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Hyster F007 (H170-280HD) Service Manual – PDF DOWNLOAD
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Description
Hyster F007 (H170-280HD) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F007 (H170-280HD) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster F007 (H170-280HD) Service Manual – PDF DOWNLOAD
897108-1600SRM0326-(03-2007)-US-EN...................................................... 1 toc................................................................................. 1 Steering Axle................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Steering Axle Assembly Repair................................................... 10 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............ 10 Remove.................................................................. 10 Install................................................................. 10 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............ 11 Remove.................................................................. 11 Install................................................................. 11 Wheels and Hubs Repair (All Units).............................................. 12 Remove and Disassemble...................................................... 12 Clean....................................................................... 12 Inspect..................................................................... 12 Assemble and Install........................................................ 12 Spindles and Bearings Repair (All Units)........................................ 14 Remove...................................................................... 14 Clean....................................................................... 14 Assemble and Install........................................................ 15 Tie Rods Repair (All Units)..................................................... 16 Remove...................................................................... 16 Clean....................................................................... 16 Install..................................................................... 16 Steering Cylinder Repair........................................................ 19 Remove and Disassemble...................................................... 19 Clean and Inspect........................................................... 19 Assemble and Install........................................................ 19 Troubleshooting................................................................. 20 897386-4000SRM0445-(08-2001)-US-EN...................................................... 25 toc................................................................................. 25 Masts........................................................................... 25 Safety Precautions Maintenance and Repair....................................... 26 General......................................................................... 29 Description..................................................................... 29 Safety Procedures When Working Near Mast........................................ 30 Operation....................................................................... 32 Two-Stage Mast.............................................................. 32 Three-Stage Mast............................................................ 32 Forks Repair.................................................................... 34 Remove...................................................................... 34 Install..................................................................... 34 Carriage Repair................................................................. 34 Remove...................................................................... 34 Sideshift Carriage, Disassemble............................................. 34 Sideshift Carriage, Assemble................................................ 36 Sideshift Cylinder, Disassemble............................................. 38 Sideshift Cylinder, Assemble................................................ 38 Fork Positioner Cylinder, Disassemble....................................... 39 Fork Positioner Cylinder, Assemble.......................................... 40 Install..................................................................... 41 Mast Repairs.................................................................... 41 Remove...................................................................... 41 Two-Stage Mast, Disassemble................................................. 41 Three-Stage Mast, Disassemble............................................... 46 Clean and Inspect........................................................... 48 Two-Stage Mast, Assemble.................................................... 48 Three-Stage Mast, Assemble.................................................. 51 Install..................................................................... 54 Lift Cylinders Description...................................................... 55 Piston-Type Cylinders....................................................... 56 Displacement-Type Cylinders................................................. 56 All Lift Cylinders Repair....................................................... 56 Remove...................................................................... 58 Disassemble................................................................. 58 Clean and Inspect........................................................... 58 Assemble.................................................................... 58 Install..................................................................... 59 Mast Operation Check............................................................ 59 Lift and Tilt System Leak Checks................................................ 59 Lift System................................................................. 59 Tilt System................................................................. 60 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment......................... 60 Lift Chain Adjustments.......................................................... 61 Mast Adjustments................................................................ 61 Bearing Blocks.............................................................. 61 Wear Plates................................................................. 62 Load Roller Adjustments..................................................... 62 Carriage Adjustment............................................................. 64 Troubleshooting................................................................. 66 tables.............................................................................. 25 Table 1. Carriage and Fork Weights.............................................. 38 Table 2. Mast Weights........................................................... 46 Table 3. Allowable Mast Movement from Internal Leakage.......................... 60 897934-0700SRM0626-(11-2001)-US-EN...................................................... 71 toc................................................................................. 71 Cooling System.................................................................. 71 Safety Precautions Maintenance and Repair....................................... 72 General......................................................................... 75 Description..................................................................... 76 Radiator.................................................................... 76 Radiator Cap................................................................ 76 Thermostat.................................................................. 76 Water Pump.................................................................. 77 Fan and Fan Shroud.......................................................... 77 Cooling System Checks........................................................... 77 Radiator.................................................................... 77 Thermostat.................................................................. 77 Water Pump.................................................................. 78 Exhaust Leaks............................................................... 78 Fan and Fan Shroud.......................................................... 78 Radiator Cleaning............................................................... 78 Drain....................................................................... 78 Clean....................................................................... 78 Fill........................................................................ 79 Troubleshooting................................................................. 80 899784-2200SRM0002-(12-2004)-US-EN...................................................... 83 toc................................................................................. 83 Alternator with Regulator....................................................... 83 Safety Precautions Maintenance and Repair....................................... 84 General......................................................................... 87 Description..................................................................... 87 Alternator Repair............................................................... 89 Alternator Type A........................................................... 89 Remove and Disassemble.................................................. 89 Clean................................................................... 90 Assemble................................................................ 91 Install................................................................. 91 Alternator Type B........................................................... 94 Remove and Disassemble.................................................. 94 Clean................................................................... 94 Assemble................................................................ 95 Install................................................................. 96 General Check and Adjustment.................................................... 97 Low Output Check (Type A or Type B)............................................. 97 High Output Check (Type A or Type B)............................................ 99 Brushes Circuit Check........................................................... 100 Delco Alternators........................................................... 100 Motorola Alternators........................................................ 101 Diodes Check.................................................................... 102 Diode Bridge Check.............................................................. 102 Delco and Leece-Neville Alternators......................................... 102 Motorola Alternators........................................................ 102 Rotor Field Winding Check....................................................... 103 Stator Windings Check........................................................... 104 Voltage Regulator Check......................................................... 104 Troubleshooting................................................................. 104 910072-1400SRM0046-(07-2007)-US-EN...................................................... 109 toc................................................................................. 109 Differential.................................................................... 109 Safety Precautions Maintenance and Repair....................................... 110 General......................................................................... 113 Description..................................................................... 113 Differential Repair............................................................. 114 Remove...................................................................... 114 Differential Carrier From Axle Housing, Remove.......................... 114 Differential and Ring Gear From Differential Carrier, Remove............ 116 Drive Pinion and Pinion Carrier From Differential Carrier, Remov........ 118 Disassemble................................................................. 119 Differential and Ring Gear Assembly, Disassemble........................ 119 Drive Pinion and Pinion Carrier, Disassemble............................ 121 Clean and Inspect........................................................... 124 Assemble.................................................................... 125 Pinion, Bearings, and Pinion Carrier, Assemble.......................... 125 Pinion Bearings, Adjust Preload......................................... 125 Press Method........................................................ 125 Yoke or Flange Method............................................... 126 Triple-Lip Seal, Install................................................ 127 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)............. 128 Differential and Ring Gear, Assemble.................................... 130 Differential Gears Rotating Torque, Check............................... 132 Differential and Ring Gear Assembly, Install............................ 133 Differential Bearings, Preload Adjust................................... 135 Ring Gear, Runout Check................................................. 136 Ring Gear Backlash, Adjust.............................................. 136 Gear Set, Tooth Contact Pattern Check................................... 138 Thrust Screw, Install and Adjust........................................ 141 Install..................................................................... 141 Differential Assembly Into Axle Housing, Install........................ 141 Specifications.................................................................. 143 Troubleshooting................................................................. 148 tables.............................................................................. 109 Table 1. Ring Gear Backlash Adjustment Specifications........................... 138 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 139 Table 3. General Specifications................................................. 143 Table 4. Rivet Installation Pressure............................................ 143 Table 5. Pinion Adjustment...................................................... 144 Table 6. Pinion Preload Pressure................................................ 144 Table 7. Torque Specifications.................................................. 145 Table 8. Torque Specifications for Metric Hardware.............................. 146 Table 9. Torque Specifications for Metric (Fine) Hardware....................... 147 910102-2100SRM0103-(03-2007)-US-EN...................................................... 151 toc................................................................................. 151 Tilt Cylinders.................................................................. 151 Safety Precautions Maintenance and Repair....................................... 152 General......................................................................... 155 Description..................................................................... 155 Tilt Cylinder Repair............................................................ 155 Remove...................................................................... 155 Disassemble................................................................. 155 Clean....................................................................... 155 Assemble.................................................................... 155 Tilt Cylinders With O-Ring or Single-Lip Seals.......................... 155 Tilt Cylinders for XM and XMS Models.................................... 157 Tilt Cylinders for XL, XLS, and XL 3 Models............................. 158 Tilt Cylinders for H700-800A and Early Model H700-920B.................. 160 Install..................................................................... 161 Tilt Cylinders Using Chevron Packing.................................... 161 Install............................................................. 162 Tilt Cylinder Leak Check........................................................ 164 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 166 Torque Specifications........................................................... 166 Piston Rod Nut.............................................................. 166 Retainer.................................................................... 167 Troubleshooting................................................................. 169 tables.............................................................................. 151 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 165 910107-2200SRM0106-(12-2004)-US-EN...................................................... 173 toc................................................................................. 173 Starter......................................................................... 173 Safety Precautions Maintenance and Repair....................................... 174 General......................................................................... 177 Description and Operation....................................................... 177 Starter Repair.................................................................. 179 Remove...................................................................... 179 Disassemble................................................................. 179 Clean....................................................................... 180 Assemble.................................................................... 180 Install..................................................................... 181 General Checks and Adjustments.................................................. 181 Troubleshooting................................................................. 184 910119-4000SRM0135-(10-2003)-US-EN...................................................... 189 toc................................................................................. 189 Lift Cylinders.................................................................. 189 Safety Precautions Maintenance and Repair....................................... 190 Safety Procedures When Working Near Mast........................................ 193 General......................................................................... 197 Description..................................................................... 197 Lowering Control Valve...................................................... 197 Cylinders (General)......................................................... 200 Cylinders (H520-620B, H700-800A)............................................ 200 Retainer, Install....................................................... 200 Cylinders (H360-460B)....................................................... 202 Cylinders (Two-Speed)....................................................... 204 Lift Cylinder Repair............................................................ 206 Lift Cylinder Removal Without Removing Mast................................. 206 Standard Masts With Main Lift Cylinder Fastened to Crossmember o........ 206 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........ 206 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ........ 206 Disassemble................................................................. 208 Assemble.................................................................... 208 Lift Cylinder Installation in Mast.......................................... 210 Standard Masts With Main Lift Cylinder Fastened to Crossmember o........ 210 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........ 210 Chevron-Style Packing....................................................... 210 Chevron-Style Packing Installation on Piston............................ 211 Chevron-Style Packing Installation in Packing Gland..................... 213 Lift Cylinders for VISTA® Masts................................................. 214 Description................................................................. 214 Lowering Control Valve.................................................. 214 Remove...................................................................... 216 Disassemble................................................................. 217 Assemble.................................................................... 218 Install..................................................................... 219 Main Lift Cylinders..................................................... 219 Free-Lift Cylinder...................................................... 219 Lift System Leak Check.......................................................... 220 Specifications.................................................................. 221 Troubleshooting................................................................. 222 tables.............................................................................. 189 Table 1. Lift Trucks with Two-Speed Lift Cylinders.............................. 205 Table 2. Cylinder Retainer Torque Specifications and Weight Guid................ 221 910442-8000SRM0231-(12-2004)-US-EN...................................................... 225 toc................................................................................. 225 Metric and Inch (SAE) Fasteners................................................. 225 Safety Precautions Maintenance and Repair....................................... 226 General......................................................................... 229 Threaded Fasteners.......................................................... 229 Nomenclature, Threads....................................................... 229 Strength Identification..................................................... 230 Cotter (Split) Pins......................................................... 230 Fastener Torque Tables...................................................... 235 Conversion Table............................................................ 237 tables.............................................................................. 225 Table 1. Bolts and Screws....................................................... 231 Table 2. Studs and Nuts......................................................... 232 Table 3. Torque Nuts............................................................ 233 Table 4. Torque Nuts With Nylon Insert.......................................... 234 Table 5. Torque Values for Metric Fasteners*.................................... 235 Table 6. Torque Values for Inch Fasteners*...................................... 236 Table 7. Conversion Table for Metric and English Units.......................... 237 Table 8. Cotter Pin Dimensional Data............................................ 238 Table 9. Cotter Pin Dimensional Data............................................ 239 Table 10. Cotter Pin Dimensional Data........................................... 240 Table 11. Cotter Pin Dimensional Data........................................... 242 1455747-0600SRM0705-(03-2006)-US-EN..................................................... 247 toc................................................................................. 247 Perkins Diesel Engines.......................................................... 247 Safety Precautions Maintenance and Repair....................................... 248 General......................................................................... 255 General Safety Rules........................................................ 255 Description..................................................................... 256 Engine Serial Number Codes.................................................. 259 Engine Data................................................................. 259 Engine Removal and Installation................................................. 261 Lift Engine................................................................. 261 Cylinder Head Assembly Repair................................................... 261 Valve Cover................................................................. 261 Remove.................................................................. 261 Install................................................................. 262 Rocker Arm Assembly......................................................... 262 Remove.................................................................. 262 Install................................................................. 262 Disassemble............................................................. 262 Inspect................................................................. 263 Assemble................................................................ 263 Valve Clearance Adjustments................................................. 263 Four-Cylinder Engines................................................... 264 Six-Cylinder Engines.................................................... 264 Valve Springs............................................................... 264 Cylinder Head Assembly...................................................... 266 Remove.................................................................. 266 Install................................................................. 268 Valves and Valve Springs.................................................... 272 Remove.................................................................. 272 Inspect................................................................. 272 Install................................................................. 273 Valve Guides................................................................ 273 Inspect................................................................. 273 Remove.................................................................. 274 Install................................................................. 274 Cylinder Head and Valve Seats............................................... 274 Inspect................................................................. 274 Repair.................................................................. 274 New Valve Seats, Install................................................ 274 Piston and Connecting Rod Assemblies Repair..................................... 276 Rod Bearings................................................................ 276 Remove.................................................................. 277 Install................................................................. 277 Piston and Connecting Rod Assembly.......................................... 278 Service Note............................................................ 278 Remove.................................................................. 278 Install................................................................. 279 Piston Rings................................................................ 280 Remove.................................................................. 280 Inspect................................................................. 280 Install................................................................. 280 Piston and Connecting Rod................................................... 281 Disassemble............................................................. 281 Inspect................................................................. 282 How to Select Correct Replacements...................................... 282 Install................................................................. 283 Piston Cooling Jets......................................................... 283 Remove.................................................................. 283 Install................................................................. 284 Crankshaft Assembly Repair...................................................... 284 General..................................................................... 284 Crankshaft Pulley........................................................... 285 Engine AR, Remove....................................................... 285 Engines YG and YH, Remove............................................... 285 Inspect................................................................. 286 Engine AR, Install...................................................... 286 Engines YG and YH, Install.............................................. 286 Rear Oil Seal............................................................... 287 Replace................................................................. 287 Main Bearings............................................................... 288 Remove.................................................................. 288 Inspect................................................................. 289 Install................................................................. 289 Thrust Washers.............................................................. 289 Crankshaft Axial Movement, Check........................................ 289 Remove.................................................................. 290 Install................................................................. 290 Crankshaft.................................................................. 291 Remove.................................................................. 291 Inspect................................................................. 291 Install................................................................. 291 Flywheel.................................................................... 293 Remove.................................................................. 293 Ring Gear, Replace...................................................... 293 Install................................................................. 293 Flywheel Housing............................................................ 294 Remove.................................................................. 294 Install................................................................. 294 Timing Case and Timing Gears Repair............................................. 295 General..................................................................... 295 Timing Case Cover........................................................... 295 Remove.................................................................. 295 Install................................................................. 296 Front Oil Seal.............................................................. 296 Remove.................................................................. 296 Install................................................................. 296 Crankshaft Pulley Wear Sleeve............................................... 297 Install................................................................. 297 Idler Gear and Hub.......................................................... 297 Remove.................................................................. 297 Install................................................................. 298 Air Compressor Drive, Bendix................................................ 299 Disassemble............................................................. 299 Assemble................................................................ 300 Fuel Injection Pump Gear.................................................... 300 Remove.................................................................. 301 Install................................................................. 301 Camshaft Gear............................................................... 302 Remove.................................................................. 302 Install................................................................. 302 Crankshaft Gear............................................................. 303 Remove.................................................................. 303 Install................................................................. 303 Timing Case................................................................. 303 Remove.................................................................. 303 Install................................................................. 304 Camshaft and Tappets........................................................ 305 Remove.................................................................. 305 Install................................................................. 305 Cylinder Block Assembly Repair.................................................. 306 Description................................................................. 306 Cylinder Block.............................................................. 306 Disassemble............................................................. 306 Inspect................................................................. 307 Assemble................................................................ 307 Cylinder Bore (Four-Cylinder Engines)....................................... 308 Cylinder Liner (Six-Cylinder Engines)....................................... 308 Inspect................................................................. 308 Cylinder Liner Condition, Check......................................... 308 Remove.................................................................. 309 Service Liner, Install.................................................. 310 Partially Finished Liner, Install....................................... 311 Engine Timing................................................................... 312 Description................................................................. 312 How to Set Number One Piston to TDC on Compression Stroke............... 313 How to Set Number One Piston to TDC on Compression Stroke (Alter........ 314 Valve Timing, Check..................................................... 314 Fuel Injection Pump Timing, Check....................................... 315 Turbocharger - Engine YH Repair................................................. 316 General..................................................................... 316 Remove.................................................................. 316 Install................................................................. 316 Impeller and Compressor Housing, Clean.................................. 317 Lubrication System Repair....................................................... 318 General..................................................................... 318 Oil Filter, Replace......................................................... 318 Filter Head................................................................. 319 Remove and Install...................................................... 319 Oil Sump.................................................................... 319 Remove.................................................................. 319 Install................................................................. 320 Oil Pump.................................................................... 320 Remove.................................................................. 320 Inspect................................................................. 320 Install................................................................. 321 Relief Valve................................................................ 321 Remove.................................................................. 321 Disassemble............................................................. 322 Inspect................................................................. 322 Assemble................................................................ 322 Install................................................................. 323 Idler Gear Shaft, Replace................................................... 323 Remove.................................................................. 323 Remove (Alternative).................................................... 323 Install................................................................. 324 Install (Alternative)................................................... 324 Install (Alternative for Four-Cylinder Engines Only).................... 325 Fuel System Repair.............................................................. 325 Description................................................................. 325 Fuel Injection Pump......................................................... 326 Remove.................................................................. 326 Install................................................................. 327 Check and Adjust........................................................ 328 Fuel System Air Removal..................................................... 328 Fuel Filter, Replace........................................................ 329 Canister Type........................................................... 330 Quick Release Canister Type............................................. 330 Fuel Injectors.............................................................. 331 Remove.................................................................. 331 Inspect................................................................. 332 Install................................................................. 332 Fuel Pump................................................................... 333 Remove.................................................................. 333 Disassemble............................................................. 333 Assemble................................................................ 333 Install................................................................. 334 Test.................................................................... 334 Cooling System Repair........................................................... 335 General..................................................................... 335 Thermostat.................................................................. 335 Remove.................................................................. 335 Install................................................................. 335 Test.................................................................... 336 Coolant Pump................................................................ 336 Remove.................................................................. 336 Disassemble............................................................. 336 Assemble................................................................ 338 Install................................................................. 340 Fan and Fan Drive........................................................... 341 Remove.................................................................. 341 Install................................................................. 341 Oil Cooler (Six-Cylinder Engines)........................................... 342 Remove.................................................................. 342 Disassemble and Assemble................................................ 342 Install................................................................. 342 Oil Cooler Bypass Valve................................................. 342 Electrical Equipment Repair..................................................... 343 Drive Belts................................................................. 343 Adjustment.............................................................. 343 Remove.................................................................. 344 Install................................................................. 344 Alternator.................................................................. 344 Remove.................................................................. 344 Install................................................................. 344 Starter Motor............................................................... 344 Remove.................................................................. 344 Install................................................................. 344 Cold Start Aid.............................................................. 344 Air Compressor - Engines YG and YH.............................................. 345 General..................................................................... 345 Repair...................................................................... 345 Remove.................................................................. 345 Install................................................................. 345 Rotary Exhauster Replacement.................................................... 347 Remove...................................................................... 347 Clean....................................................................... 347 Install..................................................................... 347 Engine Specifications........................................................... 348 Cylinder Head Assembly...................................................... 348 Piston and Connecting Rods.................................................. 351 Crankshaft Assembly......................................................... 354 Crankshaft Overhaul..................................................... 356 Timing Case and Drive Assembly.............................................. 358 Engine Block Assembly....................................................... 359 Turbocharger................................................................ 362 Lubrication System.......................................................... 362 Fuel System................................................................. 363 Cooling System.............................................................. 365 Flywheel and Housing........................................................ 365 Electrical Equipment........................................................ 366 Torque Specifications........................................................... 366 Cylinder Head Assembly...................................................... 366 Piston and Connecting Rod Assemblies........................................ 366 Crankshaft Assembly......................................................... 366 Timing Case and Drive Assembly.............................................. 367 Turbocharger................................................................ 367 Lubrication System.......................................................... 367 Fuel System................................................................. 367 Cooling System.............................................................. 367 Flywheel.................................................................... 367 Auxiliary Equipment......................................................... 367 Special Torque Specifications................................................... 368 Flywheel and Housing........................................................ 368 Turbocharger................................................................ 368 Electrical Equipment........................................................ 368 Auxiliary Equipment......................................................... 368 Special Tools*.................................................................. 369 Troubleshooting................................................................. 374 tables.............................................................................. 247 Table 1. Cylinder Head.......................................................... 348 Table 2. Valve Guides........................................................... 348 Table 3. Inlet Valves........................................................... 348 Table 4. Exhaust Valves......................................................... 349 Table 5. Valve Springs.......................................................... 351 Table 6. Tappets................................................................ 351 Table 7. Rocker Arm Shaft....................................................... 351 Table 8. Rocker Arms and Bushings............................................... 351 Table 9. Pistons (Engine AR).................................................... 351 Table 10. Pistons (Engines YG and YH)........................................... 351 Table 11. Piston Rings (Engine AR).............................................. 352 Table 12. Piston Rings (Engines YG and YH)...................................... 352 Table 13. Piston Pins........................................................... 353 Table 14. Connecting Rods....................................................... 353 Table 15. Small End Bushings.................................................... 353 Table 16. Connecting Rod Bearings (Engines AR and YG)........................... 353 Table 17. Connecting Rod Bearings (Engine YH)................................... 353 Table 18. Piston Cooling Jets................................................... 354 Table 19. Crankshaft............................................................ 354 Table 20. Main Bearings......................................................... 355 Table 21. Crankshaft Thrust Washers............................................. 355 Table 22. Crankshaft Heat Treatment............................................. 355 Table 23. Crankshaft Overhaul Specifications.................................... 356 Table 24. Maximum Variation (Run-out)........................................... 358 Table 25. Camshaft.............................................................. 358 Table 26. Camshaft Thrust Washer................................................ 358 Table 27. Camshaft Gear......................................................... 358 Table 28. Gear for Fuel Injection Pump.......................................... 359 Table 29. Crankshaft Gear....................................................... 359 Table 30. Idler Gear and Hub.................................................... 359 Table 31. Cylinder Block (Engine AR)............................................ 359 Table 32. Cylinder Bore Specifications.......................................... 360 Table 33. Cylinder Block (Engines YG and YH).................................... 361 Table 34. Cylinder Liners (Engines YG and YH)................................... 361 Table 35. Cylinder Liner Specifications (Partially Finished).................... 361 Table 36. Oil Pump (Engine AR).................................................. 362 Table 37. Oil Pump (Engines YG and YH).......................................... 362 Table 38. Idler Gear for Oil Pump............................................... 363 Table 39. Relief Valve.......................................................... 363 Table 40. Oil Filter............................................................ 363 Table 41. Lucas Fuel Injection Pump............................................. 363 Table 42. Fuel Injector Codes................................................... 364 Table 43. Fuel Pump (Engine AR)................................................. 365 Table 44. Fuel Pump (Engines YG and YH)......................................... 365 Table 45. Fuel Filter........................................................... 365 Table 46. Coolant Pump.......................................................... 365 Table 47. Thermostat............................................................ 365 Table 48. Fan Drive Housing..................................................... 365 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic................ 366 Table 50. Alternator............................................................ 366 Table 51. Starter Motor......................................................... 366 Table 52. Cold Start Aid........................................................ 366 Table 53. List of Possible Causes............................................... 374 1493991-1300SRM0930-(02-2001)-US-EN..................................................... 379 toc................................................................................. 379 Three-Speed Powershift Transmission............................................. 379 Safety Precautions Maintenance and Repair....................................... 380 General......................................................................... 383 Mechanical Description.......................................................... 383 General..................................................................... 383 Torque Converter............................................................ 387 Description............................................................. 387 Operation............................................................... 387 Clutch Assemblies........................................................... 388 Description............................................................. 388 Operation............................................................... 388 Forward and First-Speed Clutch Assembly............................. 389 Reverse and Second-Speed Shaft, First and Second Gear Shaft......... 389 Third-Speed Shaft................................................... 389 Output Shaft........................................................ 389 Hydraulic Operation............................................................. 391 Sump, Filter and Pump....................................................... 391 Transmission Control Valve.................................................. 391 Solenoid Valves......................................................... 391 Inching Spool........................................................... 392 Direction Spools........................................................ 392 Range Spool............................................................. 392 Modulator Valve............................................................. 393 Operation............................................................... 393 Modulator Operation................................................. 394 Transmission Control System................................................. 397 Monotrol Pedal.......................................................... 397 Control Lever........................................................... 398 Hydraulic Circuits.......................................................... 399 Cooling and Lubrication................................................. 399 Neutral................................................................. 399 Forward-First........................................................... 399 Reverse-First........................................................... 402 From First to Second Speed.............................................. 403 From Second to Third Speed.............................................. 404 Inching................................................................. 405 1493992-1300SRM0931-(02-2001)-US-EN..................................................... 409 toc................................................................................. 409 Three-Speed Powershift Transmission............................................. 409 Safety Precautions Maintenance and Repair....................................... 410 General......................................................................... 413 Transmission Repair............................................................. 416 Remove...................................................................... 416 Disassemble................................................................. 418 Torque Converter Housing and Pump Gears................................. 418 Transmission Cover, Remove.............................................. 419 Clutch Assemblies, Remove............................................... 421 Forward and Low-Speed Clutches.......................................... 422 Forward Clutch, Disassemble......................................... 422 First-Speed Clutch, Disassemble..................................... 424 Reverse and Second-Speed Clutches, Disassemble.......................... 424 Second-Speed Clutch, Disassemble.................................... 424 Reverse Clutch, Disassemble......................................... 426 Third-Speed Clutch, Disassemble......................................... 426 Output Gears, Disassemble............................................... 428 Clean................................................................... 428 Inspect................................................................. 428 Assemble.................................................................... 430 Output Gears, Assemble.................................................. 430 Third-Speed Clutch, Assemble............................................ 430 Reverse and Second-Speed Clutches, Assemble............................. 430 Second-Speed Clutch, Assemble....................................... 430 Reverse Clutch, Assemble............................................ 433 Forward and First-Speed Clutches, Assemble.............................. 433 Forward Clutch, Assemble............................................ 433 First-Speed Clutch, Assemble........................................ 435 Clutch Assemblies, Install.............................................. 435 Input Shaft and Forward Clutch Hub, Install............................. 436 Transmission Cover, Install............................................. 437 Torque Converter Housing................................................ 439 Install..................................................................... 441 Control Valve Repair............................................................ 443 Remove...................................................................... 443 Disassemble and Assemble.................................................... 444 Clean and Inspect........................................................... 444 Install..................................................................... 444 Modulator Valve Repair.......................................................... 446 Remove...................................................................... 446 Disassemble................................................................. 446 Clean and Inspect........................................................... 446 Install..................................................................... 446 Transmission Pump Repair........................................................ 448 Remove...................................................................... 448 Disassemble................................................................. 448 Clean and Inspect........................................................... 448 Assemble.................................................................... 448 Install..................................................................... 448 Monotrol Pedal Repair........................................................... 450 Remove and Disassemble...................................................... 450 Assemble and Install........................................................ 450 Inching/Brake Pedal Linkage Adjustment.......................................... 452 Stall Test...................................................................... 453 Transmission Oil Pressure Check................................................. 454 Troubleshooting................................................................. 456 tables.............................................................................. 409 Table 1. Transmission Pressures................................................. 455 1493993-1300SRM0932-(12-2004)-US-EN..................................................... 461 toc................................................................................. 461 Autoshift Transmission Controller............................................... 461 Safety Precautions Maintenance and Repair....................................... 462 General......................................................................... 465 Autoshift Control Module........................................................ 465 Transmission Shift Control Valve................................................ 465 Autoshift Functions............................................................. 466 System Interaction With Operator Display.................................... 466 Error Code Descriptions..................................................... 466 System Audible Alarm........................................................ 466 Park Brake Interlock........................................................ 468 System Reset/Override....................................................... 468 System Degraded Operating Mode.............................................. 468 System Failure Mode......................................................... 468 Transmission Oil High-Temperature Fault..................................... 468 Loss of Transmission Oil Pressure Fault..................................... 468 Controller Bypass........................................................... 469 Automatic/Manual Shift Mode................................................. 469 Automatic Transmission Shifting............................................. 469 Manual Transmission Shifting................................................ 470 Direction Change............................................................ 470 Direction Change Inhibit.................................................... 470 Downshift Inhibit........................................................... 471 Driveshaft Engagement Inhibit............................................... 471 Lift Height Transmission Interrupt (Optional)............................... 471 Engine Dethrottle (Optional)................................................ 472 Autoshift Hardware.............................................................. 472 Autoshift Lever............................................................. 472 Speed Sensors............................................................... 473 Transmission System Monitor Diagnostics......................................... 474 Controller Parameter Adjustment Software User Interface......................... 474 User Interface Description.................................................. 474 Components Required to Communicate With Controller.......................... 474 Userlink Installation Instructions.......................................... 474 Start Procedures............................................................ 474 Controller Product Codes.................................................... 474 Main Menu Description....................................................... 475 Language Selection.......................................................... 475 Help Menu................................................................... 475 PC Serial Communication Port................................................ 476 Monitor Screen.............................................................. 476 Event Log................................................................... 476 Parameter Adjustment........................................................ 477 Current Parameters...................................................... 477 Load Parameters......................................................... 478 Restore Factory Parameters.............................................. 478 Load Controller Software from File...................................... 478 Exit Menu................................................................... 478 Controller Connector Pin-Out Tables............................................. 480 tables.............................................................................. 461 Table 1. Error Code Descriptions................................................ 467 Table 2. Automatic Transmission Upshift......................................... 469 Table 3. Automatic Transmission Downshift....................................... 470 Table 4. Event Log Descriptions and Values...................................... 477 Table 5. Parameter Descriptions and Values...................................... 478 Table 6. J2 Controller Connector (Black)........................................ 480 Table 7. J1 Controller Connector (Blue)......................................... 481 1494123-0100SRM0927-(01-2006)-US-EN..................................................... 485 toc................................................................................. 485 Frame........................................................................... 485 Safety Precautions Maintenance and Repair....................................... 486 General......................................................................... 489 Description..................................................................... 489 Counterweight Repair............................................................ 489 Remove...................................................................... 489 Install..................................................................... 491 Fenders..................................................................... 491 Remove.................................................................. 491 Install................................................................. 491 Side Counterweights H13.00-16.00XM (H300-360HD)............................. 491 Side Counterweight, Replace................................................. 491 Hood and Air Cleaner Repair..................................................... 492 Remove...................................................................... 492 Install..................................................................... 494 Hydraulic Tank Repair........................................................... 494 Remove...................................................................... 494 Repairs, All Units.......................................................... 495 Small Leaks............................................................. 495 Large Leaks............................................................. 496 Clean....................................................................... 496 Steam Method............................................................ 496 Chemical Solution Method................................................ 497 Other Methods of Preparation for Repair..................................... 497 Install..................................................................... 497 Fuel Tank Repair................................................................ 498 Remove...................................................................... 498 Repairs..................................................................... 498 Install..................................................................... 498 Cooling System and Radiator Repair.............................................. 500 Remove...................................................................... 500 Install..................................................................... 501 Engine and Transmission Repair.................................................. 502 Hyster T-50 Transmission, Remove............................................ 502 Hyster T-50 Transmission, Install........................................... 503 TE-10 Transmission.......................................................... 504 Remove.................................................................. 504 Install................................................................. 507 Label Replacement............................................................... 509 1494139-0100SRM0935-(09-2004)-US-EN..................................................... 517 toc................................................................................. 517 Operators Cab................................................................... 517 Safety Precautions Maintenance and Repair....................................... 518 General......................................................................... 521 Cab Repair...................................................................... 522 Rear Cab Assembly........................................................... 522 Bottom Cab Assembly......................................................... 523 Raising and Lowering Cab.................................................... 523 Raise Cab............................................................... 523 Lower Cab............................................................... 524 Cab Repair.................................................................. 524 Remove.................................................................. 524 Install................................................................. 525 Oil Filling for Tilt System..................................................... 526 Inching and Brake Pedals........................................................ 526 Pedal Adjustment............................................................ 526 Inching Cable Adjustment.................................................... 526 Throttle Cable Adjustment....................................................... 527 Cable Alignment............................................................. 528 Engine Side............................................................. 528 Pedal Housing Side...................................................... 528 Throttle Pedal Sensor........................................................... 528 Check....................................................................... 528 Adjust...................................................................... 528 Seat Assembly Removal........................................................... 529 Power Assist Armrest............................................................ 530 Adjust...................................................................... 530 Steering Column Repair.......................................................... 530 Remove...................................................................... 530 Install..................................................................... 530 Window Wipers Replacement....................................................... 531 Window Wiper Assembly, Replace.............................................. 531 Front Window Wiper Motor Assembly, Replace.................................. 532 Rear Window Wiper Motor Assembly, Replace................................... 532 Top Window Wiper Motor Assembly, Replace.................................... 532 Window Washer Motors and Pumps.................................................. 533 Window Wiper and Washer Operating Switches.................................. 533 Window Replacement.............................................................. 533 Front Window, Replace....................................................... 534 Rear Window, Replace........................................................ 534 Top Window, Replace......................................................... 534 Door Window, Replace........................................................ 535 Heater and Air Conditioning Assembly............................................ 536 Heater Parts, Replace....................................................... 536 Heat Control Knob/Switches.................................................. 537 Heat Control Knob/Cable..................................................... 537 Adjust.................................................................. 537 Air Control Knob/Cable...................................................... 538 Adjust.................................................................. 538 Air Filter, Replace......................................................... 538 Air Conditioning Condenser Fan(s), Standard................................. 538 Remove.................................................................. 538 Install................................................................. 539 Air Conditioning Condenser Fan(s), Tropical................................. 539 Remove.................................................................. 539 Install................................................................. 539 Instruments, Switches, and Controls............................................. 539 Switches.................................................................... 539 Controls.................................................................... 540 Fuses and Relays................................................................ 541 Fuse Panel.................................................................. 541 Fuses....................................................................... 541 Relays...................................................................... 542 Label Replacement............................................................... 543 Electrical Schematics........................................................... 543 1494140-1600SRM0936-(03-2007)-US-EN..................................................... 547 toc................................................................................. 547 Steering System................................................................. 547 Safety Precautions Maintenance and Repair....................................... 548 General......................................................................... 551 Description..................................................................... 551 Steering Wheel and Column Assembly.............................................. 553 General..................................................................... 553 Steering Wheel and Horn..................................................... 553 Remove.................................................................. 553 Install................................................................. 553 Steering Control Unit Repair.................................................... 555 General..................................................................... 555 Description................................................................. 555 Operation................................................................... 555 Remove...................................................................... 556 Disassemble................................................................. 556 Clean....................................................................... 559 Assemble and Install........................................................ 559 Steering System Air Removal..................................................... 565 Steering Relief Pressure Check.................................................. 566 Troubleshooting................................................................. 566 1494141-1800SRM0937-(03-2007)-US-EN..................................................... 571 toc................................................................................. 571 Dry Brake System................................................................ 571 Safety Precautions Maintenance and Repair....................................... 572 General......................................................................... 575 Description..................................................................... 575 Operation....................................................................... 576 Service Brakes.............................................................. 576 Parking Brake............................................................... 578 Air Tank Repair................................................................. 579 Relief Valve................................................................ 579 Drain Valve................................................................. 579 Brake Pedal Valve Repair........................................................ 580 Remove...................................................................... 580 Disassemble, Inspect, and Assemble.......................................... 580 Install..................................................................... 580 Air Chambers Repair............................................................. 581 Remove...................................................................... 581 Disassemble................................................................. 581 Inspect..................................................................... 582 Assemble.................................................................... 583 Install..................................................................... 583 Actuator Arms Repair............................................................ 583 Remove...................................................................... 583 Inspect..................................................................... 584 Install..................................................................... 584 Brake Assemblies Repair......................................................... 585 Brake Shoe, Remove.......................................................... 585 Camshaft, Remove............................................................ 587 Clean....................................................................... 587 Inspect..................................................................... 588 Camshaft, Install........................................................... 588 Brake Shoe, Install......................................................... 589 Air Dryer....................................................................... 590 Description................................................................. 590 Cartridge................................................................... 590 Remove.................................................................. 590 Install................................................................. 590 Filter...................................................................... 590 Remove.................................................................. 590 Install................................................................. 590 Quick-Release Valve............................................................. 592 Governor Check and Adjustment for Air Compressor................................ 592 Brake Shoes Adjustment.......................................................... 593 Specifications.................................................................. 594 Troubleshooting................................................................. 594 Service Brakes.............................................................. 594 Service Brakes, Park Function .............................................. 597 tables.............................................................................. 571 Table 1. Air Chambers Operation................................................. 578 1494142-1900SRM0938-(03-2007)-US-EN..................................................... 601 toc................................................................................. 601 Hydraulic System................................................................ 601 Safety Precautions Maintenance and Repair....................................... 602 General......................................................................... 605 Description and Operation....................................................... 605 Hydraulic Tank.............................................................. 605 Hydraulic Pump.............................................................. 606 Steering Priority Flow Valve................................................ 606 Pilot Valve................................................................. 607 Main Control Valve.......................................................... 609 Unloader Valve.............................................................. 610 Hydraulic Operation......................................................... 611 Checks and Adjustments.......................................................... 614 Quick Disconnect Fittings................................................... 614 Steering Priority Flow Valve................................................ 614 Steering Relief Pressure.................................................... 614 Modulator Valve............................................................. 615 Pilot Valve and Pressure Reducing Valve..................................... 615 Accumulator................................................................. 616 Filter...................................................................... 616 Main Control Valve.......................................................... 616 Relief Pressure Check................................................... 616 Check Valves................................................................ 617 Unloader Valve.............................................................. 617 Hydraulic Pump Repair........................................................... 618 Remove...................................................................... 618 Disassemble................................................................. 618 Clean and Inspect........................................................... 618 Assemble.................................................................... 619 Install..................................................................... 620 Pilot Accumulator Replacement .................................................. 620 Remove...................................................................... 620 Install..................................................................... 620 Pilot Valve Repair.............................................................. 621 Remove...................................................................... 621 Disassemble................................................................. 622 Clean and Inspect........................................................... 622 Assemble.................................................................... 622 Install..................................................................... 622 Control Levers and Joystick Repair.............................................. 623 Remove...................................................................... 623 Install..................................................................... 623 Calibration and Diagnostics..................................................... 624 General..................................................................... 624 Description................................................................. 624 Lever and Joystick Calibration.......................................... 624 Flow Adjustment......................................................... 624 Dead Band Value Setting................................................. 625 Lowering Delay.......................................................... 626 PWM and I/O Module Readouts............................................. 626 Function Disable........................................................ 627 General Startup............................................................. 627 Minimum system requirements............................................. 627 Install the Hydraulic Controls Program.................................. 627 DelayTimeFile (Reset)................................................... 627 Select the Processor Speed.............................................. 628 Hydraulic Controls Program.................................................. 628 Calibration................................................................. 630 Joystick/Lever Calibration.............................................. 630 Levers.............................................................. 630 Joystick............................................................ 630 Valve Flow Adjustment....................................................... 631 Diagnostics................................................................. 631 Calibration System Shutdown................................................. 631 LED Diagnostics................................................................. 632 Electrical Connections.......................................................... 635 Specifications.................................................................. 639 tables.............................................................................. 601 Table 1. Main Control Valve Port Settings....................................... 607 Table 2. Processor Speed Settings............................................... 627 Table 3. PWM Board LED Error Codes.............................................. 632 Table 4. Altering PT FLT I/O Board LED's (Old Logic)............................ 633 Table 5. Altering PT FLT I/O Board LED's (New Logic)............................ 633 Table 6. Fixed PT Logic I/O Boards LED's........................................ 634 Table 7. ECH.................................................................... 634 Table 8. PWM Driver Module...................................................... 635 Table 9. Input/Output Module 1.................................................. 636 Table 10. Input/Output Module 2................................................. 637 Table 11. Altering PT FLT....................................................... 638 Table 12. Fixed PT FLT.......................................................... 638 Table 13. ECH................................................................... 639 1494143-2200SRM0939-(12-2004)-US-EN..................................................... 643 toc................................................................................. 643 Instrument Panel Indicators and Senders......................................... 643 Safety Precautions Maintenance and Repair....................................... 644 General......................................................................... 647 Description..................................................................... 647 General..................................................................... 647 Instrument Panel Meters, Indicators, and LCD Display........................ 647 Error Code Display, Transmission............................................ 654 Error Code Display, Engine.................................................. 655 Connector................................................................... 656 Seat Switch Logic....................................................... 656 Central Warning Light Output............................................ 658 Buzzer Output........................................................... 658 Engine Shutdown Output.................................................. 658 Instrument Panel Component Replacement.......................................... 661 Instrument Panel............................................................ 661 Remove.................................................................. 661 Light....................................................................... 662 Replace................................................................. 662 Sender Replacement.............................................................. 662 Fuel Level Sender........................................................... 662 Transmission Pressure and Temperature Sender, Tier 1........................ 663 Pressure Sender, Tier 2..................................................... 664 Temperature Sender, Tier 2.................................................. 664 Low Coolant Sender.......................................................... 664 Vacuum Switch............................................................... 664 Crankshaft Position Sensor.................................................. 665 Specifications.................................................................. 665 Troubleshooting................................................................. 667 tables.............................................................................. 643 Table 1. Instrument Panel and Indicators........................................ 648 Table 2. Engine Error Code Descriptions......................................... 656 Table 3. Pin Description........................................................ 657 Table 4. Sender Description..................................................... 658 1494144-8000SRM0934-(08-2001)-US-EN..................................................... 671 toc................................................................................. 671 Periodic Maintenance............................................................ 671 Safety Precautions Maintenance and Repair....................................... 672 General......................................................................... 675 How to Move Disabled Lift Truck............................................. 675 How to Tow Lift Truck................................................... 675 How to Put Lift Truck on Blocks............................................. 676 How to Raise Drive Tires................................................ 676 How to Raise Steering Tires............................................. 676 Maintenance Schedule............................................................ 677 Maintenance Procedures Every 8 Hours or Daily................................... 686 How to Make Checks with Engine Stopped...................................... 686 Tires and Wheels........................................................ 687 Forks................................................................... 688 Adjust.............................................................. 688 Remove.............................................................. 688 Install............................................................. 688 Forks, Mast, and Lift Chains, Inspect................................... 688 Safety Labels........................................................... 689 Operator Restraint System............................................... 689 Steering Column Latch................................................... 690 Drive Belts............................................................. 690 Cooling System.......................................................... 690 Fuel, Oil, or Coolant Leaks, Check...................................... 691 Cab Hydraulic System.................................................... 691 Hydraulic System........................................................ 691 Engine Oil.............................................................. 692 Fuel System............................................................. 692 Primary Fuel Filter..................................................... 693 Battery................................................................. 693 Air Filter.............................................................. 693 How to Make Checks with Engine Running...................................... 693 Gauges, Lights, Horn, and Fuses......................................... 693 Control Levers and Pedals............................................... 694 Transmission Oil........................................................ 694 Lift System Operation................................................... 695 Brakes.................................................................. 695 Steering System......................................................... 696 Maintenance Procedures Every 250 Hours or Every 2 Months........................ 696 Engine Oil and Filter - Cummins Engine...................................... 696 Empty Container Handler..................................................... 696 Maintenance Procedures Every 500 Hours or Every 2 Months........................ 696 Lift Chains................................................................. 696 Lubrication............................................................. 696 Adjust.................................................................. 696 Drive Shaft................................................................. 697 Steering Axle............................................................... 697 Wheel Nuts.................................................................. 697 Shafts for Brake Actuators.................................................. 697 Drive Axle and Differential................................................. 697 Hydraulic Tank Breather..................................................... 698 Air Filter, Engine, and Air Compressor...................................... 698 Cabin Air Filter, Heater.................................................... 698 Engine Oil and Filter - Perkins Engine...................................... 698 Drive Belts................................................................. 698 Mast........................................................................ 698 General Lubrication......................................................... 700 Forks Wear and Damage Check................................................. 700 Lift Chains Wear Check...................................................... 700 Fuel System................................................................. 700 Idle Speed.............................................................. 700 Governor Speed (Diesel)................................................. 700 Maintenance Procedures Every 1000 Hours or 6 Months............................. 702 Transmission Oil and Filter, Change......................................... 702 Final Fuel Filters, Diesel.................................................. 702 Diesel Fuel System Air Removal.......................................... 702 Fuel Injection Pump Without Vent Tube................................... 703 Fuel Injection Pump Timing.................................................. 703 Valve Adjustment............................................................ 703 Maintenance Procedures Every 2000 Hours or Yearly............................... 705 Hydraulic System............................................................ 705 Hydraulic Oil Filter, Change............................................ 705 Hydraulic Oil, Change................................................... 705 Differential and Drive Axle................................................. 705 Wheel Bearings.............................................................. 705 Steer Wheels............................................................ 705 Drive Wheels............................................................ 705 Service Brakes.............................................................. 706 Cleaning Procedures (Dry Brake Axle).................................... 706 Safety Procedures When Working Near Mast........................................ 706 Fuel Injectors Check............................................................ 707 Lift and Tilt System Leak Check................................................. 708 Lift System................................................................. 708 Tilt System................................................................. 708 Welding Repairs................................................................. 709 Wheel and Tire Replacement...................................................... 710 Remove Wheels from Lift Truck............................................... 710 Pneumatic Tires............................................................. 710 Remove Tire from Wheel.................................................. 710 Remove Tire from Three- and Four-Piece Wheel........................ 711 Install Tire on Wheel................................................... 712 Install Three- or Four-Piece Wheel in Tire.......................... 712 Add Air to Tires............................................................ 713 Solid Rubber Tires.......................................................... 714 Remove Tire from Wheel.................................................. 714 Install Tire on Wheel................................................... 715 Wheels, Install............................................................. 717 tables.............................................................................. 671 Table 1. Maintenance Schedule................................................... 678 Table 2. Maintenance Schedule (Empty Container Handler Model 553................ 683 Table 3. Maintenance Schedule (Empty Container Handler Model 555................ 684 Table 4. Maintenance Schedule (Empty Container Handler Model 558................ 685 Table 5. Allowable Mast Movement from Internal Leakage.......................... 709 1494145-8000SRM0940-(03-2008)-US-EN..................................................... 721 toc................................................................................. 721 Capacities and Specifications................................................... 721 Safety Precautions Maintenance and Repair....................................... 722 Lift Truck Weights.............................................................. 725 Capacities...................................................................... 725 Engine Specifications........................................................... 726 Perkins Diesel.............................................................. 726 Cummins Diesel/LPG.......................................................... 727 Hydraulic System................................................................ 728 Electrical System............................................................... 729 Tire Sizes...................................................................... 729 Mast Speeds..................................................................... 729 Perkins Diesel.............................................................. 729 Cummins Diesel/LPG.......................................................... 730 Torque Specifications, Cummins Diesel........................................... 731 Lubrication System.......................................................... 731 Torque Specifications, Perkins Diesel........................................... 731 Engine...................................................................... 731 Cylinder Head Assembly.................................................. 731 Piston and Connecting Rod Assemblies.................................... 731 Crankshaft Assembly..................................................... 731 Timing Case and Drive Assembly.......................................... 732 Turbocharger............................................................ 732 Lubrication System...................................................... 732 Fuel System............................................................. 732 Cooling System.......................................................... 732 Flywheel and Housing.................................................... 732 Aspiration System....................................................... 733 Electrical Equipment.................................................... 733 Auxiliary Equipment..................................................... 733 Torque Specifications - Perkins, Tier 2......................................... 733 Cylinder Head Assembly...................................................... 733 Piston and Connecting Rod Assemblies........................................ 733 Crankshaft Assembly......................................................... 733 Timing Case and Drive Assembly.............................................. 733 Turbocharger................................................................ 734 Lubrication System.......................................................... 734 Fuel System................................................................. 734 Cooling System.............................................................. 734 Flywheel.................................................................... 734 Auxiliary Equipment......................................................... 734 Torque Specifications, General.................................................. 735 Transmission................................................................ 735 Driveline and Axle.......................................................... 735 Differential................................................................ 735 Brakes - Wet................................................................ 735 Brakes - Dry................................................................ 735 Steering.................................................................... 735 Hydraulic System............................................................ 736 Mast........................................................................ 736 Carriage.................................................................... 736 Tilt Cylinders.............................................................. 736 Frame....................................................................... 736 Wiper Arms, Front........................................................... 736 Hyster T-50 Transmission Pressures (Powershift and Automatic)................... 737 TE-10 Transmission Specifications............................................... 738 Electrical.................................................................. 738 Hydraulic Cooler Lines...................................................... 738 Torque Specifications for Lubricated or Plated Screw Threads................ 739 tables.............................................................................. 721 Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp................ 738 Table 2. Grade 5................................................................ 739 Table 3. Grade 8................................................................ 739 Table 4. Grades 8.8, 10.9, and 12.9............................................. 739 Table 5. O-ring Port Plug Torque Chart.......................................... 740 Table 6. Pipe Plug Torque Chart................................................. 740 1494146-8000SRM0941-(01-2006)-US-EN..................................................... 743 toc................................................................................. 743 Diagrams........................................................................ 743 Safety Precautions Maintenance and Repair....................................... 744 General......................................................................... 747 Description..................................................................... 747 1494953-1400SRM0944-(03-2007)-US-EN..................................................... 805 toc................................................................................. 805 Planetary Drive Axle............................................................ 805 Safety Precautions Maintenance and Repair....................................... 806 General......................................................................... 809 Description..................................................................... 809 Operation....................................................................... 811 Identification.............................................................. 811 Removal......................................................................... 812 Disassembly..................................................................... 812 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 812 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 814 Wheel End................................................................... 816 Spindle and Piston Housing.................................................. 817 Cleaning........................................................................ 818 Clean Ground or Polished Parts.............................................. 818 Clean Parts With Rough Finish............................................... 818 Clean Axle Assemblies....................................................... 818 Drying Cleaned Parts........................................................ 818 Corrosion Prevention............................................................ 818 Parts Inspection................................................................ 819 Tapered Roller Bearings..................................................... 819 Bevel Pinion and Ring Gear Sets............................................. 820 Main Differential Assembly.................................................. 820 Axle Shafts................................................................. 820 Yoke........................................................................ 820 Brakes...................................................................... 820 Repair or Replace Parts..................................................... 820 Repair Welding.............................................................. 820 Apply Silicone Gasket Material.............................................. 821 Assembly........................................................................ 821 Spindle and Piston Housing to Axle Housing.................................. 821 Wet Disc Brakes............................................................. 822 Adjust Wheel Bearing Preload................................................ 823 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 824 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 825 Planetary Spider Assembly................................................... 825 Installation.................................................................... 826 Fill Wet Disc Brakes With Hydraulic Fluid................................... 826 Torque Specifications........................................................... 827 Lubrication Specification....................................................... 828 1494955-2000SRM0943-(03-2007)-US-EN..................................................... 831 toc................................................................................. 831 Main Control Valve.............................................................. 831 Safety Precautions Maintenance and Repair....................................... 832 General......................................................................... 835 Description..................................................................... 835 Operation....................................................................... 838 Lift Section................................................................ 838 Tilt/Auxiliary Section...................................................... 838 Relief Valves............................................................... 838 Unloader Valve.............................................................. 838 Main Control Valve Repair....................................................... 841 Remove...................................................................... 841 Disassemble................................................................. 841 Auxiliary Side.......................................................... 841 Lift Side............................................................... 841 Clean and Inspect........................................................... 844 Assemble.................................................................... 844 Auxiliary Side.......................................................... 844 Lift Side............................................................... 844 Install..................................................................... 844 Pressure Relief Valve Check and Adjustment...................................... 845 Check and Adjust............................................................ 845 Replace..................................................................... 845 Specifications.................................................................. 846 Troubleshooting................................................................. 846 1498445-1400SRM0945-(03-2007)-US-EN..................................................... 851 toc................................................................................. 851 Planetary Drive Axle............................................................ 851 Safety Precautions Maintenance and Repair....................................... 852 General......................................................................... 855 Description..................................................................... 855 Operation....................................................................... 857 Identification.............................................................. 857 Removal......................................................................... 858 Disassembly..................................................................... 858 Brake Drum.................................................................. 858 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 859 Dry Brakes.................................................................. 861 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 861 Spindle and Brake Spider.................................................... 863 Cleaning........................................................................ 864 Ground or Polished Parts.................................................... 864 Parts With Rough Finish..................................................... 864 Axle Assemblies............................................................. 864 Drying Cleaned Parts........................................................ 864 Corrosion Prevention............................................................ 864 Parts Inspection................................................................ 865 Tapered Roller Bearings..................................................... 865 Bevel Pinion and Ring Gear Sets............................................. 866 Main Differential Assembly.................................................. 866 Axle Shafts................................................................. 866 Yoke........................................................................ 866 Brakes...................................................................... 866 Repair or Replace Parts..................................................... 866 Repair Welding.............................................................. 866 Apply Silicone Gasket Material.............................................. 867 Assembly........................................................................ 867 Spindle, Brake Spider, and Brake............................................ 867 Wheel End................................................................... 868 Adjust Wheel Bearing Preload................................................ 869 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 870 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 871 Planetary Spider Assembly................................................... 871 Installation.................................................................... 872 Torque Specifications........................................................... 873 Lubrication Specification....................................................... 874 1498450-1800SRM0951-(03-2007)-US-EN..................................................... 877 toc................................................................................. 877 Wet Brake System................................................................ 877 Safety Precautions Maintenance and Repair....................................... 878 General......................................................................... 881 Description and Operation....................................................... 881 Service Brakes.............................................................. 881 Parking Brake............................................................... 881 Oil Cooler Circuit.......................................................... 881 Pressure Switch Replacement..................................................... 885 Accumulators Replacement........................................................ 885 Brake Treadle Valve Repair...................................................... 885 Remove and Disassemble...................................................... 885 Clean and Inspect........................................................... 886 Assemble and Install........................................................ 886 Parking Brake Valve Repair...................................................... 886 Remove...................................................................... 886 Clean and Inspect........................................................... 886 Repair...................................................................... 886 Install..................................................................... 886 Parking Brake Caliper Repair.................................................... 887 Remove...................................................................... 887 Disassemble................................................................. 889 Inspect..................................................................... 889 Install..................................................................... 889 Adjust...................................................................... 889 Brake Pad Repair................................................................ 890 Inspect..................................................................... 890 Remove...................................................................... 890 Install..................................................................... 890 Seals Repair.................................................................... 890 Remove...................................................................... 890 Install..................................................................... 891 Service Brake Repair............................................................ 891 Remove and Disassemble...................................................... 891 Drain Lubricating Oil................................................... 891 Drain Coolant Oil....................................................... 898 Disconnect Brake Lines.................................................. 898 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14......... 898 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H........ 899 Brake Disc Housing Assembly Wheel End................................... 900 Brake Piston Housing.................................................... 901 Brake Piston Housing and Wheel Spindle.................................. 902 Inspect..................................................................... 902 Clean....................................................................... 904 Assemble.................................................................... 905 Wheel Spindle........................................................... 905 Brake Piston Housing.................................................... 905 Piston Assembly......................................................... 907 Brake Disc Housing...................................................... 907 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub................. 909 Check for Correct Installation of Duo-Cone Seal......................... 910 Wheel Hub to Brake Disc Housing......................................... 911 Adjust...................................................................... 912 Fill Brake System With Coolant Oil...................................... 912 System Air Removal...................................................... 913 Adjust Brake With New Disc Pack......................................... 913 Coolant Change Intervals................................................ 914 Coolant Draining and Filling............................................ 914 Specifications.................................................................. 916 Minimum Brake Disc Thickness................................................ 919 Hydraulic Fluid for Brake Actuation......................................... 919 Brake Coolant Specifications................................................ 919 Coolant Change Intervals.................................................... 919 Hydraulic Fluid Specifications.............................................. 919 Troubleshooting................................................................. 919 Brake Does Not Apply........................................................ 919 Brake Does Not Release...................................................... 920 Brake Performance........................................................... 920 Brake Leaks Actuation Fluid................................................. 921 Brake Cooling Fluid Leakage................................................. 922 Brake Noise and Vibration................................................... 922 Brake Overheats............................................................. 922 tables.............................................................................. 877 Table 1. Brake Pad Adjustment................................................... 889 Table 2. Minimum Brake Disc Thickness........................................... 903 Table 3. Formed Seal Wear Chart................................................. 903 1503241-5000SRM0969-(10-2007)-US-EN..................................................... 927 toc................................................................................. 927 Empty Container Handling Attachment............................................. 927 Safety Precautions Maintenance and Repair....................................... 928 General......................................................................... 931 Description..................................................................... 931 Operation....................................................................... 937 General..................................................................... 937 Selector Valves............................................................. 937 Sideshift Circuit........................................................... 937 Extend and Retract Circuit.................................................. 937 Twist Lock Circuit and Control.............................................. 938 Model 553 - Horizontally Mounted........................................ 938 Model 558 - Vertically Mounted.......................................... 938 Lifting Hooks............................................................... 938 Model 555............................................................... 938 Indicator Lights and LEDs................................................... 938 Lift Interrupt and Override................................................. 939 Overlowering Interrupt and Override......................................... 939 Carriage and Attachment Repair.................................................. 939 Remove...................................................................... 939 Attachment Without Carriage Repair.............................................. 940 Remove...................................................................... 940 Sideshift Cylinders Repair...................................................... 941 Remove...................................................................... 941 Disassemble................................................................. 941 Assemble.................................................................... 941 Extension Cylinders Repair...................................................... 942 Remove...................................................................... 942 Disassemble................................................................. 942 Clean and Inspect........................................................... 942 Assemble.................................................................... 942 Install..................................................................... 942 Vertical End Beams Repair....................................................... 944 Remove...................................................................... 944 Install..................................................................... 944 Hose Replacement in End Beams............................................... 944 Twist Locks Repair for Model 553................................................ 945 Remove...................................................................... 945 Disassemble................................................................. 945 Clean and Inspect........................................................... 945 Assemble.................................................................... 945 Hooks Replacement for Model 555................................................. 946 Inspect..................................................................... 946 Remove...................................................................... 946 Install..................................................................... 946 Twist Locks Repair for Model 558................................................ 947 Disassemble................................................................. 947 Clean and Inspect........................................................... 947 Assemble.................................................................... 947 Bleed the System................................................................ 948 Valve Assembly.................................................................. 948 Slide Pad Replacement........................................................... 949 Adjustments..................................................................... 949 Twist Lock Angle Adjustment................................................. 949 Model 558 Only.......................................................... 949 LOCKED/NOT LOCKED Sensors Adjustment........................................ 950 Model 553............................................................... 950 Model 558............................................................... 950 Seated Sensor Adjustment.................................................... 950 Model 553............................................................... 950 Model 558............................................................... 950 Overlowering Protection Sensor Adjustment (Models 553 and 558).............. 950 Torque Chart................................................................ 951 Maintenance..................................................................... 951 Additional Attachment Maintenance........................................... 953 Interface Boxes............................................................. 954 Model 555............................................................... 954 Models 553 and 558...................................................... 954 Troubleshooting................................................................. 956 tables.............................................................................. 927 Table 1. Torque Chart........................................................... 951 Table 2. Inspect and Adjust (See Figure 14 ).................................... 952 Table 3. Lubricate (See Figure 14 )............................................. 953 Table 4. Replace (See Figure 14 )............................................... 953 1538764-8000SRM1066-(09-2005)-US-EN..................................................... 973 toc................................................................................. 973 Periodic Maintenance............................................................ 973 Safety Precautions Maintenance and Repair....................................... 974 General......................................................................... 977 How to Move Disabled Lift Truck............................................. 977 How to Tow Lift Truck................................................... 977 How to Put Lift Truck on Blocks............................................. 978 How to Raise Drive Tires................................................ 978 How to Raise Steering Tires............................................. 978 Maintenance Schedule............................................................ 980 Empty Container Attachment Maintenance...................................... 986 Maintenance Procedures Every 8 Hours or Daily................................... 988 How to Make Checks With Engine Stopped...................................... 988 Hydraulic System Oil.................................................... 988 Engine Oil.............................................................. 988 Cooling System.......................................................... 989 Fuel System............................................................. 990 Water Separator/Fuel Filter............................................. 990 Fuel, Oil, or Coolant Leaks, Check...................................... 990 Cab Hydraulic System.................................................... 990 Drive Belts............................................................. 991 Battery................................................................. 991 Air Filters............................................................. 991 Forks................................................................... 991 Adjust.............................................................. 991 Remove.............................................................. 991 Install............................................................. 991 Forks, Mast, and Lift Chains, Inspect................................... 992 Tires and Wheels........................................................ 993 Operator Restraint System............................................... 993 Steering Column Latch................................................... 994 Safety Labels........................................................... 994 How to Make Checks With Engine Running...................................... 995 Gauges, Lights, Horn and Fuses.......................................... 995 Control Levers and Pedals............................................... 997 Transmission Oil........................................................ 997 Lift System Operation................................................... 997 Brakes.................................................................. 997 Steering System......................................................... 997 Attachments............................................................. 997 Maintenance Procedures Every 250 Hours or Every 2 Months........................ 998 Empty Container Handler..................................................... 998 Maintenance Procedures Every 500 Hours or Every 3 Months........................ 998 Lift Chains................................................................. 998 Lubrication............................................................. 998 Adjust.................................................................. 998 Drive Shaft................................................................. 999 Steering Axle............................................................... 999 Wheel Nuts.................................................................. 999 Shafts for Brake Actuators.................................................. 999 Drive Axle and Differential................................................. 999 Hydraulic Tank Breather..................................................... 999 Air Filter, Engine, and Air Compressor...................................... 999 Cabin Air Filter, Heater.................................................... 999 Engine Oil and Filter....................................................... 999 Drive Belts.................................................................1000 Mast........................................................................1000 General Lubrication.........................................................1001 Fork Wear and Damage Check..................................................1001 Lift Chains Wear Check......................................................1002 Maintenance Procedures Every 1000 Hours or 6 Months.............................1002 Transmission Oil and Filter, Change.........................................1002 Fuel Filter.................................................................1003 Diesel Fuel System Air Removal..........................................1003 Fuel Injection Pump Without Vent Tube...................................1003 Fuel Injection Pump Timing..................................................1004 Valve Adjustment............................................................1004 Pilot Accumulator Pressure Charge Check.....................................1005 Maintenance Procedures Every 2000 Hours or Yearly...............................1005 Hydraulic System............................................................1005 Hydraulic Oil Filter, Change............................................1005 Hydraulic Oil, Change...................................................1005 Differential and Drive Axle.................................................1006 Wheel Bearings..............................................................1006 Steer Wheels............................................................1006 Drive Wheels............................................................1007 Service Brakes..............................................................1007 Cleaning Procedures (Dry Brake Axle)....................................1007 Safety Procedures When Working Near Mast........................................1007 Fuel Injectors Check............................................................1009 Perkins.....................................................................1009 Lift and Tilt System Leak Check.................................................1009 Lift System.................................................................1009 Tilt System.................................................................1009 Welding Repairs.................................................................1010 Wheel and Tire Replacement......................................................1011 Remove Wheels From Lift Truck...............................................1011 Pneumatic Tires.............................................................1011 Remove Tire From Wheel..................................................1011 Remove Tire From Three- and Four-Piece Wheel........................1012 Install Tire on Wheel...................................................1013 Install Three- or Four-Piece Wheel in Tire..........................1013 Add Air to Tires............................................................1014 Solid Rubber Tires..........................................................1015 Remove Tire From Wheel..................................................1015 Install Tire on Wheel...................................................1016 Wheels, Install.............................................................1018 tables.............................................................................. 973 Table 1. Daily Inspections − Condition Check.................................... 980 Table 2. Daily Inspections − Fluid Level Check.................................. 981 Table 3. Daily Inspections − Checks With the Engine Running..................... 981 Table 4. First Inspection After First 100 Hours of Operation.................... 982 Table 5. Periodic Maintenance Schedule − Inspect and Adjust..................... 983 Table 6. Periodic Maintenance Schedule − Lubricate.............................. 984 Table 7. Periodic Maintenance Schedule − Change................................. 984 Table 8. Empty Container Attachment Maintenance − Inspect and .................. 987 Table 9. Empty Container Attachment Maintenance − Lubricate..................... 987 Table 10. Allowable Mast Movement from Internal Leakage.........................1010 1541323-0600SRM1068-(05-2004)-US-EN.....................................................1021 toc.................................................................................1021 Perkins Tier 2 Diesel Engines...................................................1021 Safety Precautions Maintenance and Repair.......................................1022 General.........................................................................1029 General Safety Rules........................................................1029 Description.....................................................................1030 Engine Serial Number Codes..................................................1032 Engine Data.................................................................1032 Engine Removal and Installation.................................................1033 Cylinder Head Assembly Repair...................................................1033 Valve Cover.................................................................1033 Remove..................................................................1033 Install.................................................................1034 Rocker Arm Assembly.........................................................1034 Remove..................................................................1034 Disassemble.............................................................1034 Inspect.................................................................1034 Assemble................................................................1034 Install.................................................................1034 Valve Clearance Adjustments.................................................1035 Valve Springs...............................................................1036 Cylinder Head Assembly......................................................1037 Remove..................................................................1037 Install.................................................................1039 Valves and Valve Springs....................................................1042 Remove..................................................................1042 Inspect.................................................................1042 Install.................................................................1043 Valve Guides................................................................1043 Inspect.................................................................1043 Remove..................................................................1043 Install.................................................................1043 Cylinder Head and Valve Seats...............................................1044 Inspect.................................................................1044 Repair..................................................................1045 New Valve Seats, Install................................................1045 Piston and Connecting Rod Assemblies Repair.....................................1045 Rod Bearings................................................................1046 Remove..................................................................1046 Install.................................................................1046 Piston and Connecting Rod Assembly..........................................1047 Service Note............................................................1047 Remove..................................................................1047 Install.................................................................1048 Piston Rings................................................................1049 Remove..................................................................1049 Inspect.................................................................1049 Install.................................................................1050 Piston and Connecting Rod...................................................1050 Disassemble.............................................................1050 Inspect.................................................................1050 How to Select Correct Replacements......................................1051 Install.................................................................1052 Piston Cooling Jets.........................................................1052 Remove..................................................................1052 Install.................................................................1053 Crankshaft Assembly Repair......................................................1053 General.....................................................................1053 Crankshaft Pulley...........................................................1054 Remove..................................................................1054 Inspect.................................................................1054 Install.................................................................1054 Rear Oil Seal...............................................................1055 Remove..................................................................1055 Install.................................................................1055 Main Bearings...............................................................1056 Remove..................................................................1056 Inspect.................................................................1057 Install.................................................................1057 Thrust Washers..............................................................1057 Crankshaft Axial Movement, Check........................................1057 Remove..................................................................1058 Install.................................................................1058 Crankshaft..................................................................1059 Remove..................................................................1059 Inspect.................................................................1059 Install.................................................................1060 Flywheel....................................................................1061 Remove..................................................................1061 Ring Gear, Replace......................................................1061 Install.................................................................1061 Flywheel Housing............................................................1062 Remove..................................................................1062 Install.................................................................1062 Timing Case and Timing Gears Repair.............................................1063 General.....................................................................1063 Timing Case Cover...........................................................1063 Remove..................................................................1063 Install.................................................................1064 Front Oil Seal..............................................................1064 Remove..................................................................1064 Install.................................................................1064 Crankshaft Pulley Wear Sleeve...............................................1065 Install.................................................................1065 Idler Gear and Hub..........................................................1065 Remove..................................................................1065 Install.................................................................1066 Air Compressor Drive, Bendix................................................1067 Disassemble.............................................................1067 Assemble................................................................1067 Fuel Injection Pump Gear....................................................1068 Remove..................................................................1068 Install.................................................................1069 Camshaft Gear...............................................................1069 Remove..................................................................1069 Install.................................................................1070 Crankshaft Gear.............................................................1070 Remove..................................................................1070 Install.................................................................1071 Timing Case.................................................................1071 Remove..................................................................1071 Install.................................................................1071 Camshaft and Tappets........................................................1072 Remove..................................................................1072 Install.................................................................1073 Cylinder Block Assembly Repair..................................................1073 Description.................................................................1073 Cylinder Block..............................................................1073 Disassemble.............................................................1073 Inspect.................................................................1074 Assemble................................................................1074 Cylinder Liner..............................................................1075 Inspect.................................................................1075 Cylinder Liner Condition, Check.........................................1075 Remove..................................................................1076 Service Liner, Install..................................................1077 Partially Finished Liner, Install.......................................1078 Engine Timing...................................................................1079 Description.................................................................1079 How to Set Number One Piston to TDC on Compression Stroke...............1080 How to Set Number One Piston to TDC on Compression Stroke (Alter........1081 How to Set Number One Piston to 4° After TDC on Compression Stro........1082 Valve Timing, Check.....................................................1083 Fuel Injection Pump Timing, Check.......................................1084 Turbocharger....................................................................1084 General.....................................................................1084 Remove......................................................................1084 Install.....................................................................1085 Impeller and Compressor Housing, Clean......................................1085 Waste-Gate Valve Check......................................................1086 Closed Circuit Breather System (CCB)........................................1087 CCB Assembly, Remove....................................................1087 Closed Circuit Drain Valve, Remove......................................1087 CCB Assembly, Install...................................................1087 Closed Circuit Drain Valve, Install.....................................1087 Lubrication System Repair.......................................................1088 General.....................................................................1088 Oil Filter, Replace.........................................................1088 Oil Filter Head.............................................................1088 Remove..................................................................1088 Install.................................................................1088 Oil Filter Head Bypass Valve................................................1089 Remove and Install......................................................1089 Oil Sump....................................................................1089 Remove..................................................................1089 Install.................................................................1089 Oil Pump....................................................................1090 Remove..................................................................1090 Inspect.................................................................1090 Install.................................................................1091 Relief Valve................................................................1092 Remove..................................................................1092 Disassemble.............................................................1092 Inspect.................................................................1092 Assemble................................................................1092 Install.................................................................1092 Idler Gear Shaft, Replace...................................................1092 Remove..................................................................1093 Remove (Alternative)....................................................1093 Install.................................................................1094 Install (Alternative)...................................................1094 Fuel System Repair..............................................................1095 Description.................................................................1095 Fuel Injection Pump.........................................................1097 Remove..................................................................1097 Install.................................................................1099 Fuel System Air Removal.....................................................1100 Fuel Filter, Replace........................................................1102 Fuel Injectors..............................................................1102 Remove..................................................................1103 Inspect.................................................................1103 Install.................................................................1103 Fuel Lift Pump..............................................................1104 Remove..................................................................1104 Disassemble.............................................................1104 Assemble................................................................1104 Install.................................................................1105 Test....................................................................1105 Cooling System Repair...........................................................1106 General.....................................................................1106 Thermostat..................................................................1106 Remove..................................................................1106 Install.................................................................1107 Test....................................................................1107 Coolant Pump................................................................1107 Remove..................................................................1107 Disassemble.............................................................1108 Assemble................................................................1110 Install.................................................................1112 Fan and Fan Drive...........................................................1113 Remove..................................................................1113 Install.................................................................1113 Oil Cooler..................................................................1113 Remove..................................................................1113 Disassemble and Assemble................................................1114 Install.................................................................1114 Electrical Equipment Repair.....................................................1115 Drive Belts.................................................................1115 Alternator..................................................................1115 Remove..................................................................1115 Install.................................................................1115 Electronic Control Module (ECM).............................................1116 Remove..................................................................1116 Inspect.................................................................1116 Install.................................................................1116 Voltage Load and Protection Module (VLPM)...................................1117 Remove..................................................................1117 Install.................................................................1117 Engine Speed and Timing Sensor..............................................1117 Remove..................................................................1117 Install.................................................................1118 Pressure Sensors (Engine Oil and Air Intake)................................1118 Remove..................................................................1118 Install.................................................................1119 Temperature Sensor..........................................................1119 Remove..................................................................1119 Install.................................................................1120 Starter Motor...............................................................1120 Remove..................................................................1120 Install.................................................................1120 Cold Start Aid..............................................................1120 Air Compressor..................................................................1120 General.....................................................................1120 Repair......................................................................1121 Remove..................................................................1121 Install.................................................................1121 Rotary Exhauster Replacement....................................................1122 Remove......................................................................1122 Clean.......................................................................1122 Install.....................................................................1122 Engine Specifications...........................................................1123 Cylinder Head Assembly......................................................1123 Piston and Connecting Rods..................................................1126 Crankshaft Assembly.........................................................1127 Crankshaft Overhaul.....................................................1128 Timing Case and Drive Assembly..............................................1130 Engine Block Assembly.......................................................1131 Turbocharger................................................................1132 Lubrication System..........................................................1133 Cooling System..............................................................1135 Flywheel and Housing........................................................1135 Electrical Equipment........................................................1135 Torque Specifications...........................................................1136 Cylinder Head Assembly......................................................1136 Piston and Connecting Rod Assemblies........................................1136 Crankshaft Assembly.........................................................1136 Timing Case and Drive Assembly..............................................1136 Turbocharger................................................................1136 Lubrication System..........................................................1136 Fuel System.................................................................1136 Cooling System..............................................................1137 Flywheel....................................................................1137 Auxiliary Equipment.........................................................1137 Special Torque Specifications...................................................1137 Flywheel and Housing........................................................1137 Electrical Equipment........................................................1137 Auxiliary Equipment.........................................................1137 Special Tools...................................................................1138 Troubleshooting.................................................................1143 Turbocharger Troubleshooting....................................................1145 tables..............................................................................1021 Table 1. Cylinder Head..........................................................1123 Table 2. Valve Guides...........................................................1123 Table 3. Inlet Valves...........................................................1124 Table 4. Exhaust Valves.........................................................1124 Table 5. Valve Springs..........................................................1125 Table 6. Tappets................................................................1125 Table 7. Rocker Arm Shaft.......................................................1125 Table 8. Rocker Arms and Bushings...............................................1125 Table 9. Pistons................................................................1126 Table 10. Piston Rings..........................................................1126 Table 11. Piston Pins...........................................................1126 Table 12. Connecting Rods.......................................................1126 Table 13. Small End Bushings....................................................1127 Table 14. Connecting Rod Bearings...............................................1127 Table 15. Piston Cooling Jets...................................................1127 Table 16. Crankshaft............................................................1127 Table 17. Main Bearings.........................................................1128 Table 18. Crankshaft Thrust Washers.............................................1128 Table 19. Crankshaft Heat Treatment.............................................1128 Table 20. Crankshaft Overhaul Specifications....................................1128 Table 21. Maximum Variation (Run-Out)...........................................1130 Table 22. Camshaft..............................................................1130 Table 23. Camshaft Thrust Washer................................................1130 Table 24. Camshaft Gear.........................................................1130 Table 25. Gear for Fuel Injection Pump..........................................1130 Table 26. Crankshaft Gear.......................................................1131 Table 27. Idler Gear and Hub....................................................1131 Table 28. Cylinder Block........................................................1131 Table 29. Cylinder Liners.......................................................1131 Table 30. Cylinder Liner Specifications (Partially Finished)....................1132 Table 31. Oil Pump..............................................................1133 Table 32. Idler Gear for Oil Pump...............................................1133 Table 33. Relief Valve..........................................................1133 Table 34. Oil Filter............................................................1133 Table 35. Bosch Fuel Injection Pump.............................................1133 Table 36. Fuel Injector Codes...................................................1134 Table 37. Fuel Pump.............................................................1135 Table 38. Fuel Filter...........................................................1135 Table 39. Coolant Pump..........................................................1135 Table 40. Thermostat............................................................1135 Table 41. Fan Drive Housing.....................................................1135 Table 42. Limits for Flywheel Run Out and Alignment (Total Indic................1135 Table 43. Alternator............................................................1135 Table 44. Starter Motor.........................................................1135 Table 45. Cold Start Aid........................................................1135 Table 46. List of Possible Causes...............................................1143 Table 47. List of Possible Causes...............................................1145 1553599-4000SRM1062-(03-2007)-US-EN.....................................................1149 toc.................................................................................1149 Masts and Carriages.............................................................1149 Safety Precautions Maintenance and Repair.......................................1150 General.........................................................................1153 Description.....................................................................1153 Operation.......................................................................1154 Two-Stage Mast..............................................................1154 Three-Stage Mast............................................................1155 Safety Procedures When Working Near Mast........................................1156 Forks Repair....................................................................1159 Remove......................................................................1159 Inspect and Adjust..........................................................1159 Install.....................................................................1159 Carriage Repair.................................................................1160 Description.................................................................1160 Three Function..........................................................1160 Four to Six Function....................................................1160 Remove......................................................................1160 Disassemble.................................................................1161 Clean and Inspect...........................................................1163 Assemble....................................................................1163 Install.....................................................................1163 Sideshift Cylinder Repair.......................................................1164 Remove......................................................................1164 Disassemble.................................................................1164 Clean and Inspect...........................................................1164 Assemble....................................................................1164 Install.....................................................................1164 Fork Positioner Cylinders Repair................................................1168 Remove......................................................................1168 Disassemble.................................................................1168 Clean and Inspect...........................................................1168 Assemble....................................................................1168 Install.....................................................................1168 Directional Control Valve Repair................................................1175 Remove......................................................................1175 Disassemble.................................................................1175 Clean and Inspect...........................................................1175 Assemble....................................................................1176 Install.....................................................................1176 Mast Repair.....................................................................1176 Two- and Three-Stage Mast...................................................1176 Remove..................................................................1176 Disassemble.............................................................1181 Clean and Inspect.......................................................1183 Assemble................................................................1184 Install.................................................................1185 Three-Stage Mast (Four Cylinders)...........................................1185 Remove..................................................................1185 Disassemble.............................................................1187 Clean and Inspect.......................................................1189 Assemble................................................................1189 Install.................................................................1189 Fork Carriage Chains........................................................1191 Adjust..................................................................1191 Bearing Rollers.............................................................1193 Description.............................................................1193 Lubrication.............................................................1193 Clearance...............................................................1193 Remove and Disassemble..................................................1193 Assemble................................................................1194 Mast Profile................................................................1194 Lift Cylinders Description......................................................1194 Piston-Type Cylinders.......................................................1194 Displacement-Type Cylinders.................................................1194 Lift Cylinders Repair...........................................................1195 Remove......................................................................1195 Disassemble.................................................................1197 Clean and Inspect...........................................................1197 Assemble....................................................................1197 Install.....................................................................1198 Mast Operation Check............................................................1198 Lift and Tilt System Leak Checks................................................1199 Lift System.................................................................1199 Tilt System.................................................................1199 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................1200 Lift Chain Adjustments..........................................................1200 Mast Adjustments................................................................1201 Bearing Blocks, Two-Stage Masts.............................................1201 Wear Plates.................................................................1201 Carriage Adjustment.............................................................1201 Troubleshooting.................................................................1203 tables..............................................................................1149 Table 1. Allowable Mast Movement from Internal Leakage..........................1199 1553764-0600SRM1072-(06-2005)-US-EN.....................................................1207 toc.................................................................................1207 Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...................1207 Safety Precautions Maintenance and Repair.......................................1208 Electronic Troubleshooting......................................................1231 System Operation............................................................1231 Electronic Controls.........................................................1231 Engine Governor.............................................................1232 Timing Considerations.......................................................1232 Fuel Injection..............................................................1232 Diagnostic Codes............................................................1232 Diagnostic Fault Codes......................................................1232 Diagnostic Event Codes......................................................1232 Programmable Parameters.....................................................1233 Passwords...................................................................1233 Electronic Service Tools....................................................1233 Electronic Service Tool (EST)...............................................1233 Connecting the Electronic Service Tool and the Communication Ada........1233 Support for the Electronic Service Tool.................................1234 Optional Service Tools..................................................1234 Diagnostic Codes............................................................1234 Diagnostic Fault Code Access Via Indicator Lamps............................1238 Replacing the ECM...........................................................1239 Self Diagnostics............................................................1240 Glossary........................................................................1241 Sensors and Electrical Connectors...............................................1244 Engine Wiring Information.......................................................1247 Harness Wire Identification.................................................1250 Diagnostic Code Reader..........................................................1250 General.....................................................................1250 Reference Documents.........................................................1250 Abbreviations...............................................................1250 Environmental Specification.................................................1250 Hardware....................................................................1251 Connection Cable........................................................1252 Software....................................................................1252 Engine Communication....................................................1252 User Controls...............................................................1252 Power Supply............................................................1252 Display Screen..........................................................1253 Operation Controls......................................................1253 Audible Warning.........................................................1253 Operation Instructions......................................................1253 How to Connect the Diagnostic Code Reader to the Engine.................1253 How to Turn ON the Diagnostic Code Reader...............................1253 How to use the Display Screen...........................................1253 How to Operate the Diagnostic Code Reader...............................1254 Main Menu...........................................................1254 Active Codes........................................................1254 Inactive Codes......................................................1255 How to Clear Codes..................................................1255 Status Lamp.........................................................1255 Data List...........................................................1256 Diagnostics.................................................................1256 Programming Parameters..........................................................1257 Passwords...................................................................1257 Factory Passwords...........................................................1257 Customer Passwords..........................................................1258 Flash Programming...........................................................1258 Flash Programming a Personality Module......................................1258 WinFlash Error Messages.....................................................1258 System Configuration Parameters.................................................1259 Full Load Setting...........................................................1259 Full Torque Setting.........................................................1259 Rating Interlock............................................................1259 Engine Serial Number........................................................1259 ECM Software Release Date...................................................1259 Troubleshooting Without a Diagnostic Code.......................................1260 Alternator Noise (Noisy Operation)..........................................1260 Probable Causes.........................................................1260 Recommended Actions.....................................................1260 Alternator Drive Belts..............................................1260 Alternator Drive Pulley.............................................1260 Alternator Bearings.................................................1260 Alternator Will Not Charge (Charging Problem)...............................1260 Probable Causes.........................................................1260 Recommended Actions.....................................................1260 Alternator Drive Belts..............................................1260 Charging Circuit....................................................1260 Alternator or Regulator.............................................1260 Battery.....................................................................1260 Probable Causes.........................................................1260 Recommended Actions.....................................................1260 Faulty Battery......................................................1260 Auxiliary Device....................................................1260 Cannot Reach Top Engine RPM.................................................1261 Probable Causes.........................................................1261 Recommended Actions.....................................................1261 Diagnostic Codes....................................................1261 Fuel Supply.........................................................1261 Air Intake and Exhaust System.......................................1261 Individual Malfunctioning Cylinders.................................1261 Valve Lash..........................................................1261 Check for Low Compression...........................................1261 Check the Fuel Injection Nozzles....................................1262 Check the Turbocharger..............................................1262 ECM Parameters......................................................1262 Check the Signal for the Throttle Position Sensor...................1262 Coolant in Engine Oil.......................................................1262 Probable Causes.........................................................1262 Recommended Actions.....................................................1262 Engine Oil Cooler Core..............................................1262 Cylinder Head Gasket................................................1262 Cylinder Head.......................................................1263 Cylinder Block......................................................1263 Coolant Temperature Is Too High.............................................1263 Probable Causes.........................................................1263 Recommended Actions.....................................................1263 Radiator Fins.......................................................1263 Coolant Level.......................................................1263 Radiator Cap and/or Pressure Relief Valve...........................1263 Combustion Gases in the Cooling System..............................1263 Water Temperature Regulator.........................................1263 Restriction in the Coolant System...................................1263 Coolant Temperature Gauge...........................................1263 Coolant Pump........................................................1263 Excessive Load on the System........................................1264 ECM Will Not Accept Factory Passwords.......................................1264 Probable Causes.........................................................1264 Recommended Actions.....................................................1264 ECM Will Not Communicate With Other Systems or Display Modules..............1264 Probable Causes.........................................................1264 Recommended Actions.....................................................1264 Electronic Service Tool Will Not Communicate With ECM.......................1264 Probable Causes.........................................................1264 Recommended Actions.....................................................1264 Engine Cranks but Will Not Start............................................1265 Probable Causes.........................................................1265 Recommended Actions.....................................................1265 Diagnostic Codes....................................................1265 Visual Checks.......................................................1265 Crank Without Injection.............................................1265 Starting Motor Solenoid or Starting Circuit.........................1265 Valve Lash..........................................................1265 Fuel Injection Nozzles..............................................1266 Air Inlet Heater Starting Aid.......................................1266 Air Intake and Exhaust System.......................................1266 Low Compression.....................................................1266 Fuel Supply.........................................................1266 Engine Has Early Wear.......................................................1266 Probable Causes.........................................................1266 Recommended Actions.....................................................1266 Dirt in Engine Oil..................................................1266 Leaks in Air Intake System..........................................1266 Low Oil Pressure....................................................1267 Engine Misfires, Runs Rough or Is Unstable..................................1267 Probable Causes.........................................................1267 Recommended Actions.....................................................1267 Logged Codes........................................................1267 Fuel Supply.........................................................1267 Air Intake and Exhaust System.......................................1267 Individual Malfunctioning Cylinders.................................1267 Valve Lash..........................................................1267 Check for Low Compression...........................................1268 Check the Fuel Injection Nozzles....................................1268 Check the Air Inlet Heater Starting Aid.............................1268 Check the Engine Speed/Timing Sensors...............................1268 Check the Signal for the Throttle Position Sensor...................1268 Check the Fuel Injection Pump.......................................1268 Engine Oil in Cooling System................................................1268 Probable Causes.........................................................1268 Recommended Actions.....................................................1269 Engine Oil Cooler Core..............................................1269 Cylinder Head Gasket................................................1269 Cylinder Head.......................................................1269 Engine Speed Does Not Change................................................1269 Probable Causes.........................................................1269 Recommended Repairs.....................................................1269 Diagnostic Codes....................................................1269 Engine Stalls at Low RPM....................................................1269 Probable Causes.........................................................1269 Recommended Actions.....................................................1269 Diagnostic Codes....................................................1269 Fuel Injection Nozzles..............................................1269 Fuel Supply.........................................................1270 Accessory Equipment.................................................1270 Power Mode Control..................................................1270 Engine Vibration............................................................1270 Probable Causes.........................................................1270 Recommended Actions.....................................................1270 Engine Supports.....................................................1270 Malfunctioning Individual Cylinder..................................1270 Valve Lash..........................................................1270 Check for Low Compression (cylinder pressure).......................1270 Check the Fuel Injection Nozzles....................................1271 Turbocharger........................................................1271 Engine Will Not Crank.......................................................1271 Probable Causes.........................................................1271 Recommended Repairs.....................................................1271 Machine Security System.............................................1271 Battery Cables and/or Batteries.....................................1271 Starting Motor Solenoid or Starting Circuit.........................1271 Starting Motor and/or Flywheel Ring Gear............................1271 Electrical Power Supply.............................................1272 Internal Engine Problem.............................................1272 Excessive Black Smoke.......................................................1272 Probable Causes.........................................................1272 Recommended Actions.....................................................1272 Air Intake System or Exhaust System.................................1272 Individual Malfunctioning Cylinder..................................1272 Valve Lash..........................................................1272 Low Compression (cylinder pressure).................................1272 Check the Fuel Injection Nozzles....................................1272 Check the Turbocharger..............................................1273 Broken 5-Volt Supply Wire...........................................1273 Verifying the ECM Software..........................................1273 Excessive Engine Oil Consumption............................................1273 Probable Causes.........................................................1273 Recommended Actions.....................................................1273 Oil Level...........................................................1273 Engine Crankcase Breather...........................................1273 Air Intake and Exhaust System.......................................1273 Turbocharger........................................................1273 Low Compression (cylinder pressure).................................1274 Excessive Valve Lash........................................................1274 Probable Causes.........................................................1274 Recommended Actions.....................................................1274 Lubrication.........................................................1274 Valve Lash..........................................................1274 Valve Train Components..............................................1274 Excessive White Smoke.......................................................1274 Probable Causes.........................................................1274 Recommended Actions.....................................................1275 Fuel Supply.........................................................1275 Individual Malfunctioning Cylinder..................................1275 Valve Lash..........................................................1275 Low Compression (cylinder pressure).................................1275 Air Inlet Heater Starting Aid.......................................1275 Fuel Injection Nozzles..............................................1275 Coolant Temperature Sensor Circuit..................................1275 Engine Pressure Sensors.............................................1275 Intake Air Temperature Is Too High..........................................1276 Probable Causes.........................................................1276 Recommended Repairs.....................................................1276 High Ambient Air Temperature........................................1276 Coolant Temperature.................................................1276 Check for High Intake Air Restriction and/or High Altitude..........1276 Intake Air Restriction..............................................1276 High Altitude.......................................................1276 Check the Intake Manifold Air Temperature Sensor and/or the Circ....1276 Check for Sufficient Coolant Flow Through the Aftercooler (if eq....1276 Check for Sufficient Flow of Air Through the Aftercooler (if equ....1276 Intermittent Engine Shutdown................................................1276 Probable Causes.........................................................1276 Recommended Actions.....................................................1276 Logged Codes........................................................1276 Fuel Supply.........................................................1277 Engine Protection Device............................................1277 Electrical Connectors...............................................1277 Intermittent Low Power or Power Cutout......................................1277 Probable Causes.........................................................1277 Recommended Repairs.....................................................1277 Diagnostic Codes....................................................1278 Electrical Connectors...............................................1278 Fuel Supply.........................................................1278 Check the Intake Manifold Pressure..................................1278 Air Intake and Exhaust System.......................................1278 Individual Malfunctioning Cylinders.................................1278 Valve Lash..........................................................1279 Check for Low Compression...........................................1279 Check the Fuel Injection Nozzles....................................1279 Check the Turbocharger..............................................1279 ECM Parameters......................................................1279 Electronic System Problem...........................................1279 Low Engine Oil Pressure.....................................................1280 Probable Causes.........................................................1280 Recommended Actions.....................................................1280 Engine Oil Level....................................................1280 Engine Oil Pressure Gauge...........................................1280 Engine Oil Bypass Valves............................................1280 Piston Cooling Jets ................................................1280 Engine Oil Suction Tube.............................................1280 Engine Oil Pump.....................................................1280 Bearing Clearance...................................................1280 Low Power/Poor or No Response to Throttle...................................1280 Probable Causes.........................................................1280 Recommended Actions.....................................................1281 Diagnostic Codes....................................................1281 Fuel Supply.........................................................1281 Air Intake and Exhaust System.......................................1281 Individual Malfunctioning Cylinders.................................1281 Valve Lash..........................................................1281 Check for Low Compression...........................................1281 Check the Fuel Injection Nozzles....................................1282 Check the Turbocharger..............................................1282 ECM Parameters......................................................1282 Electronic System Problem...........................................1282 Mechanical Noise (Knock) in Engine..........................................1282 Probable Causes.........................................................1282 Recommended Actions.....................................................1283 Accessory Equipment.................................................1283 Valve Train Components..............................................1283 Connecting Rod and Main Bearings....................................1283 Noise Coming from Cylinder..................................................1283 Probable Causes.........................................................1283 Recommended Actions.....................................................1283 Fuel Quality........................................................1283 Fuel Injection Nozzles..............................................1283 Valve Lash..........................................................1283 Poor Acceleration or Response...............................................1283 Probable Causes.........................................................1283 Recommended Repairs.....................................................1283 Diagnostic Codes....................................................1283 Fuel Supply.........................................................1283 Individual Malfunctioning Cylinder..................................1284 Valve Lash..........................................................1284 Check for Low Compression...........................................1284 Check the Fuel Injection Nozzles....................................1284 Check the Turbocharger..............................................1284 ECM Parameters......................................................1284 Check Intake Manifold Pressure......................................1285 Troubleshooting With a Diagnostic Code..........................................1285 CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal............1285 Conditions Which Generate This Code.....................................1285 System Response.........................................................1285 Possible Performance Effect.............................................1285 Troubleshooting.........................................................1285 Results.................................................................1285 CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent............1285 Conditions Which Generate This Code.....................................1285 System Response.........................................................1285 Possible Performance Effect.............................................1285 Troubleshooting.........................................................1285 Test Step 1.............................................................1285 Results.................................................................1285 CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted............1285 Conditions Which Generate This Code.....................................1285 System Response.........................................................1285 Possible Performance Effect.............................................1286 CID 0091 FMI 04 Throttle Position Sensor Shorted Low........................1286 Conditions Which Generate This Code.....................................1286 System Response.........................................................1286 Possible Performance Effect.............................................1286 Troubleshooting.........................................................1286 Results.................................................................1286 CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal....................1286 Conditions Which Generate This Code.....................................1286 System Response.........................................................1286 Troubleshooting.........................................................1286 Results.................................................................1286 CID 0091 FMI 12 Throttle Position Sensor Out of Calibration.................1286 Conditions Which Generate This Code.....................................1286 Possible Performance Effect.............................................1286 Troubleshooting.........................................................1286 Results.................................................................1286 CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short............1286 Conditions Which Generate This Code.....................................1286 System Response.........................................................1287 Troubleshooting.........................................................1287 Results.................................................................1287 CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low......................1287 Conditions Which Generate This Code.....................................1287 System Response.........................................................1287 Troubleshooting.........................................................1287 Results.................................................................1287 CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci............1287 Conditions Which Generate This Code.....................................1287 System Response.........................................................1287 Possible Performance Effect.............................................1287 Results.................................................................1287 CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or............1287 Conditions Which Generate This Code.....................................1287 System Response.........................................................1287 Possible Performance Effect.............................................1288 Results.................................................................1288 CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low.................1288 Conditions Which Generate This Code.....................................1288 System Response.........................................................1288 Possible Performance Effect.............................................1288 Results.................................................................1288 CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope............1288 Conditions Which Generate This Code.....................................1288 System Response.........................................................1288 Results.................................................................1288 CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ............1288 Conditions Which Generate This Code.....................................1288 System Response.........................................................1288 Possible Performance Effect.............................................1289 Troubleshooting.........................................................1289 Results.................................................................1289 CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low..............1289 Conditions Which Generate This Code.....................................1289 System Response.........................................................1289 Possible Performance Effect.............................................1289 Troubleshooting.........................................................1289 Results.................................................................1289 CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o............1289 Conditions Which Generate This Code.....................................1289 System Response.........................................................1289 Possible Performance Effect.............................................1289 Troubleshooting.........................................................1289 Results.................................................................1289 CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...............1289 Conditions Which Generate This Code.....................................1289 System Response.........................................................1289 Possible Performance Effect.............................................1289 Troubleshooting.........................................................1290 Results.................................................................1290 CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...............1290 Conditions Which Generate This Code.....................................1290 System Response.........................................................1290 Possible Performance Effect.............................................1290 Troubleshooting.........................................................1290 Results.................................................................1290 CID 0247 FMI 09 J1939 Datalink, Abnormal Update.............................1290 Conditions Which Generate This Code.....................................1290 System Response.........................................................1290 Results.................................................................1290 CID 0253 FMI 02 Incorrect ECM Software......................................1290 Conditions Which Generate This Code.....................................1290 System Response.........................................................1290 Possible Performance Effect.............................................1290 Troubleshooting.........................................................1291 Expected Result.........................................................1291 Results.................................................................1291 CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal............1291 Conditions Which Generate This Code.....................................1291 System Response.........................................................1291 Possible Performance Effect.............................................1291 Troubleshooting.........................................................1291 Results.................................................................1291 CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal............1291 Conditions Which Generate This Code.....................................1291 System Response.........................................................1291 Possible Performance Effect.............................................1291 Troubleshooting.........................................................1291 Results.................................................................1291 CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs.......................1291 Conditions Which Generate This Code.....................................1291 System Response.........................................................1291 Possible Performance Effect.............................................1291 CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig............1292 Conditions Which Generate This Code.....................................1292 System Response.........................................................1292 Possible Performance Effect.............................................1292 Results.................................................................1292 CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal......................1292 Conditions Which Generate This Code.....................................1292 System Response.........................................................1292 Possible Performance Effect.............................................1292 Results.................................................................1292 CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa............1292 Conditions Which Generate This Code.....................................1292 System Response.........................................................1292 Possible Performance Effect.............................................1292 Test Step 1.............................................................1292 Results.................................................................1292 Test Step 2.............................................................1292 Results.................................................................1293 CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm............1293 Conditions Which Generate This Code.....................................1293 System Response.........................................................1293 Possible Performance Effect.............................................1293 Results.................................................................1293 CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S............1293 Conditions Which Generate This Code.....................................1293 System Response.........................................................1293 Possible Performance Effect.............................................1293 Troubleshooting.........................................................1293 Results.................................................................1293 CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low..................1293 Conditions Which Generate This Code.....................................1293 System Response.........................................................1293 Possible Performance Effect.............................................1293 Troubleshooting.........................................................1293 Results.................................................................1293 CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal..............1294 Conditions Which Generate This Code.....................................1294 System Response.........................................................1294 Possible Performance Effect.............................................1294 Results.................................................................1294 CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio............1294 Conditions Which Generate This Code.....................................1294 System Response.........................................................1294 Possible Performance Effect.............................................1294 Results.................................................................1294 CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off..................1294 Conditions Which Generate This Code.....................................1294 System Response.........................................................1294 Possible Performance Effect.............................................1294 Results.................................................................1294 CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ............1294 Conditions Which Generate This Code.....................................1294 System Response.........................................................1294 Possible Performance Effect.............................................1295 Test Step 1.............................................................1295 Results.................................................................1295 Test Step 2.............................................................1295 Results.................................................................1295 CID 1684 FMI 02 Fuel Injection Pump, Software Failure.......................1295 Conditions Which Generate This Code.....................................1295 System Response.........................................................1295 Possible Performance Effect.............................................1295 Troubleshooting.........................................................1295 Results.................................................................1295 CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault..........................1295 Conditions Which Generate This Code.....................................1295 System Response.........................................................1295 Possible Performance Effect.............................................1295 Troubleshooting.........................................................1295 Results.................................................................1295 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...................1296 Conditions Which Generate This Code.....................................1296 System Response.........................................................1296 Possible Performance Effect.............................................1296 Troubleshooting.........................................................1296 Results.................................................................1296 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width....................1296 Conditions Which Generate This Code.....................................1296 Troubleshooting.........................................................1296 Results.................................................................1296 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault.......................1296 Conditions Which Generate This Code.....................................1296 System Response.........................................................1296 Possible Performance Effect.............................................1296 Troubleshooting.........................................................1296 Results.................................................................1296 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault.............1296 Conditions Which Generate This Code.....................................1296 System Response.........................................................1297 Possible Performance Effect.............................................1297 Troubleshooting.........................................................1297 Test Step 1.............................................................1297 Results.................................................................1297 Test Step 2.............................................................1297 Results.................................................................1297 Test Step 3.............................................................1297 Results.................................................................1297 Test Step 4.............................................................1297 Expected Result.........................................................1297 Results.................................................................1297 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault..............................1297 Conditions Which Generate This Code.....................................1297 System Response.........................................................1297 Possible Performance Effect.............................................1297 Troubleshooting.........................................................1297 Expected Result.........................................................1298 Results.................................................................1298 CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error..............1298 Conditions Which Generate This Code.....................................1298 System Response.........................................................1298 Troubleshooting.........................................................1298 Test Step 1.............................................................1298 Results.................................................................1298 Test Step 2.............................................................1298 Results.................................................................1298 Test Step 3.............................................................1298 Results.................................................................1298 CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault..................1298 Conditions Which Generate This Code.....................................1298 System Response.........................................................1298 Possible Performance Effect.............................................1299 Troubleshooting.........................................................1299 Test Step 1.............................................................1299 Results.................................................................1299 Test Step 2.............................................................1299 Results.................................................................1299 CID 1684 FMI 14 Fuel Injection Pump, No Communications......................1299 Conditions Which Generate This Code.....................................1299 System Response.........................................................1299 Troubleshooting.........................................................1299 Test Step 1.............................................................1299 Results.................................................................1299 Test Step 2.............................................................1299 Results.................................................................1299 Test Step 3.............................................................1299 Results.................................................................1299 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali............1299 Conditions Which Generate This Code.....................................1299 System Response.........................................................1299 Possible Performance Effect.............................................1300 Troubleshooting.........................................................1300 Results.................................................................1300 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali............1300 Conditions Which Generate This Code.....................................1300 System Response.........................................................1300 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S............1300 Conditions Which Generate This Code.....................................1300 System Response.........................................................1300 Troubleshooting With an Event Code..............................................1300 Event Codes.................................................................1300 Programmable Engine Parameters..............................................1300 E015 High Engine Coolant Temperature Derate.................................1300 Conditions Which Generate This Code.....................................1300 System Response.........................................................1300 Possible Performance Effect.............................................1300 Troubleshooting.........................................................1300 Results.................................................................1300 E016 High Engine Coolant Temperature Shutdown...............................1301 Conditions Which Generate This Code.....................................1301 System Response.........................................................1301 Possible Performance Effect.............................................1301 Troubleshooting.........................................................1301 Results.................................................................1301 E017 High Engine Coolant Temperature Warning................................1301 Conditions Which Generate This Code.....................................1301 System Response.........................................................1301 Possible Performance Effect.............................................1301 Troubleshooting.........................................................1301 Results.................................................................1301 E025 High Intake Air Temperature Derate.....................................1301 Conditions Which Generate This Code.....................................1301 System Response.........................................................1301 Possible Performance Effect.............................................1301 Troubleshooting.........................................................1301 Results.................................................................1301 E027 High Intake Air Temperature Warning....................................1301 Conditions Which Generate This Code:....................................1301 System Response.........................................................1301 Possible Performance Effect.............................................1302 Troubleshooting.........................................................1302 Results.................................................................1302 E040 Low Engine Oil Pressure Shutdown.......................................1302 Conditions Which Generate This Code.....................................1302 System Response.........................................................1302 Possible Performance Effect.............................................1302 Troubleshooting.........................................................1302 Results.................................................................1302 E054 High Fuel Temperature Derate...........................................1302 Conditions Which Generate This Code.....................................1302 System Response.........................................................1302 Troubleshooting.........................................................1302 Test Step 1 - Check for Diagnostic Codes................................1302 Expected Result.........................................................1302 Results.................................................................1302 Test Step 2 - Perform a Check of the Fuel System........................1302 Expected Result.........................................................1303 Results.................................................................1303 E056 High Fuel Temperature Warning..........................................1303 Conditions Which Generate This Code.....................................1303 System Response.........................................................1303 Troubleshooting.........................................................1303 Test Step 1 - Check for Diagnostic Codes................................1303 Expected Result.........................................................1303 Results.................................................................1303 Test Step 2 - Perform a Check of the Fuel System........................1303 Expected Result.........................................................1303 Results.................................................................1303 E100 Low Engine Oil Pressure Warning........................................1303 Conditions Which Generate This Code.....................................1303 System Response.........................................................1303 Possible Performance Effect.............................................1303 Troubleshooting.........................................................1304 Test Step 1 - Check for Active Diagnostic Codes.........................1304 Expected Result.........................................................1304 Results.................................................................1304 Test Step 2 - Perform a Check of the Engine Lubrication System..........1304 Expected Result.........................................................1304 Results.................................................................1304 E190 Engine Overspeed Warning...............................................1304 Conditions Which Generate This Code.....................................1304 System Response.........................................................1304 Possible Performance Effect.............................................1304 Troubleshooting.........................................................1304 Engine Overspeed Warning................................................1304 Expected Result.........................................................1304 Results.................................................................1304 E442 Engine Failed to Stop With a No-Fuel Command...........................1304 Conditions Which Generate This Code.....................................1304 System Response.........................................................1304 Possible Performance Effect.............................................1305 Troubleshooting.........................................................1305 Test Step 1.............................................................1305 Results.................................................................1305 Test Step 2.............................................................1305 Results.................................................................1305 E883 Engine Failed to Stop When Fuel Solenoid Disengaged....................1305 Conditions Which Generate This Code.....................................1305 System Response.........................................................1305 Possible Performance Effect.............................................1305 Troubleshooting.........................................................1305 Test Step 1.............................................................1305 Results.................................................................1305 Test Step 2.............................................................1305 Results.................................................................1305 Test Step 3.............................................................1305 Results.................................................................1305 Diagnostic Function Tests.......................................................1306 5-Volt Engine Pressure Sensor Supply Circuit - Test.........................1306 System Operation Description............................................1306 Background Information..................................................1306 Test Step 1.............................................................1307 Inspect Electrical Connectors and Wiring............................1307 Expected Result.....................................................1307 Results.............................................................1307 Test Step 2.............................................................1308 Check for Active Diagnostic Codes...................................1308 Expected Result.....................................................1308 Results.............................................................1308 Test Step 3.............................................................1308 Disconnect the ECM Engine Harness Connector From the ECM............1308 Expected Result.....................................................1309 Results.............................................................1309 Test Step 4.............................................................1309 Disconnect the +5V Sensors While Active Diagnostic Codes are Bei....1309 Expected Result.....................................................1309 Results.............................................................1309 Test Step 5.............................................................1310 Check the Engine Harness............................................1310 Expected Result.....................................................1310 Results.............................................................1310 Air Inlet Heater Circuit - Test.............................................1310 System Operation Description............................................1310 Test Step 1.............................................................1310 Inspect Electrical Connectors and Wiring............................1310 Expected Result.....................................................1311 Results.............................................................1311 Test Step 2.............................................................1311 Check the Supply to the Power Relay for the Air Inlet Heater Sta....1311 Expected Result.....................................................1311 Results.............................................................1311 Test Step 3.............................................................1312 Check the Output From the Power Relay for the Air Inlet Heater S....1312 Expected Result.....................................................1312 Results.............................................................1312 Test Step 4.............................................................1312 Ground the Input to the Power Relay at the MIC......................1312 Expected Result.....................................................1312 Results.............................................................1312 Test Step 5.............................................................1312 Ground the Input to the Power Relay at the ECM Connector............1312 Expected Result.....................................................1312 Results.............................................................1312 Test Step 6.............................................................1312 Override the Air Inlet Heater Starting Aid to Test the ECM..........1312 Results.............................................................1313 Checking Idle Validation Switching Point (Throttle Sensor) With ............1313 Expected Result.........................................................1313 Analog Throttle Position Sensor Circuit - Test..............................1313 System Operation Description............................................1313 Checking the Throttle Sensor With Unconnected Output C..................1314 Expected Result.....................................................1314 Test Step 1.............................................................1314 Check for Connector Damage..........................................1314 Expected Result.....................................................1314 Results.............................................................1314 Test Step 2.............................................................1315 Check for Active Diagnostic Codes...................................1315 Expected Result.....................................................1315 Results.............................................................1315 Test Step 3.............................................................1315 Check the Throttle Position With the Electronic Service Tool........1315 Expected Result.....................................................1315 Results.............................................................1315 Test Step 4.............................................................1315 Check the Voltage at the Throttle Position Sensor...................1315 Expected Result.....................................................1315 Results.............................................................1315 Test Step 5.............................................................1316 Disconnect the Throttle Position Sensor and Check for Active Dia....1316 Expected Result.....................................................1316 Results.............................................................1316 Test Step 6.............................................................1316 Check the Throttle Selection Status With the Electronic Service ....1316 Expected Result.....................................................1316 Results.............................................................1317 Test Step 7.............................................................1317 Disconnect the Supply Terminals of the Throttle Position Sensor ....1317 Expected Result.....................................................1317 Results.............................................................1317 Test Step 8.............................................................1317 Check the Position of Throttle Position Sensor......................1317 Expected Result.....................................................1318 Results.............................................................1318 Test Step 9.............................................................1318 Check the Throttle Position Sensor at the ECM.......................1318 Expected Result.....................................................1318 Results.............................................................1318 CAN Data Link Circuit - Test................................................1318 System Operation Description............................................1318 Test Step 1.............................................................1319 Inspect Electrical Connectors and Wiring............................1319 Expected Result.....................................................1319 Results.............................................................1319 Test Step 2.............................................................1319 Check the CAN Data Link Between the ECM and P40 Fuel Injection P....1319 Expected Result.....................................................1319 Results.............................................................1319 Test Step 3.............................................................1319 Check the CAN Data Link Between the ECM and P40 Fuel Injection P....1319 Expected Result.....................................................1320 Results.............................................................1320 Test Step 4.............................................................1320 Verify the Supply Voltage at the Fuel Injection Pump................1320 Expected Result.....................................................1320 Results.............................................................1320 Data Link Circuit - Test....................................................1320 System Operation Description............................................1320 Background Information..................................................1321 Communication...........................................................1321 Test Step 1.............................................................1321 Inspect Electrical Connectors and Wiring............................1321 Expected Result.....................................................1321 Results.............................................................1321 Test Step 2.............................................................1321 Determine the Type of Problem With the Data Link....................1321 Expected Result.....................................................1321 Results.............................................................1322 Test Step 3.............................................................1322 Check the Battery Voltage at the ECM................................1322 Expected Result.....................................................1322 Results.............................................................1322 Test Step 4.............................................................1322 Check the Battery Voltage That is Coming to the Data Link Connec....1322 Expected Result.....................................................1323 Results.............................................................1323 Test Step 5.............................................................1323 Connect the Electronic Service Tool Directly to the ECM.............1323 Expected Result.....................................................1323 Results.............................................................1323 Test Step 6.............................................................1323 Change Electronic Service Tool Components...........................1323 Expected Result.....................................................1324 Results.............................................................1324 Test Step 7.............................................................1324 Connect an Electronic Service Tool and the ECM to Another Batter....1324 Expected Result.....................................................1324 Results.............................................................1324 Electrical Connectors - Inspect.............................................1324 System Operation Description............................................1325 Background Information..................................................1325 Test Step 1.............................................................1329 Check the Locking of the DT Connector (Deutsch) and the Lock Rin....1329 Expected Result.....................................................1329 Results.............................................................1329 Test Step 2.............................................................1329 Check the Socket Head Screw on the Connector for the Electronic ....1329 Expected Result.....................................................1329 Results.............................................................1329 Test Step 3.............................................................1329 Perform a Pull Test on Each Wire Terminal Connection................1329 Expected Result.....................................................1329 Results.............................................................1329 Test Step 4.............................................................1330 Monitor the Electronic Service Tool While the Wiring and the Con....1330 Expected Result.....................................................1330 Results.............................................................1330 Test Step 5.............................................................1330 Check Wires for Nicks and/or Abrasions in the Insulation............1330 Expected Result.....................................................1330 Results.............................................................1330 Test Step 6.............................................................1330 Check Connectors for Moisture or Corrosion..........................1330 Expected Result.....................................................1331 Results.............................................................1331 Test Step 7.............................................................1331 Inspect the Connector Terminals.....................................1331 Expected Result.....................................................1331 Results.............................................................1331 Test Step 8.............................................................1332 Check Individual Pin Retention Into the Socket......................1332 Expected Result.....................................................1332 Results.............................................................1332 Electrical Power Supply Circuit - Test......................................1332 System Operation Description............................................1332 Background Information..................................................1332 Test Step 1.............................................................1334 Check the Batteries.................................................1334 Expected Result.....................................................1334 Results.............................................................1334 Test Step 2.............................................................1334 Inspect Electrical Connectors and Wiring............................1334 Expected Result.....................................................1334 Results.............................................................1334 Test Step 3.............................................................1334 Check the Battery Voltage at the ECM................................1334 Expected Result.....................................................1335 Results.............................................................1335 Test Step 4.............................................................1335 Use the Bypass Harness for the Electronic Service Tool to Bypass....1335 Expected Result.....................................................1336 Results.............................................................1336 Engine Pressure Sensor Open or Short Circuit - Test.........................1336 System Operation Description............................................1336 Background Information..................................................1336 Test Step 1.............................................................1337 Check for Active +5V Sensor Supply Diagnostic Codes.................1337 Expected Result.....................................................1337 Results.............................................................1337 Test Step 2.............................................................1337 Verify All Active Diagnostic Codes..................................1337 Expected Result.....................................................1337 Results.............................................................1337 Test Step 3.............................................................1337 Inspect Electrical Connectors And Wiring............................1337 Expected Result.....................................................1338 Results.............................................................1338 Test Step 4.............................................................1338 Verify That the Diagnostic Code is Still Active.....................1338 Expected Result.....................................................1338 Results.............................................................1338 Test Step 5.............................................................1338 Disconnect the Sensor to Create an Open Circuit.....................1338 Expected Result.....................................................1339 Results.............................................................1339 Test Step 6.............................................................1339 Measure the Sensor Supply Voltage...................................1339 Expected Result.....................................................1339 Results.............................................................1339 Test Step 7.............................................................1340 Determine if the Short Circuit is in the Connector or in the Sen....1340 Expected Result.....................................................1340 Results.............................................................1340 Test Step 8.............................................................1340 Create a Short Circuit Between the Signal and the Common Termina....1340 Expected Result.....................................................1340 Results.............................................................1340 Test Step 9.............................................................1340 Check the Operation of the ECM by Creating Open and Short Circui....1340 Expected Result.....................................................1341 Results.............................................................1341 Test Step 10............................................................1341 Bypass the Harness Wiring Between the ECM and the Sensor Connect....1341 Expected Result.....................................................1341 Results.............................................................1341 Engine Speed/Timing Sensor Circuit - Test...................................1342 System Operation Description............................................1342 Test Step 1.............................................................1342 Inspect the Electrical Connectors and Cables........................1342 Expected Result.....................................................1342 Results.............................................................1342 Test Step 2.............................................................1343 Check the Installation of the Engine Speed/Timing Sensors...........1343 Expected Result.....................................................1343 Results.............................................................1343 Test Step 3.............................................................1343 Measure the Sensor Resistance Through the Wiring Harness............1343 Expected Result.....................................................1343 Results.............................................................1343 Test Step 4.............................................................1343 Measure the Resistance of the Sensor................................1343 Expected Result.....................................................1344 Results.............................................................1344 Test Step 5.............................................................1344 Measure the Resistance of the Cables Between the Fuel Injection ....1344 Expected Result.....................................................1345 Results.............................................................1345 Test Step 6.............................................................1345 Check the Continuity of the Cables From the ECM to the Fuel Inje....1345 Expected Result.....................................................1345 Results.............................................................1345 Engine Temperature Sensor Open or Short Circuit - Test......................1345 System Operation Description............................................1345 Background Information..................................................1345 Test Step 1.............................................................1346 Verify All Active Diagnostic Codes..................................1346 Expected Result.....................................................1346 Results.............................................................1346 Test Step 2.............................................................1347 Inspect Electrical Connectors and Wiring............................1347 Expected Result.....................................................1347 Results.............................................................1347 Test Step 3.............................................................1347 Verify That the Diagnostic Code is Still Active.....................1347 Expected Result.....................................................1347 Results.............................................................1347 Test Step 4.............................................................1347 Disconnect the Sensor to Create an Open Circuit.....................1347 Expected Result.....................................................1348 Results.............................................................1348 Test Step 5.............................................................1348 Create a Short Circuit Between the Signal and the Common Termina....1348 Expected Result.....................................................1348 Results.............................................................1348 Test Step 6.............................................................1348 Check the Operation of the ECM by Creating an Open and a Short C....1348 Expected Result.....................................................1349 Results.............................................................1349 Test Step 7.............................................................1349 Bypass the Harness Wiring Between the ECM and the Sensor Connect....1349 Expected Result.....................................................1349 Results.............................................................1349 Fuel Injection Pump Circuit - Test..........................................1350 System Operation Description............................................1350 Background Information..................................................1350 Test Step 1.............................................................1350 Check the Batteries.................................................1350 Expected Result.....................................................1350 Results.............................................................1350 Test Step 2.............................................................1350 Inspect the Electrical Connectors and Wiring........................1350 Expected Result.....................................................1351 Results.............................................................1351 Test Step 3.............................................................1351 Check the Supply Voltage at the Machine Interface Connector.........1351 Expected Result.....................................................1352 Results.............................................................1352 Test Step 4.............................................................1352 Check the Supply Voltage at the Fuel Injection Pump.................1352 Expected Result.....................................................1352 Results.............................................................1352 Test Step 5.............................................................1352 Check the Supply to the Power Relay for the Fuel Injection Pump.....1352 Expected Result.....................................................1352 Results.............................................................1352 Test Step 6.............................................................1353 Check the Output of the Power Relay for the Fuel Injection Pump.....1353 Expected Result.....................................................1353 Results.............................................................1353 Test Step 7.............................................................1353 Check the Voltage at the Relay Coil for the Fuel Injection Pump.....1353 Expected Result.....................................................1353 Results.............................................................1353 Test Step 8.............................................................1353 Check the Output of the ECM Fuel Pump Power Control at the Machi....1353 Expected Result.....................................................1353 Results.............................................................1354 Test Step 9.............................................................1354 Check the Output of the Fuel Injection Pump Power Control at the....1354 Expected Result.....................................................1354 Results.............................................................1354 Test Step 10............................................................1354 Measure the Voltage at the Pump Power Supply........................1354 Expected Result.....................................................1354 Results.............................................................1354 Test Step 11............................................................1355 Check the Voltage Load Protection Module (VLPM).....................1355 Expected Result.....................................................1355 Results.............................................................1355 Indicator Lamp Circuit - Test...............................................1355 System Operation Description............................................1355 Test Step 1.............................................................1356 Inspect Electrical Connectors and Wiring............................1356 Results.............................................................1357 Test Step 2.............................................................1357 Inspect the Lamp, the Fuse, and the Power Supply....................1357 Expected Result.....................................................1357 Results.............................................................1357 Test Step 3.............................................................1357 Inspect the Input to the Lamp at the ECM connector..................1357 Expected Result.....................................................1357 Results.............................................................1357 Test Step 4.............................................................1357 Test the Individual Lamp Circuits...................................1357 Expected Result.....................................................1357 Results.............................................................1357 Test Step 5.............................................................1358 Check the Voltage at the ECM........................................1358 Expected Result.....................................................1358 Results.............................................................1358 Idle Validation Circuit - Test..............................................1358 System Operation Description............................................1358 Test Step 1.............................................................1358 Expected Result.....................................................1358 Results.............................................................1358 tables..............................................................................1207 Table 1. Electronic Service Tool................................................1233 Table 2. Optional Service Tools.................................................1234 Table 3. CID FMI Codes and J Code FMI Codes.....................................1235 Table 4. Event Codes and CID FMI Codes..........................................1237 Table 5. CID Numbers and Flash Codes............................................1238 Table 6. Engine Connectors......................................................1246 Table 7. Color Codes for the Harness Wire.......................................1250 Table 8. Pin Connections for Perkins Deutsch Socket Connector...................1252 Table 9. Suspect Parameter Numbers..............................................1256 Table 10. Failure Mode Indicators (FMI) Codes...................................1257 Table 11. Engine Oil Pressure Trip and Reset Points.............................1302
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