Generate This Code...1058
System Response...1058
Possible Performance Effect...1058
Troubleshooting...1058
Results...1058
E017 High Engine Coolant Temperature Warning...1058
Conditions Which Generate This Code...1058
System Response...1058
Possible Performance Effect...1058
Troubleshooting...1058
Results...1058
E025 High Intake Air Temperature Derate...1058
Conditions Which Generate This Code...1058
System Response...1058
Possible Performance Effect...1058
Troubleshooting...1058
Results...1058
E027 High Intake Air Temperature Warning...1058
Conditions Which Generate This Code:...1058
System Response...1058
Possible Performance Effect...1059
Troubleshooting...1059
Results...1059
E040 Low Engine Oil Pressure Shutdown...1059
Conditions Which Generate This Code...1059
System Response...1059
Possible Performance Effect...1059
Troubleshooting...1059
Results...1059
E054 High Fuel Temperature Derate...1059
Conditions Which Generate This Code...1059
System Response...1059
Troubleshooting...1059
Test Step 1 - Check for Diagnostic Codes...1059
Expected Result...1059
Results...1059
Test Step 2 - Perform a Check of the Fuel System...1059
Expected Result...1060
Results...1060
E056 High Fuel Temperature Warning...1060
Conditions Which Generate This Code...1060
System Response...1060
Troubleshooting...1060
Test Step 1 - Check for Diagnostic Codes...1060
Expected Result...1060
Results...1060
Test Step 2 - Perform a Check of the Fuel System...1060
Expected Result...1060
Results...1060
E100 Low Engine Oil Pressure Warning...1060
Conditions Which Generate This Code...1060
System Response...1060
Possible Performance Effect...1060
Troubleshooting...1061
Test Step 1 - Check for Active Diagnostic Codes...1061
Expected Result...1061
Results...1061
Test Step 2 - Perform a Check of the Engine Lubrication System...1061
Expected Result...1061
Results...1061
E190 Engine Overspeed Warning...1061
Conditions Which Generate This Code...1061
System Response...1061
Possible Performance Effect...1061
Troubleshooting...1061
Engine Overspeed Warning...1061
Expected Result...1061
Results...1061
E442 Engine Failed to Stop With a No-Fuel Command...1061
Conditions Which Generate This Code...1061
System Response...1061
Possible Performance Effect...1062
Troubleshooting...1062
Test Step 1...1062
Results...1062
Test Step 2...1062
Results...1062
E883 Engine Failed to Stop When Fuel Solenoid Disengaged...1062
Conditions Which Generate This Code...1062
System Response...1062
Possible Performance Effect...1062
Troubleshooting...1062
Test Step 1...1062
Results...1062
Test Step 2...1062
Results...1062
Test Step 3...1062
Results...1062
Diagnostic Function Tests...1063
5-Volt Engine Pressure Sensor Supply Circuit - Test...1063
System Operation Description...1063
Background Information...1063
Test Step 1...1064
Inspect Electrical Connectors and Wiring...1064
Expected Result...1064
Results...1064
Test Step 2...1065
Check for Active Diagnostic Codes...1065
Expected Result...1065
Results...1065
Test Step 3...1065
Disconnect the ECM Engine Harness Connector From the ECM...1065
Expected Result...1066
Results...1066
Test Step 4...1066
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei...1066
Expected Result...1066
Results...1066
Test Step 5...1067
Check the Engine Harness...1067
Expected Result...1067
Results...1067
Air Inlet Heater Circuit - Test...1067
System Operation Description...1067
Test Step 1...1067
Inspect Electrical Connectors and Wiring...1067
Expected Result...1068
Results...1068
Test Step 2...1068
Check the Supply to the Power Relay for the Air Inlet Heater Sta...1068
Expected Result...1068
Results...1068
Test Step 3...1069
Check the Output From the Power Relay for the Air Inlet Heater S...1069
Expected Result...1069
Results...1069
Test Step 4...1069
Ground the Input to the Power Relay at the MIC...1069
Expected Result...1069
Results...1069
Test Step 5...1069
Ground the Input to the Power Relay at the ECM Connector...1069
Expected Result...1069
Results...1069
Test Step 6...1069
Override the Air Inlet Heater Starting Aid to Test the ECM...1069
Results...1070
Checking Idle Validation Switching Point (Throttle Sensor) With ...1070
Expected Result...1070
Analog Throttle Position Sensor Circuit - Test...1070
System Operation Description...1070
Checking the Throttle Sensor With Unconnected Output C...1071
Expected Result...1071
Test Step 1...1071
Check for Connector Damage...1071
Expected Result...1071
Results...1071
Test Step 2...1072
Check for Active Diagnostic Codes...1072
Expected Result...1072
Results...1072
Test Step 3...1072
Check the Throttle Position With the Electronic Service Tool...1072
Expected Result...1072
Results...1072
Test Step 4...1072
Check the Voltage at the Throttle Position Sensor...1072
Expected Result...1072
Results...1072
Test Step 5...1073
Disconnect the Throttle Position Sensor and Check for Active Dia...1073
Expected Result...1073
Results...1073
Test Step 6...1073
Check the Throttle Selection Status With the Electronic Service ...1073
Expected Result...1073
Results...1074
Test Step 7...1074
Disconnect the Supply Terminals of the Throttle Position Sensor ...1074
Expected Result...1074
Results...1074
Test Step 8...1074
Check the Position of Throttle Position Sensor...1074
Expected Result...1075
Results...1075
Test Step 9...1075
Check the Throttle Position Sensor at the ECM...1075
Expected Result...1075
Results...1075
CAN Data Link Circuit - Test...1075
System Operation Description...1075
Test Step 1...1076
Inspect Electrical Connectors and Wiring...1076
Expected Result...1076
Results...1076
Test Step 2...1076
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...1076
Expected Result...1076
Results...1076
Test Step 3...1076
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...1076
Expected Result...1077
Results...1077
Test Step 4...1077
Verify the Supply Voltage at the Fuel Injection Pump...1077
Expected Result...1077
Results...1077
Data Link Circuit - Test...1077
System Operation Description...1077
Background Information...1078
Communication...1078
Test Step 1...1078
Inspect Electrical Connectors and Wiring...1078
Expected Result...1078
Results...1078
Test Step 2...1078
Determine the Type of Problem With the Data Link...1078
Expected Result...1078
Results...1079
Test Step 3...1079
Check the Battery Voltage at the ECM...1079
Expected Result...1079
Results...1079
Test Step 4...1079
Check the Battery Voltage That is Coming to the Data Link Connec...1079
Expected Result...1080
Results...1080
Test Step 5...1080
Connect the Electronic Service Tool Directly to the ECM...1080
Expected Result...1080
Results...1080
Test Step 6...1080
Change Electronic Service Tool Components...1080
Expected Result...1081
Results...1081
Test Step 7...1081
Connect an Electronic Service Tool and the ECM to Another Batter...1081
Expected Result...1081
Results...1081
Electrical Connectors - Inspect...1081
System Operation Description...1082
Background Information...1082
Test Step 1...1086
Check the Locking of the DT Connector (Deutsch) and the Lock Rin...1086
Expected Result...1086
Results...1086
Test Step 2...1086
Check the Socket Head Screw on the Connector for the Electronic ...1086
Expected Result...1086
Results...1086
Test Step 3...1086
Perform a Pull Test on Each Wire Terminal Connection...1086
Expected Result...1086
Results...1086
Test Step 4...1087
Monitor the Electronic Service Tool While the Wiring and the Con...1087
Expected Result...1087
Results...1087
Test Step 5...1087
Check Wires for Nicks and/or Abrasions in the Insulation...1087
Expected Result...1087
Results...1087
Test Step 6...1087
Check Connectors for Moisture or Corrosion...1087
Expected Result...1088
Results...1088
Test Step 7...1088
Inspect the Connector Terminals...1088
Expected Result...1088
Results...1088
Test Step 8...1089
Check Individual Pin Retention Into the Socket...1089
Expected Result...1089
Results...1089
Electrical Power Supply Circuit - Test...1089
System Operation Description...1089
Background Information...1089
Test Step 1...1091
Check the Batteries...1091
Expected Result...1091
Results...1091
Test Step 2...1091
Inspect Electrical Connectors and Wiring...1091
Expected Result...1091
Results...1091
Test Step 3...1091
Check the Battery Voltage at the ECM...1091
Expected Result...1092
Results...1092
Test Step 4...1092
Use the Bypass Harness for the Electronic Service Tool to Bypass...1092
Expected Result...1093
Results...1093
Engine Pressure Sensor Open or Short Circuit - Test...1093
System Operation Description...1093
Background Information...1093
Test Step 1...1094
Check for Active +5V Sensor Supply Diagnostic Codes...1094
Expected Result...1094
Results...1094
Test Step 2...1094
Verify All Active Diagnostic Codes...1094
Expected Result...1094
Results...1094
Test Step 3...1094
Inspect Electrical Connectors And Wiring...1094
Expected Result...1095
Results...1095
Test Step 4...1095
Verify That the Diagnostic Code is Still Active...1095
Expected Result...1095
Results...1095
Test Step 5...1095
Disconnect the Sensor to Create an Open Circuit...1095
Expected Result...1096
Results...1096
Test Step 6...1096
Measure the Sensor Supply Voltage...1096
Expected Result...1096
Results...1096
Test Step 7...1097
Determine if the Short Circuit is in the Connector or in the Sen...1097
Expected Result...1097
Results...1097
Test Step 8...1097
Create a Short Circuit Between the Signal and the Common Termina...1097
Expected Result...1097
Results...1097
Test Step 9...1097
Check the Operation of the ECM by Creating Open and Short Circui...1097
Expected Result...1098
Results...1098
Test Step 10...1098
Bypass the Harness Wiring Between the ECM and the Sensor Connect...1098
Expected Result...1098
Results...1098
Engine Speed/Timing Sensor Circuit - Test...1099
System Operation Description...1099
Test Step 1...1099
Inspect the Electrical Connectors and Cables...1099
Expected Result...1099
Results...1099
Test Step 2...1100
Check the Installation of the Engine Speed/Timing Sensors...1100
Expected Result...1100
Results...1100
Test Step 3...1100
Measure the Sensor Resistance Through the Wiring Harness...1100
Expected Result...1100
Results...1100
Test Step 4...1100
Measure the Resistance of the Sensor...1100
Expected Result...1101
Results...1101
Test Step 5...1101
Measure the Resistance of the Cables Between the Fuel Injection ...1101
Expected Result...1102
Results...1102
Test Step 6...1102
Check the Continuity of the Cables From the ECM to the Fuel Inje...1102
Expected Result...1102
Results...1102
Engine Temperature Sensor Open or Short Circuit - Test...1102
System Operation Description...1102
Background Information...1102
Test Step 1...1103
Verify All Active Diagnostic Codes...1103
Expected Result...1103
Results...1103
Test Step 2...1104
Inspect Electrical Connectors and Wiring...1104
Expected Result...1104
Results...1104
Test Step 3...1104
Verify That the Diagnostic Code is Still Active...1104
Expected Result...1104
Results...1104
Test Step 4...1104
Disconnect the Sensor to Create an Open Circuit...1104
Expected Result...1105
Results...1105
Test Step 5...1105
Create a Short Circuit Between the Signal and the Common Termina...1105
Expected Result...1105
Results...1105
Test Step 6...1105
Check the Operation of the ECM by Creating an Open and a Short C...1105
Expected Result...1106
Results...1106
Test Step 7...1106
Bypass the Harness Wiring Between the ECM and the Sensor Connect...1106
Expected Result...1106
Results...1106
Fuel Injection Pump Circuit - Test...1107
System Operation Description...1107
Background Information...1107
Test Step 1...1107
Check the Batteries...1107
Expected Result...1107
Results...1107
Test Step 2...1107
Inspect the Electrical Connectors and Wiring...1107
Expected Result...1108
Results...1108
Test Step 3...1108
Check the Supply Voltage at the Machine Interface Connector...1108
Expected Result...1109
Results...1109
Test Step 4...1109
Check the Supply Voltage at the Fuel Injection Pump...1109
Expected Result...1109
Results...1109
Test Step 5...1109
Check the Supply to the Power Relay for the Fuel Injection Pump...1109
Expected Result...1109
Results...1109
Test Step 6...1110
Check the Output of the Power Relay for the Fuel Injection Pump...1110
Expected Result...1110
Results...1110
Test Step 7...1110
Check the Voltage at the Relay Coil for the Fuel Injection Pump...1110
Expected Result...1110
Results...1110
Test Step 8...1110
Check the Output of the ECM Fuel Pump Power Control at the Machi...1110
Expected Result...1110
Results...1111
Test Step 9...1111
Check the Output of the Fuel Injection Pump Power Control at the...1111
Expected Result...1111
Results...1111
Test Step 10...1111
Measure the Voltage at the Pump Power Supply...1111
Expected Result...1111
Results...1111
Test Step 11...1112
Check the Voltage Load Protection Module (VLPM)...1112
Expected Result...1112
Results...1112
Indicator Lamp Circuit - Test...1112
System Operation Description...1112
Test Step 1...1113
Inspect Electrical Connectors and Wiring...1113
Results...1114
Test Step 2...1114
Inspect the Lamp, the Fuse, and the Power Supply...1114
Expected Result...1114
Results...1114
Test Step 3...1114
Inspect the Input to the Lamp at the ECM connector...1114
Expected Result...1114
Results...1114
Test Step 4...1114
Test the Individual Lamp Circuits...1114
Expected Result...1114
Results...1114
Test Step 5...1115
Check the Voltage at the ECM...1115
Expected Result...1115
Results...1115
Idle Validation Circuit - Test...1115
System Operation Description...1115
Test Step 1...1115
Expected Result...1115
Results...1115
tables...964
Table 1. Electronic Service Tool...990
Table 2. Optional Service Tools...991
Table 3. CID FMI Codes and J Code FMI Codes...992
Table 4. Event Codes and CID FMI Codes...994
Table 5. CID Numbers and Flash Codes...995
Table 6. Engine Connectors...1003
Table 7. Color Codes for the Harness Wire...1007
Table 8. Pin Connections for Perkins Deutsch Socket Connector...1009
Table 9. Suspect Parameter Numbers...1013
Table 10. Failure Mode Indicators (FMI) Codes...1014
Table 11. Engine Oil Pressure Trip and Reset Points...1059
897108-1600SRM0326-(03-2007)-US-EN...1120
toc...1120
Steering Axle...1120
Safety Precautions Maintenance and Repair...1121
General...1124
Description...1124
Steering Axle Assembly Repair...1129
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...1129
Remove...1129
Install...1129
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...1130
Remove...1130
Install...1130
Wheels and Hubs Repair (All Units)...1131
Remove and Disassemble...1131
Clean...1131
Inspect...1131
Assemble and Install...1131
Spindles and Bearings Repair (All Units)...1133
Remove...1133
Clean...1133
Assemble and Install...1134
Tie Rods Repair (All Units)...1135
Remove...1135
Clean...1135
Install...1135
Steering Cylinder Repair...1138
Remove and Disassemble...1138
Clean and Inspect...1138
Assemble and Install...1138
Troubleshooting...1139
897386-4000SRM0445-(08-2001)-US-EN...1144
toc...1144
Masts...1144
Safety Precautions Maintenance and Repair...1145
General...1148
Description...1148
Safety Procedures When Working Near Mast...1149
Operation...1151
Two-Stage Mast...1151
Three-Stage Mast...1151
Forks Repair...1153
Remove...1153
Install...1153
Carriage Repair...1153
Remove...1153
Sideshift Carriage, Disassemble...1153
Sideshift Carriage, Assemble...1155
Sideshift Cylinder, Disassemble...1157
Sideshift Cylinder, Assemble...1157
Fork Positioner Cylinder, Disassemble...1158
Fork Positioner Cylinder, Assemble...1159
Install...1160
Mast Repairs...1160
Remove...1160
Two-Stage Mast, Disassemble...1160
Three-Stage Mast, Disassemble...1165
Clean and Inspect...1167
Two-Stage Mast, Assemble...1167
Three-Stage Mast, Assemble...1170
Install...1173
Lift Cylinders Description...1174
Piston-Type Cylinders...1175
Displacement-Type Cylinders...1175
All Lift Cylinders Repair...1175
Remove...1177
Disassemble...1177
Clean and Inspect...1177
Assemble...1177
Install...1178
Mast Operation Check...1178
Lift and Tilt System Leak Checks...1178
Lift System...1178
Tilt System...1179
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...1179
Lift Chain Adjustments...1180
Mast Adjustments...1180
Bearing Blocks...1180
Wear Plates...1181
Load Roller Adjustments...1181
Carriage Adjustment...1183
Troubleshooting...1185
tables...1144
Table 1. Carriage and Fork Weights...1157
Table 2. Mast Weights...1165
Table 3. Allowable Mast Movement from Internal Leakage...1179
897934-0700SRM0626-(11-2001)-US-EN...1190
toc...1190
Cooling System...1190
Safety Precautions Maintenance and Repair...1191
General...1194
Description...1195
Radiator...1195
Radiator Cap...1195
Thermostat...1195
Water Pump...1196
Fan and Fan Shroud...1196
Cooling System Checks...1196
Radiator...1196
Thermostat...1196
Water Pump...1197
Exhaust Leaks...1197
Fan and Fan Shroud...1197
Radiator Cleaning...1197
Drain...1197
Clean...1197
Fill...1198
Troubleshooting...1199
899784-2200SRM0002-(12-2004)-US-EN...1202
toc...1202
Alternator with Regulator...1202
Safety Precautions Maintenance and Repair...1203
General...1206
Description...1206
Alternator Repair...1208
Alternator Type A...1208
Remove and Disassemble...1208
Clean...1209
Assemble...1210
Install...1210
Alternator Type B...1213
Remove and Disassemble...1213
Clean...1213
Assemble...1214
Install...1215
General Check and Adjustment...1216
Low Output Check (Type A or Type B)...1216
High Output Check (Type A or Type B)...1218
Brushes Circuit Check...1219
Delco Alternators...1219
Motorola Alternators...1220
Diodes Check...1221
Diode Bridge Check...1221
Delco and Leece-Neville Alternators...1221
Motorola Alternators...1221
Rotor Field Winding Check...1222
Stator Windings Check...1223
Voltage Regulator Check...1223
Troubleshooting...1223
910072-1400SRM0046-(07-2007)-US-EN...1228
toc...1228
Differential...1228
Safety Precautions Maintenance and Repair...1229
General...1232
Description...1232
Differential Repair...1233
Remove...1233
Differential Carrier From Axle Housing, Remove...1233
Differential and Ring Gear From Differential Carrier, Remove...1235
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...1237
Disassemble...1238
Differential and Ring Gear Assembly, Disassemble...1238
Drive Pinion and Pinion Carrier, Disassemble...1240
Clean and Inspect...1243
Assemble...1244
Pinion, Bearings, and Pinion Carrier, Assemble...1244
Pinion Bearings, Adjust Preload...1244
Press Method...1244
Yoke or Flange Method...1245
Triple-Lip Seal, Install...1246
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...1247
Differential and Ring Gear, Assemble...1249
Differential Gears Rotating Torque, Check...1251
Differential and Ring Gear Assembly, Install...1252
Differential Bearings, Preload Adjust...1254
Ring Gear, Runout Check...1255
Ring Gear Backlash, Adjust...1255
Gear Set, Tooth Contact Pattern Check...1257
Thrust Screw, Install and Adjust...1260
Install...1260
Differential Assembly Into Axle Housing, Install...1260
Specifications...1262
Troubleshooting...1267
tables...1228
Table 1. Ring Gear Backlash Adjustment Specifications...1257
Table 2. Ring and Pinion Tooth Contact Adjustment...1258
Table 3. General Specifications...1262
Table 4. Rivet Installation Pressure...1262
Table 5. Pinion Adjustment...1263
Table 6. Pinion Preload Pressure...1263
Table 7. Torque Specifications...1264
Table 8. Torque Specifications for Metric Hardware...1265
Table 9. Torque Specifications for Metric (Fine) Hardware...1266
910102-2100SRM0103-(03-2007)-US-EN...1270
toc...1270
Tilt Cylinders...1270
Safety Precautions Maintenance and Repair...1271
General...1274
Description...1274
Tilt Cylinder Repair...1274
Remove...1274
Disassemble...1274
Clean...1274
Assemble...1274
Tilt Cylinders With O-Ring or Single-Lip Seals...1274
Tilt Cylinders for XM and XMS Models...1276
Tilt Cylinders for XL, XLS, and XL 3 Models...1277
Tilt Cylinders for H700-800A and Early Model H700-920B...1279
Install...1280
Tilt Cylinders Using Chevron Packing...1280
Install...1281
Tilt Cylinder Leak Check...1283
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...1285
Torque Specifications...1285
Piston Rod Nut...1285
Retainer...1286
Troubleshooting...1288
tables...1270
Table 1. Movement Rates (Maximum) for Tilt Cylinders...1284
910107-2200SRM0106-(12-2004)-US-EN...1292
toc...1292
Starter...1292
Safety Precautions Maintenance and Repair...1293
General...1296
Description and Operation...1296
Starter Repair...1298
Remove...1298
Disassemble...1298
Clean...1299
Assemble...1299
Install...1300
General Checks and Adjustments...1300
Troubleshooting...1303
910119-4000SRM0135-(10-2003)-US-EN...1308
toc...1308
Lift Cylinders...1308
Safety Precautions Maintenance and Repair...1309
Safety Procedures When Working Near Mast...1312
General...1316
Description...1316
Lowering Control Valve...1316
Cylinders (General)...1319
Cylinders (H520-620B, H700-800A)...1319
Retainer, Install...1319
Cylinders (H360-460B)...1321
Cylinders (Two-Speed)...1323
Lift Cylinder Repair...1325
Lift Cylinder Removal Without Removing Mast...1325
Standard Masts With Main Lift Cylinder Fastened to Crossmember o...1325
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...1325
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ...1325
Disassemble...1327
Assemble...1327
Lift Cylinder Installation in Mast...1329
Standard Masts With Main Lift Cylinder Fastened to Crossmember o...1329
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...1329
Chevron-Style Packing...1329
Chevron-Style Packing Installation on Piston...1330
Chevron-Style Packing Installation in Packing Gland...1332
Lift Cylinders for VISTA® Masts...1333
Description...1333
Lowering Control Valve...1333
Remove...1335
Disassemble...1336
Assemble...1337
Install...1338
Main Lift Cylinders...1338
Free-Lift Cylinder...1338
Lift System Leak Check...1339
Specifications...1340
Troubleshooting...1341
tables...1308
Table 1. Lift Trucks with Two-Speed Lift Cylinders...1324
Table 2. Cylinder Retainer Torque Specifications and Weight Guid...1340
910442-8000SRM0231-(12-2004)-US-EN...1344
toc...1344
Metric and Inch (SAE) Fasteners...1344
Safety Precautions Maintenance and Repair...1345
General...1348
Threaded Fasteners...1348
Nomenclature, Threads...1348
Strength Identification...1349
Cotter (Split) Pins...1349
Fastener Torque Tables...1354
Conversion Table...1356
tables...1344
Table 1. Bolts and Screws...1350
Table 2. Studs and Nuts...1351
Table 3. Torque Nuts...1352
Table 4. Torque Nuts With Nylon Insert...1353
Table 5. Torque Values for Metric Fasteners*...1354
Table 6. Torque Values for Inch Fasteners*...1355
Table 7. Conversion Table for Metric and English Units...1356
Table 8. Cotter Pin Dimensional Data...1357
Table 9. Cotter Pin Dimensional Data...1358
Table 10. Cotter Pin Dimensional Data...1359
Table 11. Cotter Pin Dimensional Data...1361
F007 (H8.00-12.00XM Europe)...1366
1455747-0600SRM0705-(03-2006)-UK-EN...1368
toc...1368
Perkins Diesel Engines...1368
Safety Precautions Maintenance and Repair...1369
General...1376
General Safety Rules...1376
Description...1377
Engine Serial Number Codes...1380
Engine Data...1380
Engine Removal and Installation...1382
Lift Engine...1382
Cylinder Head Assembly Repair...1382
Valve Cover...1382
Remove...1382
Install...1383
Rocker Arm Assembly...1383
Remove...1383
Install...1383
Disassemble...1383
Inspect...1384
Assemble...1384
Valve Clearance Adjustments...1384
Four-Cylinder Engines...1385
Six-Cylinder Engines...1385
Valve Springs...1385
Cylinder Head Assembly...1387
Remove...1387
Install...1389
Valves and Valve Springs...1393
Remove...1393
Inspect...1393
Install...1394
Valve Guides...1394
Inspect...1394
Remove...1395
Install...1395
Cylinder Head and Valve Seats...1395
Inspect...1395
Repair...1395
New Valve Seats, Install...1395
Piston and Connecting Rod Assemblies Repair...1397
Rod Bearings...1397
Remove...1398
Install...1398
Piston and Connecting Rod Assembly...1399
Service Note...1399
Remove...1399
Install...1400
Piston Rings...1401
Remove...1401
Inspect...1401
Install...1401
Piston and Connecting Rod...1402
Disassemble...1402
Inspect...1403
How to Select Correct Replacements...1403
Install...1404
Piston Cooling Jets...1404
Remove...1404
Install...1405
Crankshaft Assembly Repair...1405
General...1405
Crankshaft Pulley...1406
Engine AR, Remove...1406
Engines YG and YH, Remove...1406
Inspect...1407
Engine AR, Install...1407
Engines YG and YH, Install...1407
Rear Oil Seal...1408
Replace...1408
Main Bearings...1409
Remove...1409
Inspect...1410
Install...1410
Thrust Washers...1410
Crankshaft Axial Movement, Check...1410
Remove...1411
Install...1411
Crankshaft...1412
Remove...1412
Inspect...1412
Install...1412
Flywheel...1414
Remove...1414
Ring Gear, Replace...1414
Install...1414
Flywheel Housing...1415
Remove...1415
Install...1415
Timing Case and Timing Gears Repair...1416
General...1416
Timing Case Cover...1416
Remove...1416
Install...1417
Front Oil Seal...1417
Remove...1417
Install...1417
Crankshaft Pulley Wear Sleeve...1418
Install...1418
Idler Gear and Hub...1418
Remove...1418
Install...1419
Air Compressor Drive, Bendix...1420
Disassemble...1420
Assemble...1421
Fuel Injection Pump Gear...1421
Remove...1422
Install...1422
Camshaft Gear...1423
Remove...1423
Install...1423
Crankshaft Gear...1424
Remove...1424
Install...1424
Timing Case...1424
Remove...1424
Install...1425
Camshaft and Tappets...1426
Remove...1426
Install...1426
Cylinder Block Assembly Repair...1427
Description...1427
Cylinder Block...1427
Disassemble...1427
Inspect...1428
Assemble...1428
Cylinder Bore (Four-Cylinder Engines)...1429
Cylinder Liner (Six-Cylinder Engines)...1429
Inspect...1429
Cylinder Liner Condition, Check...1429
Remove...1430
Service Liner, Install...1431
Partially Finished Liner, Install...1432
Engine Timing...1433
Description...1433
How to Set Number One Piston to TDC on Compression Stroke...1434
How to Set Number One Piston to TDC on Compression Stroke (Alter...1435
Valve Timing, Check...1435
Fuel Injection Pump Timing, Check...1436
Turbocharger - Engine YH Repair...1437
General...1437
Remove...1437
Install...1437
Impeller and Compressor Housing, Clean...1438
Lubrication System Repair...1439
General...1439
Oil Filter, Replace...1439
Filter Head...1440
Remove and Install...1440
Oil Sump...1440
Remove...1440
Install...1441
Oil Pump...1441
Remove...1441
Inspect...1441
Install...1442
Relief Valve...1442
Remove...1442
Disassemble...1443
Inspect...1443
Assemble...1443
Install...1444
Idler Gear Shaft, Replace...1444
Remove...1444
Remove (Alternative)...1444
Install...1445
Install (Alternative)...1445
Install (Alternative for Four-Cylinder Engines Only)...1446
Fuel System Repair...1446
Description...1446
Fuel Injection Pump...1447
Remove...1447
Install...1448
Check and Adjust...1449
Fuel System Air Removal...1449
Fuel Filter, Replace...1450
Canister Type...1451
Quick Release Canister Type...1451
Fuel Injectors...1452
Remove...1452
Inspect...1453
Install...1453
Fuel Pump...1454
Remove...1454
Disassemble...1454
Assemble...1454
Install...1455
Test...1455
Cooling System Repair...1456
General...1456
Thermostat...1456
Remove...1456
Install...1456
Test...1457
Coolant Pump...1457
Remove...1457
Disassemble...1457
Assemble...1459
Install...1461
Fan and Fan Drive...1462
Remove...1462
Install...1462
Oil Cooler (Six-Cylinder Engines)...1463
Remove...1463
Disassemble and Assemble...1463
Install...1463
Oil Cooler Bypass Valve...1463
Electrical Equipment Repair...1464
Drive Belts...1464
Adjustment...1464
Remove...1465
Install...1465
Alternator...1465
Remove...1465
Install...1465
Starter Motor...1465
Remove...1465
Install...1465
Cold Start Aid...1465
Air Compressor - Engines YG and YH...1466
General...1466
Repair...1466
Remove...1466
Install...1466
Rotary Exhauster Replacement...1468
Remove...1468
Clean...1468
Install...1468
Engine Specifications...1469
Cylinder Head Assembly...1469
Piston and Connecting Rods...1472
Crankshaft Assembly...1475
Crankshaft Overhaul...1477
Timing Case and Drive Assembly...1479
Engine Block Assembly...1480
Turbocharger...1483
Lubrication System...1483
Fuel System...1484
Cooling System...1486
Flywheel and Housing...1486
Electrical Equipment...1487
Torque Specifications...1487
Cylinder Head Assembly...1487
Piston and Connecting Rod Assemblies...1487
Crankshaft Assembly...1487
Timing Case and Drive Assembly...1488
Turbocharger...1488
Lubrication System...1488
Fuel System...1488
Cooling System...1488
Flywheel...1488
Auxiliary Equipment...1488
Special Torque Specifications...1489
Flywheel and Housing...1489
Turbocharger...1489
Electrical Equipment...1489
Auxiliary Equipment...1489
Special Tools*...1490
Troubleshooting...1495
tables...1368
Table 1. Cylinder Head...1469
Table 2. Valve Guides...1469
Table 3. Inlet Valves...1469
Table 4. Exhaust Valves...1470
Table 5. Valve Springs...1472
Table 6. Tappets...1472
Table 7. Rocker Arm Shaft...1472
Table 8. Rocker Arms and Bushings...1472
Table 9. Pistons (Engine AR)...1472
Table 10. Pistons (Engines YG and YH)...1472
Table 11. Piston Rings (Engine AR)...1473
Table 12. Piston Rings (Engines YG and YH)...1473
Table 13. Piston Pins...1474
Table 14. Connecting Rods...1474
Table 15. Small End Bushings...1474
Table 16. Connecting Rod Bearings (Engines AR and YG)...1474
Table 17. Connecting Rod Bearings (Engine YH)...1474
Table 18. Piston Cooling Jets...1475
Table 19. Crankshaft...1475
Table 20. Main Bearings...1476
Table 21. Crankshaft Thrust Washers...1476
Table 22. Crankshaft Heat Treatment...1476
Table 23. Crankshaft Overhaul Specifications...1477
Table 24. Maximum Variation (Run-out)...1479
Table 25. Camshaft...1479
Table 26. Camshaft Thrust Washer...1479
Table 27. Camshaft Gear...1479
Table 28. Gear for Fuel Injection Pump...1480
Table 29. Crankshaft Gear...1480
Table 30. Idler Gear and Hub...1480
Table 31. Cylinder Block (Engine AR)...1480
Table 32. Cylinder Bore Specifications...1481
Table 33. Cylinder Block (Engines YG and YH)...1482
Table 34. Cylinder Liners (Engines YG and YH)...1482
Table 35. Cylinder Liner Specifications (Partially Finished)...1482
Table 36. Oil Pump (Engine AR)...1483
Table 37. Oil Pump (Engines YG and YH)...1483
Table 38. Idler Gear for Oil Pump...1484
Table 39. Relief Valve...1484
Table 40. Oil Filter...1484
Table 41. Lucas Fuel Injection Pump...1484
Table 42. Fuel Injector Codes...1485
Table 43. Fuel Pump (Engine AR)...1486
Table 44. Fuel Pump (Engines YG and YH)...1486
Table 45. Fuel Filter...1486
Table 46. Coolant Pump...1486
Table 47. Thermostat...1486
Table 48. Fan Drive Housing...1486
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic...1487
Table 50. Alternator...1487
Table 51. Starter Motor...1487
Table 52. Cold Start Aid...1487
Table 53. List of Possible Causes...1495
1493991-1300SRM0930-(02-2001)-UK-EN...1500
toc...1500
Three-Speed Powershift Transmission...1500
Safety Precautions Maintenance and Repair...1501
General...1504
Mechanical Description...1504
General...1504
Torque Converter...1508
Description...1508
Operation...1508
Clutch Assemblies...1509
Description...1509
Operation...1509
Forward and First-Speed Clutch Assembly...1510
Reverse and Second-Speed Shaft, First and Second Gear Shaft...1510
Third-Speed Shaft...1510
Output Shaft...1510
Hydraulic Operation...1512
Sump, Filter and Pump...1512
Transmission Control Valve...1512
Solenoid Valves...1512
Inching Spool...1513
Direction Spools...1513
Range Spool...1513
Modulator Valve...1514
Operation...1514
Modulator Operation...1515
Transmission Control System...1518
Monotrol Pedal...1518
Control Lever...1519
Hydraulic Circuits...1520
Cooling and Lubrication...1520
Neutral...1520
Forward-First...1520
Reverse-First...1523
From First to Second Speed...1524
From Second to Third Speed...1525
Inching...1526
1493992-1300SRM0931-(02-2001)-UK-EN...1530
toc...1530
Three-Speed Powershift Transmission...1530
Safety Precautions Maintenance and Repair...1531
General...1534
Transmission Repair...1537
Remove...1537
Disassemble...1539
Torque Converter Housing and Pump Gears...1539
Transmission Cover, Remove...1540
Clutch Assemblies, Remove...1542
Forward and Low-Speed Clutches...1543
Forward Clutch, Disassemble...1543
First-Speed Clutch, Disassemble...1545
Reverse and Second-Speed Clutches, Disassemble...1545
Second-Speed Clutch, Disassemble...1545
Reverse Clutch, Disassemble...1547
Third-Speed Clutch, Disassemble...1547
Output Gears, Disassemble...1549
Clean...1549
Inspect...1549
Assemble...1551
Output Gears, Assemble...1551
Third-Speed Clutch, Assemble...1551
Reverse and Second-Speed Clutches, Assemble...1551
Second-Speed Clutch, Assemble...1551
Reverse Clutch, Assemble...1554
Forward and First-Speed Clutches, Assemble...1554
Forward Clutch, Assemble...1554
First-Speed Clutch, Assemble...1556
Clutch Assemblies, Install...1556
Input Shaft and Forward Clutch Hub, Install...1557
Transmission Cover, Install...1558
Torque Converter Housing...1560
Install...1562
Control Valve Repair...1564
Remove...1564
Disassemble and Assemble...1565
Clean and Inspect...1565
Install...1565
Modulator Valve Repair...1567
Remove...1567
Disassemble...1567
Clean and Inspect...1567
Install...1567
Transmission Pump Repair...1569
Remove...1569
Disassemble...1569
Clean and Inspect...1569
Assemble...1569
Install...1569
Monotrol Pedal Repair...1571
Remove and Disassemble...1571
Assemble and Install...1571
Inching/Brake Pedal Linkage Adjustment...1573
Stall Test...1574
Transmission Oil Pressure Check...1575
Troubleshooting...1577
tables...1530
Table 1. Transmission Pressures...1576
1493993-1300SRM0932-(12-2004)-UK-EN...1582
toc...1582
Autoshift Transmission Controller...1582
Safety Precautions Maintenance and Repair...1583
General...1586
Autoshift Control Module...1586
Transmission Shift Control Valve...1586
Autoshift Functions...1587
System Interaction With Operator Display...1587
Error Code Descriptions...1587
System Audible Alarm...1587
Park Brake Interlock...1589
System Reset/Override...1589
System Degraded Operating Mode...1589
System Failure Mode...1589
Transmission Oil High-Temperature Fault...1589
Loss of Transmission Oil Pressure Fault...1589
Controller Bypass...1590
Automatic/Manual Shift Mode...1590
Automatic Transmission Shifting...1590
Manual Transmission Shifting...1591
Direction Change...1591
Direction Change Inhibit...1591
Downshift Inhibit...1592
Driveshaft Engagement Inhibit...1592
Lift Height Transmission Interrupt (Optional)...1592
Engine Dethrottle (Optional)...1593
Autoshift Hardware...1593
Autoshift Lever...1593
Speed Sensors...1594
Transmission System Monitor Diagnostics...1595
Controller Parameter Adjustment Software User Interface...1595
User Interface Description...1595
Components Required to Communicate With Controller...1595
Userlink Installation Instructions...1595
Start Procedures...1595
Controller Product Codes...1595
Main Menu Description...1596
Language Selection...1596
Help Menu...1596
PC Serial Communication Port...1597
Monitor Screen...1597
Event Log...1597
Parameter Adjustment...1598
Current Parameters...1598
Load Parameters...1599
Restore Factory Parameters...1599
Load Controller Software from File...1599
Exit Menu...1599
Controller Connector Pin-Out Tables...1601
tables...1582
Table 1. Error Code Descriptions...1588
Table 2. Automatic Transmission Upshift...1590
Table 3. Automatic Transmission Downshift...1591
Table 4. Event Log Descriptions and Values...1598
Table 5. Parameter Descriptions and Values...1599
Table 6. J2 Controller Connector (Black)...1601
Table 7. J1 Controller Connector (Blue)...1602
1494123-0100SRM0927-(01-2006)-UK-EN...1606
toc...1606
Frame...1606
Safety Precautions Maintenance and Repair...1607
General...1610
Description...1610
Counterweight Repair...1610
Remove...1610
Install...1612
Fenders...1612
Remove...1612
Install...1612
Side Counterweights H13.00-16.00XM (H300-360HD)...1612
Side Counterweight, Replace...1612
Hood and Air Cleaner Repair...1613
Remove...1613
Install...1615
Hydraulic Tank Repair...1615
Remove...1615
Repairs, All Units...1616
Small Leaks...1616
Large Leaks...1617
Clean...1617
Steam Method...1617
Chemical Solution Method...1618
Other Methods of Preparation for Repair...1618
Install...1618
Fuel Tank Repair...1619
Remove...1619
Repairs...1619
Install...1619
Cooling System and Radiator Repair...1621
Remove...1621
Install...1622
Engine and Transmission Repair...1623
Hyster T-50 Transmission, Remove...1623
Hyster T-50 Transmission, Install...1624
TE-10 Transmission...1625
Remove...1625
Install...1628
Label Replacement...1630
1494139-0100SRM0935-(09-2004)-UK-EN...1638
toc...1638
Operators Cab...1638
Safety Precautions Maintenance and Repair...1639
General...1642
Cab Repair...1643
Rear Cab Assembly...1643
Bottom Cab Assembly...1644
Raising and Lowering Cab...1644
Raise Cab...1644
Lower Cab...1645
Cab Repair...1645
Remove...1645
Install...1646
Oil Filling for Tilt System...1647
Inching and Brake Pedals...1647
Pedal Adjustment...1647
Inching Cable Adjustment...1647
Throttle Cable Adjustment...1648
Cable Alignment...1649
Engine Side...1649
Pedal Housing Side...1649
Throttle Pedal Sensor...1649
Check...1649
Adjust...1649
Seat Assembly Removal...1650
Power Assist Armrest...1651
Adjust...1651
Steering Column Repair...1651
Remove...1651
Install...1651
Window Wipers Replacement...1652
Window Wiper Assembly, Replace...1652
Front Window Wiper Motor Assembly, Replace...1653
Rear Window Wiper Motor Assembly, Replace...1653
Top Window Wiper Motor Assembly, Replace...1653
Window Washer Motors and Pumps...1654
Window Wiper and Washer Operating Switches...1654
Window Replacement...1654
Front Window, Replace...1655
Rear Window, Replace...1655
Top Window, Replace...1655
Door Window, Replace...1656
Heater and Air Conditioning Assembly...1657
Heater Parts, Replace...1657
Heat Control Knob/Switches...1658
Heat Control Knob/Cable...1658
Adjust...1658
Air Control Knob/Cable...1659
Adjust...1659
Air Filter, Replace...1659
Air Conditioning Condenser Fan(s), Standard...1659
Remove...1659
Install...1660
Air Conditioning Condenser Fan(s), Tropical...1660
Remove...1660
Install...1660
Instruments, Switches, and Controls...1660
Switches...1660
Controls...1661
Fuses and Relays...1662
Fuse Panel...1662
Fuses...1662
Relays...1663
Label Replacement...1664
Electrical Schematics...1664
1494140-1600SRM0936-(03-2007)-UK-EN...1668
toc...1668
Steering System...1668
Safety Precautions Maintenance and Repair...1669
General...1672
Description...1672
Steering Wheel and Column Assembly...1674
General...1674
Steering Wheel and Horn...1674
Remove...1674
Install...1674
Steering Control Unit Repair...1676
General...1676
Description...1676
Operation...1676
Remove...1677
Disassemble...1677
Clean...1680
Assemble and Install...1680
Steering System Air Removal...1686
Steering Relief Pressure Check...1687
Troubleshooting...1687
1494141-1800SRM0937-(03-2007)-UK-EN...1692
toc...1692
Dry Brake System...1692
Safety Precautions Maintenance and Repair...1693
General...1696
Description...1696
Operation...1697
Service Brakes...1697
Parking Brake...1699
Air Tank Repair...1700
Relief Valve...1700
Drain Valve...1700
Brake Pedal Valve Repair...1701
Remove...1701
Disassemble, Inspect, and Assemble...1701
Install...1701
Air Chambers Repair...1702
Remove...1702
Disassemble...1702
Inspect...1703
Assemble...1704
Install...1704
Actuator Arms Repair...1704
Remove...1704
Inspect...1705
Install...1705
Brake Assemblies Repair...1706
Brake Shoe, Remove...1706
Camshaft, Remove...1708
Clean...1708
Inspect...1709
Camshaft, Install...1709
Brake Shoe, Install...1710
Air Dryer...1711
Description...1711
Cartridge...1711
Remove...1711
Install...1711
Filter...1711
Remove...1711
Install...1711
Quick-Release Valve...1713
Governor Check and Adjustment for Air Compressor...1713
Brake Shoes Adjustment...1714
Specifications...1715
Troubleshooting...1715
Service Brakes...1715
Service Brakes, Park Function ...1718
tables...1692
Table 1. Air Chambers Operation...1699
1494142-1900SRM0938-(03-2007)-UK-EN...1722
toc...1722
Hydraulic System...1722
Safety Precautions Maintenance and Repair...1723
General...1726
Description and Operation...1726
Hydraulic Tank...1726
Hydraulic Pump...1727
Steering Priority Flow Valve...1727
Pilot Valve...1728
Main Control Valve...1730
Unloader Valve...1731
Hydraulic Operation...1732
Checks and Adjustments...1735
Quick Disconnect Fittings...1735
Steering Priority Flow Valve...1735
Steering Relief Pressure...1735
Modulator Valve...1736
Pilot Valve and Pressure Reducing Valve...1736
Accumulator...1737
Filter...1737
Main Control Valve...1737
Relief Pressure Check...1737
Check Valves...1738
Unloader Valve...1738
Hydraulic Pump Repair...1739
Remove...1739
Disassemble...1739
Clean and Inspect...1739
Assemble...1740
Install...1741
Pilot Accumulator Replacement ...1741
Remove...1741
Install...1741
Pilot Valve Repair...1742
Remove...1742
Disassemble...1743
Clean and Inspect...1743
Assemble...1743
Install...1743
Control Levers and Joystick Repair...1744
Remove...1744
Install...1744
Calibration and Diagnostics...1745
General...1745
Description...1745
Lever and Joystick Calibration...1745
Flow Adjustment...1745
Dead Band Value Setting...1746
Lowering Delay...1747
PWM and I/O Module Readouts...1747
Function Disable...1748
General Startup...1748
Minimum system requirements...1748
Install the Hydraulic Controls Program...1748
DelayTimeFile (Reset)...1748
Select the Processor Speed...1749
Hydraulic Controls Program...1749
Calibration...1751
Joystick/Lever Calibration...1751
Levers...1751
Joystick...1751
Valve Flow Adjustment...1752
Diagnostics...1752
Calibration System Shutdown...1752
LED Diagnostics...1753
Electrical Connections...1756
Specifications...1760
tables...1722
Table 1. Main Control Valve Port Settings...1728
Table 2. Processor Speed Settings...1748
Table 3. PWM Board LED Error Codes...1753
Table 4. Altering PT FLT I/O Board LED's (Old Logic)...1754
Table 5. Altering PT FLT I/O Board LED's (New Logic)...1754
Table 6. Fixed PT Logic I/O Boards LED's...1755
Table 7. ECH...1755
Table 8. PWM Driver Module...1756
Table 9. Input/Output Module 1...1757
Table 10. Input/Output Module 2...1758
Table 11. Altering PT FLT...1759
Table 12. Fixed PT FLT...1759
Table 13. ECH...1760
1494143-2200SRM0939-(12-2004)-UK-EN...1764
toc...1764
Instrument Panel Indicators and Senders...1764
Safety Precautions Maintenance and Repair...1765
General...1768
Description...1768
General...1768
Instrument Panel Meters, Indicators, and LCD Display...1768
Error Code Display, Transmission...1775
Error Code Display, Engine...1776
Connector...1777
Seat Switch Logic...1777
Central Warning Light Output...1779
Buzzer Output...1779
Engine Shutdown Output...1779
Instrument Panel Component Replacement...1782
Instrument Panel...1782
Remove...1782
Light...1783
Replace...1783
Sender Replacement...1783
Fuel Level Sender...1783
Transmission Pressure and Temperature Sender, Tier 1...1784
Pressure Sender, Tier 2...1785
Temperature Sender, Tier 2...1785
Low Coolant Sender...1785
Vacuum Switch...1785
Crankshaft Position Sensor...1786
Specifications...1786
Troubleshooting...1788
tables...1764
Table 1. Instrument Panel and Indicators...1769
Table 2. Engine Error Code Descriptions...1777
Table 3. Pin Description...1778
Table 4. Sender Description...1779
1494144-8000SRM0934-(08-2001)-UK-EN...1792
toc...1792
Periodic Maintenance...1792
Safety Precautions Maintenance and Repair...1793
General...1796
How to Move Disabled Lift Truck...1796
How to Tow Lift Truck...1796
How to Put Lift Truck on Blocks...1797
How to Raise Drive Tires...1797
How to Raise Steering Tires...1797
Maintenance Schedule...1798
Maintenance Procedures Every 8 Hours or Daily...1807
How to Make Checks with Engine Stopped...1807
Tires and Wheels...1808
Forks...1809
Adjust...1809
Remove...1809
Install...1809
Forks, Mast, and Lift Chains, Inspect...1809
Safety Labels...1810
Operator Restraint System...1810
Steering Column Latch...1811
Drive Belts...1811
Cooling System...1811
Fuel, Oil, or Coolant Leaks, Check...1812
Cab Hydraulic System...1812
Hydraulic System...1812
Engine Oil...1813
Fuel System...1813
Primary Fuel Filter...1814
Battery...1814
Air Filter...1814
How to Make Checks with Engine Running...1814
Gauges, Lights, Horn, and Fuses...1814
Control Levers and Pedals...1815
Transmission Oil...1815
Lift System Operation...1816
Brakes...1816
Steering System...1817
Maintenance Procedures Every 250 Hours or Every 2 Months...1817
Engine Oil and Filter - Cummins Engine...1817
Empty Container Handler...1817
Maintenance Procedures Every 500 Hours or Every 2 Months...1817
Lift Chains...1817
Lubrication...1817
Adjust...1817
Drive Shaft...1818
Steering Axle...1818
Wheel Nuts...1818
Shafts for Brake Actuators...1818
Drive Axle and Differential...1818
Hydraulic Tank Breather...1819
Air Filter, Engine, and Air Compressor...1819
Cabin Air Filter, Heater...1819
Engine Oil and Filter - Perkins Engine...1819
Drive Belts...1819
Mast...1819
General Lubrication...1821
Forks Wear and Damage Check...1821
Lift Chains Wear Check...1821
Fuel System...1821
Idle Speed...1821
Governor Speed (Diesel)...1821
Maintenance Procedures Every 1000 Hours or 6 Months...1823
Transmission Oil and Filter, Change...1823
Final Fuel Filters, Diesel...1823
Diesel Fuel System Air Removal...1823
Fuel Injection Pump Without Vent Tube...1824
Fuel Injection Pump Timing...1824
Valve Adjustment...1824
Maintenance Procedures Every 2000 Hours or Yearly...1826
Hydraulic System...1826
Hydraulic Oil Filter, Change...1826
Hydraulic Oil, Change...1826
Differential and Drive Axle...1826
Wheel Bearings...1826
Steer Wheels...1826
Drive Wheels...1826
Service Brakes...1827
Cleaning Procedures (Dry Brake Axle)...1827
Safety Procedures When Working Near Mast...1827
Fuel Injectors Check...1828
Lift and Tilt System Leak Check...1829
Lift System...1829
Tilt System...1829
Welding Repairs...1830
Wheel and Tire Replacement...1831
Remove Wheels from Lift Truck...1831
Pneumatic Tires...1831
Remove Tire from Wheel...1831
Remove Tire from Three- and Four-Piece Wheel...1832
Install Tire on Wheel...1833
Install Three- or Four-Piece Wheel in Tire...1833
Add Air to Tires...1834
Solid Rubber Tires...1835
Remove Tire from Wheel...1835
Install Tire on Wheel...1836
Wheels, Install...1838
tables...1792
Table 1. Maintenance Schedule...1799
Table 2. Maintenance Schedule (Empty Container Handler Model 553...1804
Table 3. Maintenance Schedule (Empty Container Handler Model 555...1805
Table 4. Maintenance Schedule (Empty Container Handler Model 558...1806
Table 5. Allowable Mast Movement from Internal Leakage...1830
1494145-8000SRM0940-(03-2008)-UK-EN...1842
toc...1842
Capacities and Specifications...1842
Safety Precautions Maintenance and Repair...1843
Lift Truck Weights...1846
Capacities...1846
Engine Specifications...1847
Perkins Diesel...1847
Cummins Diesel/LPG...1848
Hydraulic System...1849
Electrical System...1850
Tire Sizes...1850
Mast Speeds...1850
Perkins Diesel...1850
Cummins Diesel/LPG...1851
Torque Specifications, Cummins Diesel...1852
Lubrication System...1852
Torque Specifications, Perkins Diesel...1852
Engine...1852
Cylinder Head Assembly...1852
Piston and Connecting Rod Assemblies...1852
Crankshaft Assembly...1852
Timing Case and Drive Assembly...1853
Turbocharger...1853
Lubrication System...1853
Fuel System...1853
Cooling System...1853
Flywheel and Housing...1853
Aspiration System...1854
Electrical Equipment...1854
Auxiliary Equipment...1854
Torque Specifications - Perkins, Tier 2...1854
Cylinder Head Assembly...1854
Piston and Connecting Rod Assemblies...1854
Crankshaft Assembly...1854
Timing Case and Drive Assembly...1854
Turbocharger...1855
Lubrication System...1855
Fuel System...1855
Cooling System...1855
Flywheel...1855
Auxiliary Equipment...1855
Torque Specifications, General...1856
Transmission...1856
Driveline and Axle...1856
Differential...1856
Brakes - Wet...1856
Brakes - Dry...1856
Steering...1856
Hydraulic System...1857
Mast...1857
Carriage...1857
Tilt Cylinders...1857
Frame...1857
Wiper Arms, Front...1857
Hyster T-50 Transmission Pressures (Powershift and Automatic)...1858
TE-10 Transmission Specifications...1859
Electrical...1859
Hydraulic Cooler Lines...1859
Torque Specifications for Lubricated or Plated Screw Threads...1860
tables...1842
Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp...1859
Table 2. Grade 5...1860
Table 3. Grade 8...1860
Table 4. Grades 8.8, 10.9, and 12.9...1860
Table 5. O-ring Port Plug Torque Chart...1861
Table 6. Pipe Plug Torque Chart...1861
1494146-8000SRM0941-(01-2006)-UK-EN...1864
toc...1864
Diagrams...1864
Safety Precautions Maintenance and Repair...1865
General...1868
Description...1868
1494953-1400SRM0944-(03-2007)-UK-EN...1926
toc...1926
Planetary Drive Axle...1926
Safety Precautions Maintenance and Repair...1927
General...1930
Description...1930
Operation...1932
Identification...1932
Removal...1933
Disassembly...1933
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1933
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1935
Wheel End...1937
Spindle and Piston Housing...1938
Cleaning...1939
Clean Ground or Polished Parts...1939
Clean Parts With Rough Finish...1939
Clean Axle Assemblies...1939
Drying Cleaned Parts...1939
Corrosion Prevention...1939
Parts Inspection...1940
Tapered Roller Bearings...1940
Bevel Pinion and Ring Gear Sets...1941
Main Differential Assembly...1941
Axle Shafts...1941
Yoke...1941
Brakes...1941
Repair or Replace Parts...1941
Repair Welding...1941
Apply Silicone Gasket Material...1942
Assembly...1942
Spindle and Piston Housing to Axle Housing...1942
Wet Disc Brakes...1943
Adjust Wheel Bearing Preload...1944
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1945
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1946
Planetary Spider Assembly...1946
Installation...1947
Fill Wet Disc Brakes With Hydraulic Fluid...1947
Torque Specifications...1948
Lubrication Specification...1949
1494955-2000SRM0943-(03-2007)-UK-EN...1952
toc...1952
Main Control Valve...1952
Safety Precautions Maintenance and Repair...1953
General...1956
Description...1956
Operation...1959
Lift Section...1959
Tilt/Auxiliary Section...1959
Relief Valves...1959
Unloader Valve...1959
Main Control Valve Repair...1962
Remove...1962
Disassemble...1962
Auxiliary Side...1962
Lift Side...1962
Clean and Inspect...1965
Assemble...1965
Auxiliary Side...1965
Lift Side...1965
Install...1965
Pressure Relief Valve Check and Adjustment...1966
Check and Adjust...1966
Replace...1966
Specifications...1967
Troubleshooting...1967
1498445-1400SRM0945-(03-2007)-UK-EN...1972
toc...1972
Planetary Drive Axle...1972
Safety Precautions Maintenance and Repair...1973
General...1976
Description...1976
Operation...1978
Identification...1978
Removal...1979
Disassembly...1979
Brake Drum...1979
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1980
Dry Brakes...1982
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1982
Spindle and Brake Spider...1984
Cleaning...1985
Ground or Polished Parts...1985
Parts With Rough Finish...1985
Axle Assemblies...1985
Drying Cleaned Parts...1985
Corrosion Prevention...1985
Parts Inspection...1986
Tapered Roller Bearings...1986
Bevel Pinion and Ring Gear Sets...1987
Main Differential Assembly...1987
Axle Shafts...1987
Yoke...1987
Brakes...1987
Repair or Replace Parts...1987
Repair Welding...1987
Apply Silicone Gasket Material...1988
Assembly...1988
Spindle, Brake Spider, and Brake...1988
Wheel End...1989
Adjust Wheel Bearing Preload...1990
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1991
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1992
Planetary Spider Assembly...1992
Installation...1993
Torque Specifications...1994
Lubrication Specification...1995
1498450-1800SRM0951-(03-2007)-UK-EN...1998
toc...1998
Wet Brake System...1998
Safety Precautions Maintenance and Repair...1999
General...2002
Description and Operation...2002
Service Brakes...2002
Parking Brake...2002
Oil Cooler Circuit...2002
Pressure Switch Replacement...2006
Accumulators Replacement...2006
Brake Treadle Valve Repair...2006
Remove and Disassemble...2006
Clean and Inspect...2007
Assemble and Install...2007
Parking Brake Valve Repair...2007
Remove...2007
Clean and Inspect...2007
Repair...2007
Install...2007
Parking Brake Caliper Repair...2008
Remove...2008
Disassemble...2010
Inspect...2010
Install...2010
Adjust...2010
Brake Pad Repair...2011
Inspect...2011
Remove...2011
Install...2011
Seals Repair...2011
Remove...2011
Install...2012
Service Brake Repair...2012
Remove and Disassemble...2012
Drain Lubricating Oil...2012
Drain Coolant Oil...2019
Disconnect Brake Lines...2019
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14...2019
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...2020
Brake Disc Housing Assembly Wheel End...2021
Brake Piston Housing...2022
Brake Piston Housing and Wheel Spindle...2023
Inspect...2023
Clean...2025
Assemble...2026
Wheel Spindle...2026
Brake Piston Housing...2026
Piston Assembly...2028
Brake Disc Housing...2028
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub...2030
Check for Correct Installation of Duo-Cone Seal...2031
Wheel Hub to Brake Disc Housing...2032
Adjust...2033
Fill Brake System With Coolant Oil...2033
System Air Removal...2034
Adjust Brake With New Disc Pack...2034
Coolant Change Intervals...2035
Coolant Draining and Filling...2035
Specifications...2037
Minimum Brake Disc Thickness...2040
Hydraulic Fluid for Brake Actuation...2040
Brake Coolant Specifications...2040
Coolant Change Intervals...2040
Hydraulic Fluid Specifications...2040
Troubleshooting...2040
Brake Does Not Apply...2040
Brake Does Not Release...2041
Brake Performance...2041
Brake Leaks Actuation Fluid...2042
Brake Cooling Fluid Leakage...2043
Brake Noise and Vibration...2043
Brake Overheats...2043
tables...1998
Table 1. Brake Pad Adjustment...2010
Table 2. Minimum Brake Disc Thickness...2024
Table 3. Formed Seal Wear Chart...2024
1503241-5000SRM0969-(03-2007)-UK-EN...2048
toc...2048
Empty Container Handling Attachment...2048
Safety Precautions Maintenance and Repair...2049
General...2052
Description...2052
Operation...2057
General...2057
Selector Valves...2057
Sideshift Circuit...2057
Extend and Retract Circuit...2057
Twist Lock Circuit and Control...2058
Model 553 - Horizontally Mounted...2058
Model 558 - Vertically Mounted...2058
Lifting Hooks...2058
Model 555...2058
Indicator Lights and LEDs...2058
Lift Interrupt and Override...2059
Overlowering Interrupt and Override...2059
Carriage and Attachment Repair...2059
Remove...2059
Attachment Without Carriage Repair...2060
Remove...2060
Sideshift Cylinders Repair...2061
Remove...2061
Disassemble...2061
Assemble...2061
Extension Cylinders Repair...2062
Remove...2062
Disassemble...2062
Clean and Inspect...2062
Assemble...2062
Install...2062
Vertical End Beams Repair...2064
Remove...2064
Install...2064
Hose Replacement in End Beams...2064
Twist Locks Repair for Model 553...2065
Remove...2065
Disassemble...2065
Clean and Inspect...2065
Assemble...2065
Hooks Replacement for Model 555...2066
Inspect...2066
Remove...2066
Install...2066
Twist Locks Repair for Model 558...2067
Disassemble...2067
Clean and Inspect...2067
Assemble...2067
Bleed the System...2068
Valve Assembly...2068
Slide Pad Replacement...2069
Adjustments...2069
Twist Lock Angle Adjustment...2069
Model 558 Only...2069
LOCKED/NOT LOCKED Sensors Adjustment...2070
Model 553...2070
Model 558...2070
Seated Sensor Adjustment...2070
Model 553...2070
Model 558...2070
Overlowering Protection Sensor Adjustment (Models 553 and 558)...2070
Torque Chart...2071
Maintenance...2071
Additional Attachment Maintenance...2073
Interface Boxes...2074
Model 555...2074
Models 553 and 558...2074
Troubleshooting...2076
tables...2048
Table 1. Torque Chart...2071
Table 2. Inspect and Adjust (See Figure 14 )...2072
Table 3. Lubricate (See Figure 14 )...2073
Table 4. Replace (See Figure 14 )...2073
1538764-8000SRM1066-(09-2005)-UK-EN...2094
toc...2094
Periodic Maintenance...2094
Safety Precautions Maintenance and Repair...2095
General...2098
How to Move Disabled Lift Truck...2098
How to Tow Lift Truck...2098
How to Put Lift Truck on Blocks...2099
How to Raise Drive Tires...2099
How to Raise Steering Tires...2099
Maintenance Schedule...2101
Empty Container Attachment Maintenance...2107
Maintenance Procedures Every 8 Hours or Daily...2109
How to Make Checks With Engine Stopped...2109
Hydraulic System Oil...2109
Engine Oil...2109
Cooling System...2110
Fuel System...2111
Water Separator/Fuel Filter...2111
Fuel, Oil, or Coolant Leaks, Check...2111
Cab Hydraulic System...2111
Drive Belts...2112
Battery...2112
Air Filters...2112
Forks...2112
Adjust...2112
Remove...2112
Install...2112
Forks, Mast, and Lift Chains, Inspect...2113
Tires and Wheels...2114
Operator Restraint System...2114
Steering Column Latch...2115
Safety Labels...2115
How to Make Checks With Engine Running...2116
Gauges, Lights, Horn and Fuses...2116
Control Levers and Pedals...2118
Transmission Oil...2118
Lift System Operation...2118
Brakes...2118
Steering System...2118
Attachments...2118
Maintenance Procedures Every 250 Hours or Every 2 Months...2119
Empty Container Handler...2119
Maintenance Procedures Every 500 Hours or Every 3 Months...2119
Lift Chains...2119
Lubrication...2119
Adjust...2119
Drive Shaft...2120
Steering Axle...2120
Wheel Nuts...2120
Shafts for Brake Actuators...2120
Drive Axle and Differential...2120
Hydraulic Tank Breather...2120
Air Filter, Engine, and Air Compressor...2120
Cabin Air Filter, Heater...2120
Engine Oil and Filter...2120
Drive Belts...2121
Mast...2121
General Lubrication...2122
Fork Wear and Damage Check...2122
Lift Chains Wear Check...2123
Maintenance Procedures Every 1000 Hours or 6 Months...2123
Transmission Oil and Filter, Change...2123
Fuel Filter...2124
Diesel Fuel System Air Removal...2124
Fuel Injection Pump Without Vent Tube...2124
Fuel Injection Pump Timing...2125
Valve Adjustment...2125
Pilot Accumulator Pressure Charge Check...2126
Maintenance Procedures Every 2000 Hours or Yearly...2126
Hydraulic System...2126
Hydraulic Oil Filter, Change...2126
Hydraulic Oil, Change...2126
Differential and Drive Axle...2127
Wheel Bearings...2127
Steer Wheels...2127
Drive Wheels...2128
Service Brakes...2128
Cleaning Procedures (Dry Brake Axle)...2128
Safety Procedures When Working Near Mast...2128
Fuel Injectors Check...2130
Perkins...2130
Lift and Tilt System Leak Check...2130
Lift System...2130
Tilt System...2130
Welding Repairs...2131
Wheel and Tire Replacement...2132
Remove Wheels From Lift Truck...2132
Pneumatic Tires...2132
Remove Tire From Wheel...2132
Remove Tire From Three- and Four-Piece Wheel...2133
Install Tire on Wheel...2134
Install Three- or Four-Piece Wheel in Tire...2134
Add Air to Tires...2135
Solid Rubber Tires...2136
Remove Tire From Wheel...2136
Install Tire on Wheel...2137
Wheels, Install...2139
tables...2094
Table 1. Daily Inspections − Condition Check...2101
Table 2. Daily Inspections − Fluid Level Check...2102
Table 3. Daily Inspections − Checks With the Engine Running...2102
Table 4. First Inspection After First 100 Hours of Operation...2103
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...2104
Table 6. Periodic Maintenance Schedule − Lubricate...2105
Table 7. Periodic Maintenance Schedule − Change...2105
Table 8. Empty Container Attachment Maintenance − Inspect and ...2108
Table 9. Empty Container Attachment Maintenance − Lubricate...2108
Table 10. Allowable Mast Movement from Internal Leakage...2131
1541323-0600SRM1068-(05-2004)-UK-EN...2142
toc...2142
Perkins Tier 2 Diesel Engines...2142
Safety Precautions Maintenance and Repair...2143
General...2150
General Safety Rules...2150
Description...2151
Engine Serial Number Codes...2153
Engine Data...2153
Engine Removal and Installation...2154
Cylinder Head Assembly Repair...2154
Valve Cover...2154
Remove...2154
Install...2155
Rocker Arm Assembly...2155
Remove...2155
Disassemble...2155
Inspect...2155
Assemble...2155
Install...2155
Valve Clearance Adjustments...2156
Valve Springs...2157
Cylinder Head Assembly...2158
Remove...2158
Install...2160
Valves and Valve Springs...2163
Remove...2163
Inspect...2163
Install...2164
Valve Guides...2164
Inspect...2164
Remove...2164
Install...2164
Cylinder Head and Valve Seats...2165
Inspect...2165
Repair...2166
New Valve Seats, Install...2166
Piston and Connecting Rod Assemblies Repair...2166
Rod Bearings...2167
Remove...2167
Install...2167
Piston and Connecting Rod Assembly...2168
Service Note...2168
Remove...2168
Install...2169
Piston Rings...2170
Remove...2170
Inspect...2170
Install...2171
Piston and Connecting Rod...2171
Disassemble...2171
Inspect...2171
How to Select Correct Replacements...2172
Install...2173
Piston Cooling Jets...2173
Remove...2173
Install...2174
Crankshaft Assembly Repair...2174
General...2174
Crankshaft Pulley...2175
Remove...2175
Inspect...2175
Install...2175
Rear Oil Seal...2176
Remove...2176
Install...2176
Main Bearings...2177
Remove...2177
Inspect...2178
Install...2178
Thrust Washers...2178
Crankshaft Axial Movement, Check...2178
Remove...2179
Install...2179
Crankshaft...2180
Remove...2180
Inspect...2180
Install...2181
Flywheel...2182
Remove...2182
Ring Gear, Replace...2182
Install...2182
Flywheel Housing...2183
Remove...2183
Install...2183
Timing Case and Timing Gears Repair...2184
General...2184
Timing Case Cover...2184
Remove...2184
Install...2185
Front Oil Seal...2185
Remove...2185
Install...2185
Crankshaft Pulley Wear Sleeve...2186
Install...2186
Idler Gear and Hub...2186
Remove...2186
Install...2187
Air Compressor Drive, Bendix...2188
Disassemble...2188
Assemble...2188
Fuel Injection Pump Gear...2189
Remove...2189
Install...2190
Camshaft Gear...2190
Remove...2190
Install...2191
Crankshaft Gear...2191
Remove...2191
Install...2192
Timing Case...2192
Remove...2192
Install...2192
Camshaft and Tappets...2193
Remove...2193
Install...2194
Cylinder Block Assembly Repair...2194
Description...2194
Cylinder Block...2194
Disassemble...2194
Inspect...2195
Assemble...2195
Cylinder Liner...2196
Inspect...2196
Cylinder Liner Condition, Check...2196
Remove...2197
Service Liner, Install...2198
Partially Finished Liner, Install...2199
Engine Timing...2200
Description...2200
How to Set Number One Piston to TDC on Compression Stroke...2201
How to Set Number One Piston to TDC on Compression Stroke (Alter...2202
How to Set Number One Piston to 4° After TDC on Compression Stro...2203
Valve Timing, Check...2204
Fuel Injection Pump Timing, Check...2205
Turbocharger...2205
General...2205
Remove...2205
Install...2206
Impeller and Compressor Housing, Clean...2206
Waste-Gate Valve Check...2207
Closed Circuit Breather System (CCB)...2208
CCB Assembly, Remove...2208
Closed Circuit Drain Valve, Remove...2208
CCB Assembly, Install...2208
Closed Circuit Drain Valve, Install...2208
Lubrication System Repair...2209
General...2209
Oil Filter, Replace...2209
Oil Filter Head...2209
Remove...2209
Install...2209
Oil Filter Head Bypass Valve...2210
Remove and Install...2210
Oil Sump...2210
Remove...2210
Install...2210
Oil Pump...2211
Remove...2211
Inspect...2211
Install...2212
Relief Valve...2213
Remove...2213
Disassemble...2213
Inspect...2213
Assemble...2213
Install...2213
Idler Gear Shaft, Replace...2213
Remove...2214
Remove (Alternative)...2214
Install...2215
Install (Alternative)...2215
Fuel System Repair...2216
Description...2216
Fuel Injection Pump...2218
Remove...2218
Install...2220
Fuel System Air Removal...2221
Fuel Filter, Replace...2223
Fuel Injectors...2223
Remove...2224
Inspect...2224
Install...2224
Fuel Lift Pump...2225
Remove...2225
Disassemble...2225
Assemble...2225
Install...2226
Test...2226
Cooling System Repair...2227
General...2227
Thermostat...2227
Remove...2227
Install...2228
Test...2228
Coolant Pump...2228
Remove...2228
Disassemble...2229
Assemble...2231
Install...2233
Fan and Fan Drive...2234
Remove...2234
Install...2234
Oil Cooler...2234
Remove...2234
Disassemble and Assemble...2235
Install...2235
Electrical Equipment Repair...2236
Drive Belts...2236
Alternator...2236
Remove...2236
Install...2236
Electronic Control Module (ECM)...2237
Remove...2237
Inspect...2237
Install...2237
Voltage Load and Protection Module (VLPM)...2238
Remove...2238
Install...2238
Engine Speed and Timing Sensor...2238
Remove...2238
Install...2239
Pressure Sensors (Engine Oil and Air Intake)...2239
Remove...2239
Install...2240
Temperature Sensor...2240
Remove...2240
Install...2241
Starter Motor...2241
Remove...2241
Install...2241
Cold Start Aid...2241
Air Compressor...2241
General...2241
Repair...2242
Remove...2242
Install...2242
Rotary Exhauster Replacement...2243
Remove...2243
Clean...2243
Install...2243
Engine Specifications...2244
Cylinder Head Assembly...2244
Piston and Connecting Rods...2247
Crankshaft Assembly...2248
Crankshaft Overhaul...2249
Timing Case and Drive Assembly...2251
Engine Block Assembly...2252
Turbocharger...2253
Lubrication System...2254
Cooling System...2256
Flywheel and Housing...2256
Electrical Equipment...2256
Torque Specifications...2257
Cylinder Head Assembly...2257
Piston and Connecting Rod Assemblies...2257
Crankshaft Assembly...2257
Timing Case and Drive Assembly...2257
Turbocharger...2257
Lubrication System...2257
Fuel System...2257
Cooling System...2258
Flywheel...2258
Auxiliary Equipment...2258
Special Torque Specifications...2258
Flywheel and Housing...2258
Electrical Equipment...2258
Auxiliary Equipment...2258
Special Tools...2259
Troubleshooting...2264
Turbocharger Troubleshooting...2266
tables...2142
Table 1. Cylinder Head...2244
Table 2. Valve Guides...2244
Table 3. Inlet Valves...2245
Table 4. Exhaust Valves...2245
Table 5. Valve Springs...2246
Table 6. Tappets...2246
Table 7. Rocker Arm Shaft...2246
Table 8. Rocker Arms and Bushings...2246
Table 9. Pistons...2247
Table 10. Piston Rings...2247
Table 11. Piston Pins...2247
Table 12. Connecting Rods...2247
Table 13. Small End Bushings...2248
Table 14. Connecting Rod Bearings...2248
Table 15. Piston Cooling Jets...2248
Table 16. Crankshaft...2248
Table 17. Main Bearings...2249
Table 18. Crankshaft Thrust Washers...2249
Table 19. Crankshaft Heat Treatment...2249
Table 20. Crankshaft Overhaul Specifications...2249
Table 21. Maximum Variation (Run-Out)...2251
Table 22. Camshaft...2251
Table 23. Camshaft Thrust Washer...2251
Table 24. Camshaft Gear...2251
Table 25. Gear for Fuel Injection Pump...2251
Table 26. Crankshaft Gear...2252
Table 27. Idler Gear and Hub...2252
Table 28. Cylinder Block...2252
Table 29. Cylinder Liners...2252
Table 30. Cylinder Liner Specifications (Partially Finished)...2253
Table 31. Oil Pump...2254
Table 32. Idler Gear for Oil Pump...2254
Table 33. Relief Valve...2254
Table 34. Oil Filter...2254
Table 35. Bosch Fuel Injection Pump...2254
Table 36. Fuel Injector Codes...2255
Table 37. Fuel Pump...2256
Table 38. Fuel Filter...2256
Table 39. Coolant Pump...2256
Table 40. Thermostat...2256
Table 41. Fan Drive Housing...2256
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic...2256
Table 43. Alternator...2256
Table 44. Starter Motor...2256
Table 45. Cold Start Aid...2256
Table 46. List of Possible Causes...2264
Table 47. List of Possible Causes...2266
1553599-4000SRM1062-(03-2007)-UK-EN...2270
toc...2270
Masts and Carriages...2270
Safety Precautions Maintenance and Repair...2271
General...2274
Description...2274
Operation...2275
Two-Stage Mast...2275
Three-Stage Mast...2276
Safety Procedures When Working Near Mast...2277
Forks Repair...2280
Remove...2280
Inspect and Adjust...2280
Install...2280
Carriage Repair...2281
Description...2281
Three Function...2281
Four to Six Function...2281
Remove...2281
Disassemble...2282
Clean and Inspect...2284
Assemble...2284
Install...2284
Sideshift Cylinder Repair...2285
Remove...2285
Disassemble...2285
Clean and Inspect...2285
Assemble...2285
Install...2285
Fork Positioner Cylinders Repair...2289
Remove...2289
Disassemble...2289
Clean and Inspect...2289
Assemble...2289
Install...2289
Directional Control Valve Repair...2296
Remove...2296
Disassemble...2296
Clean and Inspect...2296
Assemble...2297
Install...2297
Mast Repair...2297
Two- and Three-Stage Mast...2297
Remove...2297
Disassemble...2302
Clean and Inspect...2304
Assemble...2305
Install...2306
Three-Stage Mast (Four Cylinders)...2306
Remove...2306
Disassemble...2308
Clean and Inspect...2310
Assemble...2310
Install...2310
Fork Carriage Chains...2312
Adjust...2312
Bearing Rollers...2314
Description...2314
Lubrication...2314
Clearance...2314
Remove and Disassemble...2314
Assemble...2315
Mast Profile...2315
Lift Cylinders Description...2315
Piston-Type Cylinders...2315
Displacement-Type Cylinders...2315
Lift Cylinders Repair...2316
Remove...2316
Disassemble...2318
Clean and Inspect...2318
Assemble...2318
Install...2319
Mast Operation Check...2319
Lift and Tilt System Leak Checks...2320
Lift System...2320
Tilt System...2320
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...2321
Lift Chain Adjustments...2321
Mast Adjustments...2322
Bearing Blocks, Two-Stage Masts...2322
Wear Plates...2322
Carriage Adjustment...2322
Troubleshooting...2324
tables...2270
Table 1. Allowable Mast Movement from Internal Leakage...2320
1553764-0600SRM1072-(06-2005)-UK-EN...2328
toc...2328
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...2328
Safety Precautions Maintenance and Repair...2329
Electronic Troubleshooting...2352
System Operation...2352
Electronic Controls...2352
Engine Governor...2353
Timing Considerations...2353
Fuel Injection...2353
Diagnostic Codes...2353
Diagnostic Fault Codes...2353
Diagnostic Event Codes...2353
Programmable Parameters...2354
Passwords...2354
Electronic Service Tools...2354
Electronic Service Tool (EST)...2354
Connecting the Electronic Service Tool and the Communication Ada...2354
Support for the Electronic Service Tool...2355
Optional Service Tools...2355
Diagnostic Codes...2355
Diagnostic Fault Code Access Via Indicator Lamps...2359
Replacing the ECM...2360
Self Diagnostics...2361
Glossary...2362
Sensors and Electrical Connectors...2365
Engine Wiring Information...2368
Harness Wire Identification...2371
Diagnostic Code Reader...2371
General...2371
Reference Documents...2371
Abbreviations...2371
Environmental Specification...2371
Hardware...2372
Connection Cable...2373
Software...2373
Engine Communication...2373
User Controls...2373
Power Supply...2373
Display Screen...2374
Operation Controls...2374
Audible Warning...2374
Operation Instructions...2374
How to Connect the Diagnostic Code Reader to the Engine...2374
How to Turn ON the Diagnostic Code Reader...2374
How to use the Display Screen...2374
How to Operate the Diagnostic Code Reader...2375
Main Menu...2375
Active Codes...2375
Inactive Codes...2376
How to Clear Codes...2376
Status Lamp...2376
Data List...2377
Diagnostics...2377
Programming Parameters...2378
Passwords...2378
Factory Passwords...2378
Customer Passwords...2379
Flash Programming...2379
Flash Programming a Personality Module...2379
WinFlash Error Messages...2379
System Configuration Parameters...2380
Full Load Setting...2380
Full Torque Setting...2380
Rating Interlock...2380
Engine Serial Number...2380
ECM Software Release Date...2380
Troubleshooting Without a Diagnostic Code...2381
Alternator Noise (Noisy Operation)...2381
Probable Causes...2381
Recommended Actions...2381
Alternator Drive Belts...2381
Alternator Drive Pulley...2381
Alternator Bearings...2381
Alternator Will Not Charge (Charging Problem)...2381
Probable Causes...2381
Recommended Actions...2381
Alternator Drive Belts...2381
Charging Circuit...2381
Alternator or Regulator...2381
Battery...2381
Probable Causes...2381
Recommended Actions...2381
Faulty Battery...2381
Auxiliary Device...2381
Cannot Reach Top Engine RPM...2382
Probable Causes...2382
Recommended Actions...2382
Diagnostic Codes...2382
Fuel Supply...2382
Air Intake and Exhaust System...2382
Individual Malfunctioning Cylinders...2382
Valve Lash...2382
Check for Low Compression...2382
Check the Fuel Injection Nozzles...2383
Check the Turbocharger...2383
ECM Parameters...2383
Check the Signal for the Throttle Position Sensor...2383
Coolant in Engine Oil...2383
Probable Causes...2383
Recommended Actions...2383
Engine Oil Cooler Core...2383
Cylinder Head Gasket...2383
Cylinder Head...2384
Cylinder Block...2384
Coolant Temperature Is Too High...2384
Probable Causes...2384
Recommended Actions...2384
Radiator Fins...2384
Coolant Level...2384
Radiator Cap and/or Pressure Relief Valve...2384
Combustion Gases in the Cooling System...2384
Water Temperature Regulator...2384
Restriction in the Coolant System...2384
Coolant Temperature Gauge...2384
Coolant Pump...2384
Excessive Load on the System...2385
ECM Will Not Accept Factory Passwords...2385
Probable Causes...2385
Recommended Actions...2385
ECM Will Not Communicate With Other Systems or Display Modules...2385
Probable Causes...2385
Recommended Actions...2385
Electronic Service Tool Will Not Communicate With ECM...2385
Probable Causes...2385
Recommended Actions...2385
Engine Cranks but Will Not Start...2386
Probable Causes...2386
Recommended Actions...2386
Diagnostic Codes...2386
Visual Checks...2386
Crank Without Injection...2386
Starting Motor Solenoid or Starting Circuit...2386
Valve Lash...2386
Fuel Injection Nozzles...2387
Air Inlet Heater Starting Aid...2387
Air Intake and Exhaust System...2387
Low Compression...2387
Fuel Supply...2387
Engine Has Early Wear...2387
Probable Causes...2387
Recommended Actions...2387
Dirt in Engine Oil...2387
Leaks in Air Intake System...2387
Low Oil Pressure...2388
Engine Misfires, Runs Rough or Is Unstable...2388
Probable Causes...2388
Recommended Actions...2388
Logged Codes...2388
Fuel Supply...2388
Air Intake and Exhaust System...2388
Individual Malfunctioning Cylinders...2388
Valve Lash...2388
Check for Low Compression...2389
Check the Fuel Injection Nozzles...2389
Check the Air Inlet Heater Starting Aid...2389
Check the Engine Speed/Timing Sensors...2389
Check the Signal for the Throttle Position Sensor...2389
Check the Fuel Injection Pump...2389
Engine Oil in Cooling System...2389
Probable Causes...2389
Recommended Actions...2390
Engine Oil Cooler Core...2390
Cylinder Head Gasket...2390
Cylinder Head...2390
Engine Speed Does Not Change...2390
Probable Causes...2390
Recommended Repairs...2390
Diagnostic Codes...2390
Engine Stalls at Low RPM...2390
Probable Causes...2390
Recommended Actions...2390
Diagnostic Codes...2390
Fuel Injection Nozzles...2390
Fuel Supply...2391
Accessory Equipment...2391
Power Mode Control...2391
Engine Vibration...2391
Probable Causes...2391
Recommended Actions...2391
Engine Supports...2391
Malfunctioning Individual Cylinder...2391
Valve Lash...2391
Check for Low Compression (cylinder pressure)...2391
Check the Fuel Injection Nozzles...2392
Turbocharger...2392
Engine Will Not Crank...2392
Probable Causes...2392
Recommended Repairs...2392
Machine Security System...2392
Battery Cables and/or Batteries...2392
Starting Motor Solenoid or Starting Circuit...2392
Starting Motor and/or Flywheel Ring Gear...2392
Electrical Power Supply...2393
Internal Engine Problem...2393
Excessive Black Smoke...2393
Probable Causes...2393
Recommended Actions...2393
Air Intake System or Exhaust System...2393
Individual Malfunctioning Cylinder...2393
Valve Lash...2393
Low Compression (cylinder pressure)...2393
Check the Fuel Injection Nozzles...2393
Check the Turbocharger...2394
Broken 5-Volt Supply Wire...2394
Verifying the ECM Software...2394
Excessive Engine Oil Consumption...2394
Probable Causes...2394
Recommended Actions...2394
Oil Level...2394
Engine Crankcase Breather...2394
Air Intake and Exhaust System...2394
Turbocharger...2394
Low Compression (cylinder pressure)...2395
Excessive Valve Lash...2395
Probable Causes...2395
Recommended Actions...2395
Lubrication...2395
Valve Lash...2395
Valve Train Components...2395
Excessive White Smoke...2395
Probable Causes...2395
Recommended Actions...2396
Fuel Supply...2396
Individual Malfunctioning Cylinder...2396
Valve Lash...2396
Low Compression (cylinder pressure)...2396
Air Inlet Heater Starting Aid...2396
Fuel Injection Nozzles...2396
Coolant Temperature Sensor Circuit...2396
Engine Pressure Sensors...2396
Intake Air Temperature Is Too High...2397
Probable Causes...2397
Recommended Repairs...2397
High Ambient Air Temperature...2397
Coolant Temperature...2397
Check for High Intake Air Restriction and/or High Altitude...2397
Intake Air Restriction...2397
High Altitude...2397
Check the Intake Manifold Air Temperature Sensor and/or the Circ...2397
Check for Sufficient Coolant Flow Through the Aftercooler (if eq...2397
Check for Sufficient Flow of Air Through the Aftercooler (if equ...2397
Intermittent Engine Shutdown...2397
Probable Causes...2397
Recommended Actions...2397
Logged Codes...2397
Fuel Supply...2398
Engine Protection Device...2398
Electrical Connectors...2398
Intermittent Low Power or Power Cutout...2398
Probable Causes...2398
Recommended Repairs...2398
Diagnostic Codes...2399
Electrical Connectors...2399
Fuel Supply...2399
Check the Intake Manifold Pressure...2399
Air Intake and Exhaust System...2399
Individual Malfunctioning Cylinders...2399
Valve Lash...2400
Check for Low Compression...2400
Check the Fuel Injection Nozzles...2400
Check the Turbocharger...2400
ECM Parameters...2400
Electronic System Problem...2400
Low Engine Oil Pressure...2401
Probable Causes...2401
Recommended Actions...2401
Engine Oil Level...2401
Engine Oil Pressure Gauge...2401
Engine Oil Bypass Valves...2401
Piston Cooling Jets ...2401
Engine Oil Suction Tube...2401
Engine Oil Pump...2401
Bearing Clearance...2401
Low Power/Poor or No Response to Throttle...2401
Probable Causes...2401
Recommended Actions...2402
Diagnostic Codes...2402
Fuel Supply...2402
Air Intake and Exhaust System...2402
Individual Malfunctioning Cylinders...2402
Valve Lash...2402
Check for Low Compression...2402
Check the Fuel Injection Nozzles...2403
Check the Turbocharger...2403
ECM Parameters...2403
Electronic System Problem...2403
Mechanical Noise (Knock) in Engine...2403
Probable Causes...2403
Recommended Actions...2404
Accessory Equipment...2404
Valve Train Components...2404
Connecting Rod and Main Bearings...2404
Noise Coming from Cylinder...2404
Probable Causes...2404
Recommended Actions...2404
Fuel Quality...2404
Fuel Injection Nozzles...2404
Valve Lash...2404
Poor Acceleration or Response...2404
Probable Causes...2404
Recommended Repairs...2404
Diagnostic Codes...2404
Fuel Supply...2404
Individual Malfunctioning Cylinder...2405
Valve Lash...2405
Check for Low Compression...2405
Check the Fuel Injection Nozzles...2405
Check the Turbocharger...2405
ECM Parameters...2405
Check Intake Manifold Pressure...2406
Troubleshooting With a Diagnostic Code...2406
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal...2406
Conditions Which Generate This Code...2406
System Response...2406
Possible Performance Effect...2406
Troubleshooting...2406
Results...2406
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent...2406
Conditions Which Generate This Code...2406
System Response...2406
Possible Performance Effect...2406
Troubleshooting...2406
Test Step 1...2406
Results...2406
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted...2406
Conditions Which Generate This Code...2406
System Response...2406
Possible Performance Effect...2407
CID 0091 FMI 04 Throttle Position Sensor Shorted Low...2407
Conditions Which Generate This Code...2407
System Response...2407
Possible Performance Effect...2407
Troubleshooting...2407
Results...2407
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal...2407
Conditions Which Generate This Code...2407
System Response...2407
Troubleshooting...2407
Results...2407
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...2407
Conditions Which Generate This Code...2407
Possible Performance Effect...2407
Troubleshooting...2407
Results...2407
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short...2407
Conditions Which Generate This Code...2407
System Response...2408
Troubleshooting...2408
Results...2408
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...2408
Conditions Which Generate This Code...2408
System Response...2408
Troubleshooting...2408
Results...2408
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci...2408
Conditions Which Generate This Code...2408
System Response...2408
Possible Performance Effect...2408
Results...2408
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or...2408
Conditions Which Generate This Code...2408
System Response...2408
Possible Performance Effect...2409
Results...2409
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...2409
Conditions Which Generate This Code...2409
System Response...2409
Possible Performance Effect...2409
Results...2409
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope...2409
Conditions Which Generate This Code...2409
System Response...2409
Results...2409
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ...2409
Conditions Which Generate This Code...2409
System Response...2409
Possible Performance Effect...2410
Troubleshooting...2410
Results...2410
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low...2410
Conditions Which Generate This Code...2410
System Response...2410
Possible Performance Effect...2410
Troubleshooting...2410
Results...2410
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o...2410
Conditions Which Generate This Code...2410
System Response...2410
Possible Performance Effect...2410
Troubleshooting...2410
Results...2410
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...2410
Conditions Which Generate This Code...2410
System Response...2410
Possible Performance Effect...2410
Troubleshooting...2411
Results...2411
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...2411
Conditions Which Generate This Code...2411
System Response...2411
Possible Performance Effect...2411
Troubleshooting...2411
Results...2411
CID 0247 FMI 09 J1939 Datalink, Abnormal Update...2411
Conditions Which Generate This Code...2411
System Response...2411
Results...2411
CID 0253 FMI 02 Incorrect ECM Software...2411
Conditions Which Generate This Code...2411
System Response...2411
Possible Performance Effect...2411
Troubleshooting...2412
Expected Result...2412
Results...2412
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal...2412
Conditions Which Generate This Code...2412
System Response...2412
Possible Performance Effect...2412
Troubleshooting...2412
Results...2412
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal...2412
Conditions Which Generate This Code...2412
System Response...2412
Possible Performance Effect...2412
Troubleshooting...2412
Results...2412
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs...2412
Conditions Which Generate This Code...2412
System Response...2412
Possible Performance Effect...2412
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig...2413
Conditions Which Generate This Code...2413
System Response...2413
Possible Performance Effect...2413
Results...2413
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...2413
Conditions Which Generate This Code...2413
System Response...2413
Possible Performance Effect...2413
Results...2413
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa...2413
Conditions Which Generate This Code...2413
System Response...2413
Possible Performance Effect...2413
Test Step 1...2413
Results...2413
Test Step 2...2413
Results...2414
CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm...2414
Conditions Which Generate This Code...2414
System Response...2414
Possible Performance Effect...2414
Results...2414
CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S...2414
Conditions Which Generate This Code...2414
System Response...2414
Possible Performance Effect...2414
Troubleshooting...2414
Results...2414
CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low...2414
Conditions Which Generate This Code...2414
System Response...2414
Possible Performance Effect...2414
Troubleshooting...2414
Results...2414
CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal...2415
Conditions Which Generate This Code...2415
System Response...2415
Possible Performance Effect...2415
Results...2415
CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio...2415
Conditions Which Generate This Code...2415
System Response...2415
Possible Performance Effect...2415
Results...2415
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off...2415
Conditions Which Generate This Code...2415
System Response...2415
Possible Performance Effect...2415
Results...2415
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ...2415
Conditions Which Generate This Code...2415
System Response...2415
Possible Performance Effect...2416
Test Step 1...2416
Results...2416
Test Step 2...2416
Results...2416
CID 1684 FMI 02 Fuel Injection Pump, Software Failure...2416
Conditions Which Generate This Code...2416
System Response...2416
Possible Performance Effect...2416
Troubleshooting...2416
Results...2416
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault...2416
Conditions Which Generate This Code...2416
System Response...2416
Possible Performance Effect...2416
Troubleshooting...2416
Results...2416
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...2417
Conditions Which Generate This Code...2417
System Response...2417
Possible Performance Effect...2417
Troubleshooting...2417
Results...2417
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width...2417
Conditions Which Generate This Code...2417
Troubleshooting...2417
Results...2417
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault...2417
Conditions Which Generate This Code...2417
System Response...2417
Possible Performance Effect...2417
Troubleshooting...2417
Results...2417
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...2417
Conditions Which Generate This Code...2417
System Response...2418
Possible Performance Effect...2418
Troubleshooting...2418
Test Step 1...2418
Results...2418
Test Step 2...2418
Results...2418
Test Step 3...2418
Results...2418
Test Step 4...2418
Expected Result...2418
Results...2418
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault...2418
Conditions Which Generate This Code...2418
System Response...2418
Possible Performance Effect...2418
Troubleshooting...2418
Expected Result...2419
Results...2419
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error...2419
Conditions Which Generate This Code...2419
System Response...2419
Troubleshooting...2419
Test Step 1...2419
Results...2419
Test Step 2...2419
Results...2419
Test Step 3...2419
Results...2419
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault...2419
Conditions Which Generate This Code...2419
System Response...2419
Possible Performance Effect...2420
Troubleshooting...2420
Test Step 1...2420
Results...2420
Test Step 2...2420
Results...2420
CID 1684 FMI 14 Fuel Injection Pump, No Communications...2420
Conditions Which Generate This Code...2420
System Response...2420
Troubleshooting...2420
Test Step 1...2420
Results...2420
Test Step 2...2420
Results...2420
Test Step 3...2420
Results...2420
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali...2420
Conditions Which Generate This Code...2420
System Response...2420
Possible Performance Effect...2421
Troubleshooting...2421
Results...2421
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali...2421
Conditions Which Generate This Code...2421
System Response...2421
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S...2421
Conditions Which Generate This Code...2421
System Response...2421
Troubleshooting With an Event Code...2421
Event Codes...2421
Programmable Engine Parameters...2421
E015 High Engine Coolant Temperature Derate...2421
Conditions Which Generate This Code...2421
System Response...2421
Possible Performance Effect...2421
Troubleshooting...2421
Results...2421
E016 High Engine Coolant Temperature Shutdown...2422
Conditions Which Generate This Code...2422
System Response...2422
Possible Performance Effect...2422
Troubleshooting...2422
Results...2422
E017 High Engine Coolant Temperature Warning...2422
Conditions Which Generate This Code...2422
System Response...2422
Possible Performance Effect...2422
Troubleshooting...2422
Results...2422
E025 High Intake Air Temperature Derate...2422
Conditions Which Generate This Code...2422
System Response...2422
Possible Performance Effect...2422
Troubleshooting...2422
Results...2422
E027 High Intake Air Temperature Warning...2422
Conditions Which Generate This Code:...2422
System Response...2422
Possible Performance Effect...2423
Troubleshooting...2423
Results...2423
E040 Low Engine Oil Pressure Shutdown...2423
Conditions Which Generate This Code...2423
System Response...2423
Possible Performance Effect...2423
Troubleshooting...2423
Results...2423
E054 High Fuel Temperature Derate...2423
Conditions Which Generate This Code...2423
System Response...2423
Troubleshooting...2423
Test Step 1 - Check for Diagnostic Codes...2423
Expected Result...2423
Results...2423
Test Step 2 - Perform a Check of the Fuel System...2423
Expected Result...2424
Results...2424
E056 High Fuel Temperature Warning...2424
Conditions Which Generate This Code...2424
System Response...2424
Troubleshooting...2424
Test Step 1 - Check for Diagnostic Codes...2424
Expected Result...2424
Results...2424
Test Step 2 - Perform a Check of the Fuel System...2424
Expected Result...2424
Results...2424
E100 Low Engine Oil Pressure Warning...2424
Conditions Which Generate This Code...2424
System Response...2424
Possible Performance Effect...2424
Troubleshooting...2425
Test Step 1 - Check for Active Diagnostic Codes...2425
Expected Result...2425
Results...2425
Test Step 2 - Perform a Check of the Engine Lubrication System...2425
Expected Result...2425
Results...2425
E190 Engine Overspeed Warning...2425
Conditions Which Generate This Code...2425
System Response...2425
Possible Performance Effect...2425
Troubleshooting...2425
Engine Overspeed Warning...2425
Expected Result...2425
Results...2425
E442 Engine Failed to Stop With a No-Fuel Command...2425
Conditions Which Generate This Code...2425
System Response...2425
Possible Performance Effect...2426
Troubleshooting...2426
Test Step 1...2426
Results...2426
Test Step 2...2426
Results...2426
E883 Engine Failed to Stop When Fuel Solenoid Disengaged...2426
Conditions Which Generate This Code...2426
System Response...2426
Possible Performance Effect...2426
Troubleshooting...2426
Test Step 1...2426
Results...2426
Test Step 2...2426
Results...2426
Test Step 3...2426
Results...2426
Diagnostic Function Tests...2427
5-Volt Engine Pressure Sensor Supply Circuit - Test...2427
System Operation Description...2427
Background Information...2427
Test Step 1...2428
Inspect Electrical Connectors and Wiring...2428
Expected Result...2428
Results...2428
Test Step 2...2429
Check for Active Diagnostic Codes...2429
Expected Result...2429
Results...2429
Test Step 3...2429
Disconnect the ECM Engine Harness Connector From the ECM...2429
Expected Result...2430
Results...2430
Test Step 4...2430
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei...2430
Expected Result...2430
Results...2430
Test Step 5...2431
Check the Engine Harness...2431
Expected Result...2431
Results...2431
Air Inlet Heater Circuit - Test...2431
System Operation Description...2431
Test Step 1...2431
Inspect Electrical Connectors and Wiring...2431
Expected Result...2432
Results...2432
Test Step 2...2432
Check the Supply to the Power Relay for the Air Inlet Heater Sta...2432
Expected Result...2432
Results...2432
Test Step 3...2433
Check the Output From the Power Relay for the Air Inlet Heater S...2433
Expected Result...2433
Results...2433
Test Step 4...2433
Ground the Input to the Power Relay at the MIC...2433
Expected Result...2433
Results...2433
Test Step 5...2433
Ground the Input to the Power Relay at the ECM Connector...2433
Expected Result...2433
Results...2433
Test Step 6...2433
Override the Air Inlet Heater Starting Aid to Test the ECM...2433
Results...2434
Checking Idle Validation Switching Point (Throttle Sensor) With ...2434
Expected Result...2434
Analog Throttle Position Sensor Circuit - Test...2434
System Operation Description...2434
Checking the Throttle Sensor With Unconnected Output C...2435
Expected Result...2435
Test Step 1...2435
Check for Connector Damage...2435
Expected Result...2435
Results...2435
Test Step 2...2436
Check for Active Diagnostic Codes...2436
Expected Result...2436
Results...2436
Test Step 3...2436
Check the Throttle Position With the Electronic Service Tool...2436
Expected Result...2436
Results...2436
Test Step 4...2436
Check the Voltage at the Throttle Position Sensor...2436
Expected Result...2436
Results...2436
Test Step 5...2437
Disconnect the Throttle Position Sensor and Check for Active Dia...2437
Expected Result...2437
Results...2437
Test Step 6...2437
Check the Throttle Selection Status With the Electronic Service ...2437
Expected Result...2437
Results...2438
Test Step 7...2438
Disconnect the Supply Terminals of the Throttle Position Sensor ...2438
Expected Result...2438
Results...2438
Test Step 8...2438
Check the Position of Throttle Position Sensor...2438
Expected Result...2439
Results...2439
Test Step 9...2439
Check the Throttle Position Sensor at the ECM...2439
Expected Result...2439
Results...2439
CAN Data Link Circuit - Test...2439
System Operation Description...2439
Test Step 1...2440
Inspect Electrical Connectors and Wiring...2440
Expected Result...2440
Results...2440
Test Step 2...2440
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...2440
Expected Result...2440
Results...2440
Test Step 3...2440
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...2440
Expected Result...2441
Results...2441
Test Step 4...2441
Verify the Supply Voltage at the Fuel Injection Pump...2441
Expected Result...2441
Results...2441
Data Link Circuit - Test...2441
System Operation Description...2441
Background Information...2442
Communication...2442
Test Step 1...2442
Inspect Electrical Connectors and Wiring...2442
Expected Result...2442
Results...2442
Test Step 2...2442
Determine the Type of Problem With the Data Link...2442
Expected Result...2442
Results...2443
Test Step 3...2443
Check the Battery Voltage at the ECM...2443
Expected Result...2443
Results...2443
Test Step 4...2443
Check the Battery Voltage That is Coming to the Data Link Connec...2443
Expected Result...2444
Results...2444
Test Step 5...2444
Connect the Electronic Service Tool Directly to the ECM...2444
Expected Result...2444
Results...2444
Test Step 6...2444
Change Electronic Service Tool Components...2444
Expected Result...2445
Results...2445
Test Step 7...2445
Connect an Electronic Service Tool and the ECM to Another Batter...2445
Expected Result...2445
Results...2445
Electrical Connectors - Inspect...2445
System Operation Description...2446
Background Information...2446
Test Step 1...2450
Check the Locking of the DT Connector (Deutsch) and the Lock Rin...2450
Expected Result...2450
Results...2450
Test Step 2...2450
Check the Socket Head Screw on the Connector for the Electronic ...2450
Expected Result...2450
Results...2450
Test Step 3...2450
Perform a Pull Test on Each Wire Terminal Connection...2450
Expected Result...2450
Results...2450
Test Step 4...2451
Monitor the Electronic Service Tool While the Wiring and the Con...2451
Expected Result...2451
Results...2451
Test Step 5...2451
Check Wires for Nicks and/or Abrasions in the Insulation...2451
Expected Result...2451
Results...2451
Test Step 6...2451
Check Connectors for Moisture or Corrosion...2451
Expected Result...2452
Results...2452
Test Step 7...2452
Inspect the Connector Terminals...2452
Expected Result...2452
Results...2452
Test Step 8...2453
Check Individual Pin Retention Into the Socket...2453
Expected Result...2453
Results...2453
Electrical Power Supply Circuit - Test...2453
System Operation Description...2453
Background Information...2453
Test Step 1...2455
Check the Batteries...2455
Expected Result...2455
Results...2455
Test Step 2...2455
Inspect Electrical Connectors and Wiring...2455
Expected Result...2455
Results...2455
Test Step 3...2455
Check the Battery Voltage at the ECM...2455
Expected Result...2456
Results...2456
Test Step 4...2456
Use the Bypass Harness for the Electronic Service Tool to Bypass...2456
Expected Result...2457
Results...2457
Engine Pressure Sensor Open or Short Circuit - Test...2457
System Operation Description...2457
Background Information...2457
Test Step 1...2458
Check for Active +5V Sensor Supply Diagnostic Codes...2458
Expected Result...2458
Results...2458
Test Step 2...2458
Verify All Active Diagnostic Codes...2458
Expected Result...2458
Results...2458
Test Step 3...2458
Inspect Electrical Connectors And Wiring...2458
Expected Result...2459
Results...2459
Test Step 4...2459
Verify That the Diagnostic Code is Still Active...2459
Expected Result...2459
Results...2459
Test Step 5...2459
Disconnect the Sensor to Create an Open Circuit...2459
Expected Result...2460
Results...2460
Test Step 6...2460
Measure the Sensor Supply Voltage...2460
Expected Result...2460
Results...2460
Test Step 7...2461
Determine if the Short Circuit is in the Connector or in the Sen...2461
Expected Result...2461
Results...2461
Test Step 8...2461
Create a Short Circuit Between the Signal and the Common Termina...2461
Expected Result...2461
Results...2461
Test Step 9...2461
Check the Operation of the ECM by Creating Open and Short Circui...2461
Expected Result...2462
Results...2462
Test Step 10...2462
Bypass the Harness Wiring Between the ECM and the Sensor Connect...2462
Expected Result...2462
Results...2462
Engine Speed/Timing Sensor Circuit - Test...2463
System Operation Description...2463
Test Step 1...2463
Inspect the Electrical Connectors and Cables...2463
Expected Result...2463
Results...2463
Test Step 2...2464
Check the Installation of the Engine Speed/Timing Sensors...2464
Expected Result...2464
Results...2464
Test Step 3...2464
Measure the Sensor Resistance Through the Wiring Harness...2464
Expected Result...2464
Results...2464
Test Step 4...2464
Measure the Resistance of the Sensor...2464
Expected Result...2465
Results...2465
Test Step 5...2465
Measure the Resistance of the Cables Between the Fuel Injection ...2465
Expected Result...2466
Results...2466
Test Step 6...2466
Check the Continuity of the Cables From the ECM to the Fuel Inje...2466
Expected Result...2466
Results...2466
Engine Temperature Sensor Open or Short Circuit - Test...2466
System Operation Description...2466
Background Information...2466
Test Step 1...2467
Verify All Active Diagnostic Codes...2467
Expected Result...2467
Results...2467
Test Step 2...2468
Inspect Electrical Connectors and Wiring...2468
Expected Result...2468
Results...2468
Test Step 3...2468
Verify That the Diagnostic Code is Still Active...2468
Expected Result...2468
Results...2468
Test Step 4...2468
Disconnect the Sensor to Create an Open Circuit...2468
Expected Result...2469
Results...2469
Test Step 5...2469
Create a Short Circuit Between the Signal and the Common Termina...2469
Expected Result...2469
Results...2469
Test Step 6...2469
Check the Operation of the ECM by Creating an Open and a Short C...2469
Expected Result...2470
Results...2470
Test Step 7...2470
Bypass the Harness Wiring Between the ECM and the Sensor Connect...2470
Expected Result...2470
Results...2470
Fuel Injection Pump Circuit - Test...2471
System Operation Description...2471
Background Information...2471
Test Step 1...2471
Check the Batteries...2471
Expected Result...2471
Results...2471
Test Step 2...2471
Inspect the Electrical Connectors and Wiring...2471
Expected Result...2472
Results...2472
Test Step 3...2472
Check the Supply Voltage at the Machine Interface Connector...2472
Expected Result...2473
Results...2473
Test Step 4...2473
Check the Supply Voltage at the Fuel Injection Pump...2473
Expected Result...2473
Results...2473
Test Step 5...2473
Check the Supply to the Power Relay for the Fuel Injection Pump...2473
Expected Result...2473
Results...2473
Test Step 6...2474
Check the Output of the Power Relay for the Fuel Injection Pump...2474
Expected Result...2474
Results...2474
Test Step 7...2474
Check the Voltage at the Relay Coil for the Fuel Injection Pump...2474
Expected Result...2474
Results...2474
Test Step 8...2474
Check the Output of the ECM Fuel Pump Power Control at the Machi...2474
Expected Result...2474
Results...2475
Test Step 9...2475
Check the Output of the Fuel Injection Pump Power Control at the...2475
Expected Result...2475
Results...2475
Test Step 10...2475
Measure the Voltage at the Pump Power Supply...2475
Expected Result...2475
Results...2475
Test Step 11...2476
Check the Voltage Load Protection Module (VLPM)...2476
Expected Result...2476
Results...2476
Indicator Lamp Circuit - Test...2476
System Operation Description...2476
Test Step 1...2477
Inspect Electrical Connectors and Wiring...2477
Results...2478
Test Step 2...2478
Inspect the Lamp, the Fuse, and the Power Supply...2478
Expected Result...2478
Results...2478
Test Step 3...2478
Inspect the Input to the Lamp at the ECM connector...2478
Expected Result...2478
Results...2478
Test Step 4...2478
Test the Individual Lamp Circuits...2478
Expected Result...2478
Results...2478
Test Step 5...2479
Check the Voltage at the ECM...2479
Expected Result...2479
Results...2479
Idle Validation Circuit - Test...2479
System Operation Description...2479
Test Step 1...2479
Expected Result...2479
Results...2479
tables...2328
Table 1. Electronic Service Tool...2354
Table 2. Optional Service Tools...2355
Table 3. CID FMI Codes and J Code FMI Codes...2356
Table 4. Event Codes and CID FMI Codes...2358
Table 5. CID Numbers and Flash Codes...2359
Table 6. Engine Connectors...2367
Table 7. Color Codes for the Harness Wire...2371
Table 8. Pin Connections for Perkins Deutsch Socket Connector...2373
Table 9. Suspect Parameter Numbers...2377
Table 10. Failure Mode Indicators (FMI) Codes...2378
Table 11. Engine Oil Pressure Trip and Reset Points...2423
897108-1600SRM0326-(03-2007)-UK-EN...2484
toc...2484
Steering Axle...2484
Safety Precautions Maintenance and Repair...2485
General...2488
Description...2488
Steering Axle Assembly Repair...2493
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...2493
Remove...2493
Install...2493
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...2494
Remove...2494
Install...2494
Wheels and Hubs Repair (All Units)...2495
Remove and Disassemble...2495
Clean...2495
Inspect...2495
Assemble and Install...2495
Spindles and Bearings Repair (All Units)...2497
Remove...2497
Clean...2497
Assemble and Install...2498
Tie Rods Repair (All Units)...2499
Remove...2499
Clean...2499
Install...2499
Steering Cylinder Repair...2502
Remove and Disassemble...2502
Clean and Inspect...2502
Assemble and Install...2502
Troubleshooting...2503
897386-4000SRM0445-(08-2001)-UK-EN...2508
toc...2508
Masts...2508
Safety Precautions Maintenance and Repair...2509
General...2512
Description...2512
Safety Procedures When Working Near Mast...2513
Operation...2515
Two-Stage Mast...2515
Three-Stage Mast...2515
Forks Repair...2517
Remove...2517
Install...2517
Carriage Repair...2517
Remove...2517
Sideshift Carriage, Disassemble...2517
Sideshift Carriage, Assemble...2519
Sideshift Cylinder, Disassemble...2521
Sideshift Cylinder, Assemble...2521
Fork Positioner Cylinder, Disassemble...2522
Fork Positioner Cylinder, Assemble...2523
Install...2524
Mast Repairs...2524
Remove...2524
Two-Stage Mast, Disassemble...2524
Three-Stage Mast, Disassemble...2529
Clean and Inspect...2531
Two-Stage Mast, Assemble...2531
Three-Stage Mast, Assemble...2534
Install...2537
Lift Cylinders Description...2538
Piston-Type Cylinders...2539
Displacement-Type Cylinders...2539
All Lift Cylinders Repair...2539
Remove...2541
Disassemble...2541
Clean and Inspect...2541
Assemble...2541
Install...2542
Mast Operation Check...2542
Lift and Tilt System Leak Checks...2542
Lift System...2542
Tilt System...2543
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...2543
Lift Chain Adjustments...2544
Mast Adjustments...2544
Bearing Blocks...2544
Wear Plates...2545
Load Roller Adjustments...2545
Carriage Adjustment...2547
Troubleshooting...2549
tables...2508
Table 1. Carriage and Fork Weights...2521
Table 2. Mast Weights...2529
Table 3. Allowable Mast Movement from Internal Leakage...2543
897507-4000SRM0522-(05-2004)-UK-EN...2554
toc...2554
Mast...2554
Safety Precautions Maintenance and Repair...2555
General...2558
Safety Procedures When Working Near Mast...2558
Forks Repair...2560
Remove...2560
Install...2561
Carriages Repair...2561
Standard Carriage, Remove...2561
Hang-On Sideshift Carriage, Remove...2562
Standard Carriage and Hang-On Sideshift Carriage, Repair...2563
Standard Carriage, Install...2563
Hang-On Sideshift Carriage, Install...2564
Integral Sideshift Carriage...2564
Remove...2564
Clean and Inspect...2566
Repair...2566
Install...2567
Mast Repair...2567
Remove...2567
Two-Stage LFL and Two-Stage FFL Masts, Disassemble...2569
Three-Stage FFL Mast...2576
Disassemble...2576
Mast and Chains, Clean and Inspect...2579
Two-Stage LFL and Two-Stage FFL Mast, Assemble...2580
Three-Stage FFL Mast, Assemble...2581
Install...2583
Lift Cylinders Repair...2584
Main Lift Cylinders, Remove...2584
Free-Lift Cylinder, Remove...2584
Lift Cylinders, Disassemble...2585
Lift Cylinders, Assemble...2585
Main Lift Cylinders, Install...2588
Free-Lift Cylinder, Install...2589
Header Hose Arrangements...2589
Two-Stage LFL Mast, New Hose Install...2589
Two-Stage LFL Mast, Adjust Hoses After Installation...2595
Two-Stage FFL Mast, New Hose Install...2595
Two-Stage FFL Mast, Adjust Hoses After Installation...2600
Three-Stage FFL Mast, New Hose Install...2602
Three-Stage FFL Mast, Adjust Hoses After Installation...2612
Header Hose Arrangement...2613
Two-Stage LFL Mast, New Hose Install...2613
Two-Stage LFL Mast, Adjust Hoses After Installation...2613
Two-Stage FFL Mast, New Hose Install...2617
Two-Stage FFL Mast, Adjust Hoses After Installation...2622
Three-Stage FFL Mast, New Hose Install...2624
Three-Stage FFL Mast, Adjust Hoses After Install...2629
Lift and Tilt System Leak Check...2633
Lift Cylinders Leak Check...2633
Tilt Cylinders Leak Check...2633
Tilt Cylinders Adjustment...2634
Lift Chains Adjustment...2635
Mast Adjustment...2637
Carriage Adjustment...2639
Troubleshooting...2639
tables...2554
Table 1. Hook-Type Carriage Chain Adjustment...2636
Table 2. Pin-Type Carriage Chain Adjustment...2636
897934-0700SRM0626-(11-2001)-UK-EN...2644
toc...2644
Cooling System...2644
Safety Precautions Maintenance and Repair...2645
General...2648
Description...2649
Radiator...2649
Radiator Cap...2649
Thermostat...2649
Water Pump...2650
Fan and Fan Shroud...2650
Cooling System Checks...2650
Radiator...2650
Thermostat...2650
Water Pump...2651
Exhaust Leaks...2651
Fan and Fan Shroud...2651
Radiator Cleaning...2651
Drain...2651
Clean...2651
Fill...2652
Troubleshooting...2653
899784-2200SRM0002-(10-2003)-UK-EN...2656
toc...2656
Alternator with Regulator...2656
Safety Precautions Maintenance and Repair...2657
General...2660
Description...2660
Alternator Repair...2662
Alternator Type A...2662
Remove and Disassemble...2662
Clean...2663
Assemble...2664
Install...2664
Alternator Type B...2667
Remove and Disassemble...2667
Clean...2667
Assemble...2668
Install...2669
General Check and Adjustment...2670
Low Output Check (Type A or Type B)...2670
High Output Check (Type A or Type B)...2672
Brushes Circuit Check...2673
Delco Alternators...2673
Motorola Alternators...2674
Diodes Check...2675
Diode Bridge Check...2675
Delco and Leece-Neville Alternators...2675
Motorola Alternators...2675
Rotor Field Winding Check...2676
Stator Windings Check...2677
Voltage Regulator Check...2677
Troubleshooting...2677
910072-1400SRM0046-(07-2007)-UK-EN...2682
toc...2682
Differential...2682
Safety Precautions Maintenance and Repair...2683
General...2686
Description...2686
Differential Repair...2687
Remove...2687
Differential Carrier From Axle Housing, Remove...2687
Differential and Ring Gear From Differential Carrier, Remove...2689
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...2691
Disassemble...2692
Differential and Ring Gear Assembly, Disassemble...2692
Drive Pinion and Pinion Carrier, Disassemble...2694
Clean and Inspect...2697
Assemble...2698
Pinion, Bearings, and Pinion Carrier, Assemble...2698
Pinion Bearings, Adjust Preload...2698
Press Method...2698
Yoke or Flange Method...2699
Triple-Lip Seal, Install...2700
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...2701
Differential and Ring Gear, Assemble...2703
Differential Gears Rotating Torque, Check...2705
Differential and Ring Gear Assembly, Install...2706
Differential Bearings, Preload Adjust...2708
Ring Gear, Runout Check...2709
Ring Gear Backlash, Adjust...2709
Gear Set, Tooth Contact Pattern Check...2711
Thrust Screw, Install and Adjust...2714
Install...2714
Differential Assembly Into Axle Housing, Install...2714
Specifications...2716
Troubleshooting...2721
tables...2682
Table 1. Ring Gear Backlash Adjustment Specifications...2711
Table 2. Ring and Pinion Tooth Contact Adjustment...2712
Table 3. General Specifications...2716
Table 4. Rivet Installation Pressure...2716
Table 5. Pinion Adjustment...2717
Table 6. Pinion Preload Pressure...2717
Table 7. Torque Specifications...2718
Table 8. Torque Specifications for Metric Hardware...2719
Table 9. Torque Specifications for Metric (Fine) Hardware...2720
910102-2100SRM0103-(03-2007)-UK-EN...2724
toc...2724
Tilt Cylinders...2724
Safety Precautions Maintenance and Repair...2725
General...2728
Description...2728
Tilt Cylinder Repair...2728
Remove...2728
Disassemble...2728
Clean...2728
Assemble...2728
Tilt Cylinders With O-Ring or Single-Lip Seals...2728
Tilt Cylinders for XM and XMS Models...2730
Tilt Cylinders for XL, XLS, and XL 3 Models...2731
Tilt Cylinders for H700-800A and Early Model H700-920B...2733
Install...2734
Tilt Cylinders Using Chevron Packing...2734
Install...2735
Tilt Cylinder Leak Check...2737
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...2739
Torque Specifications...2739
Piston Rod Nut...2739
Retainer...2740
Troubleshooting...2742
tables...2724
Table 1. Movement Rates (Maximum) for Tilt Cylinders...2738
910107-2200SRM0106-(02-2001)-UK-EN...2746
toc...2746
Starter...2746
Safety Precautions Maintenance and Repair...2747
General...2750
Description and Operation...2750
Starter Repair...2752
Remove...2752
Disassemble...2752
Clean...2753
Assemble...2753
Install...2754
General Checks and Adjustments...2754
Troubleshooting...2757
910119-4000SRM0135-(10-2003)-UK-EN...2762
toc...2762
Lift Cylinders...2762
Safety Precautions Maintenance and Repair...2763
Safety Procedures When Working Near Mast...2766
General...2770
Description...2770
Lowering Control Valve...2770
Cylinders (General)...2773
Cylinders (H520-620B, H700-800A)...2773
Retainer, Install...2773
Cylinders (H360-460B)...2775
Cylinders (Two-Speed)...2777
Lift Cylinder Repair...2779
Lift Cylinder Removal Without Removing Mast...2779
Standard Masts With Main Lift Cylinder Fastened to Crossmember o...2779
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...2779
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ...2779
Disassemble...2781
Assemble...2781
Lift Cylinder Installation in Mast...2783
Standard Masts With Main Lift Cylinder Fastened to Crossmember o...2783
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...2783
Chevron-Style Packing...2783
Chevron-Style Packing Installation on Piston...2784
Chevron-Style Packing Installation in Packing Gland...2786
Lift Cylinders for VISTA® Masts...2787
Description...2787
Lowering Control Valve...2787
Remove...2789
Disassemble...2790
Assemble...2791
Install...2792
Main Lift Cylinders...2792
Free-Lift Cylinder...2792
Lift System Leak Check...2793
Specifications...2794
Troubleshooting...2795
tables...2762
Table 1. Lift Trucks with Two-Speed Lift Cylinders...2778
Table 2. Cylinder Retainer Torque Specifications and Weight Guid...2794
910442-8000SRM0231-(12-2004)-UK-EN...2798
toc...2798
Metric and Inch (SAE) Fasteners...2798
Safety Precautions Maintenance and Repair...2799
General...2802
Threaded Fasteners...2802
Nomenclature, Threads...2802
Strength Identification...2803
Cotter (Split) Pins...2803
Fastener Torque Tables...2808
Conversion Table...2810
tables...2798
Table 1. Bolts and Screws...2804
Table 2. Studs and Nuts...2805
Table 3. Torque Nuts...2806
Table 4. Torque Nuts With Nylon Insert...2807
Table 5. Torque Values for Metric Fasteners*...2808
Table 6. Torque Values for Inch Fasteners*...2809
Table 7. Conversion Table for Metric and English Units...2810
Table 8. Cotter Pin Dimensional Data...2811
Table 9. Cotter Pin Dimensional Data...2812
Table 10. Cotter Pin Dimensional Data...2813
Table 11. Cotter Pin Dimensional Data...2815
Hyster Forklift Trucks F007 (H170-280HD & H8.00-12.00XM Europe) Repair Service Manual
