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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