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Hyster F007 (H8.00-12.00XM Europe) Service Manual – PDF DOWNLOAD


Hyster F007 (H8.00-12.00XM Europe) Service Manual – PDF DOWNLOAD

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Hyster F007 (H8.00-12.00XM Europe) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster F007 (H8.00-12.00XM Europe) 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 (H8.00-12.00XM Europe) Service Manual – PDF DOWNLOAD

897108-1600SRM0326-(03-2007)-UK-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)-UK-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
897507-4000SRM0522-(05-2004)-UK-EN......................................................  71
	toc.................................................................................  71
		Mast............................................................................  71
		Safety Precautions Maintenance and Repair.......................................  72
		General.........................................................................  75
		Safety Procedures When Working Near Mast........................................  75
		Forks Repair....................................................................  77
			Remove......................................................................  77
			Install.....................................................................  78
		Carriages Repair................................................................  78
			Standard Carriage, Remove...................................................  78
			Hang-On Sideshift Carriage, Remove..........................................  79
			Standard Carriage and Hang-On Sideshift Carriage, Repair....................  80
			Standard Carriage, Install..................................................  80
			Hang-On Sideshift Carriage, Install.........................................  81
			Integral Sideshift Carriage.................................................  81
				Remove..................................................................  81
				Clean and Inspect.......................................................  83
				Repair..................................................................  83
				Install.................................................................  84
		Mast Repair.....................................................................  84
			Remove......................................................................  84
			Two-Stage LFL and Two-Stage FFL Masts, Disassemble..........................  86
			Three-Stage FFL Mast........................................................  93
				Disassemble.............................................................  93
				Mast and Chains, Clean and Inspect......................................  96
			Two-Stage LFL and Two-Stage FFL Mast, Assemble..............................  97
			Three-Stage FFL Mast, Assemble..............................................  98
			Install..................................................................... 100
		Lift Cylinders Repair........................................................... 101
			Main Lift Cylinders, Remove................................................. 101
			Free-Lift Cylinder, Remove.................................................. 101
			Lift Cylinders, Disassemble................................................. 102
			Lift Cylinders, Assemble.................................................... 102
			Main Lift Cylinders, Install................................................ 105
			Free-Lift Cylinder, Install................................................. 106
		Header Hose Arrangements........................................................ 106
			Two-Stage LFL Mast, New Hose Install........................................ 106
			Two-Stage LFL Mast, Adjust Hoses After Installation......................... 112
			Two-Stage FFL Mast, New Hose Install........................................ 112
			Two-Stage FFL Mast, Adjust Hoses After Installation......................... 117
			Three-Stage FFL Mast, New Hose Install...................................... 119
			Three-Stage FFL Mast, Adjust Hoses After Installation....................... 129
		Header Hose Arrangement......................................................... 130
			Two-Stage LFL Mast, New Hose Install........................................ 130
			Two-Stage LFL Mast, Adjust Hoses After Installation......................... 130
			Two-Stage FFL Mast, New Hose Install........................................ 134
			Two-Stage FFL Mast, Adjust Hoses After Installation......................... 139
			Three-Stage FFL Mast, New Hose Install...................................... 141
			Three-Stage FFL Mast, Adjust Hoses After Install............................ 146
		Lift and Tilt System Leak Check................................................. 150
			Lift Cylinders Leak Check................................................... 150
			Tilt Cylinders Leak Check................................................... 150
		Tilt Cylinders Adjustment....................................................... 151
		Lift Chains Adjustment.......................................................... 152
		Mast Adjustment................................................................. 154
		Carriage Adjustment............................................................. 156
		Troubleshooting................................................................. 156
	tables..............................................................................  71
		Table 1. Hook-Type Carriage Chain Adjustment.................................... 153
		Table 2. Pin-Type Carriage Chain Adjustment..................................... 153
897934-0700SRM0626-(11-2001)-UK-EN...................................................... 161
	toc................................................................................. 161
		Cooling System.................................................................. 161
		Safety Precautions Maintenance and Repair....................................... 162
		General......................................................................... 165
		Description..................................................................... 166
			Radiator.................................................................... 166
			Radiator Cap................................................................ 166
			Thermostat.................................................................. 166
			Water Pump.................................................................. 167
			Fan and Fan Shroud.......................................................... 167
		Cooling System Checks........................................................... 167
			Radiator.................................................................... 167
			Thermostat.................................................................. 167
			Water Pump.................................................................. 168
			Exhaust Leaks............................................................... 168
			Fan and Fan Shroud.......................................................... 168
		Radiator Cleaning............................................................... 168
			Drain....................................................................... 168
			Clean....................................................................... 168
			Fill........................................................................ 169
		Troubleshooting................................................................. 170
899784-2200SRM0002-(10-2003)-UK-EN...................................................... 173
	toc................................................................................. 173
		Alternator with Regulator....................................................... 173
		Safety Precautions Maintenance and Repair....................................... 174
		General......................................................................... 177
		Description..................................................................... 177
		Alternator Repair............................................................... 179
			Alternator Type A........................................................... 179
				Remove and Disassemble.................................................. 179
				Clean................................................................... 180
				Assemble................................................................ 181
				Install................................................................. 181
			Alternator Type B........................................................... 184
				Remove and Disassemble.................................................. 184
				Clean................................................................... 184
				Assemble................................................................ 185
				Install................................................................. 186
		General Check and Adjustment.................................................... 187
		Low Output Check (Type A or Type B)............................................. 187
		High Output Check (Type A or Type B)............................................ 189
		Brushes Circuit Check........................................................... 190
			Delco Alternators........................................................... 190
			Motorola Alternators........................................................ 191
		Diodes Check.................................................................... 192
		Diode Bridge Check.............................................................. 192
			Delco and Leece-Neville Alternators......................................... 192
			Motorola Alternators........................................................ 192
		Rotor Field Winding Check....................................................... 193
		Stator Windings Check........................................................... 194
		Voltage Regulator Check......................................................... 194
		Troubleshooting................................................................. 194
910072-1400SRM0046-(07-2007)-UK-EN...................................................... 199
	toc................................................................................. 199
		Differential.................................................................... 199
		Safety Precautions Maintenance and Repair....................................... 200
		General......................................................................... 203
		Description..................................................................... 203
		Differential Repair............................................................. 204
			Remove...................................................................... 204
				Differential Carrier From Axle Housing, Remove.......................... 204
				Differential and Ring Gear From Differential Carrier, Remove............ 206
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov........ 208
			Disassemble................................................................. 209
				Differential and Ring Gear Assembly, Disassemble........................ 209
				Drive Pinion and Pinion Carrier, Disassemble............................ 211
			Clean and Inspect........................................................... 214
			Assemble.................................................................... 215
				Pinion, Bearings, and Pinion Carrier, Assemble.......................... 215
				Pinion Bearings, Adjust Preload......................................... 215
					Press Method........................................................ 215
					Yoke or Flange Method............................................... 216
				Triple-Lip Seal, Install................................................ 217
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)............. 218
				Differential and Ring Gear, Assemble.................................... 220
				Differential Gears Rotating Torque, Check............................... 222
				Differential and Ring Gear Assembly, Install............................ 223
				Differential Bearings, Preload Adjust................................... 225
				Ring Gear, Runout Check................................................. 226
				Ring Gear Backlash, Adjust.............................................. 226
				Gear Set, Tooth Contact Pattern Check................................... 228
				Thrust Screw, Install and Adjust........................................ 231
			Install..................................................................... 231
				Differential Assembly Into Axle Housing, Install........................ 231
		Specifications.................................................................. 233
		Troubleshooting................................................................. 238
	tables.............................................................................. 199
		Table 1. Ring Gear Backlash Adjustment Specifications........................... 228
		Table 2. Ring and Pinion Tooth Contact Adjustment............................... 229
		Table 3. General Specifications................................................. 233
		Table 4. Rivet Installation Pressure............................................ 233
		Table 5. Pinion Adjustment...................................................... 234
		Table 6. Pinion Preload Pressure................................................ 234
		Table 7. Torque Specifications.................................................. 235
		Table 8. Torque Specifications for Metric Hardware.............................. 236
		Table 9. Torque Specifications for Metric (Fine) Hardware....................... 237
910102-2100SRM0103-(03-2007)-UK-EN...................................................... 241
	toc................................................................................. 241
		Tilt Cylinders.................................................................. 241
		Safety Precautions Maintenance and Repair....................................... 242
		General......................................................................... 245
		Description..................................................................... 245
		Tilt Cylinder Repair............................................................ 245
			Remove...................................................................... 245
			Disassemble................................................................. 245
			Clean....................................................................... 245
			Assemble.................................................................... 245
				Tilt Cylinders With O-Ring or Single-Lip Seals.......................... 245
				Tilt Cylinders for XM and XMS Models.................................... 247
				Tilt Cylinders for XL, XLS, and XL 3 Models............................. 248
				Tilt Cylinders for H700-800A and Early Model H700-920B.................. 250
			Install..................................................................... 251
				Tilt Cylinders Using Chevron Packing.................................... 251
					Install............................................................. 252
		Tilt Cylinder Leak Check........................................................ 254
		Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 256
		Torque Specifications........................................................... 256
			Piston Rod Nut.............................................................. 256
			Retainer.................................................................... 257
		Troubleshooting................................................................. 259
	tables.............................................................................. 241
		Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 255
910107-2200SRM0106-(02-2001)-UK-EN...................................................... 263
	toc................................................................................. 263
		Starter......................................................................... 263
		Safety Precautions Maintenance and Repair....................................... 264
		General......................................................................... 267
		Description and Operation....................................................... 267
		Starter Repair.................................................................. 269
			Remove...................................................................... 269
			Disassemble................................................................. 269
			Clean....................................................................... 270
			Assemble.................................................................... 270
			Install..................................................................... 271
		General Checks and Adjustments.................................................. 271
		Troubleshooting................................................................. 274
910119-4000SRM0135-(10-2003)-UK-EN...................................................... 279
	toc................................................................................. 279
		Lift Cylinders.................................................................. 279
		Safety Precautions Maintenance and Repair....................................... 280
		Safety Procedures When Working Near Mast........................................ 283
		General......................................................................... 287
		Description..................................................................... 287
			Lowering Control Valve...................................................... 287
			Cylinders (General)......................................................... 290
			Cylinders (H520-620B, H700-800A)............................................ 290
				Retainer, Install....................................................... 290
			Cylinders (H360-460B)....................................................... 292
			Cylinders (Two-Speed)....................................................... 294
		Lift Cylinder Repair............................................................ 296
			Lift Cylinder Removal Without Removing Mast................................. 296
				Standard Masts With Main Lift Cylinder Fastened to Crossmember o........ 296
				Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........ 296
				Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ........ 296
			Disassemble................................................................. 298
			Assemble.................................................................... 298
			Lift Cylinder Installation in Mast.......................................... 300
				Standard Masts With Main Lift Cylinder Fastened to Crossmember o........ 300
				Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........ 300
			Chevron-Style Packing....................................................... 300
				Chevron-Style Packing Installation on Piston............................ 301
				Chevron-Style Packing Installation in Packing Gland..................... 303
		Lift Cylinders for VISTA® Masts................................................. 304
			Description................................................................. 304
				Lowering Control Valve.................................................. 304
			Remove...................................................................... 306
			Disassemble................................................................. 307
			Assemble.................................................................... 308
			Install..................................................................... 309
				Main Lift Cylinders..................................................... 309
				Free-Lift Cylinder...................................................... 309
		Lift System Leak Check.......................................................... 310
		Specifications.................................................................. 311
		Troubleshooting................................................................. 312
	tables.............................................................................. 279
		Table 1. Lift Trucks with Two-Speed Lift Cylinders.............................. 295
		Table 2. Cylinder Retainer Torque Specifications and Weight Guid................ 311
910442-8000SRM0231-(12-2004)-UK-EN...................................................... 315
	toc................................................................................. 315
		Metric and Inch (SAE) Fasteners................................................. 315
		Safety Precautions Maintenance and Repair....................................... 316
		General......................................................................... 319
			Threaded Fasteners.......................................................... 319
			Nomenclature, Threads....................................................... 319
			Strength Identification..................................................... 320
			Cotter (Split) Pins......................................................... 320
			Fastener Torque Tables...................................................... 325
			Conversion Table............................................................ 327
	tables.............................................................................. 315
		Table 1. Bolts and Screws....................................................... 321
		Table 2. Studs and Nuts......................................................... 322
		Table 3. Torque Nuts............................................................ 323
		Table 4. Torque Nuts With Nylon Insert.......................................... 324
		Table 5. Torque Values for Metric Fasteners*.................................... 325
		Table 6. Torque Values for Inch Fasteners*...................................... 326
		Table 7. Conversion Table for Metric and English Units.......................... 327
		Table 8. Cotter Pin Dimensional Data............................................ 328
		Table 9. Cotter Pin Dimensional Data............................................ 329
		Table 10. Cotter Pin Dimensional Data........................................... 330
		Table 11. Cotter Pin Dimensional Data........................................... 332
1455747-0600SRM0705-(03-2006)-UK-EN..................................................... 337
	toc................................................................................. 337
		Perkins Diesel Engines.......................................................... 337
		Safety Precautions Maintenance and Repair....................................... 338
		General......................................................................... 345
			General Safety Rules........................................................ 345
		Description..................................................................... 346
			Engine Serial Number Codes.................................................. 349
			Engine Data................................................................. 349
		Engine Removal and Installation................................................. 351
			Lift Engine................................................................. 351
		Cylinder Head Assembly Repair................................................... 351
			Valve Cover................................................................. 351
				Remove.................................................................. 351
				Install................................................................. 352
			Rocker Arm Assembly......................................................... 352
				Remove.................................................................. 352
				Install................................................................. 352
				Disassemble............................................................. 352
				Inspect................................................................. 353
				Assemble................................................................ 353
			Valve Clearance Adjustments................................................. 353
				Four-Cylinder Engines................................................... 354
				Six-Cylinder Engines.................................................... 354
			Valve Springs............................................................... 354
			Cylinder Head Assembly...................................................... 356
				Remove.................................................................. 356
				Install................................................................. 358
			Valves and Valve Springs.................................................... 362
				Remove.................................................................. 362
				Inspect................................................................. 362
				Install................................................................. 363
			Valve Guides................................................................ 363
				Inspect................................................................. 363
				Remove.................................................................. 364
				Install................................................................. 364
			Cylinder Head and Valve Seats............................................... 364
				Inspect................................................................. 364
				Repair.................................................................. 364
				New Valve Seats, Install................................................ 364
		Piston and Connecting Rod Assemblies Repair..................................... 366
			Rod Bearings................................................................ 366
				Remove.................................................................. 367
				Install................................................................. 367
			Piston and Connecting Rod Assembly.......................................... 368
				Service Note............................................................ 368
				Remove.................................................................. 368
				Install................................................................. 369
			Piston Rings................................................................ 370
				Remove.................................................................. 370
				Inspect................................................................. 370
				Install................................................................. 370
			Piston and Connecting Rod................................................... 371
				Disassemble............................................................. 371
				Inspect................................................................. 372
				How to Select Correct Replacements...................................... 372
				Install................................................................. 373
			Piston Cooling Jets......................................................... 373
				Remove.................................................................. 373
				Install................................................................. 374
		Crankshaft Assembly Repair...................................................... 374
			General..................................................................... 374
			Crankshaft Pulley........................................................... 375
				Engine AR, Remove....................................................... 375
				Engines YG and YH, Remove............................................... 375
				Inspect................................................................. 376
				Engine AR, Install...................................................... 376
				Engines YG and YH, Install.............................................. 376
			Rear Oil Seal............................................................... 377
				Replace................................................................. 377
			Main Bearings............................................................... 378
				Remove.................................................................. 378
				Inspect................................................................. 379
				Install................................................................. 379
			Thrust Washers.............................................................. 379
				Crankshaft Axial Movement, Check........................................ 379
				Remove.................................................................. 380
				Install................................................................. 380
			Crankshaft.................................................................. 381
				Remove.................................................................. 381
				Inspect................................................................. 381
				Install................................................................. 381
			Flywheel.................................................................... 383
				Remove.................................................................. 383
				Ring Gear, Replace...................................................... 383
				Install................................................................. 383
			Flywheel Housing............................................................ 384
				Remove.................................................................. 384
				Install................................................................. 384
		Timing Case and Timing Gears Repair............................................. 385
			General..................................................................... 385
			Timing Case Cover........................................................... 385
				Remove.................................................................. 385
				Install................................................................. 386
			Front Oil Seal.............................................................. 386
				Remove.................................................................. 386
				Install................................................................. 386
			Crankshaft Pulley Wear Sleeve............................................... 387
				Install................................................................. 387
			Idler Gear and Hub.......................................................... 387
				Remove.................................................................. 387
				Install................................................................. 388
			Air Compressor Drive, Bendix................................................ 389
				Disassemble............................................................. 389
				Assemble................................................................ 390
			Fuel Injection Pump Gear.................................................... 390
				Remove.................................................................. 391
				Install................................................................. 391
			Camshaft Gear............................................................... 392
				Remove.................................................................. 392
				Install................................................................. 392
			Crankshaft Gear............................................................. 393
				Remove.................................................................. 393
				Install................................................................. 393
			Timing Case................................................................. 393
				Remove.................................................................. 393
				Install................................................................. 394
			Camshaft and Tappets........................................................ 395
				Remove.................................................................. 395
				Install................................................................. 395
		Cylinder Block Assembly Repair.................................................. 396
			Description................................................................. 396
			Cylinder Block.............................................................. 396
				Disassemble............................................................. 396
				Inspect................................................................. 397
				Assemble................................................................ 397
			Cylinder Bore (Four-Cylinder Engines)....................................... 398
			Cylinder Liner (Six-Cylinder Engines)....................................... 398
				Inspect................................................................. 398
				Cylinder Liner Condition, Check......................................... 398
				Remove.................................................................. 399
				Service Liner, Install.................................................. 400
				Partially Finished Liner, Install....................................... 401
		Engine Timing................................................................... 402
			Description................................................................. 402
				How to Set Number One Piston to TDC on Compression Stroke............... 403
				How to Set Number One Piston to TDC on Compression Stroke (Alter........ 404
				Valve Timing, Check..................................................... 404
				Fuel Injection Pump Timing, Check....................................... 405
		Turbocharger - Engine YH Repair................................................. 406
			General..................................................................... 406
				Remove.................................................................. 406
				Install................................................................. 406
				Impeller and Compressor Housing, Clean.................................. 407
		Lubrication System Repair....................................................... 408
			General..................................................................... 408
			Oil Filter, Replace......................................................... 408
			Filter Head................................................................. 409
				Remove and Install...................................................... 409
			Oil Sump.................................................................... 409
				Remove.................................................................. 409
				Install................................................................. 410
			Oil Pump.................................................................... 410
				Remove.................................................................. 410
				Inspect................................................................. 410
				Install................................................................. 411
			Relief Valve................................................................ 411
				Remove.................................................................. 411
				Disassemble............................................................. 412
				Inspect................................................................. 412
				Assemble................................................................ 412
				Install................................................................. 413
			Idler Gear Shaft, Replace................................................... 413
				Remove.................................................................. 413
				Remove (Alternative).................................................... 413
				Install................................................................. 414
				Install (Alternative)................................................... 414
				Install (Alternative for Four-Cylinder Engines Only).................... 415
		Fuel System Repair.............................................................. 415
			Description................................................................. 415
			Fuel Injection Pump......................................................... 416
				Remove.................................................................. 416
				Install................................................................. 417
				Check and Adjust........................................................ 418
			Fuel System Air Removal..................................................... 418
			Fuel Filter, Replace........................................................ 419
				Canister Type........................................................... 420
				Quick Release Canister Type............................................. 420
			Fuel Injectors.............................................................. 421
				Remove.................................................................. 421
				Inspect................................................................. 422
				Install................................................................. 422
			Fuel Pump................................................................... 423
				Remove.................................................................. 423
				Disassemble............................................................. 423
				Assemble................................................................ 423
				Install................................................................. 424
				Test.................................................................... 424
		Cooling System Repair........................................................... 425
			General..................................................................... 425
			Thermostat.................................................................. 425
				Remove.................................................................. 425
				Install................................................................. 425
				Test.................................................................... 426
			Coolant Pump................................................................ 426
				Remove.................................................................. 426
				Disassemble............................................................. 426
				Assemble................................................................ 428
				Install................................................................. 430
			Fan and Fan Drive........................................................... 431
				Remove.................................................................. 431
				Install................................................................. 431
			Oil Cooler (Six-Cylinder Engines)........................................... 432
				Remove.................................................................. 432
				Disassemble and Assemble................................................ 432
				Install................................................................. 432
				Oil Cooler Bypass Valve................................................. 432
		Electrical Equipment Repair..................................................... 433
			Drive Belts................................................................. 433
				Adjustment.............................................................. 433
				Remove.................................................................. 434
				Install................................................................. 434
			Alternator.................................................................. 434
				Remove.................................................................. 434
				Install................................................................. 434
			Starter Motor............................................................... 434
				Remove.................................................................. 434
				Install................................................................. 434
			Cold Start Aid.............................................................. 434
		Air Compressor - Engines YG and YH.............................................. 435
			General..................................................................... 435
			Repair...................................................................... 435
				Remove.................................................................. 435
				Install................................................................. 435
		Rotary Exhauster Replacement.................................................... 437
			Remove...................................................................... 437
			Clean....................................................................... 437
			Install..................................................................... 437
		Engine Specifications........................................................... 438
			Cylinder Head Assembly...................................................... 438
			Piston and Connecting Rods.................................................. 441
			Crankshaft Assembly......................................................... 444
				Crankshaft Overhaul..................................................... 446
			Timing Case and Drive Assembly.............................................. 448
			Engine Block Assembly....................................................... 449
			Turbocharger................................................................ 452
			Lubrication System.......................................................... 452
			Fuel System................................................................. 453
			Cooling System.............................................................. 455
			Flywheel and Housing........................................................ 455
			Electrical Equipment........................................................ 456
		Torque Specifications........................................................... 456
			Cylinder Head Assembly...................................................... 456
			Piston and Connecting Rod Assemblies........................................ 456
			Crankshaft Assembly......................................................... 456
			Timing Case and Drive Assembly.............................................. 457
			Turbocharger................................................................ 457
			Lubrication System.......................................................... 457
			Fuel System................................................................. 457
			Cooling System.............................................................. 457
			Flywheel.................................................................... 457
			Auxiliary Equipment......................................................... 457
		Special Torque Specifications................................................... 458
			Flywheel and Housing........................................................ 458
			Turbocharger................................................................ 458
			Electrical Equipment........................................................ 458
			Auxiliary Equipment......................................................... 458
		Special Tools*.................................................................. 459
		Troubleshooting................................................................. 464
	tables.............................................................................. 337
		Table 1. Cylinder Head.......................................................... 438
		Table 2. Valve Guides........................................................... 438
		Table 3. Inlet Valves........................................................... 438
		Table 4. Exhaust Valves......................................................... 439
		Table 5. Valve Springs.......................................................... 441
		Table 6. Tappets................................................................ 441
		Table 7. Rocker Arm Shaft....................................................... 441
		Table 8. Rocker Arms and Bushings............................................... 441
		Table 9. Pistons (Engine AR).................................................... 441
		Table 10. Pistons (Engines YG and YH)........................................... 441
		Table 11. Piston Rings (Engine AR).............................................. 442
		Table 12. Piston Rings (Engines YG and YH)...................................... 442
		Table 13. Piston Pins........................................................... 443
		Table 14. Connecting Rods....................................................... 443
		Table 15. Small End Bushings.................................................... 443
		Table 16. Connecting Rod Bearings (Engines AR and YG)........................... 443
		Table 17. Connecting Rod Bearings (Engine YH)................................... 443
		Table 18. Piston Cooling Jets................................................... 444
		Table 19. Crankshaft............................................................ 444
		Table 20. Main Bearings......................................................... 445
		Table 21. Crankshaft Thrust Washers............................................. 445
		Table 22. Crankshaft Heat Treatment............................................. 445
		Table 23. Crankshaft Overhaul Specifications.................................... 446
		Table 24. Maximum Variation (Run-out)........................................... 448
		Table 25. Camshaft.............................................................. 448
		Table 26. Camshaft Thrust Washer................................................ 448
		Table 27. Camshaft Gear......................................................... 448
		Table 28. Gear for Fuel Injection Pump.......................................... 449
		Table 29. Crankshaft Gear....................................................... 449
		Table 30. Idler Gear and Hub.................................................... 449
		Table 31. Cylinder Block (Engine AR)............................................ 449
		Table 32. Cylinder Bore Specifications.......................................... 450
		Table 33. Cylinder Block (Engines YG and YH).................................... 451
		Table 34. Cylinder Liners (Engines YG and YH)................................... 451
		Table 35. Cylinder Liner Specifications (Partially Finished).................... 451
		Table 36. Oil Pump (Engine AR).................................................. 452
		Table 37. Oil Pump (Engines YG and YH).......................................... 452
		Table 38. Idler Gear for Oil Pump............................................... 453
		Table 39. Relief Valve.......................................................... 453
		Table 40. Oil Filter............................................................ 453
		Table 41. Lucas Fuel Injection Pump............................................. 453
		Table 42. Fuel Injector Codes................................................... 454
		Table 43. Fuel Pump (Engine AR)................................................. 455
		Table 44. Fuel Pump (Engines YG and YH)......................................... 455
		Table 45. Fuel Filter........................................................... 455
		Table 46. Coolant Pump.......................................................... 455
		Table 47. Thermostat............................................................ 455
		Table 48. Fan Drive Housing..................................................... 455
		Table 49. Limits for Flywheel Run Out and Alignment (Total Indic................ 456
		Table 50. Alternator............................................................ 456
		Table 51. Starter Motor......................................................... 456
		Table 52. Cold Start Aid........................................................ 456
		Table 53. List of Possible Causes............................................... 464
1493991-1300SRM0930-(02-2001)-UK-EN..................................................... 469
	toc................................................................................. 469
		Three-Speed Powershift Transmission............................................. 469
		Safety Precautions Maintenance and Repair....................................... 470
		General......................................................................... 473
		Mechanical Description.......................................................... 473
			General..................................................................... 473
			Torque Converter............................................................ 477
				Description............................................................. 477
				Operation............................................................... 477
			Clutch Assemblies........................................................... 478
				Description............................................................. 478
				Operation............................................................... 478
					Forward and First-Speed Clutch Assembly............................. 479
					Reverse and Second-Speed Shaft, First and Second Gear Shaft......... 479
					Third-Speed Shaft................................................... 479
					Output Shaft........................................................ 479
		Hydraulic Operation............................................................. 481
			Sump, Filter and Pump....................................................... 481
			Transmission Control Valve.................................................. 481
				Solenoid Valves......................................................... 481
				Inching Spool........................................................... 482
				Direction Spools........................................................ 482
				Range Spool............................................................. 482
			Modulator Valve............................................................. 483
				Operation............................................................... 483
					Modulator Operation................................................. 484
			Transmission Control System................................................. 487
				Monotrol Pedal.......................................................... 487
				Control Lever........................................................... 488
			Hydraulic Circuits.......................................................... 489
				Cooling and Lubrication................................................. 489
				Neutral................................................................. 489
				Forward-First........................................................... 489
				Reverse-First........................................................... 492
				From First to Second Speed.............................................. 493
				From Second to Third Speed.............................................. 494
				Inching................................................................. 495
1493992-1300SRM0931-(02-2001)-UK-EN..................................................... 499
	toc................................................................................. 499
		Three-Speed Powershift Transmission............................................. 499
		Safety Precautions Maintenance and Repair....................................... 500
		General......................................................................... 503
		Transmission Repair............................................................. 506
			Remove...................................................................... 506
			Disassemble................................................................. 508
				Torque Converter Housing and Pump Gears................................. 508
				Transmission Cover, Remove.............................................. 509
				Clutch Assemblies, Remove............................................... 511
				Forward and Low-Speed Clutches.......................................... 512
					Forward Clutch, Disassemble......................................... 512
					First-Speed Clutch, Disassemble..................................... 514
				Reverse and Second-Speed Clutches, Disassemble.......................... 514
					Second-Speed Clutch, Disassemble.................................... 514
					Reverse Clutch, Disassemble......................................... 516
				Third-Speed Clutch, Disassemble......................................... 516
				Output Gears, Disassemble............................................... 518
				Clean................................................................... 518
				Inspect................................................................. 518
			Assemble.................................................................... 520
				Output Gears, Assemble.................................................. 520
				Third-Speed Clutch, Assemble............................................ 520
				Reverse and Second-Speed Clutches, Assemble............................. 520
					Second-Speed Clutch, Assemble....................................... 520
					Reverse Clutch, Assemble............................................ 523
				Forward and First-Speed Clutches, Assemble.............................. 523
					Forward Clutch, Assemble............................................ 523
					First-Speed Clutch, Assemble........................................ 525
				Clutch Assemblies, Install.............................................. 525
				Input Shaft and Forward Clutch Hub, Install............................. 526
				Transmission Cover, Install............................................. 527
				Torque Converter Housing................................................ 529
			Install..................................................................... 531
		Control Valve Repair............................................................ 533
			Remove...................................................................... 533
			Disassemble and Assemble.................................................... 534
			Clean and Inspect........................................................... 534
			Install..................................................................... 534
		Modulator Valve Repair.......................................................... 536
			Remove...................................................................... 536
			Disassemble................................................................. 536
			Clean and Inspect........................................................... 536
			Install..................................................................... 536
		Transmission Pump Repair........................................................ 538
			Remove...................................................................... 538
			Disassemble................................................................. 538
			Clean and Inspect........................................................... 538
			Assemble.................................................................... 538
			Install..................................................................... 538
		Monotrol Pedal Repair........................................................... 540
			Remove and Disassemble...................................................... 540
			Assemble and Install........................................................ 540
		Inching/Brake Pedal Linkage Adjustment.......................................... 542
		Stall Test...................................................................... 543
		Transmission Oil Pressure Check................................................. 544
		Troubleshooting................................................................. 546
	tables.............................................................................. 499
		Table 1. Transmission Pressures................................................. 545
1493993-1300SRM0932-(12-2004)-UK-EN..................................................... 551
	toc................................................................................. 551
		Autoshift Transmission Controller............................................... 551
		Safety Precautions Maintenance and Repair....................................... 552
		General......................................................................... 555
		Autoshift Control Module........................................................ 555
		Transmission Shift Control Valve................................................ 555
		Autoshift Functions............................................................. 556
			System Interaction With Operator Display.................................... 556
			Error Code Descriptions..................................................... 556
			System Audible Alarm........................................................ 556
			Park Brake Interlock........................................................ 558
			System Reset/Override....................................................... 558
			System Degraded Operating Mode.............................................. 558
			System Failure Mode......................................................... 558
			Transmission Oil High-Temperature Fault..................................... 558
			Loss of Transmission Oil Pressure Fault..................................... 558
			Controller Bypass........................................................... 559
			Automatic/Manual Shift Mode................................................. 559
			Automatic Transmission Shifting............................................. 559
			Manual Transmission Shifting................................................ 560
			Direction Change............................................................ 560
			Direction Change Inhibit.................................................... 560
			Downshift Inhibit........................................................... 561
			Driveshaft Engagement Inhibit............................................... 561
			Lift Height Transmission Interrupt (Optional)............................... 561
			Engine Dethrottle (Optional)................................................ 562
		Autoshift Hardware.............................................................. 562
			Autoshift Lever............................................................. 562
			Speed Sensors............................................................... 563
		Transmission System Monitor Diagnostics......................................... 564
		Controller Parameter Adjustment Software User Interface......................... 564
			User Interface Description.................................................. 564
			Components Required to Communicate With Controller.......................... 564
			Userlink Installation Instructions.......................................... 564
			Start Procedures............................................................ 564
			Controller Product Codes.................................................... 564
			Main Menu Description....................................................... 565
			Language Selection.......................................................... 565
			Help Menu................................................................... 565
			PC Serial Communication Port................................................ 566
			Monitor Screen.............................................................. 566
			Event Log................................................................... 566
			Parameter Adjustment........................................................ 567
				Current Parameters...................................................... 567
				Load Parameters......................................................... 568
				Restore Factory Parameters.............................................. 568
				Load Controller Software from File...................................... 568
			Exit Menu................................................................... 568
		Controller Connector Pin-Out Tables............................................. 570
	tables.............................................................................. 551
		Table 1. Error Code Descriptions................................................ 557
		Table 2. Automatic Transmission Upshift......................................... 559
		Table 3. Automatic Transmission Downshift....................................... 560
		Table 4. Event Log Descriptions and Values...................................... 567
		Table 5. Parameter Descriptions and Values...................................... 568
		Table 6. J2 Controller Connector (Black)........................................ 570
		Table 7. J1 Controller Connector (Blue)......................................... 571
1494123-0100SRM0927-(01-2006)-UK-EN..................................................... 575
	toc................................................................................. 575
		Frame........................................................................... 575
		Safety Precautions Maintenance and Repair....................................... 576
		General......................................................................... 579
		Description..................................................................... 579
		Counterweight Repair............................................................ 579
			Remove...................................................................... 579
			Install..................................................................... 581
			Fenders..................................................................... 581
				Remove.................................................................. 581
				Install................................................................. 581
			Side Counterweights H13.00-16.00XM (H300-360HD)............................. 581
			Side Counterweight, Replace................................................. 581
		Hood and Air Cleaner Repair..................................................... 582
			Remove...................................................................... 582
			Install..................................................................... 584
		Hydraulic Tank Repair........................................................... 584
			Remove...................................................................... 584
			Repairs, All Units.......................................................... 585
				Small Leaks............................................................. 585
				Large Leaks............................................................. 586
			Clean....................................................................... 586
				Steam Method............................................................ 586
				Chemical Solution Method................................................ 587
			Other Methods of Preparation for Repair..................................... 587
			Install..................................................................... 587
		Fuel Tank Repair................................................................ 588
			Remove...................................................................... 588
			Repairs..................................................................... 588
			Install..................................................................... 588
		Cooling System and Radiator Repair.............................................. 590
			Remove...................................................................... 590
			Install..................................................................... 591
		Engine and Transmission Repair.................................................. 592
			Hyster T-50 Transmission, Remove............................................ 592
			Hyster T-50 Transmission, Install........................................... 593
			TE-10 Transmission.......................................................... 594
				Remove.................................................................. 594
				Install................................................................. 597
		Label Replacement............................................................... 599
1494139-0100SRM0935-(09-2004)-UK-EN..................................................... 607
	toc................................................................................. 607
		Operators Cab................................................................... 607
		Safety Precautions Maintenance and Repair....................................... 608
		General......................................................................... 611
		Cab Repair...................................................................... 612
			Rear Cab Assembly........................................................... 612
			Bottom Cab Assembly......................................................... 613
			Raising and Lowering Cab.................................................... 613
				Raise Cab............................................................... 613
				Lower Cab............................................................... 614
			Cab Repair.................................................................. 614
				Remove.................................................................. 614
				Install................................................................. 615
		Oil Filling for Tilt System..................................................... 616
		Inching and Brake Pedals........................................................ 616
			Pedal Adjustment............................................................ 616
			Inching Cable Adjustment.................................................... 616
		Throttle Cable Adjustment....................................................... 617
			Cable Alignment............................................................. 618
				Engine Side............................................................. 618
				Pedal Housing Side...................................................... 618
		Throttle Pedal Sensor........................................................... 618
			Check....................................................................... 618
			Adjust...................................................................... 618
		Seat Assembly Removal........................................................... 619
		Power Assist Armrest............................................................ 620
			Adjust...................................................................... 620
		Steering Column Repair.......................................................... 620
			Remove...................................................................... 620
			Install..................................................................... 620
		Window Wipers Replacement....................................................... 621
			Window Wiper Assembly, Replace.............................................. 621
			Front Window Wiper Motor Assembly, Replace.................................. 622
			Rear Window Wiper Motor Assembly, Replace................................... 622
			Top Window Wiper Motor Assembly, Replace.................................... 622
		Window Washer Motors and Pumps.................................................. 623
			Window Wiper and Washer Operating Switches.................................. 623
		Window Replacement.............................................................. 623
			Front Window, Replace....................................................... 624
			Rear Window, Replace........................................................ 624
			Top Window, Replace......................................................... 624
			Door Window, Replace........................................................ 625
		Heater and Air Conditioning Assembly............................................ 626
			Heater Parts, Replace....................................................... 626
			Heat Control Knob/Switches.................................................. 627
			Heat Control Knob/Cable..................................................... 627
				Adjust.................................................................. 627
			Air Control Knob/Cable...................................................... 628
				Adjust.................................................................. 628
			Air Filter, Replace......................................................... 628
			Air Conditioning Condenser Fan(s), Standard................................. 628
				Remove.................................................................. 628
				Install................................................................. 629
			Air Conditioning Condenser Fan(s), Tropical................................. 629
				Remove.................................................................. 629
				Install................................................................. 629
		Instruments, Switches, and Controls............................................. 629
			Switches.................................................................... 629
			Controls.................................................................... 630
		Fuses and Relays................................................................ 631
			Fuse Panel.................................................................. 631
			Fuses....................................................................... 631
			Relays...................................................................... 632
		Label Replacement............................................................... 633
		Electrical Schematics........................................................... 633
1494140-1600SRM0936-(03-2007)-UK-EN..................................................... 637
	toc................................................................................. 637
		Steering System................................................................. 637
		Safety Precautions Maintenance and Repair....................................... 638
		General......................................................................... 641
		Description..................................................................... 641
		Steering Wheel and Column Assembly.............................................. 643
			General..................................................................... 643
			Steering Wheel and Horn..................................................... 643
				Remove.................................................................. 643
				Install................................................................. 643
		Steering Control Unit Repair.................................................... 645
			General..................................................................... 645
			Description................................................................. 645
			Operation................................................................... 645
			Remove...................................................................... 646
			Disassemble................................................................. 646
			Clean....................................................................... 649
			Assemble and Install........................................................ 649
		Steering System Air Removal..................................................... 655
		Steering Relief Pressure Check.................................................. 656
		Troubleshooting................................................................. 656
1494141-1800SRM0937-(03-2007)-UK-EN..................................................... 661
	toc................................................................................. 661
		Dry Brake System................................................................ 661
		Safety Precautions Maintenance and Repair....................................... 662
		General......................................................................... 665
		Description..................................................................... 665
		Operation....................................................................... 666
			Service Brakes.............................................................. 666
			Parking Brake............................................................... 668
		Air Tank Repair................................................................. 669
			Relief Valve................................................................ 669
			Drain Valve................................................................. 669
		Brake Pedal Valve Repair........................................................ 670
			Remove...................................................................... 670
			Disassemble, Inspect, and Assemble.......................................... 670
			Install..................................................................... 670
		Air Chambers Repair............................................................. 671
			Remove...................................................................... 671
			Disassemble................................................................. 671
			Inspect..................................................................... 672
			Assemble.................................................................... 673
			Install..................................................................... 673
		Actuator Arms Repair............................................................ 673
			Remove...................................................................... 673
			Inspect..................................................................... 674
			Install..................................................................... 674
		Brake Assemblies Repair......................................................... 675
			Brake Shoe, Remove.......................................................... 675
			Camshaft, Remove............................................................ 677
			Clean....................................................................... 677
			Inspect..................................................................... 678
			Camshaft, Install........................................................... 678
			Brake Shoe, Install......................................................... 679
		Air Dryer....................................................................... 680
			Description................................................................. 680
			Cartridge................................................................... 680
				Remove.................................................................. 680
				Install................................................................. 680
			Filter...................................................................... 680
				Remove.................................................................. 680
				Install................................................................. 680
		Quick-Release Valve............................................................. 682
		Governor Check and Adjustment for Air Compressor................................ 682
		Brake Shoes Adjustment.......................................................... 683
		Specifications.................................................................. 684
		Troubleshooting................................................................. 684
			Service Brakes.............................................................. 684
			Service Brakes, Park Function .............................................. 687
	tables.............................................................................. 661
		Table 1. Air Chambers Operation................................................. 668
1494142-1900SRM0938-(03-2007)-UK-EN..................................................... 691
	toc................................................................................. 691
		Hydraulic System................................................................ 691
		Safety Precautions Maintenance and Repair....................................... 692
		General......................................................................... 695
		Description and Operation....................................................... 695
			Hydraulic Tank.............................................................. 695
			Hydraulic Pump.............................................................. 696
			Steering Priority Flow Valve................................................ 696
			Pilot Valve................................................................. 697
			Main Control Valve.......................................................... 699
			Unloader Valve.............................................................. 700
			Hydraulic Operation......................................................... 701
		Checks and Adjustments.......................................................... 704
			Quick Disconnect Fittings................................................... 704
			Steering Priority Flow Valve................................................ 704
			Steering Relief Pressure.................................................... 704
			Modulator Valve............................................................. 705
			Pilot Valve and Pressure Reducing Valve..................................... 705
			Accumulator................................................................. 706
			Filter...................................................................... 706
			Main Control Valve.......................................................... 706
				Relief Pressure Check................................................... 706
			Check Valves................................................................ 707
			Unloader Valve.............................................................. 707
		Hydraulic Pump Repair........................................................... 708
			Remove...................................................................... 708
			Disassemble................................................................. 708
			Clean and Inspect........................................................... 708
			Assemble.................................................................... 709
			Install..................................................................... 710
		Pilot Accumulator Replacement .................................................. 710
			Remove...................................................................... 710
			Install..................................................................... 710
		Pilot Valve Repair.............................................................. 711
			Remove...................................................................... 711
			Disassemble................................................................. 712
			Clean and Inspect........................................................... 712
			Assemble.................................................................... 712
			Install..................................................................... 712
		Control Levers and Joystick Repair.............................................. 713
			Remove...................................................................... 713
			Install..................................................................... 713
		Calibration and Diagnostics..................................................... 714
			General..................................................................... 714
			Description................................................................. 714
				Lever and Joystick Calibration.......................................... 714
				Flow Adjustment......................................................... 714
				Dead Band Value Setting................................................. 715
				Lowering Delay.......................................................... 716
				PWM and I/O Module Readouts............................................. 716
				Function Disable........................................................ 717
			General Startup............................................................. 717
				Minimum system requirements............................................. 717
				Install the Hydraulic Controls Program.................................. 717
				DelayTimeFile (Reset)................................................... 717
				Select the Processor Speed.............................................. 718
			Hydraulic Controls Program.................................................. 718
			Calibration................................................................. 720
				Joystick/Lever Calibration.............................................. 720
					Levers.............................................................. 720
					Joystick............................................................ 720
			Valve Flow Adjustment....................................................... 721
			Diagnostics................................................................. 721
			Calibration System Shutdown................................................. 721
		LED Diagnostics................................................................. 722
		Electrical Connections.......................................................... 725
		Specifications.................................................................. 729
	tables.............................................................................. 691
		Table 1. Main Control Valve Port Settings....................................... 697
		Table 2. Processor Speed Settings............................................... 717
		Table 3. PWM Board LED Error Codes.............................................. 722
		Table 4. Altering PT FLT I/O Board LED's (Old Logic)............................ 723
		Table 5. Altering PT FLT I/O Board LED's (New Logic)............................ 723
		Table 6. Fixed PT Logic I/O Boards LED's........................................ 724
		Table 7. ECH.................................................................... 724
		Table 8. PWM Driver Module...................................................... 725
		Table 9. Input/Output Module 1.................................................. 726
		Table 10. Input/Output Module 2................................................. 727
		Table 11. Altering PT FLT....................................................... 728
		Table 12. Fixed PT FLT.......................................................... 728
		Table 13. ECH................................................................... 729
1494143-2200SRM0939-(12-2004)-UK-EN..................................................... 733
	toc................................................................................. 733
		Instrument Panel Indicators and Senders......................................... 733
		Safety Precautions Maintenance and Repair....................................... 734
		General......................................................................... 737
		Description..................................................................... 737
			General..................................................................... 737
			Instrument Panel Meters, Indicators, and LCD Display........................ 737
			Error Code Display, Transmission............................................ 744
			Error Code Display, Engine.................................................. 745
			Connector................................................................... 746
				Seat Switch Logic....................................................... 746
				Central Warning Light Output............................................ 748
				Buzzer Output........................................................... 748
				Engine Shutdown Output.................................................. 748
		Instrument Panel Component Replacement.......................................... 751
			Instrument Panel............................................................ 751
				Remove.................................................................. 751
			Light....................................................................... 752
				Replace................................................................. 752
		Sender Replacement.............................................................. 752
			Fuel Level Sender........................................................... 752
			Transmission Pressure and Temperature Sender, Tier 1........................ 753
			Pressure Sender, Tier 2..................................................... 754
			Temperature Sender, Tier 2.................................................. 754
			Low Coolant Sender.......................................................... 754
			Vacuum Switch............................................................... 754
			Crankshaft Position Sensor.................................................. 755
		Specifications.................................................................. 755
		Troubleshooting................................................................. 757
	tables.............................................................................. 733
		Table 1. Instrument Panel and Indicators........................................ 738
		Table 2. Engine Error Code Descriptions......................................... 746
		Table 3. Pin Description........................................................ 747
		Table 4. Sender Description..................................................... 748
1494144-8000SRM0934-(08-2001)-UK-EN..................................................... 761
	toc................................................................................. 761
		Periodic Maintenance............................................................ 761
		Safety Precautions Maintenance and Repair....................................... 762
		General......................................................................... 765
			How to Move Disabled Lift Truck............................................. 765
				How to Tow Lift Truck................................................... 765
			How to Put Lift Truck on Blocks............................................. 766
				How to Raise Drive Tires................................................ 766
				How to Raise Steering Tires............................................. 766
		Maintenance Schedule............................................................ 767
		Maintenance Procedures Every 8 Hours or Daily................................... 776
			How to Make Checks with Engine Stopped...................................... 776
				Tires and Wheels........................................................ 777
				Forks................................................................... 778
					Adjust.............................................................. 778
					Remove.............................................................. 778
					Install............................................................. 778
				Forks, Mast, and Lift Chains, Inspect................................... 778
				Safety Labels........................................................... 779
				Operator Restraint System............................................... 779
				Steering Column Latch................................................... 780
				Drive Belts............................................................. 780
				Cooling System.......................................................... 780
				Fuel, Oil, or Coolant Leaks, Check...................................... 781
				Cab Hydraulic System.................................................... 781
				Hydraulic System........................................................ 781
				Engine Oil.............................................................. 782
				Fuel System............................................................. 782
				Primary Fuel Filter..................................................... 783
				Battery................................................................. 783
				Air Filter.............................................................. 783
			How to Make Checks with Engine Running...................................... 783
				Gauges, Lights, Horn, and Fuses......................................... 783
				Control Levers and Pedals............................................... 784
				Transmission Oil........................................................ 784
				Lift System Operation................................................... 785
				Brakes.................................................................. 785
				Steering System......................................................... 786
		Maintenance Procedures Every 250 Hours or Every 2 Months........................ 786
			Engine Oil and Filter - Cummins Engine...................................... 786
			Empty Container Handler..................................................... 786
		Maintenance Procedures Every 500 Hours or Every 2 Months........................ 786
			Lift Chains................................................................. 786
				Lubrication............................................................. 786
				Adjust.................................................................. 786
			Drive Shaft................................................................. 787
			Steering Axle............................................................... 787
			Wheel Nuts.................................................................. 787
			Shafts for Brake Actuators.................................................. 787
			Drive Axle and Differential................................................. 787
			Hydraulic Tank Breather..................................................... 788
			Air Filter, Engine, and Air Compressor...................................... 788
			Cabin Air Filter, Heater.................................................... 788
			Engine Oil and Filter - Perkins Engine...................................... 788
			Drive Belts................................................................. 788
			Mast........................................................................ 788
			General Lubrication......................................................... 790
			Forks Wear and Damage Check................................................. 790
			Lift Chains Wear Check...................................................... 790
			Fuel System................................................................. 790
				Idle Speed.............................................................. 790
				Governor Speed (Diesel)................................................. 790
		Maintenance Procedures Every 1000 Hours or 6 Months............................. 792
			Transmission Oil and Filter, Change......................................... 792
			Final Fuel Filters, Diesel.................................................. 792
				Diesel Fuel System Air Removal.......................................... 792
				Fuel Injection Pump Without Vent Tube................................... 793
			Fuel Injection Pump Timing.................................................. 793
			Valve Adjustment............................................................ 793
		Maintenance Procedures Every 2000 Hours or Yearly............................... 795
			Hydraulic System............................................................ 795
				Hydraulic Oil Filter, Change............................................ 795
				Hydraulic Oil, Change................................................... 795
			Differential and Drive Axle................................................. 795
			Wheel Bearings.............................................................. 795
				Steer Wheels............................................................ 795
				Drive Wheels............................................................ 795
			Service Brakes.............................................................. 796
				Cleaning Procedures (Dry Brake Axle).................................... 796
		Safety Procedures When Working Near Mast........................................ 796
		Fuel Injectors Check............................................................ 797
		Lift and Tilt System Leak Check................................................. 798
			Lift System................................................................. 798
			Tilt System................................................................. 798
		Welding Repairs................................................................. 799
		Wheel and Tire Replacement...................................................... 800
			Remove Wheels from Lift Truck............................................... 800
			Pneumatic Tires............................................................. 800
				Remove Tire from Wheel.................................................. 800
					Remove Tire from Three- and Four-Piece Wheel........................ 801
				Install Tire on Wheel................................................... 802
					Install Three- or Four-Piece Wheel in Tire.......................... 802
			Add Air to Tires............................................................ 803
			Solid Rubber Tires.......................................................... 804
				Remove Tire from Wheel.................................................. 804
				Install Tire on Wheel................................................... 805
			Wheels, Install............................................................. 807
	tables.............................................................................. 761
		Table 1. Maintenance Schedule................................................... 768
		Table 2. Maintenance Schedule (Empty Container Handler Model 553................ 773
		Table 3. Maintenance Schedule (Empty Container Handler Model 555................ 774
		Table 4. Maintenance Schedule (Empty Container Handler Model 558................ 775
		Table 5. Allowable Mast Movement from Internal Leakage.......................... 799
1494145-8000SRM0940-(03-2008)-UK-EN..................................................... 811
	toc................................................................................. 811
		Capacities and Specifications................................................... 811
		Safety Precautions Maintenance and Repair....................................... 812
		Lift Truck Weights.............................................................. 815
		Capacities...................................................................... 815
		Engine Specifications........................................................... 816
			Perkins Diesel.............................................................. 816
			Cummins Diesel/LPG.......................................................... 817
		Hydraulic System................................................................ 818
		Electrical System............................................................... 819
		Tire Sizes...................................................................... 819
		Mast Speeds..................................................................... 819
			Perkins Diesel.............................................................. 819
			Cummins Diesel/LPG.......................................................... 820
		Torque Specifications, Cummins Diesel........................................... 821
			Lubrication System.......................................................... 821
		Torque Specifications, Perkins Diesel........................................... 821
			Engine...................................................................... 821
				Cylinder Head Assembly.................................................. 821
				Piston and Connecting Rod Assemblies.................................... 821
				Crankshaft Assembly..................................................... 821
				Timing Case and Drive Assembly.......................................... 822
				Turbocharger............................................................ 822
				Lubrication System...................................................... 822
				Fuel System............................................................. 822
				Cooling System.......................................................... 822
				Flywheel and Housing.................................................... 822
				Aspiration System....................................................... 823
				Electrical Equipment.................................................... 823
				Auxiliary Equipment..................................................... 823
		Torque Specifications - Perkins, Tier 2......................................... 823
			Cylinder Head Assembly...................................................... 823
			Piston and Connecting Rod Assemblies........................................ 823
			Crankshaft Assembly......................................................... 823
			Timing Case and Drive Assembly.............................................. 823
			Turbocharger................................................................ 824
			Lubrication System.......................................................... 824
			Fuel System................................................................. 824
			Cooling System.............................................................. 824
			Flywheel.................................................................... 824
			Auxiliary Equipment......................................................... 824
		Torque Specifications, General.................................................. 825
			Transmission................................................................ 825
			Driveline and Axle.......................................................... 825
			Differential................................................................ 825
			Brakes - Wet................................................................ 825
			Brakes - Dry................................................................ 825
			Steering.................................................................... 825
			Hydraulic System............................................................ 826
			Mast........................................................................ 826
			Carriage.................................................................... 826
			Tilt Cylinders.............................................................. 826
			Frame....................................................................... 826
			Wiper Arms, Front........................................................... 826
		Hyster T-50 Transmission Pressures (Powershift and Automatic)................... 827
		TE-10 Transmission Specifications............................................... 828
			Electrical.................................................................. 828
			Hydraulic Cooler Lines...................................................... 828
			Torque Specifications for Lubricated or Plated Screw Threads................ 829
	tables.............................................................................. 811
		Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp................ 828
		Table 2. Grade 5................................................................ 829
		Table 3. Grade 8................................................................ 829
		Table 4. Grades 8.8, 10.9, and 12.9............................................. 829
		Table 5. O-ring Port Plug Torque Chart.......................................... 830
		Table 6. Pipe Plug Torque Chart................................................. 830
1494146-8000SRM0941-(01-2006)-UK-EN..................................................... 833
	toc................................................................................. 833
		Diagrams........................................................................ 833
		Safety Precautions Maintenance and Repair....................................... 834
		General......................................................................... 837
		Description..................................................................... 837
1494953-1400SRM0944-(03-2007)-UK-EN..................................................... 895
	toc................................................................................. 895
		Planetary Drive Axle............................................................ 895
		Safety Precautions Maintenance and Repair....................................... 896
		General......................................................................... 899
		Description..................................................................... 899
		Operation....................................................................... 901
			Identification.............................................................. 901
		Removal......................................................................... 902
		Disassembly..................................................................... 902
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 902
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 904
			Wheel End................................................................... 906
			Spindle and Piston Housing.................................................. 907
		Cleaning........................................................................ 908
			Clean Ground or Polished Parts.............................................. 908
			Clean Parts With Rough Finish............................................... 908
			Clean Axle Assemblies....................................................... 908
			Drying Cleaned Parts........................................................ 908
		Corrosion Prevention............................................................ 908
		Parts Inspection................................................................ 909
			Tapered Roller Bearings..................................................... 909
			Bevel Pinion and Ring Gear Sets............................................. 910
			Main Differential Assembly.................................................. 910
			Axle Shafts................................................................. 910
			Yoke........................................................................ 910
			Brakes...................................................................... 910
			Repair or Replace Parts..................................................... 910
			Repair Welding.............................................................. 910
			Apply Silicone Gasket Material.............................................. 911
		Assembly........................................................................ 911
			Spindle and Piston Housing to Axle Housing.................................. 911
			Wet Disc Brakes............................................................. 912
			Adjust Wheel Bearing Preload................................................ 913
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 914
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 915
			Planetary Spider Assembly................................................... 915
		Installation.................................................................... 916
			Fill Wet Disc Brakes With Hydraulic Fluid................................... 916
		Torque Specifications........................................................... 917
		Lubrication Specification....................................................... 918
1494955-2000SRM0943-(03-2007)-UK-EN..................................................... 921
	toc................................................................................. 921
		Main Control Valve.............................................................. 921
		Safety Precautions Maintenance and Repair....................................... 922
		General......................................................................... 925
		Description..................................................................... 925
		Operation....................................................................... 928
			Lift Section................................................................ 928
			Tilt/Auxiliary Section...................................................... 928
			Relief Valves............................................................... 928
			Unloader Valve.............................................................. 928
		Main Control Valve Repair....................................................... 931
			Remove...................................................................... 931
			Disassemble................................................................. 931
				Auxiliary Side.......................................................... 931
				Lift Side............................................................... 931
			Clean and Inspect........................................................... 934
			Assemble.................................................................... 934
				Auxiliary Side.......................................................... 934
				Lift Side............................................................... 934
			Install..................................................................... 934
		Pressure Relief Valve Check and Adjustment...................................... 935
			Check and Adjust............................................................ 935
			Replace..................................................................... 935
		Specifications.................................................................. 936
		Troubleshooting................................................................. 936
1498445-1400SRM0945-(03-2007)-UK-EN..................................................... 941
	toc................................................................................. 941
		Planetary Drive Axle............................................................ 941
		Safety Precautions Maintenance and Repair....................................... 942
		General......................................................................... 945
		Description..................................................................... 945
		Operation....................................................................... 947
			Identification.............................................................. 947
		Removal......................................................................... 948
		Disassembly..................................................................... 948
			Brake Drum.................................................................. 948
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 949
			Dry Brakes.................................................................. 951
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 951
			Spindle and Brake Spider.................................................... 953
		Cleaning........................................................................ 954
			Ground or Polished Parts.................................................... 954
			Parts With Rough Finish..................................................... 954
			Axle Assemblies............................................................. 954
			Drying Cleaned Parts........................................................ 954
		Corrosion Prevention............................................................ 954
		Parts Inspection................................................................ 955
			Tapered Roller Bearings..................................................... 955
			Bevel Pinion and Ring Gear Sets............................................. 956
			Main Differential Assembly.................................................. 956
			Axle Shafts................................................................. 956
			Yoke........................................................................ 956
			Brakes...................................................................... 956
			Repair or Replace Parts..................................................... 956
			Repair Welding.............................................................. 956
			Apply Silicone Gasket Material.............................................. 957
		Assembly........................................................................ 957
			Spindle, Brake Spider, and Brake............................................ 957
			Wheel End................................................................... 958
			Adjust Wheel Bearing Preload................................................ 959
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 960
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............ 961
			Planetary Spider Assembly................................................... 961
		Installation.................................................................... 962
		Torque Specifications........................................................... 963
		Lubrication Specification....................................................... 964
1498450-1800SRM0951-(03-2007)-UK-EN..................................................... 967
	toc................................................................................. 967
		Wet Brake System................................................................ 967
		Safety Precautions Maintenance and Repair....................................... 968
		General......................................................................... 971
		Description and Operation....................................................... 971
			Service Brakes.............................................................. 971
			Parking Brake............................................................... 971
			Oil Cooler Circuit.......................................................... 971
		Pressure Switch Replacement..................................................... 975
		Accumulators Replacement........................................................ 975
		Brake Treadle Valve Repair...................................................... 975
			Remove and Disassemble...................................................... 975
			Clean and Inspect........................................................... 976
			Assemble and Install........................................................ 976
		Parking Brake Valve Repair...................................................... 976
			Remove...................................................................... 976
			Clean and Inspect........................................................... 976
			Repair...................................................................... 976
			Install..................................................................... 976
		Parking Brake Caliper Repair.................................................... 977
			Remove...................................................................... 977
			Disassemble................................................................. 979
			Inspect..................................................................... 979
			Install..................................................................... 979
			Adjust...................................................................... 979
		Brake Pad Repair................................................................ 980
			Inspect..................................................................... 980
			Remove...................................................................... 980
			Install..................................................................... 980
		Seals Repair.................................................................... 980
			Remove...................................................................... 980
			Install..................................................................... 981
		Service Brake Repair............................................................ 981
			Remove and Disassemble...................................................... 981
				Drain Lubricating Oil................................................... 981
				Drain Coolant Oil....................................................... 988
				Disconnect Brake Lines.................................................. 988
				Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14......... 988
				Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H........ 989
				Brake Disc Housing Assembly Wheel End................................... 990
				Brake Piston Housing.................................................... 991
				Brake Piston Housing and Wheel Spindle.................................. 992
			Inspect..................................................................... 992
			Clean....................................................................... 994
			Assemble.................................................................... 995
				Wheel Spindle........................................................... 995
				Brake Piston Housing.................................................... 995
				Piston Assembly......................................................... 997
				Brake Disc Housing...................................................... 997
				Duo-Cone Face Seal Into Brake Disc Housing and Into Hub................. 999
				Check for Correct Installation of Duo-Cone Seal.........................1000
				Wheel Hub to Brake Disc Housing.........................................1001
			Adjust......................................................................1002
				Fill Brake System With Coolant Oil......................................1002
				System Air Removal......................................................1003
				Adjust Brake With New Disc Pack.........................................1003
				Coolant Change Intervals................................................1004
				Coolant Draining and Filling............................................1004
		Specifications..................................................................1006
			Minimum Brake Disc Thickness................................................1009
			Hydraulic Fluid for Brake Actuation.........................................1009
			Brake Coolant Specifications................................................1009
			Coolant Change Intervals....................................................1009
			Hydraulic Fluid Specifications..............................................1009
		Troubleshooting.................................................................1009
			Brake Does Not Apply........................................................1009
			Brake Does Not Release......................................................1010
			Brake Performance...........................................................1010
			Brake Leaks Actuation Fluid.................................................1011
			Brake Cooling Fluid Leakage.................................................1012
			Brake Noise and Vibration...................................................1012
			Brake Overheats.............................................................1012
	tables.............................................................................. 967
		Table 1. Brake Pad Adjustment................................................... 979
		Table 2. Minimum Brake Disc Thickness........................................... 993
		Table 3. Formed Seal Wear Chart................................................. 993
1503241-5000SRM0969-(03-2007)-UK-EN.....................................................1017
	toc.................................................................................1017
		Empty Container Handling Attachment.............................................1017
		Safety Precautions Maintenance and Repair.......................................1018
		General.........................................................................1021
		Description.....................................................................1021
		Operation.......................................................................1026
			General.....................................................................1026
			Selector Valves.............................................................1026
			Sideshift Circuit...........................................................1026
			Extend and Retract Circuit..................................................1026
			Twist Lock Circuit and Control..............................................1027
				Model 553 - Horizontally Mounted........................................1027
				Model 558 - Vertically Mounted..........................................1027
			Lifting Hooks...............................................................1027
				Model 555...............................................................1027
			Indicator Lights and LEDs...................................................1027
			Lift Interrupt and Override.................................................1028
			Overlowering Interrupt and Override.........................................1028
		Carriage and Attachment Repair..................................................1028
			Remove......................................................................1028
		Attachment Without Carriage Repair..............................................1029
			Remove......................................................................1029
		Sideshift Cylinders Repair......................................................1030
			Remove......................................................................1030
			Disassemble.................................................................1030
			Assemble....................................................................1030
		Extension Cylinders Repair......................................................1031
			Remove......................................................................1031
			Disassemble.................................................................1031
			Clean and Inspect...........................................................1031
			Assemble....................................................................1031
			Install.....................................................................1031
		Vertical End Beams Repair.......................................................1033
			Remove......................................................................1033
			Install.....................................................................1033
			Hose Replacement in End Beams...............................................1033
		Twist Locks Repair for Model 553................................................1034
			Remove......................................................................1034
			Disassemble.................................................................1034
			Clean and Inspect...........................................................1034
			Assemble....................................................................1034
		Hooks Replacement for Model 555.................................................1035
			Inspect.....................................................................1035
			Remove......................................................................1035
			Install.....................................................................1035
		Twist Locks Repair for Model 558................................................1036
			Disassemble.................................................................1036
			Clean and Inspect...........................................................1036
			Assemble....................................................................1036
		Bleed the System................................................................1037
		Valve Assembly..................................................................1037
		Slide Pad Replacement...........................................................1038
		Adjustments.....................................................................1038
			Twist Lock Angle Adjustment.................................................1038
				Model 558 Only..........................................................1038
			LOCKED/NOT LOCKED Sensors Adjustment........................................1039
				Model 553...............................................................1039
				Model 558...............................................................1039
			Seated Sensor Adjustment....................................................1039
				Model 553...............................................................1039
				Model 558...............................................................1039
			Overlowering Protection Sensor Adjustment (Models 553 and 558)..............1039
			Torque Chart................................................................1040
		Maintenance.....................................................................1040
			Additional Attachment Maintenance...........................................1042
			Interface Boxes.............................................................1043
				Model 555...............................................................1043
				Models 553 and 558......................................................1043
		Troubleshooting.................................................................1045
	tables..............................................................................1017
		Table 1. Torque Chart...........................................................1040
		Table 2. Inspect and Adjust (See Figure 14 )....................................1041
		Table 3. Lubricate (See Figure 14 ).............................................1042
		Table 4. Replace (See Figure 14 )...............................................1042
1538764-8000SRM1066-(09-2005)-UK-EN.....................................................1063
	toc.................................................................................1063
		Periodic Maintenance............................................................1063
		Safety Precautions Maintenance and Repair.......................................1064
		General.........................................................................1067
			How to Move Disabled Lift Truck.............................................1067
				How to Tow Lift Truck...................................................1067
			How to Put Lift Truck on Blocks.............................................1068
				How to Raise Drive Tires................................................1068
				How to Raise Steering Tires.............................................1068
		Maintenance Schedule............................................................1070
			Empty Container Attachment Maintenance......................................1076
		Maintenance Procedures Every 8 Hours or Daily...................................1078
			How to Make Checks With Engine Stopped......................................1078
				Hydraulic System Oil....................................................1078
				Engine Oil..............................................................1078
				Cooling System..........................................................1079
				Fuel System.............................................................1080
				Water Separator/Fuel Filter.............................................1080
				Fuel, Oil, or Coolant Leaks, Check......................................1080
				Cab Hydraulic System....................................................1080
				Drive Belts.............................................................1081
				Battery.................................................................1081
				Air Filters.............................................................1081
				Forks...................................................................1081
					Adjust..............................................................1081
					Remove..............................................................1081
					Install.............................................................1081
				Forks, Mast, and Lift Chains, Inspect...................................1082
				Tires and Wheels........................................................1083
				Operator Restraint System...............................................1083
				Steering Column Latch...................................................1084
				Safety Labels...........................................................1084
			How to Make Checks With Engine Running......................................1085
				Gauges, Lights, Horn and Fuses..........................................1085
				Control Levers and Pedals...............................................1087
				Transmission Oil........................................................1087
				Lift System Operation...................................................1087
				Brakes..................................................................1087
				Steering System.........................................................1087
				Attachments.............................................................1087
		Maintenance Procedures Every 250 Hours or Every 2 Months........................1088
			Empty Container Handler.....................................................1088
		Maintenance Procedures Every 500 Hours or Every 3 Months........................1088
			Lift Chains.................................................................1088
				Lubrication.............................................................1088
				Adjust..................................................................1088
			Drive Shaft.................................................................1089
			Steering Axle...............................................................1089
			Wheel Nuts..................................................................1089
			Shafts for Brake Actuators..................................................1089
			Drive Axle and Differential.................................................1089
			Hydraulic Tank Breather.....................................................1089
			Air Filter, Engine, and Air Compressor......................................1089
			Cabin Air Filter, Heater....................................................1089
			Engine Oil and Filter.......................................................1089
			Drive Belts.................................................................1090
			Mast........................................................................1090
			General Lubrication.........................................................1091
			Fork Wear and Damage Check..................................................1091
			Lift Chains Wear Check......................................................1092
		Maintenance Procedures Every 1000 Hours or 6 Months.............................1092
			Transmission Oil and Filter, Change.........................................1092
			Fuel Filter.................................................................1093
				Diesel Fuel System Air Removal..........................................1093
				Fuel Injection Pump Without Vent Tube...................................1093
			Fuel Injection Pump Timing..................................................1094
			Valve Adjustment............................................................1094
			Pilot Accumulator Pressure Charge Check.....................................1095
		Maintenance Procedures Every 2000 Hours or Yearly...............................1095
			Hydraulic System............................................................1095
				Hydraulic Oil Filter, Change............................................1095
				Hydraulic Oil, Change...................................................1095
			Differential and Drive Axle.................................................1096
			Wheel Bearings..............................................................1096
				Steer Wheels............................................................1096
				Drive Wheels............................................................1097
			Service Brakes..............................................................1097
				Cleaning Procedures (Dry Brake Axle)....................................1097
		Safety Procedures When Working Near Mast........................................1097
		Fuel Injectors Check............................................................1099
			Perkins.....................................................................1099
		Lift and Tilt System Leak Check.................................................1099
			Lift System.................................................................1099
			Tilt System.................................................................1099
		Welding Repairs.................................................................1100
		Wheel and Tire Replacement......................................................1101
			Remove Wheels From Lift Truck...............................................1101
			Pneumatic Tires.............................................................1101
				Remove Tire From Wheel..................................................1101
					Remove Tire From Three- and Four-Piece Wheel........................1102
				Install Tire on Wheel...................................................1103
					Install Three- or Four-Piece Wheel in Tire..........................1103
			Add Air to Tires............................................................1104
			Solid Rubber Tires..........................................................1105
				Remove Tire From Wheel..................................................1105
				Install Tire on Wheel...................................................1106
			Wheels, Install.............................................................1108
	tables..............................................................................1063
		Table 1. Daily Inspections − Condition Check....................................1070
		Table 2. Daily Inspections − Fluid Level Check..................................1071
		Table 3. Daily Inspections − Checks With the Engine Running.....................1071
		Table 4. First Inspection After First 100 Hours of Operation....................1072
		Table 5. Periodic Maintenance Schedule − Inspect and Adjust.....................1073
		Table 6. Periodic Maintenance Schedule − Lubricate..............................1074
		Table 7. Periodic Maintenance Schedule − Change.................................1074
		Table 8. Empty Container Attachment Maintenance − Inspect and ..................1077
		Table 9. Empty Container Attachment Maintenance − Lubricate.....................1077
		Table 10. Allowable Mast Movement from Internal Leakage.........................1100
1541323-0600SRM1068-(05-2004)-UK-EN.....................................................1111
	toc.................................................................................1111
		Perkins Tier 2 Diesel Engines...................................................1111
		Safety Precautions Maintenance and Repair.......................................1112
		General.........................................................................1119
			General Safety Rules........................................................1119
		Description.....................................................................1120
			Engine Serial Number Codes..................................................1122
			Engine Data.................................................................1122
		Engine Removal and Installation.................................................1123
		Cylinder Head Assembly Repair...................................................1123
			Valve Cover.................................................................1123
				Remove..................................................................1123
				Install.................................................................1124
			Rocker Arm Assembly.........................................................1124
				Remove..................................................................1124
				Disassemble.............................................................1124
				Inspect.................................................................1124
				Assemble................................................................1124
				Install.................................................................1124
			Valve Clearance Adjustments.................................................1125
			Valve Springs...............................................................1126
			Cylinder Head Assembly......................................................1127
				Remove..................................................................1127
				Install.................................................................1129
			Valves and Valve Springs....................................................1132
				Remove..................................................................1132
				Inspect.................................................................1132
				Install.................................................................1133
			Valve Guides................................................................1133
				Inspect.................................................................1133
				Remove..................................................................1133
				Install.................................................................1133
			Cylinder Head and Valve Seats...............................................1134
				Inspect.................................................................1134
				Repair..................................................................1135
				New Valve Seats, Install................................................1135
		Piston and Connecting Rod Assemblies Repair.....................................1135
			Rod Bearings................................................................1136
				Remove..................................................................1136
				Install.................................................................1136
			Piston and Connecting Rod Assembly..........................................1137
				Service Note............................................................1137
				Remove..................................................................1137
				Install.................................................................1138
			Piston Rings................................................................1139
				Remove..................................................................1139
				Inspect.................................................................1139
				Install.................................................................1140
			Piston and Connecting Rod...................................................1140
				Disassemble.............................................................1140
				Inspect.................................................................1140
				How to Select Correct Replacements......................................1141
				Install.................................................................1142
			Piston Cooling Jets.........................................................1142
				Remove..................................................................1142
				Install.................................................................1143
		Crankshaft Assembly Repair......................................................1143
			General.....................................................................1143
			Crankshaft Pulley...........................................................1144
				Remove..................................................................1144
				Inspect.................................................................1144
				Install.................................................................1144
			Rear Oil Seal...............................................................1145
				Remove..................................................................1145
				Install.................................................................1145
			Main Bearings...............................................................1146
				Remove..................................................................1146
				Inspect.................................................................1147
				Install.................................................................1147
			Thrust Washers..............................................................1147
				Crankshaft Axial Movement, Check........................................1147
				Remove..................................................................1148
				Install.................................................................1148
			Crankshaft..................................................................1149
				Remove..................................................................1149
				Inspect.................................................................1149
				Install.................................................................1150
			Flywheel....................................................................1151
				Remove..................................................................1151
				Ring Gear, Replace......................................................1151
				Install.................................................................1151
			Flywheel Housing............................................................1152
				Remove..................................................................1152
				Install.................................................................1152
		Timing Case and Timing Gears Repair.............................................1153
			General.....................................................................1153
			Timing Case Cover...........................................................1153
				Remove..................................................................1153
				Install.................................................................1154
			Front Oil Seal..............................................................1154
				Remove..................................................................1154
				Install.................................................................1154
			Crankshaft Pulley Wear Sleeve...............................................1155
				Install.................................................................1155
			Idler Gear and Hub..........................................................1155
				Remove..................................................................1155
				Install.................................................................1156
			Air Compressor Drive, Bendix................................................1157
				Disassemble.............................................................1157
				Assemble................................................................1157
			Fuel Injection Pump Gear....................................................1158
				Remove..................................................................1158
				Install.................................................................1159
			Camshaft Gear...............................................................1159
				Remove..................................................................1159
				Install.................................................................1160
			Crankshaft Gear.............................................................1160
				Remove..................................................................1160
				Install.................................................................1161
			Timing Case.................................................................1161
				Remove..................................................................1161
				Install.................................................................1161
			Camshaft and Tappets........................................................1162
				Remove..................................................................1162
				Install.................................................................1163
		Cylinder Block Assembly Repair..................................................1163
			Description.................................................................1163
			Cylinder Block..............................................................1163
				Disassemble.............................................................1163
				Inspect.................................................................1164
				Assemble................................................................1164
			Cylinder Liner..............................................................1165
				Inspect.................................................................1165
				Cylinder Liner Condition, Check.........................................1165
				Remove..................................................................1166
				Service Liner, Install..................................................1167
				Partially Finished Liner, Install.......................................1168
		Engine Timing...................................................................1169
			Description.................................................................1169
				How to Set Number One Piston to TDC on Compression Stroke...............1170
				How to Set Number One Piston to TDC on Compression Stroke (Alter........1171
				How to Set Number One Piston to 4° After TDC on Compression Stro........1172
				Valve Timing, Check.....................................................1173
				Fuel Injection Pump Timing, Check.......................................1174
		Turbocharger....................................................................1174
			General.....................................................................1174
			Remove......................................................................1174
			Install.....................................................................1175
			Impeller and Compressor Housing, Clean......................................1175
			Waste-Gate Valve Check......................................................1176
			Closed Circuit Breather System (CCB)........................................1177
				CCB Assembly, Remove....................................................1177
				Closed Circuit Drain Valve, Remove......................................1177
				CCB Assembly, Install...................................................1177
				Closed Circuit Drain Valve, Install.....................................1177
		Lubrication System Repair.......................................................1178
			General.....................................................................1178
			Oil Filter, Replace.........................................................1178
			Oil Filter Head.............................................................1178
				Remove..................................................................1178
				Install.................................................................1178
			Oil Filter Head Bypass Valve................................................1179
				Remove and Install......................................................1179
			Oil Sump....................................................................1179
				Remove..................................................................1179
				Install.................................................................1179
			Oil Pump....................................................................1180
				Remove..................................................................1180
				Inspect.................................................................1180
				Install.................................................................1181
			Relief Valve................................................................1182
				Remove..................................................................1182
				Disassemble.............................................................1182
				Inspect.................................................................1182
				Assemble................................................................1182
				Install.................................................................1182
			Idler Gear Shaft, Replace...................................................1182
				Remove..................................................................1183
				Remove (Alternative)....................................................1183
				Install.................................................................1184
				Install (Alternative)...................................................1184
		Fuel System Repair..............................................................1185
			Description.................................................................1185
			Fuel Injection Pump.........................................................1187
				Remove..................................................................1187
				Install.................................................................1189
			Fuel System Air Removal.....................................................1190
			Fuel Filter, Replace........................................................1192
			Fuel Injectors..............................................................1192
				Remove..................................................................1193
				Inspect.................................................................1193
				Install.................................................................1193
			Fuel Lift Pump..............................................................1194
				Remove..................................................................1194
				Disassemble.............................................................1194
				Assemble................................................................1194
				Install.................................................................1195
				Test....................................................................1195
		Cooling System Repair...........................................................1196
			General.....................................................................1196
			Thermostat..................................................................1196
				Remove..................................................................1196
				Install.................................................................1197
				Test....................................................................1197
			Coolant Pump................................................................1197
				Remove..................................................................1197
				Disassemble.............................................................1198
				Assemble................................................................1200
				Install.................................................................1202
			Fan and Fan Drive...........................................................1203
				Remove..................................................................1203
				Install.................................................................1203
			Oil Cooler..................................................................1203
				Remove..................................................................1203
				Disassemble and Assemble................................................1204
				Install.................................................................1204
		Electrical Equipment Repair.....................................................1205
			Drive Belts.................................................................1205
			Alternator..................................................................1205
				Remove..................................................................1205
				Install.................................................................1205
			Electronic Control Module (ECM).............................................1206
				Remove..................................................................1206
				Inspect.................................................................1206
				Install.................................................................1206
			Voltage Load and Protection Module (VLPM)...................................1207
				Remove..................................................................1207
				Install.................................................................1207
			Engine Speed and Timing Sensor..............................................1207
				Remove..................................................................1207
				Install.................................................................1208
			Pressure Sensors (Engine Oil and Air Intake)................................1208
				Remove..................................................................1208
				Install.................................................................1209
			Temperature Sensor..........................................................1209
				Remove..................................................................1209
				Install.................................................................1210
			Starter Motor...............................................................1210
				Remove..................................................................1210
				Install.................................................................1210
			Cold Start Aid..............................................................1210
		Air Compressor..................................................................1210
			General.....................................................................1210
			Repair......................................................................1211
				Remove..................................................................1211
				Install.................................................................1211
		Rotary Exhauster Replacement....................................................1212
			Remove......................................................................1212
			Clean.......................................................................1212
			Install.....................................................................1212
		Engine Specifications...........................................................1213
			Cylinder Head Assembly......................................................1213
			Piston and Connecting Rods..................................................1216
			Crankshaft Assembly.........................................................1217
				Crankshaft Overhaul.....................................................1218
			Timing Case and Drive Assembly..............................................1220
			Engine Block Assembly.......................................................1221
			Turbocharger................................................................1222
			Lubrication System..........................................................1223
			Cooling System..............................................................1225
			Flywheel and Housing........................................................1225
			Electrical Equipment........................................................1225
		Torque Specifications...........................................................1226
			Cylinder Head Assembly......................................................1226
			Piston and Connecting Rod Assemblies........................................1226
			Crankshaft Assembly.........................................................1226
			Timing Case and Drive Assembly..............................................1226
			Turbocharger................................................................1226
			Lubrication System..........................................................1226
			Fuel System.................................................................1226
			Cooling System..............................................................1227
			Flywheel....................................................................1227
			Auxiliary Equipment.........................................................1227
		Special Torque Specifications...................................................1227
			Flywheel and Housing........................................................1227
			Electrical Equipment........................................................1227
			Auxiliary Equipment.........................................................1227
		Special Tools...................................................................1228
		Troubleshooting.................................................................1233
		Turbocharger Troubleshooting....................................................1235
	tables..............................................................................1111
		Table 1. Cylinder Head..........................................................1213
		Table 2. Valve Guides...........................................................1213
		Table 3. Inlet Valves...........................................................1214
		Table 4. Exhaust Valves.........................................................1214
		Table 5. Valve Springs..........................................................1215
		Table 6. Tappets................................................................1215
		Table 7. Rocker Arm Shaft.......................................................1215
		Table 8. Rocker Arms and Bushings...............................................1215
		Table 9. Pistons................................................................1216
		Table 10. Piston Rings..........................................................1216
		Table 11. Piston Pins...........................................................1216
		Table 12. Connecting Rods.......................................................1216
		Table 13. Small End Bushings....................................................1217
		Table 14. Connecting Rod Bearings...............................................1217
		Table 15. Piston Cooling Jets...................................................1217
		Table 16. Crankshaft............................................................1217
		Table 17. Main Bearings.........................................................1218
		Table 18. Crankshaft Thrust Washers.............................................1218
		Table 19. Crankshaft Heat Treatment.............................................1218
		Table 20. Crankshaft Overhaul Specifications....................................1218
		Table 21. Maximum Variation (Run-Out)...........................................1220
		Table 22. Camshaft..............................................................1220
		Table 23. Camshaft Thrust Washer................................................1220
		Table 24. Camshaft Gear.........................................................1220
		Table 25. Gear for Fuel Injection Pump..........................................1220
		Table 26. Crankshaft Gear.......................................................1221
		Table 27. Idler Gear and Hub....................................................1221
		Table 28. Cylinder Block........................................................1221
		Table 29. Cylinder Liners.......................................................1221
		Table 30. Cylinder Liner Specifications (Partially Finished)....................1222
		Table 31. Oil Pump..............................................................1223
		Table 32. Idler Gear for Oil Pump...............................................1223
		Table 33. Relief Valve..........................................................1223
		Table 34. Oil Filter............................................................1223
		Table 35. Bosch Fuel Injection Pump.............................................1223
		Table 36. Fuel Injector Codes...................................................1224
		Table 37. Fuel Pump.............................................................1225
		Table 38. Fuel Filter...........................................................1225
		Table 39. Coolant Pump..........................................................1225
		Table 40. Thermostat............................................................1225
		Table 41. Fan Drive Housing.....................................................1225
		Table 42. Limits for Flywheel Run Out and Alignment (Total Indic................1225
		Table 43. Alternator............................................................1225
		Table 44. Starter Motor.........................................................1225
		Table 45. Cold Start Aid........................................................1225
		Table 46. List of Possible Causes...............................................1233
		Table 47. List of Possible Causes...............................................1235
1553599-4000SRM1062-(03-2007)-UK-EN.....................................................1239
	toc.................................................................................1239
		Masts and Carriages.............................................................1239
		Safety Precautions Maintenance and Repair.......................................1240
		General.........................................................................1243
		Description.....................................................................1243
		Operation.......................................................................1244
			Two-Stage Mast..............................................................1244
			Three-Stage Mast............................................................1245
		Safety Procedures When Working Near Mast........................................1246
		Forks Repair....................................................................1249
			Remove......................................................................1249
			Inspect and Adjust..........................................................1249
			Install.....................................................................1249
		Carriage Repair.................................................................1250
			Description.................................................................1250
				Three Function..........................................................1250
				Four to Six Function....................................................1250
			Remove......................................................................1250
			Disassemble.................................................................1251
			Clean and Inspect...........................................................1253
			Assemble....................................................................1253
			Install.....................................................................1253
		Sideshift Cylinder Repair.......................................................1254
			Remove......................................................................1254
			Disassemble.................................................................1254
			Clean and Inspect...........................................................1254
			Assemble....................................................................1254
			Install.....................................................................1254
		Fork Positioner Cylinders Repair................................................1258
			Remove......................................................................1258
			Disassemble.................................................................1258
			Clean and Inspect...........................................................1258
			Assemble....................................................................1258
			Install.....................................................................1258
		Directional Control Valve Repair................................................1265
			Remove......................................................................1265
			Disassemble.................................................................1265
			Clean and Inspect...........................................................1265
			Assemble....................................................................1266
			Install.....................................................................1266
		Mast Repair.....................................................................1266
			Two- and Three-Stage Mast...................................................1266
				Remove..................................................................1266
				Disassemble.............................................................1271
				Clean and Inspect.......................................................1273
				Assemble................................................................1274
				Install.................................................................1275
			Three-Stage Mast (Four Cylinders)...........................................1275
				Remove..................................................................1275
				Disassemble.............................................................1277
				Clean and Inspect.......................................................1279
				Assemble................................................................1279
				Install.................................................................1279
			Fork Carriage Chains........................................................1281
				Adjust..................................................................1281
			Bearing Rollers.............................................................1283
				Description.............................................................1283
				Lubrication.............................................................1283
				Clearance...............................................................1283
				Remove and Disassemble..................................................1283
				Assemble................................................................1284
			Mast Profile................................................................1284
		Lift Cylinders Description......................................................1284
			Piston-Type Cylinders.......................................................1284
			Displacement-Type Cylinders.................................................1284
		Lift Cylinders Repair...........................................................1285
			Remove......................................................................1285
			Disassemble.................................................................1287
			Clean and Inspect...........................................................1287
			Assemble....................................................................1287
			Install.....................................................................1288
		Mast Operation Check............................................................1288
		Lift and Tilt System Leak Checks................................................1289
			Lift System.................................................................1289
			Tilt System.................................................................1289
		Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................1290
		Lift Chain Adjustments..........................................................1290
		Mast Adjustments................................................................1291
			Bearing Blocks, Two-Stage Masts.............................................1291
			Wear Plates.................................................................1291
		Carriage Adjustment.............................................................1291
		Troubleshooting.................................................................1293
	tables..............................................................................1239
		Table 1. Allowable Mast Movement from Internal Leakage..........................1289
1553764-0600SRM1072-(06-2005)-UK-EN.....................................................1297
	toc.................................................................................1297
		Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...................1297
		Safety Precautions Maintenance and Repair.......................................1298
		Electronic Troubleshooting......................................................1321
			System Operation............................................................1321
			Electronic Controls.........................................................1321
			Engine Governor.............................................................1322
			Timing Considerations.......................................................1322
			Fuel Injection..............................................................1322
			Diagnostic Codes............................................................1322
			Diagnostic Fault Codes......................................................1322
			Diagnostic Event Codes......................................................1322
			Programmable Parameters.....................................................1323
			Passwords...................................................................1323
			Electronic Service Tools....................................................1323
			Electronic Service Tool (EST)...............................................1323
				Connecting the Electronic Service Tool and the Communication Ada........1323
				Support for the Electronic Service Tool.................................1324
				Optional Service Tools..................................................1324
			Diagnostic Codes............................................................1324
			Diagnostic Fault Code Access Via Indicator Lamps............................1328
			Replacing the ECM...........................................................1329
			Self Diagnostics............................................................1330
		Glossary........................................................................1331
		Sensors and Electrical Connectors...............................................1334
		Engine Wiring Information.......................................................1337
			Harness Wire Identification.................................................1340
		Diagnostic Code Reader..........................................................1340
			General.....................................................................1340
			Reference Documents.........................................................1340
			Abbreviations...............................................................1340
			Environmental Specification.................................................1340
			Hardware....................................................................1341
				Connection Cable........................................................1342
			Software....................................................................1342
				Engine Communication....................................................1342
			User Controls...............................................................1342
				Power Supply............................................................1342
				Display Screen..........................................................1343
				Operation Controls......................................................1343
				Audible Warning.........................................................1343
			Operation Instructions......................................................1343
				How to Connect the Diagnostic Code Reader to the Engine.................1343
				How to Turn ON the Diagnostic Code Reader...............................1343
				How to use the Display Screen...........................................1343
				How to Operate the Diagnostic Code Reader...............................1344
					Main Menu...........................................................1344
					Active Codes........................................................1344
					Inactive Codes......................................................1345
					How to Clear Codes..................................................1345
					Status Lamp.........................................................1345
					Data List...........................................................1346
			Diagnostics.................................................................1346
		Programming Parameters..........................................................1347
			Passwords...................................................................1347
			Factory Passwords...........................................................1347
			Customer Passwords..........................................................1348
			Flash Programming...........................................................1348
			Flash Programming a Personality Module......................................1348
			WinFlash Error Messages.....................................................1348
		System Configuration Parameters.................................................1349
			Full Load Setting...........................................................1349
			Full Torque Setting.........................................................1349
			Rating Interlock............................................................1349
			Engine Serial Number........................................................1349
			ECM Software Release Date...................................................1349
		Troubleshooting Without a Diagnostic Code.......................................1350
			Alternator Noise (Noisy Operation)..........................................1350
				Probable Causes.........................................................1350
				Recommended Actions.....................................................1350
					Alternator Drive Belts..............................................1350
					Alternator Drive Pulley.............................................1350
					Alternator Bearings.................................................1350
			Alternator Will Not Charge (Charging Problem)...............................1350
				Probable Causes.........................................................1350
				Recommended Actions.....................................................1350
					Alternator Drive Belts..............................................1350
					Charging Circuit....................................................1350
					Alternator or Regulator.............................................1350
			Battery.....................................................................1350
				Probable Causes.........................................................1350
				Recommended Actions.....................................................1350
					Faulty Battery......................................................1350
					Auxiliary Device....................................................1350
			Cannot Reach Top Engine RPM.................................................1351
				Probable Causes.........................................................1351
				Recommended Actions.....................................................1351
					Diagnostic Codes....................................................1351
					Fuel Supply.........................................................1351
					Air Intake and Exhaust System.......................................1351
					Individual Malfunctioning Cylinders.................................1351
					Valve Lash..........................................................1351
					Check for Low Compression...........................................1351
					Check the Fuel Injection Nozzles....................................1352
					Check the Turbocharger..............................................1352
					ECM Parameters......................................................1352
					Check the Signal for the Throttle Position Sensor...................1352
			Coolant in Engine Oil.......................................................1352
				Probable Causes.........................................................1352
				Recommended Actions.....................................................1352
					Engine Oil Cooler Core..............................................1352
					Cylinder Head Gasket................................................1352
					Cylinder Head.......................................................1353
					Cylinder Block......................................................1353
			Coolant Temperature Is Too High.............................................1353
				Probable Causes.........................................................1353
				Recommended Actions.....................................................1353
					Radiator Fins.......................................................1353
					Coolant Level.......................................................1353
					Radiator Cap and/or Pressure Relief Valve...........................1353
					Combustion Gases in the Cooling System..............................1353
					Water Temperature Regulator.........................................1353
					Restriction in the Coolant System...................................1353
					Coolant Temperature Gauge...........................................1353
					Coolant Pump........................................................1353
					Excessive Load on the System........................................1354
			ECM Will Not Accept Factory Passwords.......................................1354
				Probable Causes.........................................................1354
				Recommended Actions.....................................................1354
			ECM Will Not Communicate With Other Systems or Display Modules..............1354
				Probable Causes.........................................................1354
				Recommended Actions.....................................................1354
			Electronic Service Tool Will Not Communicate With ECM.......................1354
				Probable Causes.........................................................1354
				Recommended Actions.....................................................1354
			Engine Cranks but Will Not Start............................................1355
				Probable Causes.........................................................1355
				Recommended Actions.....................................................1355
					Diagnostic Codes....................................................1355
					Visual Checks.......................................................1355
					Crank Without Injection.............................................1355
					Starting Motor Solenoid or Starting Circuit.........................1355
					Valve Lash..........................................................1355
					Fuel Injection Nozzles..............................................1356
					Air Inlet Heater Starting Aid.......................................1356
					Air Intake and Exhaust System.......................................1356
					Low Compression.....................................................1356
					Fuel Supply.........................................................1356
			Engine Has Early Wear.......................................................1356
				Probable Causes.........................................................1356
				Recommended Actions.....................................................1356
					Dirt in Engine Oil..................................................1356
					Leaks in Air Intake System..........................................1356
					Low Oil Pressure....................................................1357
			Engine Misfires, Runs Rough or Is Unstable..................................1357
				Probable Causes.........................................................1357
				Recommended Actions.....................................................1357
					Logged Codes........................................................1357
					Fuel Supply.........................................................1357
					Air Intake and Exhaust System.......................................1357
					Individual Malfunctioning Cylinders.................................1357
					Valve Lash..........................................................1357
					Check for Low Compression...........................................1358
					Check the Fuel Injection Nozzles....................................1358
					Check the Air Inlet Heater Starting Aid.............................1358
					Check the Engine Speed/Timing Sensors...............................1358
					Check the Signal for the Throttle Position Sensor...................1358
					Check the Fuel Injection Pump.......................................1358
			Engine Oil in Cooling System................................................1358
				Probable Causes.........................................................1358
				Recommended Actions.....................................................1359
					Engine Oil Cooler Core..............................................1359
					Cylinder Head Gasket................................................1359
					Cylinder Head.......................................................1359
			Engine Speed Does Not Change................................................1359
				Probable Causes.........................................................1359
				Recommended Repairs.....................................................1359
					Diagnostic Codes....................................................1359
			Engine Stalls at Low RPM....................................................1359
				Probable Causes.........................................................1359
				Recommended Actions.....................................................1359
					Diagnostic Codes....................................................1359
					Fuel Injection Nozzles..............................................1359
					Fuel Supply.........................................................1360
					Accessory Equipment.................................................1360
					Power Mode Control..................................................1360
			Engine Vibration............................................................1360
				Probable Causes.........................................................1360
				Recommended Actions.....................................................1360
					Engine Supports.....................................................1360
					Malfunctioning Individual Cylinder..................................1360
					Valve Lash..........................................................1360
					Check for Low Compression (cylinder pressure).......................1360
					Check the Fuel Injection Nozzles....................................1361
					Turbocharger........................................................1361
			Engine Will Not Crank.......................................................1361
				Probable Causes.........................................................1361
				Recommended Repairs.....................................................1361
					Machine Security System.............................................1361
					Battery Cables and/or Batteries.....................................1361
					Starting Motor Solenoid or Starting Circuit.........................1361
					Starting Motor and/or Flywheel Ring Gear............................1361
					Electrical Power Supply.............................................1362
					Internal Engine Problem.............................................1362
			Excessive Black Smoke.......................................................1362
				Probable Causes.........................................................1362
				Recommended Actions.....................................................1362
					Air Intake System or Exhaust System.................................1362
					Individual Malfunctioning Cylinder..................................1362
					Valve Lash..........................................................1362
					Low Compression (cylinder pressure).................................1362
					Check the Fuel Injection Nozzles....................................1362
					Check the Turbocharger..............................................1363
					Broken 5-Volt Supply Wire...........................................1363
					Verifying the ECM Software..........................................1363
			Excessive Engine Oil Consumption............................................1363
				Probable Causes.........................................................1363
				Recommended Actions.....................................................1363
					Oil Level...........................................................1363
					Engine Crankcase Breather...........................................1363
					Air Intake and Exhaust System.......................................1363
					Turbocharger........................................................1363
					Low Compression (cylinder pressure).................................1364
			Excessive Valve Lash........................................................1364
				Probable Causes.........................................................1364
				Recommended Actions.....................................................1364
					Lubrication.........................................................1364
					Valve Lash..........................................................1364
					Valve Train Components..............................................1364
			Excessive White Smoke.......................................................1364
				Probable Causes.........................................................1364
				Recommended Actions.....................................................1365
					Fuel Supply.........................................................1365
					Individual Malfunctioning Cylinder..................................1365
					Valve Lash..........................................................1365
					Low Compression (cylinder pressure).................................1365
					Air Inlet Heater Starting Aid.......................................1365
					Fuel Injection Nozzles..............................................1365
					Coolant Temperature Sensor Circuit..................................1365
					Engine Pressure Sensors.............................................1365
			Intake Air Temperature Is Too High..........................................1366
				Probable Causes.........................................................1366
				Recommended Repairs.....................................................1366
					High Ambient Air Temperature........................................1366
					Coolant Temperature.................................................1366
					Check for High Intake Air Restriction and/or High Altitude..........1366
					Intake Air Restriction..............................................1366
					High Altitude.......................................................1366
					Check the Intake Manifold Air Temperature Sensor and/or the Circ....1366
					Check for Sufficient Coolant Flow Through the Aftercooler (if eq....1366
					Check for Sufficient Flow of Air Through the Aftercooler (if equ....1366
			Intermittent Engine Shutdown................................................1366
				Probable Causes.........................................................1366
				Recommended Actions.....................................................1366
					Logged Codes........................................................1366
					Fuel Supply.........................................................1367
					Engine Protection Device............................................1367
					Electrical Connectors...............................................1367
			Intermittent Low Power or Power Cutout......................................1367
				Probable Causes.........................................................1367
				Recommended Repairs.....................................................1367
					Diagnostic Codes....................................................1368
					Electrical Connectors...............................................1368
					Fuel Supply.........................................................1368
					Check the Intake Manifold Pressure..................................1368
					Air Intake and Exhaust System.......................................1368
					Individual Malfunctioning Cylinders.................................1368
					Valve Lash..........................................................1369
					Check for Low Compression...........................................1369
					Check the Fuel Injection Nozzles....................................1369
					Check the Turbocharger..............................................1369
					ECM Parameters......................................................1369
					Electronic System Problem...........................................1369
			Low Engine Oil Pressure.....................................................1370
				Probable Causes.........................................................1370
				Recommended Actions.....................................................1370
					Engine Oil Level....................................................1370
					Engine Oil Pressure Gauge...........................................1370
					Engine Oil Bypass Valves............................................1370
					Piston Cooling Jets ................................................1370
					Engine Oil Suction Tube.............................................1370
					Engine Oil Pump.....................................................1370
					Bearing Clearance...................................................1370
			Low Power/Poor or No Response to Throttle...................................1370
				Probable Causes.........................................................1370
				Recommended Actions.....................................................1371
					Diagnostic Codes....................................................1371
					Fuel Supply.........................................................1371
					Air Intake and Exhaust System.......................................1371
					Individual Malfunctioning Cylinders.................................1371
					Valve Lash..........................................................1371
					Check for Low Compression...........................................1371
					Check the Fuel Injection Nozzles....................................1372
					Check the Turbocharger..............................................1372
					ECM Parameters......................................................1372
					Electronic System Problem...........................................1372
			Mechanical Noise (Knock) in Engine..........................................1372
				Probable Causes.........................................................1372
				Recommended Actions.....................................................1373
					Accessory Equipment.................................................1373
					Valve Train Components..............................................1373
					Connecting Rod and Main Bearings....................................1373
			Noise Coming from Cylinder..................................................1373
				Probable Causes.........................................................1373
				Recommended Actions.....................................................1373
					Fuel Quality........................................................1373
					Fuel Injection Nozzles..............................................1373
					Valve Lash..........................................................1373
			Poor Acceleration or Response...............................................1373
				Probable Causes.........................................................1373
				Recommended Repairs.....................................................1373
					Diagnostic Codes....................................................1373
					Fuel Supply.........................................................1373
					Individual Malfunctioning Cylinder..................................1374
					Valve Lash..........................................................1374
					Check for Low Compression...........................................1374
					Check the Fuel Injection Nozzles....................................1374
					Check the Turbocharger..............................................1374
					ECM Parameters......................................................1374
					Check Intake Manifold Pressure......................................1375
		Troubleshooting With a Diagnostic Code..........................................1375
			CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal............1375
				Conditions Which Generate This Code.....................................1375
				System Response.........................................................1375
				Possible Performance Effect.............................................1375
				Troubleshooting.........................................................1375
				Results.................................................................1375
			CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent............1375
				Conditions Which Generate This Code.....................................1375
				System Response.........................................................1375
				Possible Performance Effect.............................................1375
				Troubleshooting.........................................................1375
				Test Step 1.............................................................1375
				Results.................................................................1375
			CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted............1375
				Conditions Which Generate This Code.....................................1375
				System Response.........................................................1375
				Possible Performance Effect.............................................1376
			CID 0091 FMI 04 Throttle Position Sensor Shorted Low........................1376
				Conditions Which Generate This Code.....................................1376
				System Response.........................................................1376
				Possible Performance Effect.............................................1376
				Troubleshooting.........................................................1376
				Results.................................................................1376
			CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal....................1376
				Conditions Which Generate This Code.....................................1376
				System Response.........................................................1376
				Troubleshooting.........................................................1376
				Results.................................................................1376
			CID 0091 FMI 12 Throttle Position Sensor Out of Calibration.................1376
				Conditions Which Generate This Code.....................................1376
				Possible Performance Effect.............................................1376
				Troubleshooting.........................................................1376
				Results.................................................................1376
			CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short............1376
				Conditions Which Generate This Code.....................................1376
				System Response.........................................................1377
				Troubleshooting.........................................................1377
				Results.................................................................1377
			CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low......................1377
				Conditions Which Generate This Code.....................................1377
				System Response.........................................................1377
				Troubleshooting.........................................................1377
				Results.................................................................1377
			CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci............1377
				Conditions Which Generate This Code.....................................1377
				System Response.........................................................1377
				Possible Performance Effect.............................................1377
				Results.................................................................1377
			CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or............1377
				Conditions Which Generate This Code.....................................1377
				System Response.........................................................1377
				Possible Performance Effect.............................................1378
				Results.................................................................1378
			CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low.................1378
				Conditions Which Generate This Code.....................................1378
				System Response.........................................................1378
				Possible Performance Effect.............................................1378
				Results.................................................................1378
			CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope............1378
				Conditions Which Generate This Code.....................................1378
				System Response.........................................................1378
				Results.................................................................1378
			CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ............1378
				Conditions Which Generate This Code.....................................1378
				System Response.........................................................1378
				Possible Performance Effect.............................................1379
				Troubleshooting.........................................................1379
				Results.................................................................1379
			CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low..............1379
				Conditions Which Generate This Code.....................................1379
				System Response.........................................................1379
				Possible Performance Effect.............................................1379
				Troubleshooting.........................................................1379
				Results.................................................................1379
			CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o............1379
				Conditions Which Generate This Code.....................................1379
				System Response.........................................................1379
				Possible Performance Effect.............................................1379
				Troubleshooting.........................................................1379
				Results.................................................................1379
			CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...............1379
				Conditions Which Generate This Code.....................................1379
				System Response.........................................................1379
				Possible Performance Effect.............................................1379
				Troubleshooting.........................................................1380
				Results.................................................................1380
			CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...............1380
				Conditions Which Generate This Code.....................................1380
				System Response.........................................................1380
				Possible Performance Effect.............................................1380
				Troubleshooting.........................................................1380
				Results.................................................................1380
			CID 0247 FMI 09 J1939 Datalink, Abnormal Update.............................1380
				Conditions Which Generate This Code.....................................1380
				System Response.........................................................1380
				Results.................................................................1380
			CID 0253 FMI 02 Incorrect ECM Software......................................1380
				Conditions Which Generate This Code.....................................1380
				System Response.........................................................1380
				Possible Performance Effect.............................................1380
				Troubleshooting.........................................................1381
				Expected Result.........................................................1381
				Results.................................................................1381
			CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal............1381
				Conditions Which Generate This Code.....................................1381
				System Response.........................................................1381
				Possible Performance Effect.............................................1381
				Troubleshooting.........................................................1381
				Results.................................................................1381
			CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal............1381
				Conditions Which Generate This Code.....................................1381
				System Response.........................................................1381
				Possible Performance Effect.............................................1381
				Troubleshooting.........................................................1381
				Results.................................................................1381
			CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs.......................1381
				Conditions Which Generate This Code.....................................1381
				System Response.........................................................1381
				Possible Performance Effect.............................................1381
			CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig............1382
				Conditions Which Generate This Code.....................................1382
				System Response.........................................................1382
				Possible Performance Effect.............................................1382
				Results.................................................................1382
			CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal......................1382
				Conditions Which Generate This Code.....................................1382
				System Response.........................................................1382
				Possible Performance Effect.............................................1382
				Results.................................................................1382
			CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa............1382
				Conditions Which Generate This Code.....................................1382
				System Response.........................................................1382
				Possible Performance Effect.............................................1382
				Test Step 1.............................................................1382
				Results.................................................................1382
				Test Step 2.............................................................1382
				Results.................................................................1383
			CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm............1383
				Conditions Which Generate This Code.....................................1383
				System Response.........................................................1383
				Possible Performance Effect.............................................1383
				Results.................................................................1383
			CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S............1383
				Conditions Which Generate This Code.....................................1383
				System Response.........................................................1383
				Possible Performance Effect.............................................1383
				Troubleshooting.........................................................1383
				Results.................................................................1383
			CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low..................1383
				Conditions Which Generate This Code.....................................1383
				System Response.........................................................1383
				Possible Performance Effect.............................................1383
				Troubleshooting.........................................................1383
				Results.................................................................1383
			CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal..............1384
				Conditions Which Generate This Code.....................................1384
				System Response.........................................................1384
				Possible Performance Effect.............................................1384
				Results.................................................................1384
			CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio............1384
				Conditions Which Generate This Code.....................................1384
				System Response.........................................................1384
				Possible Performance Effect.............................................1384
				Results.................................................................1384
			CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off..................1384
				Conditions Which Generate This Code.....................................1384
				System Response.........................................................1384
				Possible Performance Effect.............................................1384
				Results.................................................................1384
			CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ............1384
				Conditions Which Generate This Code.....................................1384
				System Response.........................................................1384
				Possible Performance Effect.............................................1385
				Test Step 1.............................................................1385
				Results.................................................................1385
				Test Step 2.............................................................1385
				Results.................................................................1385
			CID 1684 FMI 02 Fuel Injection Pump, Software Failure.......................1385
				Conditions Which Generate This Code.....................................1385
				System Response.........................................................1385
				Possible Performance Effect.............................................1385
				Troubleshooting.........................................................1385
				Results.................................................................1385
			CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault..........................1385
				Conditions Which Generate This Code.....................................1385
				System Response.........................................................1385
				Possible Performance Effect.............................................1385
				Troubleshooting.........................................................1385
				Results.................................................................1385
			CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...................1386
				Conditions Which Generate This Code.....................................1386
				System Response.........................................................1386
				Possible Performance Effect.............................................1386
				Troubleshooting.........................................................1386
				Results.................................................................1386
			CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width....................1386
				Conditions Which Generate This Code.....................................1386
				Troubleshooting.........................................................1386
				Results.................................................................1386
			CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault.......................1386
				Conditions Which Generate This Code.....................................1386
				System Response.........................................................1386
				Possible Performance Effect.............................................1386
				Troubleshooting.........................................................1386
				Results.................................................................1386
			CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault.............1386
				Conditions Which Generate This Code.....................................1386
				System Response.........................................................1387
				Possible Performance Effect.............................................1387
				Troubleshooting.........................................................1387
				Test Step 1.............................................................1387
				Results.................................................................1387
				Test Step 2.............................................................1387
				Results.................................................................1387
				Test Step 3.............................................................1387
				Results.................................................................1387
				Test Step 4.............................................................1387
				Expected Result.........................................................1387
				Results.................................................................1387
			CID 1684 FMI 09 Fuel Injection Pump, CAN Fault..............................1387
				Conditions Which Generate This Code.....................................1387
				System Response.........................................................1387
				Possible Performance Effect.............................................1387
				Troubleshooting.........................................................1387
				Expected Result.........................................................1388
				Results.................................................................1388
			CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error..............1388
				Conditions Which Generate This Code.....................................1388
				System Response.........................................................1388
				Troubleshooting.........................................................1388
				Test Step 1.............................................................1388
				Results.................................................................1388
				Test Step 2.............................................................1388
				Results.................................................................1388
				Test Step 3.............................................................1388
				Results.................................................................1388
			CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault..................1388
				Conditions Which Generate This Code.....................................1388
				System Response.........................................................1388
				Possible Performance Effect.............................................1389
				Troubleshooting.........................................................1389
				Test Step 1.............................................................1389
				Results.................................................................1389
				Test Step 2.............................................................1389
				Results.................................................................1389
			CID 1684 FMI 14 Fuel Injection Pump, No Communications......................1389
				Conditions Which Generate This Code.....................................1389
				System Response.........................................................1389
				Troubleshooting.........................................................1389
				Test Step 1.............................................................1389
				Results.................................................................1389
				Test Step 2.............................................................1389
				Results.................................................................1389
				Test Step 3.............................................................1389
				Results.................................................................1389
			CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali............1389
				Conditions Which Generate This Code.....................................1389
				System Response.........................................................1389
				Possible Performance Effect.............................................1390
				Troubleshooting.........................................................1390
				Results.................................................................1390
			CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali............1390
				Conditions Which Generate This Code.....................................1390
				System Response.........................................................1390
			CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S............1390
				Conditions Which Generate This Code.....................................1390
				System Response.........................................................1390
		Troubleshooting With an Event Code..............................................1390
			Event Codes.................................................................1390
			Programmable Engine Parameters..............................................1390
			E015 High Engine Coolant Temperature Derate.................................1390
				Conditions Which Generate This Code.....................................1390
				System Response.........................................................1390
				Possible Performance Effect.............................................1390
				Troubleshooting.........................................................1390
				Results.................................................................1390
			E016 High Engine Coolant Temperature Shutdown...............................1391
				Conditions Which Generate This Code.....................................1391
				System Response.........................................................1391
				Possible Performance Effect.............................................1391
				Troubleshooting.........................................................1391
				Results.................................................................1391
			E017 High Engine Coolant Temperature Warning................................1391
				Conditions Which Generate This Code.....................................1391
				System Response.........................................................1391
				Possible Performance Effect.............................................1391
				Troubleshooting.........................................................1391
				Results.................................................................1391
			E025 High Intake Air Temperature Derate.....................................1391
				Conditions Which Generate This Code.....................................1391
				System Response.........................................................1391
				Possible Performance Effect.............................................1391
				Troubleshooting.........................................................1391
				Results.................................................................1391
			E027 High Intake Air Temperature Warning....................................1391
				Conditions Which Generate This Code:....................................1391
				System Response.........................................................1391
				Possible Performance Effect.............................................1392
				Troubleshooting.........................................................1392
				Results.................................................................1392
			E040 Low Engine Oil Pressure Shutdown.......................................1392
				Conditions Which Generate This Code.....................................1392
				System Response.........................................................1392
				Possible Performance Effect.............................................1392
				Troubleshooting.........................................................1392
				Results.................................................................1392
			E054 High Fuel Temperature Derate...........................................1392
				Conditions Which Generate This Code.....................................1392
				System Response.........................................................1392
				Troubleshooting.........................................................1392
				Test Step 1 - Check for Diagnostic Codes................................1392
				Expected Result.........................................................1392
				Results.................................................................1392
				Test Step 2 - Perform a Check of the Fuel System........................1392
				Expected Result.........................................................1393
				Results.................................................................1393
			E056 High Fuel Temperature Warning..........................................1393
				Conditions Which Generate This Code.....................................1393
				System Response.........................................................1393
				Troubleshooting.........................................................1393
				Test Step 1 - Check for Diagnostic Codes................................1393
				Expected Result.........................................................1393
				Results.................................................................1393
				Test Step 2 - Perform a Check of the Fuel System........................1393
				Expected Result.........................................................1393
				Results.................................................................1393
			E100 Low Engine Oil Pressure Warning........................................1393
				Conditions Which Generate This Code.....................................1393
				System Response.........................................................1393
				Possible Performance Effect.............................................1393
				Troubleshooting.........................................................1394
				Test Step 1 - Check for Active Diagnostic Codes.........................1394
				Expected Result.........................................................1394
				Results.................................................................1394
				Test Step 2 - Perform a Check of the Engine Lubrication System..........1394
				Expected Result.........................................................1394
				Results.................................................................1394
			E190 Engine Overspeed Warning...............................................1394
				Conditions Which Generate This Code.....................................1394
				System Response.........................................................1394
				Possible Performance Effect.............................................1394
				Troubleshooting.........................................................1394
				Engine Overspeed Warning................................................1394
				Expected Result.........................................................1394
				Results.................................................................1394
			E442 Engine Failed to Stop With a No-Fuel Command...........................1394
				Conditions Which Generate This Code.....................................1394
				System Response.........................................................1394
				Possible Performance Effect.............................................1395
				Troubleshooting.........................................................1395
				Test Step 1.............................................................1395
				Results.................................................................1395
				Test Step 2.............................................................1395
				Results.................................................................1395
			E883 Engine Failed to Stop When Fuel Solenoid Disengaged....................1395
				Conditions Which Generate This Code.....................................1395
				System Response.........................................................1395
				Possible Performance Effect.............................................1395
				Troubleshooting.........................................................1395
				Test Step 1.............................................................1395
				Results.................................................................1395
				Test Step 2.............................................................1395
				Results.................................................................1395
				Test Step 3.............................................................1395
				Results.................................................................1395
		Diagnostic Function Tests.......................................................1396
			5-Volt Engine Pressure Sensor Supply Circuit - Test.........................1396
				System Operation Description............................................1396
				Background Information..................................................1396
				Test Step 1.............................................................1397
					Inspect Electrical Connectors and Wiring............................1397
					Expected Result.....................................................1397
					Results.............................................................1397
				Test Step 2.............................................................1398
					Check for Active Diagnostic Codes...................................1398
					Expected Result.....................................................1398
					Results.............................................................1398
				Test Step 3.............................................................1398
					Disconnect the ECM Engine Harness Connector From the ECM............1398
					Expected Result.....................................................1399
					Results.............................................................1399
				Test Step 4.............................................................1399
					Disconnect the +5V Sensors While Active Diagnostic Codes are Bei....1399
					Expected Result.....................................................1399
					Results.............................................................1399
				Test Step 5.............................................................1400
					Check the Engine Harness............................................1400
					Expected Result.....................................................1400
					Results.............................................................1400
			Air Inlet Heater Circuit - Test.............................................1400
				System Operation Description............................................1400
				Test Step 1.............................................................1400
					Inspect Electrical Connectors and Wiring............................1400
					Expected Result.....................................................1401
					Results.............................................................1401
				Test Step 2.............................................................1401
					Check the Supply to the Power Relay for the Air Inlet Heater Sta....1401
					Expected Result.....................................................1401
					Results.............................................................1401
				Test Step 3.............................................................1402
					Check the Output From the Power Relay for the Air Inlet Heater S....1402
					Expected Result.....................................................1402
					Results.............................................................1402
				Test Step 4.............................................................1402
					Ground the Input to the Power Relay at the MIC......................1402
					Expected Result.....................................................1402
					Results.............................................................1402
				Test Step 5.............................................................1402
					Ground the Input to the Power Relay at the ECM Connector............1402
					Expected Result.....................................................1402
					Results.............................................................1402
				Test Step 6.............................................................1402
					Override the Air Inlet Heater Starting Aid to Test the ECM..........1402
					Results.............................................................1403
			Checking Idle Validation Switching Point (Throttle Sensor) With ............1403
				Expected Result.........................................................1403
			Analog Throttle Position Sensor Circuit - Test..............................1403
				System Operation Description............................................1403
				Checking the Throttle Sensor With Unconnected Output C..................1404
					Expected Result.....................................................1404
				Test Step 1.............................................................1404
					Check for Connector Damage..........................................1404
					Expected Result.....................................................1404
					Results.............................................................1404
				Test Step 2.............................................................1405
					Check for Active Diagnostic Codes...................................1405
					Expected Result.....................................................1405
					Results.............................................................1405
				Test Step 3.............................................................1405
					Check the Throttle Position With the Electronic Service Tool........1405
					Expected Result.....................................................1405
					Results.............................................................1405
				Test Step 4.............................................................1405
					Check the Voltage at the Throttle Position Sensor...................1405
					Expected Result.....................................................1405
					Results.............................................................1405
				Test Step 5.............................................................1406
					Disconnect the Throttle Position Sensor and Check for Active Dia....1406
					Expected Result.....................................................1406
					Results.............................................................1406
				Test Step 6.............................................................1406
					Check the Throttle Selection Status With the Electronic Service ....1406
					Expected Result.....................................................1406
					Results.............................................................1407
				Test Step 7.............................................................1407
					Disconnect the Supply Terminals of the Throttle Position Sensor ....1407
					Expected Result.....................................................1407
					Results.............................................................1407
				Test Step 8.............................................................1407
					Check the Position of Throttle Position Sensor......................1407
					Expected Result.....................................................1408
					Results.............................................................1408
				Test Step 9.............................................................1408
					Check the Throttle Position Sensor at the ECM.......................1408
					Expected Result.....................................................1408
					Results.............................................................1408
			CAN Data Link Circuit - Test................................................1408
				System Operation Description............................................1408
				Test Step 1.............................................................1409
					Inspect Electrical Connectors and Wiring............................1409
					Expected Result.....................................................1409
					Results.............................................................1409
				Test Step 2.............................................................1409
					Check the CAN Data Link Between the ECM and P40 Fuel Injection P....1409
					Expected Result.....................................................1409
					Results.............................................................1409
				Test Step 3.............................................................1409
					Check the CAN Data Link Between the ECM and P40 Fuel Injection P....1409
					Expected Result.....................................................1410
					Results.............................................................1410
				Test Step 4.............................................................1410
					Verify the Supply Voltage at the Fuel Injection Pump................1410
					Expected Result.....................................................1410
					Results.............................................................1410
			Data Link Circuit - Test....................................................1410
				System Operation Description............................................1410
				Background Information..................................................1411
				Communication...........................................................1411
				Test Step 1.............................................................1411
					Inspect Electrical Connectors and Wiring............................1411
					Expected Result.....................................................1411
					Results.............................................................1411
				Test Step 2.............................................................1411
					Determine the Type of Problem With the Data Link....................1411
					Expected Result.....................................................1411
					Results.............................................................1412
				Test Step 3.............................................................1412
					Check the Battery Voltage at the ECM................................1412
					Expected Result.....................................................1412
					Results.............................................................1412
				Test Step 4.............................................................1412
					Check the Battery Voltage That is Coming to the Data Link Connec....1412
					Expected Result.....................................................1413
					Results.............................................................1413
				Test Step 5.............................................................1413
					Connect the Electronic Service Tool Directly to the ECM.............1413
					Expected Result.....................................................1413
					Results.............................................................1413
				Test Step 6.............................................................1413
					Change Electronic Service Tool Components...........................1413
					Expected Result.....................................................1414
					Results.............................................................1414
				Test Step 7.............................................................1414
					Connect an Electronic Service Tool and the ECM to Another Batter....1414
					Expected Result.....................................................1414
					Results.............................................................1414
			Electrical Connectors - Inspect.............................................1414
				System Operation Description............................................1415
				Background Information..................................................1415
				Test Step 1.............................................................1419
					Check the Locking of the DT Connector (Deutsch) and the Lock Rin....1419
					Expected Result.....................................................1419
					Results.............................................................1419
				Test Step 2.............................................................1419
					Check the Socket Head Screw on the Connector for the Electronic ....1419
					Expected Result.....................................................1419
					Results.............................................................1419
				Test Step 3.............................................................1419
					Perform a Pull Test on Each Wire Terminal Connection................1419
					Expected Result.....................................................1419
					Results.............................................................1419
				Test Step 4.............................................................1420
					Monitor the Electronic Service Tool While the Wiring and the Con....1420
					Expected Result.....................................................1420
					Results.............................................................1420
				Test Step 5.............................................................1420
					Check Wires for Nicks and/or Abrasions in the Insulation............1420
					Expected Result.....................................................1420
					Results.............................................................1420
				Test Step 6.............................................................1420
					Check Connectors for Moisture or Corrosion..........................1420
					Expected Result.....................................................1421
					Results.............................................................1421
				Test Step 7.............................................................1421
					Inspect the Connector Terminals.....................................1421
					Expected Result.....................................................1421
					Results.............................................................1421
				Test Step 8.............................................................1422
					Check Individual Pin Retention Into the Socket......................1422
					Expected Result.....................................................1422
					Results.............................................................1422
			Electrical Power Supply Circuit - Test......................................1422
				System Operation Description............................................1422
				Background Information..................................................1422
				Test Step 1.............................................................1424
					Check the Batteries.................................................1424
					Expected Result.....................................................1424
					Results.............................................................1424
				Test Step 2.............................................................1424
					Inspect Electrical Connectors and Wiring............................1424
					Expected Result.....................................................1424
					Results.............................................................1424
				Test Step 3.............................................................1424
					Check the Battery Voltage at the ECM................................1424
					Expected Result.....................................................1425
					Results.............................................................1425
				Test Step 4.............................................................1425
					Use the Bypass Harness for the Electronic Service Tool to Bypass....1425
					Expected Result.....................................................1426
					Results.............................................................1426
			Engine Pressure Sensor Open or Short Circuit - Test.........................1426
				System Operation Description............................................1426
				Background Information..................................................1426
				Test Step 1.............................................................1427
					Check for Active +5V Sensor Supply Diagnostic Codes.................1427
					Expected Result.....................................................1427
					Results.............................................................1427
				Test Step 2.............................................................1427
					Verify All Active Diagnostic Codes..................................1427
					Expected Result.....................................................1427
					Results.............................................................1427
				Test Step 3.............................................................1427
					Inspect Electrical Connectors And Wiring............................1427
					Expected Result.....................................................1428
					Results.............................................................1428
				Test Step 4.............................................................1428
					Verify That the Diagnostic Code is Still Active.....................1428
					Expected Result.....................................................1428
					Results.............................................................1428
				Test Step 5.............................................................1428
					Disconnect the Sensor to Create an Open Circuit.....................1428
					Expected Result.....................................................1429
					Results.............................................................1429
				Test Step 6.............................................................1429
					Measure the Sensor Supply Voltage...................................1429
					Expected Result.....................................................1429
					Results.............................................................1429
				Test Step 7.............................................................1430
					Determine if the Short Circuit is in the Connector or in the Sen....1430
					Expected Result.....................................................1430
					Results.............................................................1430
				Test Step 8.............................................................1430
					Create a Short Circuit Between the Signal and the Common Termina....1430
					Expected Result.....................................................1430
					Results.............................................................1430
				Test Step 9.............................................................1430
					Check the Operation of the ECM by Creating Open and Short Circui....1430
					Expected Result.....................................................1431
					Results.............................................................1431
				Test Step 10............................................................1431
					Bypass the Harness Wiring Between the ECM and the Sensor Connect....1431
					Expected Result.....................................................1431
					Results.............................................................1431
			Engine Speed/Timing Sensor Circuit - Test...................................1432
				System Operation Description............................................1432
				Test Step 1.............................................................1432
					Inspect the Electrical Connectors and Cables........................1432
					Expected Result.....................................................1432
					Results.............................................................1432
				Test Step 2.............................................................1433
					Check the Installation of the Engine Speed/Timing Sensors...........1433
					Expected Result.....................................................1433
					Results.............................................................1433
				Test Step 3.............................................................1433
					Measure the Sensor Resistance Through the Wiring Harness............1433
					Expected Result.....................................................1433
					Results.............................................................1433
				Test Step 4.............................................................1433
					Measure the Resistance of the Sensor................................1433
					Expected Result.....................................................1434
					Results.............................................................1434
				Test Step 5.............................................................1434
					Measure the Resistance of the Cables Between the Fuel Injection ....1434
					Expected Result.....................................................1435
					Results.............................................................1435
				Test Step 6.............................................................1435
					Check the Continuity of the Cables From the ECM to the Fuel Inje....1435
					Expected Result.....................................................1435
					Results.............................................................1435
			Engine Temperature Sensor Open or Short Circuit - Test......................1435
				System Operation Description............................................1435
				Background Information..................................................1435
				Test Step 1.............................................................1436
					Verify All Active Diagnostic Codes..................................1436
					Expected Result.....................................................1436
					Results.............................................................1436
				Test Step 2.............................................................1437
					Inspect Electrical Connectors and Wiring............................1437
					Expected Result.....................................................1437
					Results.............................................................1437
				Test Step 3.............................................................1437
					Verify That the Diagnostic Code is Still Active.....................1437
					Expected Result.....................................................1437
					Results.............................................................1437
				Test Step 4.............................................................1437
					Disconnect the Sensor to Create an Open Circuit.....................1437
					Expected Result.....................................................1438
					Results.............................................................1438
				Test Step 5.............................................................1438
					Create a Short Circuit Between the Signal and the Common Termina....1438
					Expected Result.....................................................1438
					Results.............................................................1438
				Test Step 6.............................................................1438
					Check the Operation of the ECM by Creating an Open and a Short C....1438
					Expected Result.....................................................1439
					Results.............................................................1439
				Test Step 7.............................................................1439
					Bypass the Harness Wiring Between the ECM and the Sensor Connect....1439
					Expected Result.....................................................1439
					Results.............................................................1439
			Fuel Injection Pump Circuit - Test..........................................1440
				System Operation Description............................................1440
				Background Information..................................................1440
				Test Step 1.............................................................1440
					Check the Batteries.................................................1440
					Expected Result.....................................................1440
					Results.............................................................1440
				Test Step 2.............................................................1440
					Inspect the Electrical Connectors and Wiring........................1440
					Expected Result.....................................................1441
					Results.............................................................1441
				Test Step 3.............................................................1441
					Check the Supply Voltage at the Machine Interface Connector.........1441
					Expected Result.....................................................1442
					Results.............................................................1442
				Test Step 4.............................................................1442
					Check the Supply Voltage at the Fuel Injection Pump.................1442
					Expected Result.....................................................1442
					Results.............................................................1442
				Test Step 5.............................................................1442
					Check the Supply to the Power Relay for the Fuel Injection Pump.....1442
					Expected Result.....................................................1442
					Results.............................................................1442
				Test Step 6.............................................................1443
					Check the Output of the Power Relay for the Fuel Injection Pump.....1443
					Expected Result.....................................................1443
					Results.............................................................1443
				Test Step 7.............................................................1443
					Check the Voltage at the Relay Coil for the Fuel Injection Pump.....1443
					Expected Result.....................................................1443
					Results.............................................................1443
				Test Step 8.............................................................1443
					Check the Output of the ECM Fuel Pump Power Control at the Machi....1443
					Expected Result.....................................................1443
					Results.............................................................1444
				Test Step 9.............................................................1444
					Check the Output of the Fuel Injection Pump Power Control at the....1444
					Expected Result.....................................................1444
					Results.............................................................1444
				Test Step 10............................................................1444
					Measure the Voltage at the Pump Power Supply........................1444
					Expected Result.....................................................1444
					Results.............................................................1444
				Test Step 11............................................................1445
					Check the Voltage Load Protection Module (VLPM).....................1445
					Expected Result.....................................................1445
					Results.............................................................1445
			Indicator Lamp Circuit - Test...............................................1445
				System Operation Description............................................1445
				Test Step 1.............................................................1446
					Inspect Electrical Connectors and Wiring............................1446
					Results.............................................................1447
				Test Step 2.............................................................1447
					Inspect the Lamp, the Fuse, and the Power Supply....................1447
					Expected Result.....................................................1447
					Results.............................................................1447
				Test Step 3.............................................................1447
					Inspect the Input to the Lamp at the ECM connector..................1447
					Expected Result.....................................................1447
					Results.............................................................1447
				Test Step 4.............................................................1447
					Test the Individual Lamp Circuits...................................1447
					Expected Result.....................................................1447
					Results.............................................................1447
				Test Step 5.............................................................1448
					Check the Voltage at the ECM........................................1448
					Expected Result.....................................................1448
					Results.............................................................1448
			Idle Validation Circuit - Test..............................................1448
				System Operation Description............................................1448
				Test Step 1.............................................................1448
					Expected Result.....................................................1448
					Results.............................................................1448
	tables..............................................................................1297
		Table 1. Electronic Service Tool................................................1323
		Table 2. Optional Service Tools.................................................1324
		Table 3. CID FMI Codes and J Code FMI Codes.....................................1325
		Table 4. Event Codes and CID FMI Codes..........................................1327
		Table 5. CID Numbers and Flash Codes............................................1328
		Table 6. Engine Connectors......................................................1336
		Table 7. Color Codes for the Harness Wire.......................................1340
		Table 8. Pin Connections for Perkins Deutsch Socket Connector...................1342
		Table 9. Suspect Parameter Numbers..............................................1346
		Table 10. Failure Mode Indicators (FMI) Codes...................................1347
		Table 11. Engine Oil Pressure Trip and Reset Points.............................1392

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