Hyster Forklift Trucks F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe & H300-350HD; H360HD-EC) Repair Service Manual
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Model:
Complete service repair manual for Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe & H300-350HD; H360HD-EC) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe & H300-350HD; H360HD-EC) 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 F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe & H300-350HD; H360HD-EC) Service Manual.pdf
Total Pages: 1,452 + 1,458 pages
File Format: PDF
Language: English
F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe)...2
1494123-0100SRM0927-(01-2006)-UK-EN...3
toc...3
Frame...3
Safety Precautions Maintenance and Repair...4
General...7
Description...7
Counterweight Repair...7
Remove...7
Install...9
Fenders...9
Remove...9
Install...9
Side Counterweights H13.00-16.00XM (H300-360HD)...9
Side Counterweight, Replace...9
Hood and Air Cleaner Repair...10
Remove...10
Install...12
Hydraulic Tank Repair...12
Remove...12
Repairs, All Units...13
Small Leaks...13
Large Leaks...14
Clean...14
Steam Method...14
Chemical Solution Method...15
Other Methods of Preparation for Repair...15
Install...15
Fuel Tank Repair...16
Remove...16
Repairs...16
Install...16
Cooling System and Radiator Repair...18
Remove...18
Install...19
Engine and Transmission Repair...20
Hyster T-50 Transmission, Remove...20
Hyster T-50 Transmission, Install...21
TE-10 Transmission...22
Remove...22
Install...25
Label Replacement...27
1494140-1600SRM0936-(03-2007)-UK-EN...35
toc...35
Steering System...35
Safety Precautions Maintenance and Repair...36
General...39
Description...39
Steering Wheel and Column Assembly...41
General...41
Steering Wheel and Horn...41
Remove...41
Install...41
Steering Control Unit Repair...43
General...43
Description...43
Operation...43
Remove...44
Disassemble...44
Clean...47
Assemble and Install...47
Steering System Air Removal...53
Steering Relief Pressure Check...54
Troubleshooting...54
1494141-1800SRM0937-(03-2007)-UK-EN...59
toc...59
Dry Brake System...59
Safety Precautions Maintenance and Repair...60
General...63
Description...63
Operation...64
Service Brakes...64
Parking Brake...66
Air Tank Repair...67
Relief Valve...67
Drain Valve...67
Brake Pedal Valve Repair...68
Remove...68
Disassemble, Inspect, and Assemble...68
Install...68
Air Chambers Repair...69
Remove...69
Disassemble...69
Inspect...70
Assemble...71
Install...71
Actuator Arms Repair...71
Remove...71
Inspect...72
Install...72
Brake Assemblies Repair...73
Brake Shoe, Remove...73
Camshaft, Remove...75
Clean...75
Inspect...76
Camshaft, Install...76
Brake Shoe, Install...77
Air Dryer...78
Description...78
Cartridge...78
Remove...78
Install...78
Filter...78
Remove...78
Install...78
Quick-Release Valve...80
Governor Check and Adjustment for Air Compressor...80
Brake Shoes Adjustment...81
Specifications...82
Troubleshooting...82
Service Brakes...82
Service Brakes, Park Function ...85
tables...59
Table 1. Air Chambers Operation...66
1494142-1900SRM0938-(03-2007)-UK-EN...89
toc...89
Hydraulic System...89
Safety Precautions Maintenance and Repair...90
General...93
Description and Operation...93
Hydraulic Tank...93
Hydraulic Pump...94
Steering Priority Flow Valve...94
Pilot Valve...95
Main Control Valve...97
Unloader Valve...98
Hydraulic Operation...99
Checks and Adjustments...102
Quick Disconnect Fittings...102
Steering Priority Flow Valve...102
Steering Relief Pressure...102
Modulator Valve...103
Pilot Valve and Pressure Reducing Valve...103
Accumulator...104
Filter...104
Main Control Valve...104
Relief Pressure Check...104
Check Valves...105
Unloader Valve...105
Hydraulic Pump Repair...106
Remove...106
Disassemble...106
Clean and Inspect...106
Assemble...107
Install...108
Pilot Accumulator Replacement ...108
Remove...108
Install...108
Pilot Valve Repair...109
Remove...109
Disassemble...110
Clean and Inspect...110
Assemble...110
Install...110
Control Levers and Joystick Repair...111
Remove...111
Install...111
Calibration and Diagnostics...112
General...112
Description...112
Lever and Joystick Calibration...112
Flow Adjustment...112
Dead Band Value Setting...113
Lowering Delay...114
PWM and I/O Module Readouts...114
Function Disable...115
General Startup...115
Minimum system requirements...115
Install the Hydraulic Controls Program...115
DelayTimeFile (Reset)...115
Select the Processor Speed...116
Hydraulic Controls Program...116
Calibration...118
Joystick/Lever Calibration...118
Levers...118
Joystick...118
Valve Flow Adjustment...119
Diagnostics...119
Calibration System Shutdown...119
LED Diagnostics...120
Electrical Connections...123
Specifications...127
tables...89
Table 1. Main Control Valve Port Settings...95
Table 2. Processor Speed Settings...115
Table 3. PWM Board LED Error Codes...120
Table 4. Altering PT FLT I/O Board LED's (Old Logic)...121
Table 5. Altering PT FLT I/O Board LED's (New Logic)...121
Table 6. Fixed PT Logic I/O Boards LED's...122
Table 7. ECH...122
Table 8. PWM Driver Module...123
Table 9. Input/Output Module 1...124
Table 10. Input/Output Module 2...125
Table 11. Altering PT FLT...126
Table 12. Fixed PT FLT...126
Table 13. ECH...127
1494145-8000SRM0940-(03-2008)-UK-EN...131
toc...131
Capacities and Specifications...131
Safety Precautions Maintenance and Repair...132
Lift Truck Weights...135
Capacities...135
Engine Specifications...136
Perkins Diesel...136
Cummins Diesel/LPG...137
Hydraulic System...138
Electrical System...139
Tire Sizes...139
Mast Speeds...139
Perkins Diesel...139
Cummins Diesel/LPG...140
Torque Specifications, Cummins Diesel...141
Lubrication System...141
Torque Specifications, Perkins Diesel...141
Engine...141
Cylinder Head Assembly...141
Piston and Connecting Rod Assemblies...141
Crankshaft Assembly...141
Timing Case and Drive Assembly...142
Turbocharger...142
Lubrication System...142
Fuel System...142
Cooling System...142
Flywheel and Housing...142
Aspiration System...143
Electrical Equipment...143
Auxiliary Equipment...143
Torque Specifications - Perkins, Tier 2...143
Cylinder Head Assembly...143
Piston and Connecting Rod Assemblies...143
Crankshaft Assembly...143
Timing Case and Drive Assembly...143
Turbocharger...144
Lubrication System...144
Fuel System...144
Cooling System...144
Flywheel...144
Auxiliary Equipment...144
Torque Specifications, General...145
Transmission...145
Driveline and Axle...145
Differential...145
Brakes - Wet...145
Brakes - Dry...145
Steering...145
Hydraulic System...146
Mast...146
Carriage...146
Tilt Cylinders...146
Frame...146
Wiper Arms, Front...146
Hyster T-50 Transmission Pressures (Powershift and Automatic)...147
TE-10 Transmission Specifications...148
Electrical...148
Hydraulic Cooler Lines...148
Torque Specifications for Lubricated or Plated Screw Threads...149
tables...131
Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp...148
Table 2. Grade 5...149
Table 3. Grade 8...149
Table 4. Grades 8.8, 10.9, and 12.9...149
Table 5. O-ring Port Plug Torque Chart...150
Table 6. Pipe Plug Torque Chart...150
1494953-1400SRM0944-(03-2007)-UK-EN...153
toc...153
Planetary Drive Axle...153
Safety Precautions Maintenance and Repair...154
General...157
Description...157
Operation...159
Identification...159
Removal...160
Disassembly...160
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...160
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...162
Wheel End...164
Spindle and Piston Housing...165
Cleaning...166
Clean Ground or Polished Parts...166
Clean Parts With Rough Finish...166
Clean Axle Assemblies...166
Drying Cleaned Parts...166
Corrosion Prevention...166
Parts Inspection...167
Tapered Roller Bearings...167
Bevel Pinion and Ring Gear Sets...168
Main Differential Assembly...168
Axle Shafts...168
Yoke...168
Brakes...168
Repair or Replace Parts...168
Repair Welding...168
Apply Silicone Gasket Material...169
Assembly...169
Spindle and Piston Housing to Axle Housing...169
Wet Disc Brakes...170
Adjust Wheel Bearing Preload...171
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...172
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...173
Planetary Spider Assembly...173
Installation...174
Fill Wet Disc Brakes With Hydraulic Fluid...174
Torque Specifications...175
Lubrication Specification...176
1494955-2000SRM0943-(03-2007)-UK-EN...179
toc...179
Main Control Valve...179
Safety Precautions Maintenance and Repair...180
General...183
Description...183
Operation...186
Lift Section...186
Tilt/Auxiliary Section...186
Relief Valves...186
Unloader Valve...186
Main Control Valve Repair...189
Remove...189
Disassemble...189
Auxiliary Side...189
Lift Side...189
Clean and Inspect...192
Assemble...192
Auxiliary Side...192
Lift Side...192
Install...192
Pressure Relief Valve Check and Adjustment...193
Check and Adjust...193
Replace...193
Specifications...194
Troubleshooting...194
1498445-1400SRM0945-(03-2007)-UK-EN...199
toc...199
Planetary Drive Axle...199
Safety Precautions Maintenance and Repair...200
General...203
Description...203
Operation...205
Identification...205
Removal...206
Disassembly...206
Brake Drum...206
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...207
Dry Brakes...209
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...209
Spindle and Brake Spider...211
Cleaning...212
Ground or Polished Parts...212
Parts With Rough Finish...212
Axle Assemblies...212
Drying Cleaned Parts...212
Corrosion Prevention...212
Parts Inspection...213
Tapered Roller Bearings...213
Bevel Pinion and Ring Gear Sets...214
Main Differential Assembly...214
Axle Shafts...214
Yoke...214
Brakes...214
Repair or Replace Parts...214
Repair Welding...214
Apply Silicone Gasket Material...215
Assembly...215
Spindle, Brake Spider, and Brake...215
Wheel End...216
Adjust Wheel Bearing Preload...217
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...218
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...219
Planetary Spider Assembly...219
Installation...220
Torque Specifications...221
Lubrication Specification...222
1498450-1800SRM0951-(03-2007)-UK-EN...225
toc...225
Wet Brake System...225
Safety Precautions Maintenance and Repair...226
General...229
Description and Operation...229
Service Brakes...229
Parking Brake...229
Oil Cooler Circuit...229
Pressure Switch Replacement...233
Accumulators Replacement...233
Brake Treadle Valve Repair...233
Remove and Disassemble...233
Clean and Inspect...234
Assemble and Install...234
Parking Brake Valve Repair...234
Remove...234
Clean and Inspect...234
Repair...234
Install...234
Parking Brake Caliper Repair...235
Remove...235
Disassemble...237
Inspect...237
Install...237
Adjust...237
Brake Pad Repair...238
Inspect...238
Remove...238
Install...238
Seals Repair...238
Remove...238
Install...239
Service Brake Repair...239
Remove and Disassemble...239
Drain Lubricating Oil...239
Drain Coolant Oil...246
Disconnect Brake Lines...246
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14...246
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...247
Brake Disc Housing Assembly Wheel End...248
Brake Piston Housing...249
Brake Piston Housing and Wheel Spindle...250
Inspect...250
Clean...252
Assemble...253
Wheel Spindle...253
Brake Piston Housing...253
Piston Assembly...255
Brake Disc Housing...255
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub...257
Check for Correct Installation of Duo-Cone Seal...258
Wheel Hub to Brake Disc Housing...259
Adjust...260
Fill Brake System With Coolant Oil...260
System Air Removal...261
Adjust Brake With New Disc Pack...261
Coolant Change Intervals...262
Coolant Draining and Filling...262
Specifications...264
Minimum Brake Disc Thickness...267
Hydraulic Fluid for Brake Actuation...267
Brake Coolant Specifications...267
Coolant Change Intervals...267
Hydraulic Fluid Specifications...267
Troubleshooting...267
Brake Does Not Apply...267
Brake Does Not Release...268
Brake Performance...268
Brake Leaks Actuation Fluid...269
Brake Cooling Fluid Leakage...270
Brake Noise and Vibration...270
Brake Overheats...270
tables...225
Table 1. Brake Pad Adjustment...237
Table 2. Minimum Brake Disc Thickness...251
Table 3. Formed Seal Wear Chart...251
1503241-5000SRM0969-(03-2007)-UK-EN...275
toc...275
Empty Container Handling Attachment...275
Safety Precautions Maintenance and Repair...276
General...279
Description...279
Operation...284
General...284
Selector Valves...284
Sideshift Circuit...284
Extend and Retract Circuit...284
Twist Lock Circuit and Control...285
Model 553 - Horizontally Mounted...285
Model 558 - Vertically Mounted...285
Lifting Hooks...285
Model 555...285
Indicator Lights and LEDs...285
Lift Interrupt and Override...286
Overlowering Interrupt and Override...286
Carriage and Attachment Repair...286
Remove...286
Attachment Without Carriage Repair...287
Remove...287
Sideshift Cylinders Repair...288
Remove...288
Disassemble...288
Assemble...288
Extension Cylinders Repair...289
Remove...289
Disassemble...289
Clean and Inspect...289
Assemble...289
Install...289
Vertical End Beams Repair...291
Remove...291
Install...291
Hose Replacement in End Beams...291
Twist Locks Repair for Model 553...292
Remove...292
Disassemble...292
Clean and Inspect...292
Assemble...292
Hooks Replacement for Model 555...293
Inspect...293
Remove...293
Install...293
Twist Locks Repair for Model 558...294
Disassemble...294
Clean and Inspect...294
Assemble...294
Bleed the System...295
Valve Assembly...295
Slide Pad Replacement...296
Adjustments...296
Twist Lock Angle Adjustment...296
Model 558 Only...296
LOCKED/NOT LOCKED Sensors Adjustment...297
Model 553...297
Model 558...297
Seated Sensor Adjustment...297
Model 553...297
Model 558...297
Overlowering Protection Sensor Adjustment (Models 553 and 558)...297
Torque Chart...298
Maintenance...298
Additional Attachment Maintenance...300
Interface Boxes...301
Model 555...301
Models 553 and 558...301
Troubleshooting...303
tables...275
Table 1. Torque Chart...298
Table 2. Inspect and Adjust (See Figure 14 )...299
Table 3. Lubricate (See Figure 14 )...300
Table 4. Replace (See Figure 14 )...300
1541323-0600SRM1068-(05-2004)-UK-EN...321
toc...321
Perkins Tier 2 Diesel Engines...321
Safety Precautions Maintenance and Repair...322
General...329
General Safety Rules...329
Description...330
Engine Serial Number Codes...332
Engine Data...332
Engine Removal and Installation...333
Cylinder Head Assembly Repair...333
Valve Cover...333
Remove...333
Install...334
Rocker Arm Assembly...334
Remove...334
Disassemble...334
Inspect...334
Assemble...334
Install...334
Valve Clearance Adjustments...335
Valve Springs...336
Cylinder Head Assembly...337
Remove...337
Install...339
Valves and Valve Springs...342
Remove...342
Inspect...342
Install...343
Valve Guides...343
Inspect...343
Remove...343
Install...343
Cylinder Head and Valve Seats...344
Inspect...344
Repair...345
New Valve Seats, Install...345
Piston and Connecting Rod Assemblies Repair...345
Rod Bearings...346
Remove...346
Install...346
Piston and Connecting Rod Assembly...347
Service Note...347
Remove...347
Install...348
Piston Rings...349
Remove...349
Inspect...349
Install...350
Piston and Connecting Rod...350
Disassemble...350
Inspect...350
How to Select Correct Replacements...351
Install...352
Piston Cooling Jets...352
Remove...352
Install...353
Crankshaft Assembly Repair...353
General...353
Crankshaft Pulley...354
Remove...354
Inspect...354
Install...354
Rear Oil Seal...355
Remove...355
Install...355
Main Bearings...356
Remove...356
Inspect...357
Install...357
Thrust Washers...357
Crankshaft Axial Movement, Check...357
Remove...358
Install...358
Crankshaft...359
Remove...359
Inspect...359
Install...360
Flywheel...361
Remove...361
Ring Gear, Replace...361
Install...361
Flywheel Housing...362
Remove...362
Install...362
Timing Case and Timing Gears Repair...363
General...363
Timing Case Cover...363
Remove...363
Install...364
Front Oil Seal...364
Remove...364
Install...364
Crankshaft Pulley Wear Sleeve...365
Install...365
Idler Gear and Hub...365
Remove...365
Install...366
Air Compressor Drive, Bendix...367
Disassemble...367
Assemble...367
Fuel Injection Pump Gear...368
Remove...368
Install...369
Camshaft Gear...369
Remove...369
Install...370
Crankshaft Gear...370
Remove...370
Install...371
Timing Case...371
Remove...371
Install...371
Camshaft and Tappets...372
Remove...372
Install...373
Cylinder Block Assembly Repair...373
Description...373
Cylinder Block...373
Disassemble...373
Inspect...374
Assemble...374
Cylinder Liner...375
Inspect...375
Cylinder Liner Condition, Check...375
Remove...376
Service Liner, Install...377
Partially Finished Liner, Install...378
Engine Timing...379
Description...379
How to Set Number One Piston to TDC on Compression Stroke...380
How to Set Number One Piston to TDC on Compression Stroke (Alter...381
How to Set Number One Piston to 4° After TDC on Compression Stro...382
Valve Timing, Check...383
Fuel Injection Pump Timing, Check...384
Turbocharger...384
General...384
Remove...384
Install...385
Impeller and Compressor Housing, Clean...385
Waste-Gate Valve Check...386
Closed Circuit Breather System (CCB)...387
CCB Assembly, Remove...387
Closed Circuit Drain Valve, Remove...387
CCB Assembly, Install...387
Closed Circuit Drain Valve, Install...387
Lubrication System Repair...388
General...388
Oil Filter, Replace...388
Oil Filter Head...388
Remove...388
Install...388
Oil Filter Head Bypass Valve...389
Remove and Install...389
Oil Sump...389
Remove...389
Install...389
Oil Pump...390
Remove...390
Inspect...390
Install...391
Relief Valve...392
Remove...392
Disassemble...392
Inspect...392
Assemble...392
Install...392
Idler Gear Shaft, Replace...392
Remove...393
Remove (Alternative)...393
Install...394
Install (Alternative)...394
Fuel System Repair...395
Description...395
Fuel Injection Pump...397
Remove...397
Install...399
Fuel System Air Removal...400
Fuel Filter, Replace...402
Fuel Injectors...402
Remove...403
Inspect...403
Install...403
Fuel Lift Pump...404
Remove...404
Disassemble...404
Assemble...404
Install...405
Test...405
Cooling System Repair...406
General...406
Thermostat...406
Remove...406
Install...407
Test...407
Coolant Pump...407
Remove...407
Disassemble...408
Assemble...410
Install...412
Fan and Fan Drive...413
Remove...413
Install...413
Oil Cooler...413
Remove...413
Disassemble and Assemble...414
Install...414
Electrical Equipment Repair...415
Drive Belts...415
Alternator...415
Remove...415
Install...415
Electronic Control Module (ECM)...416
Remove...416
Inspect...416
Install...416
Voltage Load and Protection Module (VLPM)...417
Remove...417
Install...417
Engine Speed and Timing Sensor...417
Remove...417
Install...418
Pressure Sensors (Engine Oil and Air Intake)...418
Remove...418
Install...419
Temperature Sensor...419
Remove...419
Install...420
Starter Motor...420
Remove...420
Install...420
Cold Start Aid...420
Air Compressor...420
General...420
Repair...421
Remove...421
Install...421
Rotary Exhauster Replacement...422
Remove...422
Clean...422
Install...422
Engine Specifications...423
Cylinder Head Assembly...423
Piston and Connecting Rods...426
Crankshaft Assembly...427
Crankshaft Overhaul...428
Timing Case and Drive Assembly...430
Engine Block Assembly...431
Turbocharger...432
Lubrication System...433
Cooling System...435
Flywheel and Housing...435
Electrical Equipment...435
Torque Specifications...436
Cylinder Head Assembly...436
Piston and Connecting Rod Assemblies...436
Crankshaft Assembly...436
Timing Case and Drive Assembly...436
Turbocharger...436
Lubrication System...436
Fuel System...436
Cooling System...437
Flywheel...437
Auxiliary Equipment...437
Special Torque Specifications...437
Flywheel and Housing...437
Electrical Equipment...437
Auxiliary Equipment...437
Special Tools...438
Troubleshooting...443
Turbocharger Troubleshooting...445
tables...321
Table 1. Cylinder Head...423
Table 2. Valve Guides...423
Table 3. Inlet Valves...424
Table 4. Exhaust Valves...424
Table 5. Valve Springs...425
Table 6. Tappets...425
Table 7. Rocker Arm Shaft...425
Table 8. Rocker Arms and Bushings...425
Table 9. Pistons...426
Table 10. Piston Rings...426
Table 11. Piston Pins...426
Table 12. Connecting Rods...426
Table 13. Small End Bushings...427
Table 14. Connecting Rod Bearings...427
Table 15. Piston Cooling Jets...427
Table 16. Crankshaft...427
Table 17. Main Bearings...428
Table 18. Crankshaft Thrust Washers...428
Table 19. Crankshaft Heat Treatment...428
Table 20. Crankshaft Overhaul Specifications...428
Table 21. Maximum Variation (Run-Out)...430
Table 22. Camshaft...430
Table 23. Camshaft Thrust Washer...430
Table 24. Camshaft Gear...430
Table 25. Gear for Fuel Injection Pump...430
Table 26. Crankshaft Gear...431
Table 27. Idler Gear and Hub...431
Table 28. Cylinder Block...431
Table 29. Cylinder Liners...431
Table 30. Cylinder Liner Specifications (Partially Finished)...432
Table 31. Oil Pump...433
Table 32. Idler Gear for Oil Pump...433
Table 33. Relief Valve...433
Table 34. Oil Filter...433
Table 35. Bosch Fuel Injection Pump...433
Table 36. Fuel Injector Codes...434
Table 37. Fuel Pump...435
Table 38. Fuel Filter...435
Table 39. Coolant Pump...435
Table 40. Thermostat...435
Table 41. Fan Drive Housing...435
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic...435
Table 43. Alternator...435
Table 44. Starter Motor...435
Table 45. Cold Start Aid...435
Table 46. List of Possible Causes...443
Table 47. List of Possible Causes...445
1553599-4000SRM1062-(03-2007)-UK-EN...449
toc...449
Masts and Carriages...449
Safety Precautions Maintenance and Repair...450
General...453
Description...453
Operation...454
Two-Stage Mast...454
Three-Stage Mast...455
Safety Procedures When Working Near Mast...456
Forks Repair...459
Remove...459
Inspect and Adjust...459
Install...459
Carriage Repair...460
Description...460
Three Function...460
Four to Six Function...460
Remove...460
Disassemble...461
Clean and Inspect...463
Assemble...463
Install...463
Sideshift Cylinder Repair...464
Remove...464
Disassemble...464
Clean and Inspect...464
Assemble...464
Install...464
Fork Positioner Cylinders Repair...468
Remove...468
Disassemble...468
Clean and Inspect...468
Assemble...468
Install...468
Directional Control Valve Repair...475
Remove...475
Disassemble...475
Clean and Inspect...475
Assemble...476
Install...476
Mast Repair...476
Two- and Three-Stage Mast...476
Remove...476
Disassemble...481
Clean and Inspect...483
Assemble...484
Install...485
Three-Stage Mast (Four Cylinders)...485
Remove...485
Disassemble...487
Clean and Inspect...489
Assemble...489
Install...489
Fork Carriage Chains...491
Adjust...491
Bearing Rollers...493
Description...493
Lubrication...493
Clearance...493
Remove and Disassemble...493
Assemble...494
Mast Profile...494
Lift Cylinders Description...494
Piston-Type Cylinders...494
Displacement-Type Cylinders...494
Lift Cylinders Repair...495
Remove...495
Disassemble...497
Clean and Inspect...497
Assemble...497
Install...498
Mast Operation Check...498
Lift and Tilt System Leak Checks...499
Lift System...499
Tilt System...499
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...500
Lift Chain Adjustments...500
Mast Adjustments...501
Bearing Blocks, Two-Stage Masts...501
Wear Plates...501
Carriage Adjustment...501
Troubleshooting...503
tables...449
Table 1. Allowable Mast Movement from Internal Leakage...499
1556599-0100SRM1100-(09-2008)-UK-EN...507
toc...507
Operator's Cab...507
Safety Precautions Maintenance and Repair...508
General...511
Cab Repair...512
Rear Cab Assembly...512
Bottom Cab Assembly...513
Raising and Lowering Cab...513
Raise Cab...513
Lower Cab...514
Cab Repair...514
Remove...514
Install...515
Oil Filling for Tilt System...516
Inching and Brake Pedals...517
Brake Pedal, Adjust...517
Inching Pedal, Adjust...517
Inching Pedal Sensor, Adjust...517
Throttle Pedal Sensor...518
Check...518
Adjust...518
Seat Assembly Removal...519
Power Assist Armrest...519
Adjust...519
Steering Column Repair...520
Remove...520
Install...520
Window Wipers Replacement...521
Window Wiper Assembly, Replace...521
Front Window Wiper Motor Assembly, Replace...521
Rear Window Wiper Motor Assembly, Replace...522
Top Window Wiper Motor Assembly, Replace...522
Window Washer Motors and Pumps...523
Window Wiper and Washer Operating Switches...523
Window Replacement...524
Front Window, Replace...525
Rear Window, Replace...525
Top Window, Replace...525
Door Window, Replace...526
Heater and Air Conditioning Assembly...527
Heater Parts, Replace...528
Heat Control Knob/Switches...528
Heat Control Knob/Cable...528
Adjust...528
Air Control Knob/Cable...529
Adjust...529
Air Filter, Replace...529
Air Conditioning Condenser Fan(s)...530
Remove...530
Install...530
Instruments, Switches, and Controls...530
Switches...530
Controls...531
Fuses and Relays...532
Fuse Panel...532
Fuses...532
Relays...533
Label Replacement...534
Electrical Schematics...534
1556600-1300SRM1082-(09-2008)-UK-EN...537
toc...537
Transmission...537
Safety Precautions Maintenance and Repair...538
Description of Operation...543
General...543
Torque Convertor, Pump Drive, and Pressure Regulating Valve...543
Input Shaft and Directional Clutches...543
Range Clutches...545
Output Section...545
Transmission Controls...546
Operation of the Valve...547
Selection of Range...551
Pressure Switch...551
Electric Solenoid Controls...552
Transmission Specifications...568
Transmission Identification...568
Weight, Dimensions, and Oil Capacity...568
Transmission Repair...570
Remove...570
Disassemble...572
Transmission Case, Disassemble...573
Torque Converter Housing, Disassemble...590
Forward Clutch, Disassemble...595
First-Speed Clutch, Disassemble...597
Reverse and Second-Speed Clutch...602
Reverse Clutch, Disassemble...602
Second-Speed Clutch, Disassemble...607
Third-Speed Clutch, Disassemble...609
Third Clutch Shaft, Disassemble...611
Turbine Shaft, Disassemble...612
Output Shaft, Disassemble...613
Impeller, Disassemble...614
Turbine, Disassemble...616
Clean and Inspect...618
Housings...618
Oil Seals and Gaskets...619
Bearings...619
Gears and Shafts...619
Assemble...620
Turbine, Assemble...620
Impeller, Assemble...621
Output Shaft, Assemble...623
Turbine Shaft, Assemble...625
Third Clutch Shaft, Assemble...626
Third-Speed Clutch, Assemble...627
Reverse and Second-Speed Clutch...630
Second-Speed Clutch, Assemble...630
Reverse Clutch, Assemble...633
First-Speed Clutch, Assemble...637
Forward Clutch, Assemble...642
Torque Converter Housing, Assemble...645
Transmission Case, Assemble...650
Install...671
Control Valve Repair...673
Remove...673
Disassemble and Assemble...673
Clean and Inspect...675
Housings...675
Oil Seals and Gaskets...675
Install...676
Stall Test...677
Transmission Calibration and Electrical Troubleshooting...678
Userlink®...678
Connection...678
Clutch Filling Calibration...678
Purpose...678
Clutch Filling Calibration Procedure...679
Alternative Clutch Filling Calibration Procedure...679
Heat-up Mode...680
Heat-up Mode Stall Test...680
Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 300...681
Purpose...681
Brake Pedal Adjustment...681
Dry Brake...681
Wet Brake...681
Inching Pedal Adjustment...681
Inching Pedal Sensor Adjustment...682
Inching Pedal Calibration Procedure...682
Verification/Adjustment of Inching Pedal Sensor When the Pedal i...682
Manual Inching Pedal Sensor Calibration Procedure...683
Inching Pedal Calibration [S/N 2326 and Up (F019)], [S/N 3002 an...683
Purpose...683
Brake Pedal Adjustment...683
Dry Brake...683
Wet Brake...683
Inching Pedal Adjustment...684
Dry Brake...684
Wet Brake...684
Inching Pedal Sensor Adjustment Using Userlink® Program...684
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr...685
Inching Pedal Sensor Adjustment Using the APC200...685
Inching Pedal Sensor Calibration Procedure Using the APC200...686
Troubleshooting...686
Transmission Display Warning Codes...686
Access...686
Clear...687
Exit...687
Limp Home Mode...722
Shutdown Mode...723
Pressure Feedback Sensor...723
Transmission Oil Pressure Check...723
Pressure and Temperature Specifications...723
Electrical Specifications...728
Hydraulic Cooler Lines Specifications...728
Torque Specifications...728
Torque Specifications for Lubricated or Plated Screw Threads...728
Troubleshooting...731
tables...537
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere...687
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere...688
Table 3. Common Calibration Condition Messages...690
Table 4. Calibration Codes During Calibration...691
Table 5. Error Codes During Calibration...691
Table 6. Display Warning Codes...692
Table 7. Display Warning Exceed Codes...721
Table 8. Type of Warning Codes...722
Table 9. Temperature Sensor (In Speed Sensor) Resistance Versus ...728
Table 10. Grade 5...728
Table 11. Grade 8...729
Table 12. Grades 8.8, 10.9, and 12.9...730
Table 13. O-ring Port Plug Torque Chart...730
Table 14. Pipe Plug Torque Chart...731
1556602-8000SRM1099-(06-2006)-UK-EN...739
toc...739
Periodic Maintenance...739
Safety Precautions Maintenance and Repair...740
General...745
How to Move Disabled Lift Truck...745
How to Tow Lift Truck...745
How to Put Lift Truck on Blocks...746
How to Raise Drive Tires...746
How to Raise Steering Tires...746
Maintenance Schedule...748
Empty Container Attachment Maintenance...760
Maintenance Procedures Every 8 Hours or Daily...762
How to Make Checks With Engine Stopped...762
Safety Labels...762
Forks...762
Adjust...762
Remove...762
Install...762
Forks, Mast, and Lift Chains, Inspect...763
Operator Restraint System...764
Steering Column Latch...765
Tires and Wheels...765
Fuel, Oil, or Coolant Leaks, Check...766
Air Intake Piping...766
Cooling Fan...766
Crankcase Breather Tube...766
Drive Belts...767
Hydraulic System Oil...767
Cab Hydraulic System...768
Engine Oil...768
Cooling System...770
Battery...771
Fuel System (Diesel Engines Only)...771
Water Separator/Fuel Filter (Diesel Engines Only)...771
How to Make Checks With Engine Running...772
Fault Codes...772
Access...772
Exit...772
Clear...772
Gauges, Lights, Horn and Fuses...772
Control Levers and Pedals...775
Steering System...775
Air Filters...776
Transmission Oil...776
Brakes...776
Lift System Operation...776
Attachments...776
Maintenance Procedures Every 250 Hours or Every 2 Months...777
Empty Container Handler...777
Maintenance Procedures Every 500 Hours or Every 3 Months...777
Lift Chains...777
Lubrication...777
Adjust...777
Drive Shaft...777
Steering Axle...778
Wheel Nuts...778
Shafts for Brake Actuators...778
Drive Axle and Differential...778
Hydraulic Tank Breather...778
Cabin Air Filter, Heater...778
Air Filter, Engine...778
Engine Oil and Filter...778
Drive Belts...779
Perkins...779
Cummins...779
Mast...780
Bearing Rollers (Three-Stage Only)...781
Lubrication...781
Clearance...781
General Lubrication...781
Fork Wear and Damage Check...781
Lift Chains Wear Check...782
Empty Container Handler...782
Maintenance Procedures Every 500 Hours or 6 Months...782
Charge Air Cooler...782
Dry Brakes Air Compressor (Cummins)...782
Fuel Pump (Cummins)...783
Fuel Filter...783
Perkins...783
Remove...783
Install...783
Cummins...784
Remove...784
Install...784
Fuel System Air Removal (Perkins)...784
Fuel System Air Removal (Cummins)...784
Fuel Injection Pump Without Vent Tube...784
Coolant...786
Maintenance Procedures Every 1000 Hours or 6 Months...786
Transmission Oil and Filter, Change...786
Fuel Injection Pump Timing (Perkins Only)...786
Valve Adjustment...786
Perkins...786
Differential and Drive Axle...786
Pilot Accumulator Pressure Charge Check...787
Maintenance Procedures Every 1000 Hours or Yearly...787
Coolant Fan Belt Tensioner...787
Belt Driven Fan Hub...789
Valve Adjustment...789
Cummins...789
Accumulator and Wet Brakes...790
Wet Brake Oil Filter...790
Air Dryer Cartridge (Dry Brakes)...790
Air Compressor Air Filter (Dry Brakes)...790
Maintenance Procedures Every 2000 Hours or Yearly...791
Hydraulic System...791
Hydraulic Oil Filter, Change...791
Hydraulic Oil, Change...791
Hydraulic Pilot Valve Filter, Change...791
Transmission Calibration...792
Wheel Bearings...792
Steer Wheels...792
Drive Wheels...792
Service Brakes...792
Cleaning Procedures (Dry Brake Axle)...792
Maintenance Procedures Every 2000 Hours or 2 Years...793
Air Compressor Discharge Lines...793
Rubber Vibration Damper...794
Engine Coolant...794
Maintenance Procedures Every 5000 Hours...794
Empty Container Handler...794
Safety Procedures When Working Near Mast...795
Fuel Injectors Check...795
Perkins...795
Lift and Tilt System Leak Check...796
Lift System...796
Tilt System...797
Welding Repairs...798
Wheel and Tire Replacement...798
Remove Wheels From Lift Truck...798
Pneumatic Tires...799
Remove Tire From Wheel...799
Remove Tire From Three- and Four-Piece Wheel...799
Install Tire on Wheel...800
Install Three- or Four-Piece Wheel in Tire...801
Add Air to Tires...802
Solid Rubber Tires...802
Remove Tire From Wheel...802
Install Tire on Wheel...804
Wheels, Install...805
tables...739
Table 1. Daily Inspections − Condition Check...749
Table 2. Daily Inspections − Fluid Level Check...750
Table 3. Daily Inspections − Checks With the Engine Running...751
Table 4. First Inspection After First 100 Hours of Operation...752
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...752
Table 6. Periodic Maintenance Schedule − Lubricate...755
Table 7. Periodic Maintenance Schedule − Change...756
Table 8. Empty Container Attachment Maintenance − Inspect and ...760
Table 9. Empty Container Attachment Maintenance − Lubricate...761
Table 10. Empty Container Attachment Maintenance − Replace...761
Table 11. Nominal Valve Clearance...790
Table 12. Allowable Mast Movement from Internal Leakage...797
1556604-8000SRM1103-(11-2006)-UK-EN...809
toc...809
Diagrams...809
Safety Precautions Maintenance and Repair...810
1556871-2200SRM1105-(03-2007)-UK-EN...897
toc...897
Instrument Panel Indicators and Senders...897
Safety Precautions Maintenance and Repair...898
General...901
Description...901
General...901
Instrument Panel Meters, Indicators, and LCD Display...901
Connector...907
Seat Switch Logic...908
Central Warning Light Output...908
Buzzer Output...908
Instrument Panel...910
Remove...910
Sender Replacement...911
Fuel Level Sender (Diesel Engine Only)...911
Engine Oil Pressure Sender...912
Brake Pressure Sender...912
Low Coolant Sender...912
Vacuum Switch...912
Specifications...913
Troubleshooting...914
tables...897
Table 1. Instrument Panel and Indicators...902
Table 2. Pin Description...907
Table 3. Sender Description...908
1564053-0600SRM1101-(11-2007)-UK-EN...919
toc...919
Cummins Diesel/LPG Engine Fault Code Guide...919
Safety Precautions Maintenance and Repair...920
General...923
Fault Codes...923
Normal Mode...923
Fault Log Mode...923
Access...923
Exit...924
Clear...924
Electronic Throttle Calibration...924
Electronic Throttle Calibration Procedure...924
tables...919
Table 1. Error Code Descriptions...925
1566673-0600SRM1158-(06-2005)-UK-EN...941
toc...941
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...941
Safety Precautions Maintenance and Repair...942
Electronic Troubleshooting...965
System Operation...965
Electronic Controls...965
Engine Governor...966
Timing Considerations...966
Fuel Injection...966
Diagnostic Codes...966
Diagnostic Fault Codes...966
Diagnostic Event Codes...966
Programmable Parameters...967
Passwords...967
Electronic Service Tools...967
Electronic Service Tool (EST)...967
Connecting the Electronic Service Tool and the Communication Ada...967
Support for the Electronic Service Tool...968
Optional Service Tools...968
Diagnostic Codes...968
Engine Display Warning Codes...972
Access...972
Exit...972
Clear...972
Replacing the ECM...974
Self Diagnostics...975
Glossary...976
Sensors and Electrical Connectors...979
Engine Wiring Information...982
Harness Wire Identification...986
Diagnostic Code Reader...986
General...986
Reference Documents...986
Abbreviations...986
Environmental Specification...986
Hardware...987
Connection Cable...988
Software...988
Engine Communication...988
User Controls...988
Power Supply...988
Display Screen...988
Operation Controls...988
Audible Warning...989
Operation Instructions...989
How to Connect the Diagnostic Code Reader to the Engine...989
How to Turn ON the Diagnostic Code Reader...989
How to use the Display Screen...989
How to Operate the Diagnostic Code Reader...990
Main Menu...990
Active Codes...990
Inactive Codes...990
How to Clear Codes...991
Status Lamp...991
Data List...992
Diagnostics...992
Programming Parameters...993
Passwords...993
Factory Passwords...993
Customer Passwords...994
Flash Programming...994
Flash Programming a Personality Module...994
WinFlash Error Messages...994
System Configuration Parameters...995
Full Load Setting...995
Full Torque Setting...995
Rating Interlock...995
Engine Serial Number...995
ECM Software Release Date...995
Troubleshooting Without A Diagnostic Code...996
Alternator Noise (Noisy Operation)...996
Probable Causes...996
Recommended Actions...996
Alternator Drive Belts...996
Alternator Drive Pulley...996
Alternator Bearings...996
Alternator Will Not Charge (Charging Problem)...996
Probable Causes...996
Recommended Actions...996
Alternator Drive Belts...996
Charging Circuit...996
Alternator or Regulator...996
Battery...996
Probable Causes...996
Recommended Actions...996
Faulty Battery...996
Auxiliary Device...996
Cannot Reach Top Engine RPM...996
Probable Causes...997
Recommended Actions...997
Diagnostic Codes...997
Fuel Supply...997
Air Intake and Exhaust System...997
Individual Malfunctioning Cylinders...997
Valve Lash...997
Check for Low Compression...997
Check the Fuel Injection Nozzles...998
Check the Turbocharger...998
ECM Parameters...998
Check the Signal for the Throttle Position Sensor...998
Coolant in Engine Oil...998
Probable Causes...998
Recommended Actions...998
Engine Oil Cooler Core...998
Cylinder Head Gasket...998
Cylinder Head...999
Cylinder Block...999
Coolant Temperature Is Too High...999
Probable Causes...999
Recommended Actions...999
Radiator Fins...999
Coolant Level...999
Radiator Cap and/or Pressure Relief Valve...999
Combustion Gases in the Cooling System...999
Water Temperature Regulator...999
Restriction in the Coolant System...999
Coolant Temperature Gauge...999
Coolant Pump...999
Excessive Load on the System...999
ECM Will Not Accept Factory Passwords...1000
Probable Causes...1000
Recommended Actions...1000
ECM Will Not Communicate With Other Systems or Display Modules...1000
Probable Causes...1000
Recommended Actions...1000
Electronic Service Tool Will Not Communicate With ECM...1000
Probable Causes...1000
Recommended Actions...1000
Engine Cranks but Will Not Start...1001
Probable Causes...1001
Recommended Actions...1001
Diagnostic Codes...1001
Visual Checks...1001
Crank Without Injection...1001
Starting Motor Solenoid or Starting Circuit...1001
Valve Lash...1001
Fuel Injection Nozzles...1001
Air Inlet Heater Starting Aid...1002
Air Intake and Exhaust System...1002
Low Compression...1002
Fuel Supply...1002
Engine Has Early Wear...1002
Probable Causes...1002
Recommended Actions...1002
Dirt in Engine Oil...1002
Leaks in Air Intake System...1002
Low Oil Pressure...1002
Engine Misfires, Runs Rough or Is Unstable...1003
Probable Causes...1003
Recommended Actions...1003
Logged Codes...1003
Fuel Supply...1003
Air Intake and Exhaust System...1003
Individual Malfunctioning Cylinders...1003
Valve Lash...1003
Check for Low Compression...1003
Check the Fuel Injection Nozzles...1004
Check the Air Inlet Heater Starting Aid...1004
Check the Engine Speed/Timing Sensors...1004
Check the Signal for the Throttle Position Sensor...1004
Check the Fuel Injection Pump...1004
Engine Oil in Cooling System...1004
Probable Causes...1004
Recommended Actions...1004
Engine Oil Cooler Core...1004
Cylinder Head Gasket...1005
Cylinder Head...1005
Engine Speed Does Not Change...1005
Probable Causes...1005
Recommended Repairs...1005
Diagnostic Codes...1005
Engine Stalls at Low RPM...1005
Probable Causes...1005
Recommended Actions...1005
Diagnostic Codes...1005
Fuel Injection Nozzles...1005
Fuel Supply...1005
Accessory Equipment...1006
Power Mode Control...1006
Engine Vibration...1006
Probable Causes...1006
Recommended Actions...1006
Engine Supports...1006
Malfunctioning Individual Cylinder...1006
Valve Lash...1006
Check for Low Compression (cylinder pressure)...1006
Check the Fuel Injection Nozzles...1006
Turbocharger...1007
Engine Will Not Crank...1007
Probable Causes...1007
Recommended Repairs...1007
Machine Security System...1007
Battery Cables and/or Batteries...1007
Starting Motor Solenoid or Starting Circuit...1007
Starting Motor and/or Flywheel Ring Gear...1007
Electrical Power Supply...1007
Internal Engine Problem...1007
Excessive Black Smoke...1007
Probable Causes...1007
Recommended Actions...1008
Air Intake System or Exhaust System...1008
Individual Malfunctioning Cylinder...1008
Valve Lash...1008
Low Compression (cylinder pressure)...1008
Check the Fuel Injection Nozzles...1008
Check the Turbocharger...1008
Broken 5-Volt Supply Wire...1009
Verifying the ECM Software...1009
Excessive Engine Oil Consumption...1009
Probable Causes...1009
Recommended Actions...1009
Oil Level...1009
Engine Crankcase Breather...1009
Air Intake and Exhaust System...1009
Turbocharger...1009
Low Compression (cylinder pressure)...1009
Excessive Valve Lash...1010
Probable Causes...1010
Recommended Actions...1010
Lubrication...1010
Valve Lash...1010
Valve Train Components...1010
Excessive White Smoke...1010
Probable Causes...1010
Recommended Actions...1010
Fuel Supply...1010
Individual Malfunctioning Cylinder...1011
Valve Lash...1011
Low Compression (cylinder pressure)...1011
Air Inlet Heater Starting Aid...1011
Fuel Injection Nozzles...1011
Coolant Temperature Sensor Circuit...1011
Engine Pressure Sensors...1011
Intake Air Temperature Is Too High...1011
Probable Causes...1011
Recommended Repairs...1011
High Ambient Air Temperature...1011
Coolant Temperature...1011
Check for High Intake Air Restriction and/or High Altitude...1012
Intake Air Restriction...1012
High Altitude...1012
Check the Intake Manifold Air Temperature Sensor and/or the Circ...1012
Check for Sufficient Coolant Flow Through the Aftercooler (if eq...1012
Check for Sufficient Flow of Air Through the Aftercooler (if equ...1012
Intermittent Engine Shutdown...1012
Probable Causes...1012
Recommended Actions...1012
Logged Codes...1012
Fuel Supply...1012
Engine Protection Device...1012
Electrical Connectors...1013
Intermittent Low Power or Power Cutout...1013
Probable Causes...1013
Recommended Repairs...1013
Diagnostic Codes...1013
Electrical Connectors...1013
Fuel Supply...1013
Check the Intake Manifold Pressure...1014
Air Intake and Exhaust System...1014
Individual Malfunctioning Cylinders...1014
Valve Lash...1014
Check for Low Compression...1014
Check the Fuel Injection Nozzles...1014
Check the Turbocharger...1014
ECM Parameters...1015
Electronic System Problem...1015
Low Engine Oil Pressure...1015
Probable Causes...1015
Recommended Actions...1015
Engine Oil Level...1015
Engine Oil Pressure Gauge...1015
Engine Oil Bypass Valves...1015
Piston Cooling Jets ...1016
Engine Oil Suction Tube...1016
Engine Oil Pump...1016
Bearing Clearance...1016
Low Power/Poor or No Response to Throttle...1016
Probable Causes...1016
Recommended Actions...1016
Diagnostic Codes...1016
Fuel Supply...1016
Air Intake and Exhaust System...1016
Individual Malfunctioning Cylinders...1017
Valve Lash...1017
Check for Low Compression...1017
Check the Fuel Injection Nozzles...1017
Check the Turbocharger...1017
ECM Parameters...1017
Electronic System Problem...1018
Mechanical Noise (Knock) in Engine...1018
Probable Causes...1018
Recommended Actions...1018
Accessory Equipment...1018
Valve Train Components...1018
Connecting Rod and Main Bearings...1018
Noise Coming from Cylinder...1018
Probable Causes...1018
Recommended Actions...1018
Fuel Quality...1018
Fuel Injection Nozzles...1018
Valve Lash...1018
Poor Acceleration or Response...1019
Probable Causes...1019
Recommended Repairs...1019
Diagnostic Codes...1019
Fuel Supply...1019
Individual Malfunctioning Cylinder...1019
Valve Lash...1019
Check for Low Compression...1019
Check the Fuel Injection Nozzles...1019
Check the Turbocharger...1020
ECM Parameters...1020
Check Intake Manifold Pressure...1020
Troubleshooting With a Diagnostic Code...1020
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal...1020
Conditions Which Generate This Code...1020
System Response...1020
Possible Performance Effect...1020
Troubleshooting...1020
Results...1020
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent...1020
Conditions Which Generate This Code...1020
System Response...1021
Possible Performance Effect...1021
Troubleshooting...1021
Test Step 1...1021
Results...1021
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted...1021
Conditions Which Generate This Code...1021
System Response...1021
Possible Performance Effect...1021
CID 0091 FMI 04 Throttle Position Sensor Shorted Low...1021
Conditions Which Generate This Code...1021
System Response...1021
Possible Performance Effect...1021
Troubleshooting...1021
Results...1021
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal...1021
Conditions Which Generate This Code...1021
System Response...1021
Troubleshooting...1022
Results...1022
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...1022
Conditions Which Generate This Code...1022
Possible Performance Effect...1022
Troubleshooting...1022
Results...1022
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short...1022
Conditions Which Generate This Code...1022
System Response...1022
Troubleshooting...1022
Results...1022
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...1022
Conditions Which Generate This Code...1022
System Response...1022
Troubleshooting...1022
Results...1022
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci...1023
Conditions Which Generate This Code...1023
System Response...1023
Possible Performance Effect...1023
Results...1023
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or...1023
Conditions Which Generate This Code...1023
System Response...1023
Possible Performance Effect...1023
Results...1023
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...1023
Conditions Which Generate This Code...1023
System Response...1023
Possible Performance Effect...1023
Results...1023
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope...1024
Conditions Which Generate This Code...1024
System Response...1024
Results...1024
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ...1024
Conditions Which Generate This Code...1024
System Response...1024
Possible Performance Effect...1024
Troubleshooting...1024
Results...1024
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low...1024
Conditions Which Generate This Code...1024
System Response...1024
Possible Performance Effect...1024
Troubleshooting...1024
Results...1024
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o...1024
Conditions Which Generate This Code...1024
System Response...1025
Possible Performance Effect...1025
Troubleshooting...1025
Results...1025
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...1025
Conditions Which Generate This Code...1025
System Response...1025
Possible Performance Effect...1025
Troubleshooting...1025
Results...1025
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...1025
Conditions Which Generate This Code...1025
System Response...1025
Possible Performance Effect...1025
Troubleshooting...1025
Results...1025
CID 0247 FMI 09 J1939 Datalink, Abnormal Update...1026
Conditions Which Generate This Code...1026
System Response...1026
Results...1026
CID 0253 FMI 02 Incorrect ECM Software...1026
Conditions Which Generate This Code...1026
System Response...1026
Possible Performance Effect...1026
Troubleshooting...1026
Expected Result...1026
Results...1026
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal...1026
Conditions Which Generate This Code...1026
System Response...1026
Possible Performance Effect...1026
Troubleshooting...1026
Results...1026
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal...1027
Conditions Which Generate This Code...1027
System Response...1027
Possible Performance Effect...1027
Troubleshooting...1027
Results...1027
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs...1027
Conditions Which Generate This Code...1027
System Response...1027
Possible Performance Effect...1027
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig...1027
Conditions Which Generate This Code...1027
System Response...1027
Possible Performance Effect...1027
Results...1027
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...1027
Conditions Which Generate This Code...1027
System Response...1027
Possible Performance Effect...1027
Results...1028
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa...1028
Conditions Which Generate This Code...1028
System Response...1028
Possible Performance Effect...1028
Test Step 1...1028
Results...1028
Test Step 2...1028
Results...1028
CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm...1028
Conditions Which Generate This Code...1028
System Response...1028
Possible Performance Effect...1028
Results...1028
CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S...1028
Conditions Which Generate This Code...1028
System Response...1029
Possible Performance Effect...1029
Troubleshooting...1029
Results...1029
CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low...1029
Conditions Which Generate This Code...1029
System Response...1029
Possible Performance Effect...1029
Troubleshooting...1029
Results...1029
CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal...1029
Conditions Which Generate This Code...1029
System Response...1029
Possible Performance Effect...1029
Results...1029
CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio...1029
Conditions Which Generate This Code...1029
System Response...1029
Possible Performance Effect...1029
Results...1029
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off...1030
Conditions Which Generate This Code...1030
System Response...1030
Possible Performance Effect...1030
Results...1030
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ...1030
Conditions Which Generate This Code...1030
System Response...1030
Possible Performance Effect...1030
Test Step 1...1030
Results...1030
Test Step 2...1030
Results...1030
CID 1684 FMI 02 Fuel Injection Pump, Software Failure...1030
Conditions Which Generate This Code...1030
System Response...1030
Possible Performance Effect...1030
Troubleshooting...1030
Results...1031
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault...1031
Conditions Which Generate This Code...1031
System Response...1031
Possible Performance Effect...1031
Troubleshooting...1031
Results...1031
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...1031
Conditions Which Generate This Code...1031
System Response...1031
Possible Performance Effect...1031
Troubleshooting...1031
Results...1031
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width...1031
Conditions Which Generate This Code...1031
Troubleshooting...1031
Results...1032
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault...1032
Conditions Which Generate This Code...1032
System Response...1032
Possible Performance Effect...1032
Troubleshooting...1032
Results...1032
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...1032
Conditions Which Generate This Code...1032
System Response...1032
Possible Performance Effect...1032
Troubleshooting...1032
Test Step 1...1032
Results...1032
Test Step 2...1032
Results...1032
Test Step 3...1032
Results...1033
Test Step 4...1033
Expected Result...1033
Results...1033
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault...1033
Conditions Which Generate This Code...1033
System Response...1033
Possible Performance Effect...1033
Troubleshooting...1033
Expected Result...1033
Results...1033
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error...1033
Conditions Which Generate This Code...1033
System Response...1033
Troubleshooting...1033
Test Step 1...1033
Results...1034
Test Step 2...1034
Results...1034
Test Step 3...1034
Results...1034
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault...1034
Conditions Which Generate This Code...1034
System Response...1034
Possible Performance Effect...1034
Troubleshooting...1034
Test Step 1...1034
Results...1034
Test Step 2...1034
Results...1034
CID 1684 FMI 14 Fuel Injection Pump, No Communications...1034
Conditions Which Generate This Code...1034
System Response...1034
Troubleshooting...1034
Test Step 1...1034
Results...1034
Test Step 2...1035
Results...1035
Test Step 3...1035
Results...1035
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali...1035
Conditions Which Generate This Code...1035
System Response...1035
Possible Performance Effect...1035
Troubleshooting...1035
Results...1035
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali...1035
Conditions Which Generate This Code...1035
System Response...1035
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S...1035
Conditions Which Generate This Code...1035
System Response...1035
Troubleshooting With an Event Code...1036
Event Codes...1036
Programmable Engine Parameters...1036
E015 High Engine Coolant Temperature Derate...1036
Conditions Which Generate This Code...1036
System Response...1036
Possible Performance Effect...1036
Troubleshooting...1036
Results...1036
E016 High Engine Coolant Temperature Shutdown...1036
Conditions Which Generate This Code...1036
System Response...1036
Possible Performance Effect...1036
Troubleshooting...1036
Results...1036
E017 High Engine Coolant Temperature Warning...1036
Conditions Which Generate This Code...1036
System Response...1036
Possible Performance Effect...1036
Troubleshooting...1036
Results...1036
E025 High Intake Air Temperature Derate...1037
Conditions Which Generate This Code...1037
System Response...1037
Possible Performance Effect...1037
Troubleshooting...1037
Results...1037
E027 High Intake Air Temperature Warning...1037
Conditions Which Generate This Code:...1037
System Response...1037
Possible Performance Effect...1037
Troubleshooting...1037
Results...1037
E040 Low Engine Oil Pressure Shutdown...1037
Conditions Which Generate This Code...1037
System Response...1037
Possible Performance Effect...1037
Troubleshooting...1037
Results...1037
E054 High Fuel Temperature Derate...1038
Conditions Which Generate This Code...1038
System Response...1038
Troubleshooting...1038
Test Step 1 - Check for Diagnostic Codes...1038
Expected Result...1038
Results...1038
Test Step 2 - Perform a Check of the Fuel System...1038
Expected Result...1038
Results...1038
E056 High Fuel Temperature Warning...1038
Conditions Which Generate This Code...1038
System Response...1038
Troubleshooting...1038
Test Step 1 - Check for Diagnostic Codes...1038
Expected Result...1038
Results...1039
Test Step 2 - Perform a Check of the Fuel System...1039
Expected Result...1039
Results...1039
E100 Low Engine Oil Pressure Warning...1039
Conditions Which Generate This Code...1039
System Response...1039
Possible Performance Effect...1039
Troubleshooting...1039
Test Step 1 - Check for Active Diagnostic Codes...1039
Expected Result...1039
Results...1039
Test Step 2 - Perform a Check of the Engine Lubrication System...1039
Expected Result...1039
Results...1039
E190 Engine Overspeed Warning...1040
Conditions Which Generate This Code...1040
System Response...1040
Possible Performance Effect...1040
Troubleshooting...1040
Engine Overspeed Warning...1040
Expected Result...1040
Results...1040
E442 Engine Failed to Stop With a No-Fuel Command...1040
Conditions Which Generate This Code...1040
System Response...1040
Possible Performance Effect...1040
Troubleshooting...1040
Test Step 1...1040
Results...1040
Test Step 2...1040
Results...1040
E883 Engine Failed to Stop When Fuel Solenoid Disengaged...1040
Conditions Which Generate This Code...1040
System Response...1040
Possible Performance Effect...1041
Troubleshooting...1041
Test Step 1...1041
Results...1041
Test Step 2...1041
Results...1041
Test Step 3...1041
Results...1041
Diagnostic Function Tests...1041
5-Volt Engine Pressure Sensor Supply Circuit - Test...1041
System Operation Description...1041
Background Information...1041
Test Step 1...1042
Inspect Electrical Connectors and Wiring...1042
Expected Result...1042
Results...1043
Test Step 2...1043
Check for Active Diagnostic Codes...1043
Expected Result...1043
Results...1043
Test Step 3...1043
Disconnect the ECM Engine Harness Connector From the ECM...1043
Expected Result...1044
Results...1044
Test Step 4...1044
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei...1044
Expected Result...1045
Results...1045
Test Step 5...1045
Check the Engine Harness...1045
Expected Result...1045
Results...1045
Air Inlet Heater Circuit - Test...1045
System Operation Description...1045
Test Step 1...1046
Inspect Electrical Connectors and Wiring...1046
Expected Result...1046
Results...1046
Test Step 2...1046
Check the Supply to the Power Relay for the Air Inlet Heater Sta...1046
Expected Result...1047
Results...1047
Test Step 3...1047
Check the Output From the Power Relay for the Air Inlet Heater S...1047
Expected Result...1047
Results...1047
Test Step 4...1047
Ground the Input to the Power Relay at the MIC...1047
Expected Result...1047
Results...1047
Test Step 5...1047
Ground the Input to the Power Relay at the ECM Connector...1047
Expected Result...1047
Results...1047
Test Step 6...1048
Override the Air Inlet Heater Starting Aid to Test the ECM...1048
Results...1048
Checking Idle Validation Switching Point (Throttle Sensor) With ...1048
Expected Result...1048
Analog Throttle Position Sensor Circuit - Test...1048
System Operation Description...1048
Checking the Throttle Sensor With Unconnected Output C...1049
Expected Result...1049
Test Step 1...1049
Check for Connector Damage...1049
Expected Result...1050
Results...1050
Test Step 2...1050
Check for Active Diagnostic Codes...1050
Expected Result...1050
Results...1050
Test Step 3...1050
Check the Throttle Position With the Electronic Service Tool...1050
Expected Result...1050
Results...1050
Test Step 4...1050
Check the Voltage at the Throttle Position Sensor...1050
Expected Result...1050
Results...1050
Test Step 5...1051
Disconnect the Throttle Position Sensor and Check for Active Dia...1051
Expected Result...1051
Results...1051
Test Step 6...1051
Check the Throttle Selection Status With the Electronic Service ...1051
Expected Result...1051
Results...1051
Test Step 7...1052
Disconnect the Supply Terminals of the Throttle Position Sensor ...1052
Expected Result...1052
Results...1052
Test Step 8...1052
Check the Position of Throttle Position Sensor...1052
Expected Result...1052
Results...1053
Test Step 9...1053
Check the Throttle Position Sensor at the ECM...1053
Expected Result...1053
Results...1053
CAN Data Link Circuit - Test...1053
System Operation Description...1053
Test Step 1...1054
Inspect Electrical Connectors and Wiring...1054
Expected Result...1054
Results...1054
Test Step 2...1054
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...1054
Expected Result...1054
Results...1054
Test Step 3...1054
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...1054
Expected Result...1054
Results...1055
Test Step 4...1055
Verify the Supply Voltage at the Fuel Injection Pump...1055
Expected Result...1055
Results...1055
Data Link Circuit - Test...1055
System Operation Description...1055
Background Information...1056
Communication...1056
Test Step 1...1056
Inspect Electrical Connectors and Wiring...1056
Expected Result...1056
Results...1056
Test Step 2...1056
Determine the Type of Problem With the Data Link...1056
Expected Result...1056
Results...1057
Test Step 3...1057
Check the Battery Voltage at the ECM...1057
Expected Result...1057
Results...1057
Test Step 4...1057
Check the Battery Voltage That is Coming to the Data Link Connec...1057
Expected Result...1058
Results...1058
Test Step 5...1058
Connect the Electronic Service Tool Directly to the ECM...1058
Expected Result...1058
Results...1058
Test Step 6...1058
Change Electronic Service Tool Components...1058
Expected Result...1059
Results...1059
Test Step 7...1059
Connect an Electronic Service Tool and the ECM to Another Batter...1059
Expected Result...1059
Results...1059
Electrical Connectors - Inspect...1059
System Operation Description...1059
Background Information...1060
Test Step 1...1063
Check the Locking of the DT Connector (Deutsch) and the Lock Rin...1063
Expected Result...1063
Results...1063
Test Step 2...1064
Check the Socket Head Screw on the Connector for the Electronic ...1064
Expected Result...1064
Results...1064
Test Step 3...1064
Perform a Pull Test on Each Wire Terminal Connection...1064
Expected Result...1064
Results...1064
Test Step 4...1064
Monitor the Electronic Service Tool While the Wiring and the Con...1064
Expected Result...1065
Results...1065
Test Step 5...1065
Check Wires for Nicks and/or Abrasions in the Insulation...1065
Expected Result...1065
Results...1065
Test Step 6...1065
Check Connectors for Moisture or Corrosion...1065
Expected Result...1066
Results...1066
Test Step 7...1066
Inspect the Connector Terminals...1066
Expected Result...1066
Results...1066
Test Step 8...1066
Check Individual Pin Retention Into the Socket...1066
Expected Result...1067
Results...1067
Electrical Power Supply Circuit - Test...1067
System Operation Description...1067
Background Information...1067
Test Step 1...1068
Check the Batteries...1068
Expected Result...1068
Results...1068
Test Step 2...1069
Inspect Electrical Connectors and Wiring...1069
Expected Result...1069
Results...1069
Test Step 3...1069
Check the Battery Voltage at the ECM...1069
Expected Result...1069
Results...1070
Test Step 4...1070
Use the Bypass Harness for the Electronic Service Tool to Bypass...1070
Expected Result...1071
Results...1071
Engine Pressure Sensor Open or Short Circuit - Test...1071
System Operation Description...1071
Background Information...1071
Test Step 1...1071
Check for Active +5V Sensor Supply Diagnostic Codes...1071
Expected Result...1072
Results...1072
Test Step 2...1072
Verify All Active Diagnostic Codes...1072
Expected Result...1072
Results...1072
Test Step 3...1072
Inspect Electrical Connectors And Wiring...1072
Expected Result...1073
Results...1073
Test Step 4...1073
Verify That the Diagnostic Code is Still Active...1073
Expected Result...1073
Results...1073
Test Step 5...1073
Disconnect the Sensor to Create an Open Circuit...1073
Expected Result...1073
Results...1073
Test Step 6...1073
Measure the Sensor Supply Voltage...1073
Expected Result...1074
Results...1074
Test Step 7...1074
Determine if the Short Circuit is in the Connector or in the Sen...1074
Expected Result...1074
Results...1074
Test Step 8...1074
Create a Short Circuit Between the Signal and the Common Termina...1074
Expected Result...1075
Results...1075
Test Step 9...1075
Check the Operation of the ECM by Creating Open and Short Circui...1075
Expected Result...1075
Results...1075
Test Step 10...1076
Bypass the Harness Wiring Between the ECM and the Sensor Connect...1076
Expected Result...1076
Results...1076
Engine Speed/Timing Sensor Circuit - Test...1076
System Operation Description...1076
Test Step 1...1077
Inspect the Electrical Connectors and Cables...1077
Expected Result...1077
Results...1077
Test Step 2...1077
Check the Installation of the Engine Speed/Timing Sensors...1077
Expected Result...1077
Results...1077
Test Step 3...1077
Measure the Sensor Resistance Through the Wiring Harness...1077
Expected Result...1078
Results...1078
Test Step 4...1078
Measure the Resistance of the Sensor...1078
Expected Result...1078
Results...1078
Test Step 5...1079
Measure the Resistance of the Cables Between the Fuel Injection ...1079
Expected Result...1079
Results...1079
Test Step 6...1079
Check the Continuity of the Cables From the ECM to the Fuel Inje...1079
Expected Result...1079
Results...1080
Engine Temperature Sensor Open or Short Circuit - Test...1080
System Operation Description...1080
Background Information...1080
Test Step 1...1081
Verify All Active Diagnostic Codes...1081
Expected Result...1081
Results...1081
Test Step 2...1081
Inspect Electrical Connectors and Wiring...1081
Expected Result...1081
Results...1082
Test Step 3...1082
Verify That the Diagnostic Code is Still Active...1082
Expected Result...1082
Results...1082
Test Step 4...1082
Disconnect the Sensor to Create an Open Circuit...1082
Expected Result...1082
Results...1082
Test Step 5...1082
Create a Short Circuit Between the Signal and the Common Termina...1082
Expected Result...1083
Results...1083
Test Step 6...1083
Check the Operation of the ECM by Creating an Open and a Short C...1083
Expected Result...1083
Results...1083
Test Step 7...1083
Bypass the Harness Wiring Between the ECM and the Sensor Connect...1083
Expected Result...1084
Results...1084
Fuel Injection Pump Circuit - Test...1084
System Operation Description...1084
Background Information...1084
Test Step 1...1084
Check the Batteries...1084
Expected Result...1084
Results...1085
Test Step 2...1085
Inspect the Electrical Connectors and Wiring...1085
Expected Result...1086
Results...1086
Test Step 3...1086
Check the Supply Voltage at the Machine Interface Connector...1086
Expected Result...1086
Results...1086
Test Step 4...1086
Check the Supply Voltage at the Fuel Injection Pump...1086
Expected Result...1086
Results...1086
Test Step 5...1087
Check the Supply to the Power Relay for the Fuel Injection Pump...1087
Expected Result...1087
Results...1087
Test Step 6...1087
Check the Output of the Power Relay for the Fuel Injection Pump...1087
Expected Result...1087
Results...1087
Test Step 7...1087
Check the Voltage at the Relay Coil for the Fuel Injection Pump...1087
Expected Result...1087
Results...1087
Test Step 8...1088
Check the Output of the ECM Fuel Pump Power Control at the Machi...1088
Expected Result...1088
Results...1088
Test Step 9...1088
Check the Output of the Fuel Injection Pump Power Control at the...1088
Expected Result...1088
Results...1088
Test Step 10...1088
Measure the Voltage at the Pump Power Supply...1088
Expected Result...1089
Results...1089
Test Step 11...1089
Check the Voltage Load Protection Module (VLPM)...1089
Expected Result...1090
Results...1090
Indicator Lamp Circuit - Test...1090
System Operation Description...1090
Test Step 1...1090
Inspect Electrical Connectors and Wiring...1090
Results...1091
Test Step 2...1091
Inspect the Lamp, the Fuse, and the Power Supply...1091
Expected Result...1091
Results...1091
Test Step 3...1091
Inspect the Input to the Lamp at the ECM connector...1091
Expected Result...1091
Results...1092
Test Step 4...1092
Test the Individual Lamp Circuits...1092
Expected Result...1092
Results...1092
Test Step 5...1092
Check the Voltage at the ECM...1092
Expected Result...1092
Results...1092
Idle Validation Circuit - Test...1092
System Operation Description...1092
Test Step 1...1092
Expected Result...1092
Results...1093
tables...941
Table 1. Electronic Service Tool...967
Table 2. Optional Service Tools...968
Table 3. CID FMI Codes and J Code FMI Codes...969
Table 4. Event Codes and CID FMI Codes...971
Table 5. Diagnostics Supported Over J1939...972
Table 6. Events Supported Over J1939...974
Table 7. Engine Connectors...981
Table 8. Color Codes for the Harness Wire...986
Table 9. Pin Connections for Perkins Deutsch Socket Connector...988
Table 10. Suspect Parameter Numbers...992
Table 11. Failure Mode Indicators (FMI) Codes...993
Table 12. Engine Oil Pressure Trip and Reset Points...1037
1586990-8000SRM1181-(03-2007)-UK-EN...1097
toc...1097
Assembly Guide...1097
Safety Precautions Maintenance and Repair...1098
List of All Special Tools and Equipment Needed for the Assembly...1101
General Considerations Before Starting the Job...1101
Preparation of the Components Before Assembly...1102
Liquefied Petroleum Gas (LPG Engines Only)...1102
Remove...1102
Install...1103
Checking of the Wheels...1103
Air Pressure...1103
Drive Wheels...1104
Steer Wheels...1108
Wheel Nut Torque...1111
Mast Label Placement...1112
Safety Procedures When Working Near Mast...1113
Mast Installation...1115
Mast...1115
Tilt Cylinder Pin Installation...1118
Lift Cylinder Hose Connection...1119
Truck Header Hoses and Electrical Cable Connections...1120
Mast Light Connection...1122
Carriage Installation...1123
Carriage Header Hoses and Electrical Cable Connection...1124
Fork Installation...1127
Exhaust Extension Tube Installation...1128
Lights Installation - Operator Compartment...1130
Hydraulic Oil Check...1131
Lubrication Points...1132
Check Points...1133
Checkpoint 1...1133
Checkpoint 2...1133
Checkpoint 3...1133
Checkpoint 4...1133
Checkpoint 5...1133
General Truck Install Procedures...1133
tables...1097
Table 1. Mast Hanger Pins Capscrew Torques...1118
1612615-5000SRM1221-(11-2006)-UK-EN...1137
toc...1137
Extendable Container Attachment (Elme)...1137
Safety Precautions Maintenance and Repair...1138
General...1143
Description...1143
Operation...1147
General...1147
Optional Powered Pile Slope...1147
Sideshift...1148
Extend and Retract Circuit...1149
Container locking Model 582...1151
Sequence Valve...1151
Pilot Check Valve...1152
Container Locking Model 583...1153
Container Locking Model 584...1153
Container Locking Model 585...1154
Container Locking Models 586, 588, and 589...1154
Electrical System...1156
Indicator Lights...1156
Flashing Indicator Lights...1157
Automatic Locking...1157
Lift Interrupt and Override...1157
Overlowering Interrupt and Override...1157
Second Container Detection Sensor (Model 582 Only)...1158
Carriage and Attachment Removal...1158
Carriage...1158
Spreader...1159
Sideshift Cylinder Removal and Installation...1159
Remove...1159
Install...1159
Extension Cylinder Removal and Installation...1160
Remove...1160
Upper, Right-Hand...1160
Lower, Left-Hand...1160
Install...1160
Floating End Beams Repair...1161
Remove...1161
Install...1161
Hose, Replace...1162
Twist Lock Repair for Model 582...1163
Remove...1163
Upper Twist Lock...1163
Lower Twist Lock...1163
Disassemble...1164
Clean and Inspect...1164
Assemble...1165
Install...1165
Hook Repair for Model 584 and 585...1165
Remove...1165
Inspect...1165
Install...1165
Side Clamp Replacement for Model 584...1166
Remove...1166
Install...1167
Twist Lock Repair for Models 586, 588, and 589...1167
Disassemble...1167
Clean and Inspect...1167
Assemble...1168
Extension Beam Repair...1169
Remove...1169
Inspect...1169
Assemble...1170
Cylinder Repair...1171
Extension Cylinder...1171
Disassemble...1171
Clean and Inspect...1171
Assemble...1171
Guide for Extension Cylinder...1172
Remove...1172
Install...1172
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde...1172
Disassemble...1172
Assemble...1172
Wear Pad Replacement...1173
General...1173
Floating End Beam Wear Pads...1173
Upper Wear Pads...1173
Lower Wear Pads...1173
Main Frame Wear Pads at Large (Right-Hand) Extension Beam...1173
Main Frame Wear Pads at Small (Left-Hand) Extension Beam...1173
Guide for Extension Cylinder...1174
Large Extension Beam Internal Wear Pads...1175
Spreader Frame...1175
Upper Wear Pads...1175
Lower Wear Pads...1175
Powered Pile Slope Carriage...1175
Upper Wear Pads...1175
Lower Wear Pads...1175
Adjustments...1175
Twist Lock Angle Adjustment...1175
Model 586, 588 and 589...1175
LOCKED/NOT LOCKED Sensors Adjustment...1176
Model 582...1176
Model 586, 588 and 589...1176
Side Clamp Open/Closed Sensor Adjustment (Model 584)...1176
Hook in Sensor Adjustment (Model 584)...1176
Seated Sensor Adjustment...1177
Model 582...1177
Model 586, 588 and 589...1177
Overlowering Protection Sensor Adjustment (All 580 Models)...1177
Schematics...1178
tables...1137
Table 1. Elme Schematic Overview...1178
897108-1600SRM0326-(03-2007)-UK-EN...1265
toc...1265
Steering Axle...1265
Safety Precautions Maintenance and Repair...1266
General...1269
Description...1269
Steering Axle Assembly Repair...1274
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...1274
Remove...1274
Install...1274
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...1275
Remove...1275
Install...1275
Wheels and Hubs Repair (All Units)...1276
Remove and Disassemble...1276
Clean...1276
Inspect...1276
Assemble and Install...1276
Spindles and Bearings Repair (All Units)...1278
Remove...1278
Clean...1278
Assemble and Install...1279
Tie Rods Repair (All Units)...1280
Remove...1280
Clean...1280
Install...1280
Steering Cylinder Repair...1283
Remove and Disassemble...1283
Clean and Inspect...1283
Assemble and Install...1283
Troubleshooting...1284
897934-0700SRM0626-(11-2001)-UK-EN...1289
toc...1289
Cooling System...1289
Safety Precautions Maintenance and Repair...1290
General...1293
Description...1294
Radiator...1294
Radiator Cap...1294
Thermostat...1294
Water Pump...1295
Fan and Fan Shroud...1295
Cooling System Checks...1295
Radiator...1295
Thermostat...1295
Water Pump...1296
Exhaust Leaks...1296
Fan and Fan Shroud...1296
Radiator Cleaning...1296
Drain...1296
Clean...1296
Fill...1297
Troubleshooting...1298
899784-2200SRM0002-(10-2003)-UK-EN...1301
toc...1301
Alternator with Regulator...1301
Safety Precautions Maintenance and Repair...1302
General...1305
Description...1305
Alternator Repair...1307
Alternator Type A...1307
Remove and Disassemble...1307
Clean...1308
Assemble...1309
Install...1309
Alternator Type B...1312
Remove and Disassemble...1312
Clean...1312
Assemble...1313
Install...1314
General Check and Adjustment...1315
Low Output Check (Type A or Type B)...1315
High Output Check (Type A or Type B)...1317
Brushes Circuit Check...1318
Delco Alternators...1318
Motorola Alternators...1319
Diodes Check...1320
Diode Bridge Check...1320
Delco and Leece-Neville Alternators...1320
Motorola Alternators...1320
Rotor Field Winding Check...1321
Stator Windings Check...1322
Voltage Regulator Check...1322
Troubleshooting...1322
910072-1400SRM0046-(07-2007)-UK-EN...1327
toc...1327
Differential...1327
Safety Precautions Maintenance and Repair...1328
General...1331
Description...1331
Differential Repair...1332
Remove...1332
Differential Carrier From Axle Housing, Remove...1332
Differential and Ring Gear From Differential Carrier, Remove...1334
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...1336
Disassemble...1337
Differential and Ring Gear Assembly, Disassemble...1337
Drive Pinion and Pinion Carrier, Disassemble...1339
Clean and Inspect...1342
Assemble...1343
Pinion, Bearings, and Pinion Carrier, Assemble...1343
Pinion Bearings, Adjust Preload...1343
Press Method...1343
Yoke or Flange Method...1344
Triple-Lip Seal, Install...1345
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...1346
Differential and Ring Gear, Assemble...1348
Differential Gears Rotating Torque, Check...1350
Differential and Ring Gear Assembly, Install...1351
Differential Bearings, Preload Adjust...1353
Ring Gear, Runout Check...1354
Ring Gear Backlash, Adjust...1354
Gear Set, Tooth Contact Pattern Check...1356
Thrust Screw, Install and Adjust...1359
Install...1359
Differential Assembly Into Axle Housing, Install...1359
Specifications...1361
Troubleshooting...1366
tables...1327
Table 1. Ring Gear Backlash Adjustment Specifications...1356
Table 2. Ring and Pinion Tooth Contact Adjustment...1357
Table 3. General Specifications...1361
Table 4. Rivet Installation Pressure...1361
Table 5. Pinion Adjustment...1362
Table 6. Pinion Preload Pressure...1362
Table 7. Torque Specifications...1363
Table 8. Torque Specifications for Metric Hardware...1364
Table 9. Torque Specifications for Metric (Fine) Hardware...1365
910102-2100SRM0103-(03-2007)-UK-EN...1369
toc...1369
Tilt Cylinders...1369
Safety Precautions Maintenance and Repair...1370
General...1373
Description...1373
Tilt Cylinder Repair...1373
Remove...1373
Disassemble...1373
Clean...1373
Assemble...1373
Tilt Cylinders With O-Ring or Single-Lip Seals...1373
Tilt Cylinders for XM and XMS Models...1375
Tilt Cylinders for XL, XLS, and XL 3 Models...1376
Tilt Cylinders for H700-800A and Early Model H700-920B...1378
Install...1379
Tilt Cylinders Using Chevron Packing...1379
Install...1380
Tilt Cylinder Leak Check...1382
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...1384
Torque Specifications...1384
Piston Rod Nut...1384
Retainer...1385
Troubleshooting...1387
tables...1369
Table 1. Movement Rates (Maximum) for Tilt Cylinders...1383
910107-2200SRM0106-(02-2001)-UK-EN...1391
toc...1391
Starter...1391
Safety Precautions Maintenance and Repair...1392
General...1395
Description and Operation...1395
Starter Repair...1397
Remove...1397
Disassemble...1397
Clean...1398
Assemble...1398
Install...1399
General Checks and Adjustments...1399
Troubleshooting...1402
910442-8000SRM0231-(12-2004)-UK-EN...1407
toc...1407
Metric and Inch (SAE) Fasteners...1407
Safety Precautions Maintenance and Repair...1408
General...1411
Threaded Fasteners...1411
Nomenclature, Threads...1411
Strength Identification...1412
Cotter (Split) Pins...1412
Fastener Torque Tables...1417
Conversion Table...1419
tables...1407
Table 1. Bolts and Screws...1413
Table 2. Studs and Nuts...1414
Table 3. Torque Nuts...1415
Table 4. Torque Nuts With Nylon Insert...1416
Table 5. Torque Values for Metric Fasteners*...1417
Table 6. Torque Values for Inch Fasteners*...1418
Table 7. Conversion Table for Metric and English Units...1419
Table 8. Cotter Pin Dimensional Data...1420
Table 9. Cotter Pin Dimensional Data...1421
Table 10. Cotter Pin Dimensional Data...1422
Table 11. Cotter Pin Dimensional Data...1424
Aurora_AC...1429
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...1430
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...1436
Compressors are machines under pressure and as such require special care in handling...1436
Only qualified personnel are allowed to perform any work on refrigeration compressors...1436
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...1436
Never put the safety switch out of action...1436
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...1436
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...1436
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...1436
Caution! Danger of burning because of high surface temperatures...1436
Never grab rotating parts during operation. Danger of injury!...1436
Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov...1436
Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri...1436
No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion...1436
Full bottles of refrigerant must not be thrown or...1436
It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only...1436
4. Troubleshooting...1437
...1437
...1437
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...1437
By wrong refrigerant level there is a danger of compressor malfunction...1437
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...1437
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...1437
Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o...1437
NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with...1437
Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click...1437
912-100-0007_e.pdf...0
Technical modifications reserved...1438
912-100-0258_e.pdf...0
Condenser unit, 24V...1449
...1449
...1449
...1449
...1449
part no.:175-FR2-0002...1449
Safety advices...1449
- we reserve the right to make technical modifications -...1449
1Safety advices...1450
Maintenance work on the refrigeration circuit:...1450
...1451
2.2Condenser blowers...1451
5Electrical connection...1452
every six months – authorised workshop:...1453
...1453
...1453
...1453
State of the refrigerant hoses...1453
State of the condenser...1453
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...1453
every month sight checks - Operator...1454
...1454
...1454
...1454
State of the refrigerant hoses...1454
State of the condenser...1454
Check condenser of contamination by dust, insects or parts of plants...1454
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...1454
Installation of replacement parts...1454
8Technical data...1454
9Fault diagnosis...1455
F019 (H300-350HD; H360HD-EC)...1460
1494123-0100SRM0927-(01-2006)-US-EN...1461
toc...1461
Frame...1461
Safety Precautions Maintenance and Repair...1462
General...1465
Description...1465
Counterweight Repair...1465
Remove...1465
Install...1467
Fenders...1467
Remove...1467
Install...1467
Side Counterweights H13.00-16.00XM (H300-360HD)...1467
Side Counterweight, Replace...1467
Hood and Air Cleaner Repair...1468
Remove...1468
Install...1470
Hydraulic Tank Repair...1470
Remove...1470
Repairs, All Units...1471
Small Leaks...1471
Large Leaks...1472
Clean...1472
Steam Method...1472
Chemical Solution Method...1473
Other Methods of Preparation for Repair...1473
Install...1473
Fuel Tank Repair...1474
Remove...1474
Repairs...1474
Install...1474
Cooling System and Radiator Repair...1476
Remove...1476
Install...1477
Engine and Transmission Repair...1478
Hyster T-50 Transmission, Remove...1478
Hyster T-50 Transmission, Install...1479
TE-10 Transmission...1480
Remove...1480
Install...1483
Label Replacement...1485
1494140-1600SRM0936-(03-2007)-US-EN...1493
toc...1493
Steering System...1493
Safety Precautions Maintenance and Repair...1494
General...1497
Description...1497
Steering Wheel and Column Assembly...1499
General...1499
Steering Wheel and Horn...1499
Remove...1499
Install...1499
Steering Control Unit Repair...1501
General...1501
Description...1501
Operation...1501
Remove...1502
Disassemble...1502
Clean...1505
Assemble and Install...1505
Steering System Air Removal...1511
Steering Relief Pressure Check...1512
Troubleshooting...1512
1494141-1800SRM0937-(03-2007)-US-EN...1517
toc...1517
Dry Brake System...1517
Safety Precautions Maintenance and Repair...1518
General...1521
Description...1521
Operation...1522
Service Brakes...1522
Parking Brake...1524
Air Tank Repair...1525
Relief Valve...1525
Drain Valve...1525
Brake Pedal Valve Repair...1526
Remove...1526
Disassemble, Inspect, and Assemble...1526
Install...1526
Air Chambers Repair...1527
Remove...1527
Disassemble...1527
Inspect...1528
Assemble...1529
Install...1529
Actuator Arms Repair...1529
Remove...1529
Inspect...1530
Install...1530
Brake Assemblies Repair...1531
Brake Shoe, Remove...1531
Camshaft, Remove...1533
Clean...1533
Inspect...1534
Camshaft, Install...1534
Brake Shoe, Install...1535
Air Dryer...1536
Description...1536
Cartridge...1536
Remove...1536
Install...1536
Filter...1536
Remove...1536
Install...1536
Quick-Release Valve...1538
Governor Check and Adjustment for Air Compressor...1538
Brake Shoes Adjustment...1539
Specifications...1540
Troubleshooting...1540
Service Brakes...1540
Service Brakes, Park Function ...1543
tables...1517
Table 1. Air Chambers Operation...1524
1494142-1900SRM0938-(03-2007)-US-EN...1547
toc...1547
Hydraulic System...1547
Safety Precautions Maintenance and Repair...1548
General...1551
Description and Operation...1551
Hydraulic Tank...1551
Hydraulic Pump...1552
Steering Priority Flow Valve...1552
Pilot Valve...1553
Main Control Valve...1555
Unloader Valve...1556
Hydraulic Operation...1557
Checks and Adjustments...1560
Quick Disconnect Fittings...1560
Steering Priority Flow Valve...1560
Steering Relief Pressure...1560
Modulator Valve...1561
Pilot Valve and Pressure Reducing Valve...1561
Accumulator...1562
Filter...1562
Main Control Valve...1562
Relief Pressure Check...1562
Check Valves...1563
Unloader Valve...1563
Hydraulic Pump Repair...1564
Remove...1564
Disassemble...1564
Clean and Inspect...1564
Assemble...1565
Install...1566
Pilot Accumulator Replacement ...1566
Remove...1566
Install...1566
Pilot Valve Repair...1567
Remove...1567
Disassemble...1568
Clean and Inspect...1568
Assemble...1568
Install...1568
Control Levers and Joystick Repair...1569
Remove...1569
Install...1569
Calibration and Diagnostics...1570
General...1570
Description...1570
Lever and Joystick Calibration...1570
Flow Adjustment...1570
Dead Band Value Setting...1571
Lowering Delay...1572
PWM and I/O Module Readouts...1572
Function Disable...1573
General Startup...1573
Minimum system requirements...1573
Install the Hydraulic Controls Program...1573
DelayTimeFile (Reset)...1573
Select the Processor Speed...1574
Hydraulic Controls Program...1574
Calibration...1576
Joystick/Lever Calibration...1576
Levers...1576
Joystick...1576
Valve Flow Adjustment...1577
Diagnostics...1577
Calibration System Shutdown...1577
LED Diagnostics...1578
Electrical Connections...1581
Specifications...1585
tables...1547
Table 1. Main Control Valve Port Settings...1553
Table 2. Processor Speed Settings...1573
Table 3. PWM Board LED Error Codes...1578
Table 4. Altering PT FLT I/O Board LED's (Old Logic)...1579
Table 5. Altering PT FLT I/O Board LED's (New Logic)...1579
Table 6. Fixed PT Logic I/O Boards LED's...1580
Table 7. ECH...1580
Table 8. PWM Driver Module...1581
Table 9. Input/Output Module 1...1582
Table 10. Input/Output Module 2...1583
Table 11. Altering PT FLT...1584
Table 12. Fixed PT FLT...1584
Table 13. ECH...1585
1494145-8000SRM0940-(03-2008)-US-EN...1589
toc...1589
Capacities and Specifications...1589
Safety Precautions Maintenance and Repair...1590
Lift Truck Weights...1593
Capacities...1593
Engine Specifications...1594
Perkins Diesel...1594
Cummins Diesel/LPG...1595
Hydraulic System...1596
Electrical System...1597
Tire Sizes...1597
Mast Speeds...1597
Perkins Diesel...1597
Cummins Diesel/LPG...1598
Torque Specifications, Cummins Diesel...1599
Lubrication System...1599
Torque Specifications, Perkins Diesel...1599
Engine...1599
Cylinder Head Assembly...1599
Piston and Connecting Rod Assemblies...1599
Crankshaft Assembly...1599
Timing Case and Drive Assembly...1600
Turbocharger...1600
Lubrication System...1600
Fuel System...1600
Cooling System...1600
Flywheel and Housing...1600
Aspiration System...1601
Electrical Equipment...1601
Auxiliary Equipment...1601
Torque Specifications - Perkins, Tier 2...1601
Cylinder Head Assembly...1601
Piston and Connecting Rod Assemblies...1601
Crankshaft Assembly...1601
Timing Case and Drive Assembly...1601
Turbocharger...1602
Lubrication System...1602
Fuel System...1602
Cooling System...1602
Flywheel...1602
Auxiliary Equipment...1602
Torque Specifications, General...1603
Transmission...1603
Driveline and Axle...1603
Differential...1603
Brakes - Wet...1603
Brakes - Dry...1603
Steering...1603
Hydraulic System...1604
Mast...1604
Carriage...1604
Tilt Cylinders...1604
Frame...1604
Wiper Arms, Front...1604
Hyster T-50 Transmission Pressures (Powershift and Automatic)...1605
TE-10 Transmission Specifications...1606
Electrical...1606
Hydraulic Cooler Lines...1606
Torque Specifications for Lubricated or Plated Screw Threads...1607
tables...1589
Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp...1606
Table 2. Grade 5...1607
Table 3. Grade 8...1607
Table 4. Grades 8.8, 10.9, and 12.9...1607
Table 5. O-ring Port Plug Torque Chart...1608
Table 6. Pipe Plug Torque Chart...1608
1494953-1400SRM0944-(03-2007)-US-EN...1611
toc...1611
Planetary Drive Axle...1611
Safety Precautions Maintenance and Repair...1612
General...1615
Description...1615
Operation...1617
Identification...1617
Removal...1618
Disassembly...1618
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1618
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1620
Wheel End...1622
Spindle and Piston Housing...1623
Cleaning...1624
Clean Ground or Polished Parts...1624
Clean Parts With Rough Finish...1624
Clean Axle Assemblies...1624
Drying Cleaned Parts...1624
Corrosion Prevention...1624
Parts Inspection...1625
Tapered Roller Bearings...1625
Bevel Pinion and Ring Gear Sets...1626
Main Differential Assembly...1626
Axle Shafts...1626
Yoke...1626
Brakes...1626
Repair or Replace Parts...1626
Repair Welding...1626
Apply Silicone Gasket Material...1627
Assembly...1627
Spindle and Piston Housing to Axle Housing...1627
Wet Disc Brakes...1628
Adjust Wheel Bearing Preload...1629
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1630
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1631
Planetary Spider Assembly...1631
Installation...1632
Fill Wet Disc Brakes With Hydraulic Fluid...1632
Torque Specifications...1633
Lubrication Specification...1634
1494955-2000SRM0943-(03-2007)-US-EN...1637
toc...1637
Main Control Valve...1637
Safety Precautions Maintenance and Repair...1638
General...1641
Description...1641
Operation...1644
Lift Section...1644
Tilt/Auxiliary Section...1644
Relief Valves...1644
Unloader Valve...1644
Main Control Valve Repair...1647
Remove...1647
Disassemble...1647
Auxiliary Side...1647
Lift Side...1647
Clean and Inspect...1650
Assemble...1650
Auxiliary Side...1650
Lift Side...1650
Install...1650
Pressure Relief Valve Check and Adjustment...1651
Check and Adjust...1651
Replace...1651
Specifications...1652
Troubleshooting...1652
1498445-1400SRM0945-(03-2007)-US-EN...1657
toc...1657
Planetary Drive Axle...1657
Safety Precautions Maintenance and Repair...1658
General...1661
Description...1661
Operation...1663
Identification...1663
Removal...1664
Disassembly...1664
Brake Drum...1664
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1665
Dry Brakes...1667
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1667
Spindle and Brake Spider...1669
Cleaning...1670
Ground or Polished Parts...1670
Parts With Rough Finish...1670
Axle Assemblies...1670
Drying Cleaned Parts...1670
Corrosion Prevention...1670
Parts Inspection...1671
Tapered Roller Bearings...1671
Bevel Pinion and Ring Gear Sets...1672
Main Differential Assembly...1672
Axle Shafts...1672
Yoke...1672
Brakes...1672
Repair or Replace Parts...1672
Repair Welding...1672
Apply Silicone Gasket Material...1673
Assembly...1673
Spindle, Brake Spider, and Brake...1673
Wheel End...1674
Adjust Wheel Bearing Preload...1675
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1676
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1677
Planetary Spider Assembly...1677
Installation...1678
Torque Specifications...1679
Lubrication Specification...1680
1498450-1800SRM0951-(03-2007)-US-EN...1683
toc...1683
Wet Brake System...1683
Safety Precautions Maintenance and Repair...1684
General...1687
Description and Operation...1687
Service Brakes...1687
Parking Brake...1687
Oil Cooler Circuit...1687
Pressure Switch Replacement...1691
Accumulators Replacement...1691
Brake Treadle Valve Repair...1691
Remove and Disassemble...1691
Clean and Inspect...1692
Assemble and Install...1692
Parking Brake Valve Repair...1692
Remove...1692
Clean and Inspect...1692
Repair...1692
Install...1692
Parking Brake Caliper Repair...1693
Remove...1693
Disassemble...1695
Inspect...1695
Install...1695
Adjust...1695
Brake Pad Repair...1696
Inspect...1696
Remove...1696
Install...1696
Seals Repair...1696
Remove...1696
Install...1697
Service Brake Repair...1697
Remove and Disassemble...1697
Drain Lubricating Oil...1697
Drain Coolant Oil...1704
Disconnect Brake Lines...1704
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14...1704
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...1705
Brake Disc Housing Assembly Wheel End...1706
Brake Piston Housing...1707
Brake Piston Housing and Wheel Spindle...1708
Inspect...1708
Clean...1710
Assemble...1711
Wheel Spindle...1711
Brake Piston Housing...1711
Piston Assembly...1713
Brake Disc Housing...1713
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub...1715
Check for Correct Installation of Duo-Cone Seal...1716
Wheel Hub to Brake Disc Housing...1717
Adjust...1718
Fill Brake System With Coolant Oil...1718
System Air Removal...1719
Adjust Brake With New Disc Pack...1719
Coolant Change Intervals...1720
Coolant Draining and Filling...1720
Specifications...1722
Minimum Brake Disc Thickness...1725
Hydraulic Fluid for Brake Actuation...1725
Brake Coolant Specifications...1725
Coolant Change Intervals...1725
Hydraulic Fluid Specifications...1725
Troubleshooting...1725
Brake Does Not Apply...1725
Brake Does Not Release...1726
Brake Performance...1726
Brake Leaks Actuation Fluid...1727
Brake Cooling Fluid Leakage...1728
Brake Noise and Vibration...1728
Brake Overheats...1728
tables...1683
Table 1. Brake Pad Adjustment...1695
Table 2. Minimum Brake Disc Thickness...1709
Table 3. Formed Seal Wear Chart...1709
1503241-5000SRM0969-(10-2007)-US-EN...1733
toc...1733
Empty Container Handling Attachment...1733
Safety Precautions Maintenance and Repair...1734
General...1737
Description...1737
Operation...1743
General...1743
Selector Valves...1743
Sideshift Circuit...1743
Extend and Retract Circuit...1743
Twist Lock Circuit and Control...1744
Model 553 - Horizontally Mounted...1744
Model 558 - Vertically Mounted...1744
Lifting Hooks...1744
Model 555...1744
Indicator Lights and LEDs...1744
Lift Interrupt and Override...1745
Overlowering Interrupt and Override...1745
Carriage and Attachment Repair...1745
Remove...1745
Attachment Without Carriage Repair...1746
Remove...1746
Sideshift Cylinders Repair...1747
Remove...1747
Disassemble...1747
Assemble...1747
Extension Cylinders Repair...1748
Remove...1748
Disassemble...1748
Clean and Inspect...1748
Assemble...1748
Install...1748
Vertical End Beams Repair...1750
Remove...1750
Install...1750
Hose Replacement in End Beams...1750
Twist Locks Repair for Model 553...1751
Remove...1751
Disassemble...1751
Clean and Inspect...1751
Assemble...1751
Hooks Replacement for Model 555...1752
Inspect...1752
Remove...1752
Install...1752
Twist Locks Repair for Model 558...1753
Disassemble...1753
Clean and Inspect...1753
Assemble...1753
Bleed the System...1754
Valve Assembly...1754
Slide Pad Replacement...1755
Adjustments...1755
Twist Lock Angle Adjustment...1755
Model 558 Only...1755
LOCKED/NOT LOCKED Sensors Adjustment...1756
Model 553...1756
Model 558...1756
Seated Sensor Adjustment...1756
Model 553...1756
Model 558...1756
Overlowering Protection Sensor Adjustment (Models 553 and 558)...1756
Torque Chart...1757
Maintenance...1757
Additional Attachment Maintenance...1759
Interface Boxes...1760
Model 555...1760
Models 553 and 558...1760
Troubleshooting...1762
tables...1733
Table 1. Torque Chart...1757
Table 2. Inspect and Adjust (See Figure 14 )...1758
Table 3. Lubricate (See Figure 14 )...1759
Table 4. Replace (See Figure 14 )...1759
1541323-0600SRM1068-(05-2004)-US-EN...1779
toc...1779
Perkins Tier 2 Diesel Engines...1779
Safety Precautions Maintenance and Repair...1780
General...1787
General Safety Rules...1787
Description...1788
Engine Serial Number Codes...1790
Engine Data...1790
Engine Removal and Installation...1791
Cylinder Head Assembly Repair...1791
Valve Cover...1791
Remove...1791
Install...1792
Rocker Arm Assembly...1792
Remove...1792
Disassemble...1792
Inspect...1792
Assemble...1792
Install...1792
Valve Clearance Adjustments...1793
Valve Springs...1794
Cylinder Head Assembly...1795
Remove...1795
Install...1797
Valves and Valve Springs...1800
Remove...1800
Inspect...1800
Install...1801
Valve Guides...1801
Inspect...1801
Remove...1801
Install...1801
Cylinder Head and Valve Seats...1802
Inspect...1802
Repair...1803
New Valve Seats, Install...1803
Piston and Connecting Rod Assemblies Repair...1803
Rod Bearings...1804
Remove...1804
Install...1804
Piston and Connecting Rod Assembly...1805
Service Note...1805
Remove...1805
Install...1806
Piston Rings...1807
Remove...1807
Inspect...1807
Install...1808
Piston and Connecting Rod...1808
Disassemble...1808
Inspect...1808
How to Select Correct Replacements...1809
Install...1810
Piston Cooling Jets...1810
Remove...1810
Install...1811
Crankshaft Assembly Repair...1811
General...1811
Crankshaft Pulley...1812
Remove...1812
Inspect...1812
Install...1812
Rear Oil Seal...1813
Remove...1813
Install...1813
Main Bearings...1814
Remove...1814
Inspect...1815
Install...1815
Thrust Washers...1815
Crankshaft Axial Movement, Check...1815
Remove...1816
Install...1816
Crankshaft...1817
Remove...1817
Inspect...1817
Install...1818
Flywheel...1819
Remove...1819
Ring Gear, Replace...1819
Install...1819
Flywheel Housing...1820
Remove...1820
Install...1820
Timing Case and Timing Gears Repair...1821
General...1821
Timing Case Cover...1821
Remove...1821
Install...1822
Front Oil Seal...1822
Remove...1822
Install...1822
Crankshaft Pulley Wear Sleeve...1823
Install...1823
Idler Gear and Hub...1823
Remove...1823
Install...1824
Air Compressor Drive, Bendix...1825
Disassemble...1825
Assemble...1825
Fuel Injection Pump Gear...1826
Remove...1826
Install...1827
Camshaft Gear...1827
Remove...1827
Install...1828
Crankshaft Gear...1828
Remove...1828
Install...1829
Timing Case...1829
Remove...1829
Install...1829
Camshaft and Tappets...1830
Remove...1830
Install...1831
Cylinder Block Assembly Repair...1831
Description...1831
Cylinder Block...1831
Disassemble...1831
Inspect...1832
Assemble...1832
Cylinder Liner...1833
Inspect...1833
Cylinder Liner Condition, Check...1833
Remove...1834
Service Liner, Install...1835
Partially Finished Liner, Install...1836
Engine Timing...1837
Description...1837
How to Set Number One Piston to TDC on Compression Stroke...1838
How to Set Number One Piston to TDC on Compression Stroke (Alter...1839
How to Set Number One Piston to 4° After TDC on Compression Stro...1840
Valve Timing, Check...1841
Fuel Injection Pump Timing, Check...1842
Turbocharger...1842
General...1842
Remove...1842
Install...1843
Impeller and Compressor Housing, Clean...1843
Waste-Gate Valve Check...1844
Closed Circuit Breather System (CCB)...1845
CCB Assembly, Remove...1845
Closed Circuit Drain Valve, Remove...1845
CCB Assembly, Install...1845
Closed Circuit Drain Valve, Install...1845
Lubrication System Repair...1846
General...1846
Oil Filter, Replace...1846
Oil Filter Head...1846
Remove...1846
Install...1846
Oil Filter Head Bypass Valve...1847
Remove and Install...1847
Oil Sump...1847
Remove...1847
Install...1847
Oil Pump...1848
Remove...1848
Inspect...1848
Install...1849
Relief Valve...1850
Remove...1850
Disassemble...1850
Inspect...1850
Assemble...1850
Install...1850
Idler Gear Shaft, Replace...1850
Remove...1851
Remove (Alternative)...1851
Install...1852
Install (Alternative)...1852
Fuel System Repair...1853
Description...1853
Fuel Injection Pump...1855
Remove...1855
Install...1857
Fuel System Air Removal...1858
Fuel Filter, Replace...1860
Fuel Injectors...1860
Remove...1861
Inspect...1861
Install...1861
Fuel Lift Pump...1862
Remove...1862
Disassemble...1862
Assemble...1862
Install...1863
Test...1863
Cooling System Repair...1864
General...1864
Thermostat...1864
Remove...1864
Install...1865
Test...1865
Coolant Pump...1865
Remove...1865
Disassemble...1866
Assemble...1868
Install...1870
Fan and Fan Drive...1871
Remove...1871
Install...1871
Oil Cooler...1871
Remove...1871
Disassemble and Assemble...1872
Install...1872
Electrical Equipment Repair...1873
Drive Belts...1873
Alternator...1873
Remove...1873
Install...1873
Electronic Control Module (ECM)...1874
Remove...1874
Inspect...1874
Install...1874
Voltage Load and Protection Module (VLPM)...1875
Remove...1875
Install...1875
Engine Speed and Timing Sensor...1875
Remove...1875
Install...1876
Pressure Sensors (Engine Oil and Air Intake)...1876
Remove...1876
Install...1877
Temperature Sensor...1877
Remove...1877
Install...1878
Starter Motor...1878
Remove...1878
Install...1878
Cold Start Aid...1878
Air Compressor...1878
General...1878
Repair...1879
Remove...1879
Install...1879
Rotary Exhauster Replacement...1880
Remove...1880
Clean...1880
Install...1880
Engine Specifications...1881
Cylinder Head Assembly...1881
Piston and Connecting Rods...1884
Crankshaft Assembly...1885
Crankshaft Overhaul...1886
Timing Case and Drive Assembly...1888
Engine Block Assembly...1889
Turbocharger...1890
Lubrication System...1891
Cooling System...1893
Flywheel and Housing...1893
Electrical Equipment...1893
Torque Specifications...1894
Cylinder Head Assembly...1894
Piston and Connecting Rod Assemblies...1894
Crankshaft Assembly...1894
Timing Case and Drive Assembly...1894
Turbocharger...1894
Lubrication System...1894
Fuel System...1894
Cooling System...1895
Flywheel...1895
Auxiliary Equipment...1895
Special Torque Specifications...1895
Flywheel and Housing...1895
Electrical Equipment...1895
Auxiliary Equipment...1895
Special Tools...1896
Troubleshooting...1901
Turbocharger Troubleshooting...1903
tables...1779
Table 1. Cylinder Head...1881
Table 2. Valve Guides...1881
Table 3. Inlet Valves...1882
Table 4. Exhaust Valves...1882
Table 5. Valve Springs...1883
Table 6. Tappets...1883
Table 7. Rocker Arm Shaft...1883
Table 8. Rocker Arms and Bushings...1883
Table 9. Pistons...1884
Table 10. Piston Rings...1884
Table 11. Piston Pins...1884
Table 12. Connecting Rods...1884
Table 13. Small End Bushings...1885
Table 14. Connecting Rod Bearings...1885
Table 15. Piston Cooling Jets...1885
Table 16. Crankshaft...1885
Table 17. Main Bearings...1886
Table 18. Crankshaft Thrust Washers...1886
Table 19. Crankshaft Heat Treatment...1886
Table 20. Crankshaft Overhaul Specifications...1886
Table 21. Maximum Variation (Run-Out)...1888
Table 22. Camshaft...1888
Table 23. Camshaft Thrust Washer...1888
Table 24. Camshaft Gear...1888
Table 25. Gear for Fuel Injection Pump...1888
Table 26. Crankshaft Gear...1889
Table 27. Idler Gear and Hub...1889
Table 28. Cylinder Block...1889
Table 29. Cylinder Liners...1889
Table 30. Cylinder Liner Specifications (Partially Finished)...1890
Table 31. Oil Pump...1891
Table 32. Idler Gear for Oil Pump...1891
Table 33. Relief Valve...1891
Table 34. Oil Filter...1891
Table 35. Bosch Fuel Injection Pump...1891
Table 36. Fuel Injector Codes...1892
Table 37. Fuel Pump...1893
Table 38. Fuel Filter...1893
Table 39. Coolant Pump...1893
Table 40. Thermostat...1893
Table 41. Fan Drive Housing...1893
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic...1893
Table 43. Alternator...1893
Table 44. Starter Motor...1893
Table 45. Cold Start Aid...1893
Table 46. List of Possible Causes...1901
Table 47. List of Possible Causes...1903
1553599-4000SRM1062-(03-2007)-US-EN...1907
toc...1907
Masts and Carriages...1907
Safety Precautions Maintenance and Repair...1908
General...1911
Description...1911
Operation...1912
Two-Stage Mast...1912
Three-Stage Mast...1913
Safety Procedures When Working Near Mast...1914
Forks Repair...1917
Remove...1917
Inspect and Adjust...1917
Install...1917
Carriage Repair...1918
Description...1918
Three Function...1918
Four to Six Function...1918
Remove...1918
Disassemble...1919
Clean and Inspect...1921
Assemble...1921
Install...1921
Sideshift Cylinder Repair...1922
Remove...1922
Disassemble...1922
Clean and Inspect...1922
Assemble...1922
Install...1922
Fork Positioner Cylinders Repair...1926
Remove...1926
Disassemble...1926
Clean and Inspect...1926
Assemble...1926
Install...1926
Directional Control Valve Repair...1933
Remove...1933
Disassemble...1933
Clean and Inspect...1933
Assemble...1934
Install...1934
Mast Repair...1934
Two- and Three-Stage Mast...1934
Remove...1934
Disassemble...1939
Clean and Inspect...1941
Assemble...1942
Install...1943
Three-Stage Mast (Four Cylinders)...1943
Remove...1943
Disassemble...1945
Clean and Inspect...1947
Assemble...1947
Install...1947
Fork Carriage Chains...1949
Adjust...1949
Bearing Rollers...1951
Description...1951
Lubrication...1951
Clearance...1951
Remove and Disassemble...1951
Assemble...1952
Mast Profile...1952
Lift Cylinders Description...1952
Piston-Type Cylinders...1952
Displacement-Type Cylinders...1952
Lift Cylinders Repair...1953
Remove...1953
Disassemble...1955
Clean and Inspect...1955
Assemble...1955
Install...1956
Mast Operation Check...1956
Lift and Tilt System Leak Checks...1957
Lift System...1957
Tilt System...1957
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...1958
Lift Chain Adjustments...1958
Mast Adjustments...1959
Bearing Blocks, Two-Stage Masts...1959
Wear Plates...1959
Carriage Adjustment...1959
Troubleshooting...1961
tables...1907
Table 1. Allowable Mast Movement from Internal Leakage...1957
1556599-0100SRM1100-(09-2008)-US-EN...1965
toc...1965
Operator's Cab...1965
Safety Precautions Maintenance and Repair...1966
General...1969
Cab Repair...1970
Rear Cab Assembly...1970
Bottom Cab Assembly...1971
Raising and Lowering Cab...1971
Raise Cab...1971
Lower Cab...1972
Cab Repair...1972
Remove...1972
Install...1973
Oil Filling for Tilt System...1974
Inching and Brake Pedals...1975
Brake Pedal, Adjust...1975
Inching Pedal, Adjust...1975
Inching Pedal Sensor, Adjust...1975
Throttle Pedal Sensor...1976
Check...1976
Adjust...1976
Seat Assembly Removal...1977
Power Assist Armrest...1977
Adjust...1977
Steering Column Repair...1978
Remove...1978
Install...1978
Window Wipers Replacement...1979
Window Wiper Assembly, Replace...1979
Front Window Wiper Motor Assembly, Replace...1979
Rear Window Wiper Motor Assembly, Replace...1980
Top Window Wiper Motor Assembly, Replace...1980
Window Washer Motors and Pumps...1981
Window Wiper and Washer Operating Switches...1981
Window Replacement...1982
Front Window, Replace...1983
Rear Window, Replace...1983
Top Window, Replace...1983
Door Window, Replace...1984
Heater and Air Conditioning Assembly...1985
Heater Parts, Replace...1986
Heat Control Knob/Switches...1986
Heat Control Knob/Cable...1986
Adjust...1986
Air Control Knob/Cable...1987
Adjust...1987
Air Filter, Replace...1987
Air Conditioning Condenser Fan(s)...1988
Remove...1988
Install...1988
Instruments, Switches, and Controls...1988
Switches...1988
Controls...1989
Fuses and Relays...1990
Fuse Panel...1990
Fuses...1990
Relays...1991
Label Replacement...1992
Electrical Schematics...1992
1556600-1300SRM1082-(09-2008)-US-EN...1995
toc...1995
Transmission...1995
Safety Precautions Maintenance and Repair...1996
Description of Operation...2001
General...2001
Torque Convertor, Pump Drive, and Pressure Regulating Valve...2001
Input Shaft and Directional Clutches...2001
Range Clutches...2003
Output Section...2003
Transmission Controls...2004
Operation of the Valve...2005
Selection of Range...2009
Pressure Switch...2009
Electric Solenoid Controls...2010
Transmission Specifications...2026
Transmission Identification...2026
Weight, Dimensions, and Oil Capacity...2026
Transmission Repair...2028
Remove...2028
Disassemble...2030
Transmission Case, Disassemble...2031
Torque Converter Housing, Disassemble...2048
Forward Clutch, Disassemble...2053
First-Speed Clutch, Disassemble...2055
Reverse and Second-Speed Clutch...2060
Reverse Clutch, Disassemble...2060
Second-Speed Clutch, Disassemble...2065
Third-Speed Clutch, Disassemble...2067
Third Clutch Shaft, Disassemble...2069
Turbine Shaft, Disassemble...2070
Output Shaft, Disassemble...2071
Impeller, Disassemble...2072
Turbine, Disassemble...2074
Clean and Inspect...2076
Housings...2076
Oil Seals and Gaskets...2077
Bearings...2077
Gears and Shafts...2077
Assemble...2078
Turbine, Assemble...2078
Impeller, Assemble...2079
Output Shaft, Assemble...2081
Turbine Shaft, Assemble...2083
Third Clutch Shaft, Assemble...2084
Third-Speed Clutch, Assemble...2085
Reverse and Second-Speed Clutch...2088
Second-Speed Clutch, Assemble...2088
Reverse Clutch, Assemble...2091
First-Speed Clutch, Assemble...2095
Forward Clutch, Assemble...2100
Torque Converter Housing, Assemble...2103
Transmission Case, Assemble...2108
Install...2129
Control Valve Repair...2131
Remove...2131
Disassemble and Assemble...2131
Clean and Inspect...2133
Housings...2133
Oil Seals and Gaskets...2133
Install...2134
Stall Test...2135
Transmission Calibration and Electrical Troubleshooting...2136
Userlink®...2136
Connection...2136
Clutch Filling Calibration...2136
Purpose...2136
Clutch Filling Calibration Procedure...2137
Alternative Clutch Filling Calibration Procedure...2137
Heat-up Mode...2138
Heat-up Mode Stall Test...2138
Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 300...2139
Purpose...2139
Brake Pedal Adjustment...2139
Dry Brake...2139
Wet Brake...2139
Inching Pedal Adjustment...2139
Inching Pedal Sensor Adjustment...2140
Inching Pedal Calibration Procedure...2140
Verification/Adjustment of Inching Pedal Sensor When the Pedal i...2140
Manual Inching Pedal Sensor Calibration Procedure...2141
Inching Pedal Calibration [S/N 2326 and Up (F019)], [S/N 3002 an...2141
Purpose...2141
Brake Pedal Adjustment...2141
Dry Brake...2141
Wet Brake...2141
Inching Pedal Adjustment...2142
Dry Brake...2142
Wet Brake...2142
Inching Pedal Sensor Adjustment Using Userlink® Program...2142
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr...2143
Inching Pedal Sensor Adjustment Using the APC200...2143
Inching Pedal Sensor Calibration Procedure Using the APC200...2144
Troubleshooting...2144
Transmission Display Warning Codes...2144
Access...2144
Clear...2145
Exit...2145
Limp Home Mode...2180
Shutdown Mode...2181
Pressure Feedback Sensor...2181
Transmission Oil Pressure Check...2181
Pressure and Temperature Specifications...2181
Electrical Specifications...2186
Hydraulic Cooler Lines Specifications...2186
Torque Specifications...2186
Torque Specifications for Lubricated or Plated Screw Threads...2186
Troubleshooting...2189
tables...1995
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere...2145
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere...2146
Table 3. Common Calibration Condition Messages...2148
Table 4. Calibration Codes During Calibration...2149
Table 5. Error Codes During Calibration...2149
Table 6. Display Warning Codes...2150
Table 7. Display Warning Exceed Codes...2179
Table 8. Type of Warning Codes...2180
Table 9. Temperature Sensor (In Speed Sensor) Resistance Versus ...2186
Table 10. Grade 5...2186
Table 11. Grade 8...2187
Table 12. Grades 8.8, 10.9, and 12.9...2188
Table 13. O-ring Port Plug Torque Chart...2188
Table 14. Pipe Plug Torque Chart...2189
1556602-8000SRM1099-(06-2006)-US-EN...2197
toc...2197
Periodic Maintenance...2197
Safety Precautions Maintenance and Repair...2198
General...2203
How to Move Disabled Lift Truck...2203
How to Tow Lift Truck...2203
How to Put Lift Truck on Blocks...2204
How to Raise Drive Tires...2204
How to Raise Steering Tires...2204
Maintenance Schedule...2206
Empty Container Attachment Maintenance...2218
Maintenance Procedures Every 8 Hours or Daily...2220
How to Make Checks With Engine Stopped...2220
Safety Labels...2220
Forks...2220
Adjust...2220
Remove...2220
Install...2220
Forks, Mast, and Lift Chains, Inspect...2221
Operator Restraint System...2222
Steering Column Latch...2223
Tires and Wheels...2223
Fuel, Oil, or Coolant Leaks, Check...2224
Air Intake Piping...2224
Cooling Fan...2224
Crankcase Breather Tube...2224
Drive Belts...2225
Hydraulic System Oil...2225
Cab Hydraulic System...2226
Engine Oil...2226
Cooling System...2228
Battery...2229
Fuel System (Diesel Engines Only)...2229
Water Separator/Fuel Filter (Diesel Engines Only)...2229
How to Make Checks With Engine Running...2230
Fault Codes...2230
Access...2230
Exit...2230
Clear...2230
Gauges, Lights, Horn and Fuses...2230
Control Levers and Pedals...2233
Steering System...2233
Air Filters...2234
Transmission Oil...2234
Brakes...2234
Lift System Operation...2234
Attachments...2234
Maintenance Procedures Every 250 Hours or Every 2 Months...2235
Empty Container Handler...2235
Maintenance Procedures Every 500 Hours or Every 3 Months...2235
Lift Chains...2235
Lubrication...2235
Adjust...2235
Drive Shaft...2235
Steering Axle...2236
Wheel Nuts...2236
Shafts for Brake Actuators...2236
Drive Axle and Differential...2236
Hydraulic Tank Breather...2236
Cabin Air Filter, Heater...2236
Air Filter, Engine...2236
Engine Oil and Filter...2236
Drive Belts...2237
Perkins...2237
Cummins...2237
Mast...2238
Bearing Rollers (Three-Stage Only)...2239
Lubrication...2239
Clearance...2239
General Lubrication...2239
Fork Wear and Damage Check...2239
Lift Chains Wear Check...2240
Empty Container Handler...2240
Maintenance Procedures Every 500 Hours or 6 Months...2240
Charge Air Cooler...2240
Dry Brakes Air Compressor (Cummins)...2240
Fuel Pump (Cummins)...2241
Fuel Filter...2241
Perkins...2241
Remove...2241
Install...2241
Cummins...2242
Remove...2242
Install...2242
Fuel System Air Removal (Perkins)...2242
Fuel System Air Removal (Cummins)...2242
Fuel Injection Pump Without Vent Tube...2242
Coolant...2244
Maintenance Procedures Every 1000 Hours or 6 Months...2244
Transmission Oil and Filter, Change...2244
Fuel Injection Pump Timing (Perkins Only)...2244
Valve Adjustment...2244
Perkins...2244
Differential and Drive Axle...2244
Pilot Accumulator Pressure Charge Check...2245
Maintenance Procedures Every 1000 Hours or Yearly...2245
Coolant Fan Belt Tensioner...2245
Belt Driven Fan Hub...2247
Valve Adjustment...2247
Cummins...2247
Accumulator and Wet Brakes...2248
Wet Brake Oil Filter...2248
Air Dryer Cartridge (Dry Brakes)...2248
Air Compressor Air Filter (Dry Brakes)...2248
Maintenance Procedures Every 2000 Hours or Yearly...2249
Hydraulic System...2249
Hydraulic Oil Filter, Change...2249
Hydraulic Oil, Change...2249
Hydraulic Pilot Valve Filter, Change...2249
Transmission Calibration...2250
Wheel Bearings...2250
Steer Wheels...2250
Drive Wheels...2250
Service Brakes...2250
Cleaning Procedures (Dry Brake Axle)...2250
Maintenance Procedures Every 2000 Hours or 2 Years...2251
Air Compressor Discharge Lines...2251
Rubber Vibration Damper...2252
Engine Coolant...2252
Maintenance Procedures Every 5000 Hours...2252
Empty Container Handler...2252
Safety Procedures When Working Near Mast...2253
Fuel Injectors Check...2253
Perkins...2253
Lift and Tilt System Leak Check...2254
Lift System...2254
Tilt System...2255
Welding Repairs...2256
Wheel and Tire Replacement...2256
Remove Wheels From Lift Truck...2256
Pneumatic Tires...2257
Remove Tire From Wheel...2257
Remove Tire From Three- and Four-Piece Wheel...2257
Install Tire on Wheel...2258
Install Three- or Four-Piece Wheel in Tire...2259
Add Air to Tires...2260
Solid Rubber Tires...2260
Remove Tire From Wheel...2260
Install Tire on Wheel...2262
Wheels, Install...2263
tables...2197
Table 1. Daily Inspections − Condition Check...2207
Table 2. Daily Inspections − Fluid Level Check...2208
Table 3. Daily Inspections − Checks With the Engine Running...2209
Table 4. First Inspection After First 100 Hours of Operation...2210
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...2210
Table 6. Periodic Maintenance Schedule − Lubricate...2213
Table 7. Periodic Maintenance Schedule − Change...2214
Table 8. Empty Container Attachment Maintenance − Inspect and ...2218
Table 9. Empty Container Attachment Maintenance − Lubricate...2219
Table 10. Empty Container Attachment Maintenance − Replace...2219
Table 11. Nominal Valve Clearance...2248
Table 12. Allowable Mast Movement from Internal Leakage...2255
1556604-8000SRM1103-(11-2006)-US-EN...2267
toc...2267
Diagrams...2267
Safety Precautions Maintenance and Repair...2268
1556871-2200SRM1105-(03-2007)-US-EN...2355
toc...2355
Instrument Panel Indicators and Senders...2355
Safety Precautions Maintenance and Repair...2356
General...2359
Description...2359
General...2359
Instrument Panel Meters, Indicators, and LCD Display...2359
Connector...2365
Seat Switch Logic...2366
Central Warning Light Output...2366
Buzzer Output...2366
Instrument Panel...2368
Remove...2368
Sender Replacement...2369
Fuel Level Sender (Diesel Engine Only)...2369
Engine Oil Pressure Sender...2370
Brake Pressure Sender...2370
Low Coolant Sender...2370
Vacuum Switch...2370
Specifications...2371
Troubleshooting...2372
tables...2355
Table 1. Instrument Panel and Indicators...2360
Table 2. Pin Description...2365
Table 3. Sender Description...2366
1564053-0600SRM1101-(11-2007)-US-EN...2377
toc...2377
Cummins Diesel/LPG Engine Fault Code Guide...2377
Safety Precautions Maintenance and Repair...2378
General...2381
Fault Codes...2381
Normal Mode...2381
Fault Log Mode...2381
Access...2381
Exit...2382
Clear...2382
Electronic Throttle Calibration...2382
Electronic Throttle Calibration Procedure...2382
tables...2377
Table 1. Error Code Descriptions...2383
1566673-0600SRM1158-(06-2005)-US-EN...2399
toc...2399
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...2399
Safety Precautions Maintenance and Repair...2400
Electronic Troubleshooting...2423
System Operation...2423
Electronic Controls...2423
Engine Governor...2424
Timing Considerations...2424
Fuel Injection...2424
Diagnostic Codes...2424
Diagnostic Fault Codes...2424
Diagnostic Event Codes...2424
Programmable Parameters...2425
Passwords...2425
Electronic Service Tools...2425
Electronic Service Tool (EST)...2425
Connecting the Electronic Service Tool and the Communication Ada...2425
Support for the Electronic Service Tool...2426
Optional Service Tools...2426
Diagnostic Codes...2426
Engine Display Warning Codes...2430
Access...2430
Exit...2430
Clear...2430
Replacing the ECM...2432
Self Diagnostics...2433
Glossary...2434
Sensors and Electrical Connectors...2437
Engine Wiring Information...2440
Harness Wire Identification...2444
Diagnostic Code Reader...2444
General...2444
Reference Documents...2444
Abbreviations...2444
Environmental Specification...2444
Hardware...2445
Connection Cable...2446
Software...2446
Engine Communication...2446
User Controls...2446
Power Supply...2446
Display Screen...2446
Operation Controls...2446
Audible Warning...2447
Operation Instructions...2447
How to Connect the Diagnostic Code Reader to the Engine...2447
How to Turn ON the Diagnostic Code Reader...2447
How to use the Display Screen...2447
How to Operate the Diagnostic Code Reader...2448
Main Menu...2448
Active Codes...2448
Inactive Codes...2448
How to Clear Codes...2449
Status Lamp...2449
Data List...2450
Diagnostics...2450
Programming Parameters...2451
Passwords...2451
Factory Passwords...2451
Customer Passwords...2452
Flash Programming...2452
Flash Programming a Personality Module...2452
WinFlash Error Messages...2452
System Configuration Parameters...2453
Full Load Setting...2453
Full Torque Setting...2453
Rating Interlock...2453
Engine Serial Number...2453
ECM Software Release Date...2453
Troubleshooting Without A Diagnostic Code...2454
Alternator Noise (Noisy Operation)...2454
Probable Causes...2454
Recommended Actions...2454
Alternator Drive Belts...2454
Alternator Drive Pulley...2454
Alternator Bearings...2454
Alternator Will Not Charge (Charging Problem)...2454
Probable Causes...2454
Recommended Actions...2454
Alternator Drive Belts...2454
Charging Circuit...2454
Alternator or Regulator...2454
Battery...2454
Probable Causes...2454
Recommended Actions...2454
Faulty Battery...2454
Auxiliary Device...2454
Cannot Reach Top Engine RPM...2454
Probable Causes...2455
Recommended Actions...2455
Diagnostic Codes...2455
Fuel Supply...2455
Air Intake and Exhaust System...2455
Individual Malfunctioning Cylinders...2455
Valve Lash...2455
Check for Low Compression...2455
Check the Fuel Injection Nozzles...2456
Check the Turbocharger...2456
ECM Parameters...2456
Check the Signal for the Throttle Position Sensor...2456
Coolant in Engine Oil...2456
Probable Causes...2456
Recommended Actions...2456
Engine Oil Cooler Core...2456
Cylinder Head Gasket...2456
Cylinder Head...2457
Cylinder Block...2457
Coolant Temperature Is Too High...2457
Probable Causes...2457
Recommended Actions...2457
Radiator Fins...2457
Coolant Level...2457
Radiator Cap and/or Pressure Relief Valve...2457
Combustion Gases in the Cooling System...2457
Water Temperature Regulator...2457
Restriction in the Coolant System...2457
Coolant Temperature Gauge...2457
Coolant Pump...2457
Excessive Load on the System...2457
ECM Will Not Accept Factory Passwords...2458
Probable Causes...2458
Recommended Actions...2458
ECM Will Not Communicate With Other Systems or Display Modules...2458
Probable Causes...2458
Recommended Actions...2458
Electronic Service Tool Will Not Communicate With ECM...2458
Probable Causes...2458
Recommended Actions...2458
Engine Cranks but Will Not Start...2459
Probable Causes...2459
Recommended Actions...2459
Diagnostic Codes...2459
Visual Checks...2459
Crank Without Injection...2459
Starting Motor Solenoid or Starting Circuit...2459
Valve Lash...2459
Fuel Injection Nozzles...2459
Air Inlet Heater Starting Aid...2460
Air Intake and Exhaust System...2460
Low Compression...2460
Fuel Supply...2460
Engine Has Early Wear...2460
Probable Causes...2460
Recommended Actions...2460
Dirt in Engine Oil...2460
Leaks in Air Intake System...2460
Low Oil Pressure...2460
Engine Misfires, Runs Rough or Is Unstable...2461
Probable Causes...2461
Recommended Actions...2461
Logged Codes...2461
Fuel Supply...2461
Air Intake and Exhaust System...2461
Individual Malfunctioning Cylinders...2461
Valve Lash...2461
Check for Low Compression...2461
Check the Fuel Injection Nozzles...2462
Check the Air Inlet Heater Starting Aid...2462
Check the Engine Speed/Timing Sensors...2462
Check the Signal for the Throttle Position Sensor...2462
Check the Fuel Injection Pump...2462
Engine Oil in Cooling System...2462
Probable Causes...2462
Recommended Actions...2462
Engine Oil Cooler Core...2462
Cylinder Head Gasket...2463
Cylinder Head...2463
Engine Speed Does Not Change...2463
Probable Causes...2463
Recommended Repairs...2463
Diagnostic Codes...2463
Engine Stalls at Low RPM...2463
Probable Causes...2463
Recommended Actions...2463
Diagnostic Codes...2463
Fuel Injection Nozzles...2463
Fuel Supply...2463
Accessory Equipment...2464
Power Mode Control...2464
Engine Vibration...2464
Probable Causes...2464
Recommended Actions...2464
Engine Supports...2464
Malfunctioning Individual Cylinder...2464
Valve Lash...2464
Check for Low Compression (cylinder pressure)...2464
Check the Fuel Injection Nozzles...2464
Turbocharger...2465
Engine Will Not Crank...2465
Probable Causes...2465
Recommended Repairs...2465
Machine Security System...2465
Battery Cables and/or Batteries...2465
Starting Motor Solenoid or Starting Circuit...2465
Starting Motor and/or Flywheel Ring Gear...2465
Electrical Power Supply...2465
Internal Engine Problem...2465
Excessive Black Smoke...2465
Probable Causes...2465
Recommended Actions...2466
Air Intake System or Exhaust System...2466
Individual Malfunctioning Cylinder...2466
Valve Lash...2466
Low Compression (cylinder pressure)...2466
Check the Fuel Injection Nozzles...2466
Check the Turbocharger...2466
Broken 5-Volt Supply Wire...2467
Verifying the ECM Software...2467
Excessive Engine Oil Consumption...2467
Probable Causes...2467
Recommended Actions...2467
Oil Level...2467
Engine Crankcase Breather...2467
Air Intake and Exhaust System...2467
Turbocharger...2467
Low Compression (cylinder pressure)...2467
Excessive Valve Lash...2468
Probable Causes...2468
Recommended Actions...2468
Lubrication...2468
Valve Lash...2468
Valve Train Components...2468
Excessive White Smoke...2468
Probable Causes...2468
Recommended Actions...2468
Fuel Supply...2468
Individual Malfunctioning Cylinder...2469
Valve Lash...2469
Low Compression (cylinder pressure)...2469
Air Inlet Heater Starting Aid...2469
Fuel Injection Nozzles...2469
Coolant Temperature Sensor Circuit...2469
Engine Pressure Sensors...2469
Intake Air Temperature Is Too High...2469
Probable Causes...2469
Recommended Repairs...2469
High Ambient Air Temperature...2469
Coolant Temperature...2469
Check for High Intake Air Restriction and/or High Altitude...2470
Intake Air Restriction...2470
High Altitude...2470
Check the Intake Manifold Air Temperature Sensor and/or the Circ...2470
Check for Sufficient Coolant Flow Through the Aftercooler (if eq...2470
Check for Sufficient Flow of Air Through the Aftercooler (if equ...2470
Intermittent Engine Shutdown...2470
Probable Causes...2470
Recommended Actions...2470
Logged Codes...2470
Fuel Supply...2470
Engine Protection Device...2470
Electrical Connectors...2471
Intermittent Low Power or Power Cutout...2471
Probable Causes...2471
Recommended Repairs...2471
Diagnostic Codes...2471
Electrical Connectors...2471
Fuel Supply...2471
Check the Intake Manifold Pressure...2472
Air Intake and Exhaust System...2472
Individual Malfunctioning Cylinders...2472
Valve Lash...2472
Check for Low Compression...2472
Check the Fuel Injection Nozzles...2472
Check the Turbocharger...2472
ECM Parameters...2473
Electronic System Problem...2473
Low Engine Oil Pressure...2473
Probable Causes...2473
Recommended Actions...2473
Engine Oil Level...2473
Engine Oil Pressure Gauge...2473
Engine Oil Bypass Valves...2473
Piston Cooling Jets ...2474
Engine Oil Suction Tube...2474
Engine Oil Pump...2474
Bearing Clearance...2474
Low Power/Poor or No Response to Throttle...2474
Probable Causes...2474
Recommended Actions...2474
Diagnostic Codes...2474
Fuel Supply...2474
Air Intake and Exhaust System...2474
Individual Malfunctioning Cylinders...2475
Valve Lash...2475
Check for Low Compression...2475
Check the Fuel Injection Nozzles...2475
Check the Turbocharger...2475
ECM Parameters...2475
Electronic System Problem...2476
Mechanical Noise (Knock) in Engine...2476
Probable Causes...2476
Recommended Actions...2476
Accessory Equipment...2476
Valve Train Components...2476
Connecting Rod and Main Bearings...2476
Noise Coming from Cylinder...2476
Probable Causes...2476
Recommended Actions...2476
Fuel Quality...2476
Fuel Injection Nozzles...2476
Valve Lash...2476
Poor Acceleration or Response...2477
Probable Causes...2477
Recommended Repairs...2477
Diagnostic Codes...2477
Fuel Supply...2477
Individual Malfunctioning Cylinder...2477
Valve Lash...2477
Check for Low Compression...2477
Check the Fuel Injection Nozzles...2477
Check the Turbocharger...2478
ECM Parameters...2478
Check Intake Manifold Pressure...2478
Troubleshooting With a Diagnostic Code...2478
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal...2478
Conditions Which Generate This Code...2478
System Response...2478
Possible Performance Effect...2478
Troubleshooting...2478
Results...2478
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent...2478
Conditions Which Generate This Code...2478
System Response...2479
Possible Performance Effect...2479
Troubleshooting...2479
Test Step 1...2479
Results...2479
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted...2479
Conditions Which Generate This Code...2479
System Response...2479
Possible Performance Effect...2479
CID 0091 FMI 04 Throttle Position Sensor Shorted Low...2479
Conditions Which Generate This Code...2479
System Response...2479
Possible Performance Effect...2479
Troubleshooting...2479
Results...2479
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal...2479
Conditions Which Generate This Code...2479
System Response...2479
Troubleshooting...2480
Results...2480
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...2480
Conditions Which Generate This Code...2480
Possible Performance Effect...2480
Troubleshooting...2480
Results...2480
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short...2480
Conditions Which Generate This Code...2480
System Response...2480
Troubleshooting...2480
Results...2480
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...2480
Conditions Which Generate This Code...2480
System Response...2480
Troubleshooting...2480
Results...2480
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci...2481
Conditions Which Generate This Code...2481
System Response...2481
Possible Performance Effect...2481
Results...2481
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or...2481
Conditions Which Generate This Code...2481
System Response...2481
Possible Performance Effect...2481
Results...2481
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...2481
Conditions Which Generate This Code...2481
System Response...2481
Possible Performance Effect...2481
Results...2481
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope...2482
Conditions Which Generate This Code...2482
System Response...2482
Results...2482
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ...2482
Conditions Which Generate This Code...2482
System Response...2482
Possible Performance Effect...2482
Troubleshooting...2482
Results...2482
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low...2482
Conditions Which Generate This Code...2482
System Response...2482
Possible Performance Effect...2482
Troubleshooting...2482
Results...2482
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o...2482
Conditions Which Generate This Code...2482
System Response...2483
Possible Performance Effect...2483
Troubleshooting...2483
Results...2483
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...2483
Conditions Which Generate This Code...2483
System Response...2483
Possible Performance Effect...2483
Troubleshooting...2483
Results...2483
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...2483
Conditions Which Generate This Code...2483
System Response...2483
Possible Performance Effect...2483
Troubleshooting...2483
Results...2483
CID 0247 FMI 09 J1939 Datalink, Abnormal Update...2484
Conditions Which Generate This Code...2484
System Response...2484
Results...2484
CID 0253 FMI 02 Incorrect ECM Software...2484
Conditions Which Generate This Code...2484
System Response...2484
Possible Performance Effect...2484
Troubleshooting...2484
Expected Result...2484
Results...2484
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal...2484
Conditions Which Generate This Code...2484
System Response...2484
Possible Performance Effect...2484
Troubleshooting...2484
Results...2484
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal...2485
Conditions Which Generate This Code...2485
System Response...2485
Possible Performance Effect...2485
Troubleshooting...2485
Results...2485
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs...2485
Conditions Which Generate This Code...2485
System Response...2485
Possible Performance Effect...2485
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig...2485
Conditions Which Generate This Code...2485
System Response...2485
Possible Performance Effect...2485
Results...2485
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...2485
Conditions Which Generate This Code...2485
System Response...2485
Possible Performance Effect...2485
Results...2486
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa...2486
Conditions Which Generate This Code...2486
System Response...2486
Possible Performance Effect...2486
Test Step 1...2486
Results...2486
Test Step 2...2486
Results...2486
CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm...2486
Conditions Which Generate This Code...2486
System Response...2486
Possible Performance Effect...2486
Results...2486
CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S...2486
Conditions Which Generate This Code...2486
System Response...2487
Possible Performance Effect...2487
Troubleshooting...2487
Results...2487
CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low...2487
Conditions Which Generate This Code...2487
System Response...2487
Possible Performance Effect...2487
Troubleshooting...2487
Results...2487
CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal...2487
Conditions Which Generate This Code...2487
System Response...2487
Possible Performance Effect...2487
Results...2487
CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio...2487
Conditions Which Generate This Code...2487
System Response...2487
Possible Performance Effect...2487
Results...2487
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off...2488
Conditions Which Generate This Code...2488
System Response...2488
Possible Performance Effect...2488
Results...2488
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ...2488
Conditions Which Generate This Code...2488
System Response...2488
Possible Performance Effect...2488
Test Step 1...2488
Results...2488
Test Step 2...2488
Results...2488
CID 1684 FMI 02 Fuel Injection Pump, Software Failure...2488
Conditions Which Generate This Code...2488
System Response...2488
Possible Performance Effect...2488
Troubleshooting...2488
Results...2489
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault...2489
Conditions Which Generate This Code...2489
System Response...2489
Possible Performance Effect...2489
Troubleshooting...2489
Results...2489
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...2489
Conditions Which Generate This Code...2489
System Response...2489
Possible Performance Effect...2489
Troubleshooting...2489
Results...2489
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width...2489
Conditions Which Generate This Code...2489
Troubleshooting...2489
Results...2490
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault...2490
Conditions Which Generate This Code...2490
System Response...2490
Possible Performance Effect...2490
Troubleshooting...2490
Results...2490
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...2490
Conditions Which Generate This Code...2490
System Response...2490
Possible Performance Effect...2490
Troubleshooting...2490
Test Step 1...2490
Results...2490
Test Step 2...2490
Results...2490
Test Step 3...2490
Results...2491
Test Step 4...2491
Expected Result...2491
Results...2491
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault...2491
Conditions Which Generate This Code...2491
System Response...2491
Possible Performance Effect...2491
Troubleshooting...2491
Expected Result...2491
Results...2491
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error...2491
Conditions Which Generate This Code...2491
System Response...2491
Troubleshooting...2491
Test Step 1...2491
Results...2492
Test Step 2...2492
Results...2492
Test Step 3...2492
Results...2492
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault...2492
Conditions Which Generate This Code...2492
System Response...2492
Possible Performance Effect...2492
Troubleshooting...2492
Test Step 1...2492
Results...2492
Test Step 2...2492
Results...2492
CID 1684 FMI 14 Fuel Injection Pump, No Communications...2492
Conditions Which Generate This Code...2492
System Response...2492
Troubleshooting...2492
Test Step 1...2492
Results...2492
Test Step 2...2493
Results...2493
Test Step 3...2493
Results...2493
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali...2493
Conditions Which Generate This Code...2493
System Response...2493
Possible Performance Effect...2493
Troubleshooting...2493
Results...2493
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali...2493
Conditions Which Generate This Code...2493
System Response...2493
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S...2493
Conditions Which Generate This Code...2493
System Response...2493
Troubleshooting With an Event Code...2494
Event Codes...2494
Programmable Engine Parameters...2494
E015 High Engine Coolant Temperature Derate...2494
Conditions Which Generate This Code...2494
System Response...2494
Possible Performance Effect...2494
Troubleshooting...2494
Results...2494
E016 High Engine Coolant Temperature Shutdown...2494
Conditions Which Generate This Code...2494
System Response...2494
Possible Performance Effect...2494
Troubleshooting...2494
Results...2494
E017 High Engine Coolant Temperature Warning...2494
Conditions Which Generate This Code...2494
System Response...2494
Possible Performance Effect...2494
Troubleshooting...2494
Results...2494
E025 High Intake Air Temperature Derate...2495
Conditions Which Generate This Code...2495
System Response...2495
Possible Performance Effect...2495
Troubleshooting...2495
Results...2495
E027 High Intake Air Temperature Warning...2495
Conditions Which Generate This Code:...2495
System Response...2495
Possible Performance Effect...2495
Troubleshooting...2495
Results...2495
E040 Low Engine Oil Pressure Shutdown...2495
Conditions Which Generate This Code...2495
System Response...2495
Possible Performance Effect...2495
Troubleshooting...2495
Results...2495
E054 High Fuel Temperature Derate...2496
Conditions Which Generate This Code...2496
System Response...2496
Troubleshooting...2496
Test Step 1 - Check for Diagnostic Codes...2496
Expected Result...2496
Results...2496
Test Step 2 - Perform a Check of the Fuel System...2496
Expected Result...2496
Results...2496
E056 High Fuel Temperature Warning...2496
Conditions Which Generate This Code...2496
System Response...2496
Troubleshooting...2496
Test Step 1 - Check for Diagnostic Codes...2496
Expected Result...2496
Results...2497
Test Step 2 - Perform a Check of the Fuel System...2497
Expected Result...2497
Results...2497
E100 Low Engine Oil Pressure Warning...2497
Conditions Which Generate This Code...2497
System Response...2497
Possible Performance Effect...2497
Troubleshooting...2497
Test Step 1 - Check for Active Diagnostic Codes...2497
Expected Result...2497
Results...2497
Test Step 2 - Perform a Check of the Engine Lubrication System...2497
Expected Result...2497
Results...2497
E190 Engine Overspeed Warning...2498
Conditions Which Generate This Code...2498
System Response...2498
Possible Performance Effect...2498
Troubleshooting...2498
Engine Overspeed Warning...2498
Expected Result...2498
Results...2498
E442 Engine Failed to Stop With a No-Fuel Command...2498
Conditions Which Generate This Code...2498
System Response...2498
Possible Performance Effect...2498
Troubleshooting...2498
Test Step 1...2498
Results...2498
Test Step 2...2498
Results...2498
E883 Engine Failed to Stop When Fuel Solenoid Disengaged...2498
Conditions Which Generate This Code...2498
System Response...2498
Possible Performance Effect...2499
Troubleshooting...2499
Test Step 1...2499
Results...2499
Test Step 2...2499
Results...2499
Test Step 3...2499
Results...2499
Diagnostic Function Tests...2499
5-Volt Engine Pressure Sensor Supply Circuit - Test...2499
System Operation Description...2499
Background Information...2499
Test Step 1...2500
Inspect Electrical Connectors and Wiring...2500
Expected Result...2500
Results...2501
Test Step 2...2501
Check for Active Diagnostic Codes...2501
Expected Result...2501
Results...2501
Test Step 3...2501
Disconnect the ECM Engine Harness Connector From the ECM...2501
Expected Result...2502
Results...2502
Test Step 4...2502
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei...2502
Expected Result...2503
Results...2503
Test Step 5...2503
Check the Engine Harness...2503
Expected Result...2503
Results...2503
Air Inlet Heater Circuit - Test...2503
System Operation Description...2503
Test Step 1...2504
Inspect Electrical Connectors and Wiring...2504
Expected Result...2504
Results...2504
Test Step 2...2504
Check the Supply to the Power Relay for the Air Inlet Heater Sta...2504
Expected Result...2505
Results...2505
Test Step 3...2505
Check the Output From the Power Relay for the Air Inlet Heater S...2505
Expected Result...2505
Results...2505
Test Step 4...2505
Ground the Input to the Power Relay at the MIC...2505
Expected Result...2505
Results...2505
Test Step 5...2505
Ground the Input to the Power Relay at the ECM Connector...2505
Expected Result...2505
Results...2505
Test Step 6...2506
Override the Air Inlet Heater Starting Aid to Test the ECM...2506
Results...2506
Checking Idle Validation Switching Point (Throttle Sensor) With ...2506
Expected Result...2506
Analog Throttle Position Sensor Circuit - Test...2506
System Operation Description...2506
Checking the Throttle Sensor With Unconnected Output C...2507
Expected Result...2507
Test Step 1...2507
Check for Connector Damage...2507
Expected Result...2508
Results...2508
Test Step 2...2508
Check for Active Diagnostic Codes...2508
Expected Result...2508
Results...2508
Test Step 3...2508
Check the Throttle Position With the Electronic Service Tool...2508
Expected Result...2508
Results...2508
Test Step 4...2508
Check the Voltage at the Throttle Position Sensor...2508
Expected Result...2508
Results...2508
Test Step 5...2509
Disconnect the Throttle Position Sensor and Check for Active Dia...2509
Expected Result...2509
Results...2509
Test Step 6...2509
Check the Throttle Selection Status With the Electronic Service ...2509
Expected Result...2509
Results...2509
Test Step 7...2510
Disconnect the Supply Terminals of the Throttle Position Sensor ...2510
Expected Result...2510
Results...2510
Test Step 8...2510
Check the Position of Throttle Position Sensor...2510
Expected Result...2510
Results...2511
Test Step 9...2511
Check the Throttle Position Sensor at the ECM...2511
Expected Result...2511
Results...2511
CAN Data Link Circuit - Test...2511
System Operation Description...2511
Test Step 1...2512
Inspect Electrical Connectors and Wiring...2512
Expected Result...2512
Results...2512
Test Step 2...2512
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...2512
Expected Result...2512
Results...2512
Test Step 3...2512
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...2512
Expected Result...2512
Results...2513
Test Step 4...2513
Verify the Supply Voltage at the Fuel Injection Pump...2513
Expected Result...2513
Results...2513
Data Link Circuit - Test...2513
System Operation Description...2513
Background Information...2514
Communication...2514
Test Step 1...2514
Inspect Electrical Connectors and Wiring...2514
Expected Result...2514
Results...2514
Test Step 2...2514
Determine the Type of Problem With the Data Link...2514
Expected Result...2514
Results...2515
Test Step 3...2515
Check the Battery Voltage at the ECM...2515
Expected Result...2515
Results...2515
Test Step 4...2515
Check the Battery Voltage That is Coming to the Data Link Connec...2515
Expected Result...2516
Results...2516
Test Step 5...2516
Connect the Electronic Service Tool Directly to the ECM...2516
Expected Result...2516
Results...2516
Test Step 6...2516
Change Electronic Service Tool Components...2516
Expected Result...2517
Results...2517
Test Step 7...2517
Connect an Electronic Service Tool and the ECM to Another Batter...2517
Expected Result...2517
Results...2517
Electrical Connectors - Inspect...2517
System Operation Description...2517
Background Information...2518
Test Step 1...2521
Check the Locking of the DT Connector (Deutsch) and the Lock Rin...2521
Expected Result...2521
Results...2521
Test Step 2...2522
Check the Socket Head Screw on the Connector for the Electronic ...2522
Expected Result...2522
Results...2522
Test Step 3...2522
Perform a Pull Test on Each Wire Terminal Connection...2522
Expected Result...2522
Results...2522
Test Step 4...2522
Monitor the Electronic Service Tool While the Wiring and the Con...2522
Expected Result...2523
Results...2523
Test Step 5...2523
Check Wires for Nicks and/or Abrasions in the Insulation...2523
Expected Result...2523
Results...2523
Test Step 6...2523
Check Connectors for Moisture or Corrosion...2523
Expected Result...2524
Results...2524
Test Step 7...2524
Inspect the Connector Terminals...2524
Expected Result...2524
Results...2524
Test Step 8...2524
Check Individual Pin Retention Into the Socket...2524
Expected Result...2525
Results...2525
Electrical Power Supply Circuit - Test...2525
System Operation Description...2525
Background Information...2525
Test Step 1...2526
Check the Batteries...2526
Expected Result...2526
Results...2526
Test Step 2...2527
Inspect Electrical Connectors and Wiring...2527
Expected Result...2527
Results...2527
Test Step 3...2527
Check the Battery Voltage at the ECM...2527
Expected Result...2527
Results...2528
Test Step 4...2528
Use the Bypass Harness for the Electronic Service Tool to Bypass...2528
Expected Result...2529
Results...2529
Engine Pressure Sensor Open or Short Circuit - Test...2529
System Operation Description...2529
Background Information...2529
Test Step 1...2529
Check for Active +5V Sensor Supply Diagnostic Codes...2529
Expected Result...2530
Results...2530
Test Step 2...2530
Verify All Active Diagnostic Codes...2530
Expected Result...2530
Results...2530
Test Step 3...2530
Inspect Electrical Connectors And Wiring...2530
Expected Result...2531
Results...2531
Test Step 4...2531
Verify That the Diagnostic Code is Still Active...2531
Expected Result...2531
Results...2531
Test Step 5...2531
Disconnect the Sensor to Create an Open Circuit...2531
Expected Result...2531
Results...2531
Test Step 6...2531
Measure the Sensor Supply Voltage...2531
Expected Result...2532
Results...2532
Test Step 7...2532
Determine if the Short Circuit is in the Connector or in the Sen...2532
Expected Result...2532
Results...2532
Test Step 8...2532
Create a Short Circuit Between the Signal and the Common Termina...2532
Expected Result...2533
Results...2533
Test Step 9...2533
Check the Operation of the ECM by Creating Open and Short Circui...2533
Expected Result...2533
Results...2533
Test Step 10...2534
Bypass the Harness Wiring Between the ECM and the Sensor Connect...2534
Expected Result...2534
Results...2534
Engine Speed/Timing Sensor Circuit - Test...2534
System Operation Description...2534
Test Step 1...2535
Inspect the Electrical Connectors and Cables...2535
Expected Result...2535
Results...2535
Test Step 2...2535
Check the Installation of the Engine Speed/Timing Sensors...2535
Expected Result...2535
Results...2535
Test Step 3...2535
Measure the Sensor Resistance Through the Wiring Harness...2535
Expected Result...2536
Results...2536
Test Step 4...2536
Measure the Resistance of the Sensor...2536
Expected Result...2536
Results...2536
Test Step 5...2537
Measure the Resistance of the Cables Between the Fuel Injection ...2537
Expected Result...2537
Results...2537
Test Step 6...2537
Check the Continuity of the Cables From the ECM to the Fuel Inje...2537
Expected Result...2537
Results...2538
Engine Temperature Sensor Open or Short Circuit - Test...2538
System Operation Description...2538
Background Information...2538
Test Step 1...2539
Verify All Active Diagnostic Codes...2539
Expected Result...2539
Results...2539
Test Step 2...2539
Inspect Electrical Connectors and Wiring...2539
Expected Result...2539
Results...2540
Test Step 3...2540
Verify That the Diagnostic Code is Still Active...2540
Expected Result...2540
Results...2540
Test Step 4...2540
Disconnect the Sensor to Create an Open Circuit...2540
Expected Result...2540
Results...2540
Test Step 5...2540
Create a Short Circuit Between the Signal and the Common Termina...2540
Expected Result...2541
Results...2541
Test Step 6...2541
Check the Operation of the ECM by Creating an Open and a Short C...2541
Expected Result...2541
Results...2541
Test Step 7...2541
Bypass the Harness Wiring Between the ECM and the Sensor Connect...2541
Expected Result...2542
Results...2542
Fuel Injection Pump Circuit - Test...2542
System Operation Description...2542
Background Information...2542
Test Step 1...2542
Check the Batteries...2542
Expected Result...2542
Results...2543
Test Step 2...2543
Inspect the Electrical Connectors and Wiring...2543
Expected Result...2544
Results...2544
Test Step 3...2544
Check the Supply Voltage at the Machine Interface Connector...2544
Expected Result...2544
Results...2544
Test Step 4...2544
Check the Supply Voltage at the Fuel Injection Pump...2544
Expected Result...2544
Results...2544
Test Step 5...2545
Check the Supply to the Power Relay for the Fuel Injection Pump...2545
Expected Result...2545
Results...2545
Test Step 6...2545
Check the Output of the Power Relay for the Fuel Injection Pump...2545
Expected Result...2545
Results...2545
Test Step 7...2545
Check the Voltage at the Relay Coil for the Fuel Injection Pump...2545
Expected Result...2545
Results...2545
Test Step 8...2546
Check the Output of the ECM Fuel Pump Power Control at the Machi...2546
Expected Result...2546
Results...2546
Test Step 9...2546
Check the Output of the Fuel Injection Pump Power Control at the...2546
Expected Result...2546
Results...2546
Test Step 10...2546
Measure the Voltage at the Pump Power Supply...2546
Expected Result...2547
Results...2547
Test Step 11...2547
Check the Voltage Load Protection Module (VLPM)...2547
Expected Result...2548
Results...2548
Indicator Lamp Circuit - Test...2548
System Operation Description...2548
Test Step 1...2548
Inspect Electrical Connectors and Wiring...2548
Results...2549
Test Step 2...2549
Inspect the Lamp, the Fuse, and the Power Supply...2549
Expected Result...2549
Results...2549
Test Step 3...2549
Inspect the Input to the Lamp at the ECM connector...2549
Expected Result...2549
Results...2550
Test Step 4...2550
Test the Individual Lamp Circuits...2550
Expected Result...2550
Results...2550
Test Step 5...2550
Check the Voltage at the ECM...2550
Expected Result...2550
Results...2550
Idle Validation Circuit - Test...2550
System Operation Description...2550
Test Step 1...2550
Expected Result...2550
Results...2551
tables...2399
Table 1. Electronic Service Tool...2425
Table 2. Optional Service Tools...2426
Table 3. CID FMI Codes and J Code FMI Codes...2427
Table 4. Event Codes and CID FMI Codes...2429
Table 5. Diagnostics Supported Over J1939...2430
Table 6. Events Supported Over J1939...2432
Table 7. Engine Connectors...2439
Table 8. Color Codes for the Harness Wire...2444
Table 9. Pin Connections for Perkins Deutsch Socket Connector...2446
Table 10. Suspect Parameter Numbers...2450
Table 11. Failure Mode Indicators (FMI) Codes...2451
Table 12. Engine Oil Pressure Trip and Reset Points...2495
1586990-8000SRM1181-(03-2007)-US-EN...2555
toc...2555
Assembly Guide...2555
Safety Precautions Maintenance and Repair...2556
List of All Special Tools and Equipment Needed for the Assembly...2559
General Considerations Before Starting the Job...2559
Preparation of the Components Before Assembly...2560
Liquefied Petroleum Gas (LPG Engines Only)...2560
Remove...2560
Install...2561
Checking of the Wheels...2561
Air Pressure...2561
Drive Wheels...2562
Steer Wheels...2566
Wheel Nut Torque...2569
Mast Label Placement...2570
Safety Procedures When Working Near Mast...2571
Mast Installation...2573
Mast...2573
Tilt Cylinder Pin Installation...2576
Lift Cylinder Hose Connection...2577
Truck Header Hoses and Electrical Cable Connections...2578
Mast Light Connection...2580
Carriage Installation...2581
Carriage Header Hoses and Electrical Cable Connection...2582
Fork Installation...2585
Exhaust Extension Tube Installation...2586
Lights Installation - Operator Compartment...2588
Hydraulic Oil Check...2589
Lubrication Points...2590
Check Points...2591
Checkpoint 1...2591
Checkpoint 2...2591
Checkpoint 3...2591
Checkpoint 4...2591
Checkpoint 5...2591
General Truck Install Procedures...2591
tables...2555
Table 1. Mast Hanger Pins Capscrew Torques...2576
1612615-5000SRM1221-(11-2006)-US-EN...2595
toc...2595
Extendable Container Attachment (Elme)...2595
Safety Precautions Maintenance and Repair...2596
General...2601
Description...2601
Operation...2605
General...2605
Optional Powered Pile Slope...2605
Sideshift...2606
Extend and Retract Circuit...2607
Container locking Model 582...2609
Sequence Valve...2609
Pilot Check Valve...2610
Container Locking Model 583...2611
Container Locking Model 584...2611
Container Locking Model 585...2612
Container Locking Models 586, 588, and 589...2612
Electrical System...2614
Indicator Lights...2614
Flashing Indicator Lights...2615
Automatic Locking...2615
Lift Interrupt and Override...2615
Overlowering Interrupt and Override...2615
Second Container Detection Sensor (Model 582 Only)...2616
Carriage and Attachment Removal...2616
Carriage...2616
Spreader...2617
Sideshift Cylinder Removal and Installation...2617
Remove...2617
Install...2617
Extension Cylinder Removal and Installation...2618
Remove...2618
Upper, Right-Hand...2618
Lower, Left-Hand...2618
Install...2618
Floating End Beams Repair...2619
Remove...2619
Install...2619
Hose, Replace...2620
Twist Lock Repair for Model 582...2621
Remove...2621
Upper Twist Lock...2621
Lower Twist Lock...2621
Disassemble...2622
Clean and Inspect...2622
Assemble...2623
Install...2623
Hook Repair for Model 584 and 585...2623
Remove...2623
Inspect...2623
Install...2623
Side Clamp Replacement for Model 584...2624
Remove...2624
Install...2625
Twist Lock Repair for Models 586, 588, and 589...2625
Disassemble...2625
Clean and Inspect...2625
Assemble...2626
Extension Beam Repair...2627
Remove...2627
Inspect...2627
Assemble...2628
Cylinder Repair...2629
Extension Cylinder...2629
Disassemble...2629
Clean and Inspect...2629
Assemble...2629
Guide for Extension Cylinder...2630
Remove...2630
Install...2630
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde...2630
Disassemble...2630
Assemble...2630
Wear Pad Replacement...2631
General...2631
Floating End Beam Wear Pads...2631
Upper Wear Pads...2631
Lower Wear Pads...2631
Main Frame Wear Pads at Large (Right-Hand) Extension Beam...2631
Main Frame Wear Pads at Small (Left-Hand) Extension Beam...2631
Guide for Extension Cylinder...2632
Large Extension Beam Internal Wear Pads...2633
Spreader Frame...2633
Upper Wear Pads...2633
Lower Wear Pads...2633
Powered Pile Slope Carriage...2633
Upper Wear Pads...2633
Lower Wear Pads...2633
Adjustments...2633
Twist Lock Angle Adjustment...2633
Model 586, 588 and 589...2633
LOCKED/NOT LOCKED Sensors Adjustment...2634
Model 582...2634
Model 586, 588 and 589...2634
Side Clamp Open/Closed Sensor Adjustment (Model 584)...2634
Hook in Sensor Adjustment (Model 584)...2634
Seated Sensor Adjustment...2635
Model 582...2635
Model 586, 588 and 589...2635
Overlowering Protection Sensor Adjustment (All 580 Models)...2635
Schematics...2636
tables...2595
Table 1. Elme Schematic Overview...2636
897108-1600SRM0326-(03-2007)-US-EN...2723
toc...2723
Steering Axle...2723
Safety Precautions Maintenance and Repair...2724
General...2727
Description...2727
Steering Axle Assembly Repair...2732
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...2732
Remove...2732
Install...2732
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...2733
Remove...2733
Install...2733
Wheels and Hubs Repair (All Units)...2734
Remove and Disassemble...2734
Clean...2734
Inspect...2734
Assemble and Install...2734
Spindles and Bearings Repair (All Units)...2736
Remove...2736
Clean...2736
Assemble and Install...2737
Tie Rods Repair (All Units)...2738
Remove...2738
Clean...2738
Install...2738
Steering Cylinder Repair...2741
Remove and Disassemble...2741
Clean and Inspect...2741
Assemble and Install...2741
Troubleshooting...2742
897934-0700SRM0626-(11-2001)-US-EN...2747
toc...2747
Cooling System...2747
Safety Precautions Maintenance and Repair...2748
General...2751
Description...2752
Radiator...2752
Radiator Cap...2752
Thermostat...2752
Water Pump...2753
Fan and Fan Shroud...2753
Cooling System Checks...2753
Radiator...2753
Thermostat...2753
Water Pump...2754
Exhaust Leaks...2754
Fan and Fan Shroud...2754
Radiator Cleaning...2754
Drain...2754
Clean...2754
Fill...2755
Troubleshooting...2756
899784-2200SRM0002-(12-2004)-US-EN...2759
toc...2759
Alternator with Regulator...2759
Safety Precautions Maintenance and Repair...2760
General...2763
Description...2763
Alternator Repair...2765
Alternator Type A...2765
Remove and Disassemble...2765
Clean...2766
Assemble...2767
Install...2767
Alternator Type B...2770
Remove and Disassemble...2770
Clean...2770
Assemble...2771
Install...2772
General Check and Adjustment...2773
Low Output Check (Type A or Type B)...2773
High Output Check (Type A or Type B)...2775
Brushes Circuit Check...2776
Delco Alternators...2776
Motorola Alternators...2777
Diodes Check...2778
Diode Bridge Check...2778
Delco and Leece-Neville Alternators...2778
Motorola Alternators...2778
Rotor Field Winding Check...2779
Stator Windings Check...2780
Voltage Regulator Check...2780
Troubleshooting...2780
910072-1400SRM0046-(07-2007)-US-EN...2785
toc...2785
Differential...2785
Safety Precautions Maintenance and Repair...2786
General...2789
Description...2789
Differential Repair...2790
Remove...2790
Differential Carrier From Axle Housing, Remove...2790
Differential and Ring Gear From Differential Carrier, Remove...2792
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...2794
Disassemble...2795
Differential and Ring Gear Assembly, Disassemble...2795
Drive Pinion and Pinion Carrier, Disassemble...2797
Clean and Inspect...2800
Assemble...2801
Pinion, Bearings, and Pinion Carrier, Assemble...2801
Pinion Bearings, Adjust Preload...2801
Press Method...2801
Yoke or Flange Method...2802
Triple-Lip Seal, Install...2803
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...2804
Differential and Ring Gear, Assemble...2806
Differential Gears Rotating Torque, Check...2808
Differential and Ring Gear Assembly, Install...2809
Differential Bearings, Preload Adjust...2811
Ring Gear, Runout Check...2812
Ring Gear Backlash, Adjust...2812
Gear Set, Tooth Contact Pattern Check...2814
Thrust Screw, Install and Adjust...2817
Install...2817
Differential Assembly Into Axle Housing, Install...2817
Specifications...2819
Troubleshooting...2824
tables...2785
Table 1. Ring Gear Backlash Adjustment Specifications...2814
Table 2. Ring and Pinion Tooth Contact Adjustment...2815
Table 3. General Specifications...2819
Table 4. Rivet Installation Pressure...2819
Table 5. Pinion Adjustment...2820
Table 6. Pinion Preload Pressure...2820
Table 7. Torque Specifications...2821
Table 8. Torque Specifications for Metric Hardware...2822
Table 9. Torque Specifications for Metric (Fine) Hardware...2823
910102-2100SRM0103-(03-2007)-US-EN...2827
toc...2827
Tilt Cylinders...2827
Safety Precautions Maintenance and Repair...2828
General...2831
Description...2831
Tilt Cylinder Repair...2831
Remove...2831
Disassemble...2831
Clean...2831
Assemble...2831
Tilt Cylinders With O-Ring or Single-Lip Seals...2831
Tilt Cylinders for XM and XMS Models...2833
Tilt Cylinders for XL, XLS, and XL 3 Models...2834
Tilt Cylinders for H700-800A and Early Model H700-920B...2836
Install...2837
Tilt Cylinders Using Chevron Packing...2837
Install...2838
Tilt Cylinder Leak Check...2840
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...2842
Torque Specifications...2842
Piston Rod Nut...2842
Retainer...2843
Troubleshooting...2845
tables...2827
Table 1. Movement Rates (Maximum) for Tilt Cylinders...2841
910107-2200SRM0106-(12-2004)-US-EN...2849
toc...2849
Starter...2849
Safety Precautions Maintenance and Repair...2850
General...2853
Description and Operation...2853
Starter Repair...2855
Remove...2855
Disassemble...2855
Clean...2856
Assemble...2856
Install...2857
General Checks and Adjustments...2857
Troubleshooting...2860
910442-8000SRM0231-(12-2004)-US-EN...2865
toc...2865
Metric and Inch (SAE) Fasteners...2865
Safety Precautions Maintenance and Repair...2866
General...2869
Threaded Fasteners...2869
Nomenclature, Threads...2869
Strength Identification...2870
Cotter (Split) Pins...2870
Fastener Torque Tables...2875
Conversion Table...2877
tables...2865
Table 1. Bolts and Screws...2871
Table 2. Studs and Nuts...2872
Table 3. Torque Nuts...2873
Table 4. Torque Nuts With Nylon Insert...2874
Table 5. Torque Values for Metric Fasteners*...2875
Table 6. Torque Values for Inch Fasteners*...2876
Table 7. Conversion Table for Metric and English Units...2877
Table 8. Cotter Pin Dimensional Data...2878
Table 9. Cotter Pin Dimensional Data...2879
Table 10. Cotter Pin Dimensional Data...2880
Table 11. Cotter Pin Dimensional Data...2882
Aurora_AC...2887
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...2888
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...2894
Compressors are machines under pressure and as such require special care in handling...2894
Only qualified personnel are allowed to perform any work on refrigeration compressors...2894
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...2894
Never put the safety switch out of action...2894
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...2894
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...2894
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...2894
Caution! Danger of burning because of high surface temperatures...2894
Never grab rotating parts during operation. Danger of injury!...2894
Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov...2894
Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri...2894
No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion...2894
Full bottles of refrigerant must not be thrown or...2894
It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only...2894
4. Troubleshooting...2895
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...2895
By wrong refrigerant level there is a danger of compressor malfunction...2895
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...2895
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...2895
Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o...2895
NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with...2895
Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click...2895
912-100-0007_e.pdf...0
Technical modifications reserved...2896
912-100-0258_e.pdf...0
Condenser unit, 24V...2907
part no.:175-FR2-0002...2907
Safety advices...2907
- we reserve the right to make technical modifications -...2907
1Safety advices...2908
Maintenance work on the refrigeration circuit:...2908
...2909
2.2Condenser blowers...2909
5Electrical connection...2910
every six months – authorised workshop:...2911
State of the refrigerant hoses...2911
State of the condenser...2911
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...2911
every month sight checks - Operator...2912
State of the refrigerant hoses...2912
State of the condenser...2912
Check condenser of contamination by dust, insects or parts of plants...2912
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...2912
Installation of replacement parts...2912
8Technical data...2912
9Fault diagnosis...2913
Hyster Forklift Trucks F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe & H300-350HD; H360HD-EC) Repair Service Manual
