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Hyster F007 Service Manual – PDF DOWNLOAD
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Description
Hyster F007 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F007 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 Service Manual – PDF DOWNLOAD
897934-0700SRM0626-(11-2001)-US-EN...................................................... 1 toc................................................................................. 1 Cooling System.................................................................. 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 6 Radiator.................................................................... 6 Radiator Cap................................................................ 6 Thermostat.................................................................. 6 Water Pump.................................................................. 7 Fan and Fan Shroud.......................................................... 7 Cooling System Checks........................................................... 7 Radiator.................................................................... 7 Thermostat.................................................................. 7 Water Pump.................................................................. 8 Exhaust Leaks............................................................... 8 Fan and Fan Shroud.......................................................... 8 Radiator Cleaning............................................................... 8 Drain....................................................................... 8 Clean....................................................................... 8 Fill........................................................................ 9 Troubleshooting................................................................. 10 1494142-1900SRM0938-(09-2003)-US-EN..................................................... 13 toc................................................................................. 13 Hydraulic System................................................................ 13 Safety Precautions Maintenance and Repair....................................... 14 General......................................................................... 17 Description and Operation....................................................... 17 Hydraulic Pump.............................................................. 17 Main Control Valve.......................................................... 17 Steering Control Unit....................................................... 18 Pilot Block................................................................. 18 Tilt Relief Valve........................................................... 18 Hydraulic Pump Repair........................................................... 18 Remove...................................................................... 18 Disassemble................................................................. 19 Clean and Inspect........................................................... 19 Assemble.................................................................... 19 Install..................................................................... 19 Priority Valve Repair........................................................... 21 Remove...................................................................... 21 Install..................................................................... 21 Pilot Valve Repair.............................................................. 22 Remove...................................................................... 22 Disassemble................................................................. 23 Clean and Inspect........................................................... 23 Assemble.................................................................... 23 Install..................................................................... 23 Control Levers and Joystick Repair.............................................. 24 Remove...................................................................... 24 Install..................................................................... 24 Pump Output Check............................................................... 24 First Method................................................................ 24 Second Method............................................................... 25 Steering Relief Pressure Check and Adjustment................................... 26 Calibration Procedure for Hydraulic Controls.................................... 27 General and Calibration Startup............................................. 27 Joystick/Lever Calibration.................................................. 29 Levers.................................................................. 29 Joystick................................................................ 30 Valve Flow Adjustment....................................................... 30 PWM Board Readouts/PV3 Readouts............................................. 31 I/O Board Readouts.......................................................... 31 Diagnostics................................................................. 32 Calibration System Shutdown................................................. 32 Diagnostics..................................................................... 32 Specifications.................................................................. 36 Troubleshooting................................................................. 36 Lift, Lower, Tilt, and Attachment Circuits (Also see Main Contro............ 37 Steering Circuit (Also see Steering System 1600 SRM 936 )................... 38 tables.............................................................................. 13 Table 1. Error Code Display..................................................... 32 Table 2. Altering PT FLT (Old Logic)............................................ 34 Table 3. Altering PT FLT (New Logic)............................................ 34 Table 4. Fixed PT Logic......................................................... 35 Table 5. ECH.................................................................... 35 1494146-8000SRM0941-(01-2004)-US........................................................ 49 toc................................................................................. 49 Diagrams........................................................................ 49 Safety Precautions Maintenance and Repair....................................... 50 General......................................................................... 53 Description..................................................................... 53 1494146-8000SRM0941-(01-2006)-US-EN.....................................................111 toc.................................................................................111 Diagrams........................................................................111 Safety Precautions Maintenance and Repair.......................................112 General.........................................................................115 Description.....................................................................115 1494953-1400SRM0944-(03-2007)-US-EN.....................................................173 toc.................................................................................173 Planetary Drive Axle............................................................173 Safety Precautions Maintenance and Repair.......................................174 General.........................................................................177 Description.....................................................................177 Operation.......................................................................179 Identification..............................................................179 Removal.........................................................................180 Disassembly.....................................................................180 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............180 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............182 Wheel End...................................................................184 Spindle and Piston Housing..................................................185 Cleaning........................................................................186 Clean Ground or Polished Parts..............................................186 Clean Parts With Rough Finish...............................................186 Clean Axle Assemblies.......................................................186 Drying Cleaned Parts........................................................186 Corrosion Prevention............................................................186 Parts Inspection................................................................187 Tapered Roller Bearings.....................................................187 Bevel Pinion and Ring Gear Sets.............................................188 Main Differential Assembly..................................................188 Axle Shafts.................................................................188 Yoke........................................................................188 Brakes......................................................................188 Repair or Replace Parts.....................................................188 Repair Welding..............................................................188 Apply Silicone Gasket Material..............................................189 Assembly........................................................................189 Spindle and Piston Housing to Axle Housing..................................189 Wet Disc Brakes.............................................................190 Adjust Wheel Bearing Preload................................................191 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............192 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD............193 Planetary Spider Assembly...................................................193 Installation....................................................................194 Fill Wet Disc Brakes With Hydraulic Fluid...................................194 Torque Specifications...........................................................195 Lubrication Specification.......................................................196 1498450-1800SRM0951-(03-2007)-US-EN.....................................................199 toc.................................................................................199 Wet Brake System................................................................199 Safety Precautions Maintenance and Repair.......................................200 General.........................................................................203 Description and Operation.......................................................203 Service Brakes..............................................................203 Parking Brake...............................................................203 Oil Cooler Circuit..........................................................203 Pressure Switch Replacement.....................................................207 Accumulators Replacement........................................................207 Brake Treadle Valve Repair......................................................207 Remove and Disassemble......................................................207 Clean and Inspect...........................................................208 Assemble and Install........................................................208 Parking Brake Valve Repair......................................................208 Remove......................................................................208 Clean and Inspect...........................................................208 Repair......................................................................208 Install.....................................................................208 Parking Brake Caliper Repair....................................................209 Remove......................................................................209 Disassemble.................................................................211 Inspect.....................................................................211 Install.....................................................................211 Adjust......................................................................211 Brake Pad Repair................................................................212 Inspect.....................................................................212 Remove......................................................................212 Install.....................................................................212 Seals Repair....................................................................212 Remove......................................................................212 Install.....................................................................213 Service Brake Repair............................................................213 Remove and Disassemble......................................................213 Drain Lubricating Oil...................................................213 Drain Coolant Oil.......................................................220 Disconnect Brake Lines..................................................220 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14.........220 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H........221 Brake Disc Housing Assembly Wheel End...................................222 Brake Piston Housing....................................................223 Brake Piston Housing and Wheel Spindle..................................224 Inspect.....................................................................224 Clean.......................................................................226 Assemble....................................................................227 Wheel Spindle...........................................................227 Brake Piston Housing....................................................227 Piston Assembly.........................................................229 Brake Disc Housing......................................................229 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub.................231 Check for Correct Installation of Duo-Cone Seal.........................232 Wheel Hub to Brake Disc Housing.........................................233 Adjust......................................................................234 Fill Brake System With Coolant Oil......................................234 System Air Removal......................................................235 Adjust Brake With New Disc Pack.........................................235 Coolant Change Intervals................................................236 Coolant Draining and Filling............................................236 Specifications..................................................................238 Minimum Brake Disc Thickness................................................241 Hydraulic Fluid for Brake Actuation.........................................241 Brake Coolant Specifications................................................241 Coolant Change Intervals....................................................241 Hydraulic Fluid Specifications..............................................241 Troubleshooting.................................................................241 Brake Does Not Apply........................................................241 Brake Does Not Release......................................................242 Brake Performance...........................................................242 Brake Leaks Actuation Fluid.................................................243 Brake Cooling Fluid Leakage.................................................244 Brake Noise and Vibration...................................................244 Brake Overheats.............................................................244 tables..............................................................................199 Table 1. Brake Pad Adjustment...................................................211 Table 2. Minimum Brake Disc Thickness...........................................225 Table 3. Formed Seal Wear Chart.................................................225 1556600-1300SRM1082-(01-2004)-US........................................................249 toc.................................................................................249 Transmission....................................................................249 Safety Precautions Maintenance and Repair.......................................250 Description of Operation........................................................253 General.....................................................................253 Torque Converter, Pump Drive, and Pressure Regulating Valve.................253 Input Shaft and Directional Clutches........................................253 Range Clutches..............................................................255 Output Section..............................................................255 Transmission Controls.......................................................256 Operation of the Valve..................................................256 Selection of Range......................................................256 Pressure Switch.........................................................256 Electric Solenoid Controls..................................................258 Transmission Specifications.................................................278 Transmission Identification.............................................278 Weight, Dimensions, and Oil Capacity....................................278 Transmission Repair.............................................................279 Remove......................................................................279 Disassemble.................................................................282 Transmission Case, Disassemble..........................................282 Torque Converter Housing, Disassemble...................................300 Forward Clutch, Disassemble.............................................305 First-Speed Clutch, Disassemble.........................................307 Reverse and Second-Speed Clutch.........................................312 Reverse Clutch, Disassemble.........................................312 Second-Speed Clutch, Disassemble....................................317 Third-Speed Clutch, Disassemble.........................................319 Third Clutch Shaft, Disassemble.........................................321 Turbine Shaft, Disassemble..............................................322 Output Shaft, Disassemble...............................................323 Impeller, Disassemble...................................................324 Turbine, Disassemble....................................................326 Clean and Inspect...........................................................328 Housings................................................................328 Oil Seals and Gaskets...................................................328 Bearings................................................................329 Gears and Shafts........................................................329 Assemble....................................................................329 Turbine, Assemble.......................................................329 Impeller, Assemble......................................................331 Output Shaft, Assemble..................................................333 Turbine Shaft, Assemble.................................................335 Third Clutch Shaft, Assemble............................................336 Third-Speed Clutch, Assemble............................................337 Reverse and Second-Speed Clutch.........................................339 Second-Speed Clutch, Assemble.......................................339 Reverse Clutch, Assemble............................................342 First-Speed Clutch, Assemble............................................346 Forward Clutch, Assemble................................................351 Torque Converter Housing, Assemble......................................354 Transmission Case, Assemble.............................................359 Install.....................................................................380 Control Valve Repair............................................................382 Remove......................................................................382 Disassemble and Assemble....................................................382 Clean and Inspect...........................................................384 Housings................................................................384 Oil Seals and Gaskets...................................................384 Install.....................................................................385 Stall Test......................................................................386 Transmission Calibration and Troubleshooting....................................386 Calibration.................................................................386 Clutch Filling Calibration..................................................386 Purpose.................................................................386 Clutch Filling Calibration Procedure....................................387 Heat-up Mode............................................................387 Alternative Clutch Filling Calibration..................................387 Inching Pedal Calibration...................................................388 Purpose.................................................................388 Inching Pedal Calibration Procedure.....................................388 Troubleshooting.............................................................388 Transmission Oil Pressure Check.................................................388 Pressure and Temperature Specifications.....................................388 Electrical Specifications.......................................................392 Hydraulic Cooler Lines Specifications...........................................392 Torque Specifications...........................................................393 Torque Specifications for Lubricated or Plated Screw Threads................393 tables..............................................................................249 Table 1. Temperature Sensor (In Speed Sensor) Resistance Versus ................392 Table 2. Grade 5................................................................393 Table 3. Grade 8................................................................393 Table 4. Grades 8.8, 10.9, and 12.9.............................................394 Table 5. O-ring Port Plug Torque Chart..........................................395 Table 6. Pipe Plug Torque Chart.................................................395 1556604-8000SRM1103-(07-2004)-US-EN.....................................................399 toc.................................................................................399 Diagrams........................................................................399 Safety Precautions Maintenance and Repair.......................................400 1566673-0600SRM1158-(06-2005)-US-EN.....................................................439 toc.................................................................................439 Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...................439 Safety Precautions Maintenance and Repair.......................................440 Electronic Troubleshooting......................................................463 System Operation............................................................463 Electronic Controls.........................................................463 Engine Governor.............................................................464 Timing Considerations.......................................................464 Fuel Injection..............................................................464 Diagnostic Codes............................................................464 Diagnostic Fault Codes......................................................464 Diagnostic Event Codes......................................................464 Programmable Parameters.....................................................465 Passwords...................................................................465 Electronic Service Tools....................................................465 Electronic Service Tool (EST)...............................................465 Connecting the Electronic Service Tool and the Communication Ada........465 Support for the Electronic Service Tool.................................466 Optional Service Tools..................................................466 Diagnostic Codes............................................................466 Engine Display Warning Codes................................................470 Access..................................................................470 Exit....................................................................470 Clear...................................................................470 Replacing the ECM...........................................................472 Self Diagnostics............................................................473 Glossary........................................................................474 Sensors and Electrical Connectors...............................................477 Engine Wiring Information.......................................................480 Harness Wire Identification.................................................484 Diagnostic Code Reader..........................................................484 General.....................................................................484 Reference Documents.........................................................484 Abbreviations...............................................................484 Environmental Specification.................................................484 Hardware....................................................................485 Connection Cable........................................................486 Software....................................................................486 Engine Communication....................................................486 User Controls...............................................................486 Power Supply............................................................486 Display Screen..........................................................486 Operation Controls......................................................486 Audible Warning.........................................................487 Operation Instructions......................................................487 How to Connect the Diagnostic Code Reader to the Engine.................487 How to Turn ON the Diagnostic Code Reader...............................487 How to use the Display Screen...........................................487 How to Operate the Diagnostic Code Reader...............................488 Main Menu...........................................................488 Active Codes........................................................488 Inactive Codes......................................................488 How to Clear Codes..................................................489 Status Lamp.........................................................489 Data List...........................................................490 Diagnostics.................................................................490 Programming Parameters..........................................................491 Passwords...................................................................491 Factory Passwords...........................................................491 Customer Passwords..........................................................492 Flash Programming...........................................................492 Flash Programming a Personality Module......................................492 WinFlash Error Messages.....................................................492 System Configuration Parameters.................................................493 Full Load Setting...........................................................493 Full Torque Setting.........................................................493 Rating Interlock............................................................493 Engine Serial Number........................................................493 ECM Software Release Date...................................................493 Troubleshooting Without A Diagnostic Code.......................................494 Alternator Noise (Noisy Operation)..........................................494 Probable Causes.........................................................494 Recommended Actions.....................................................494 Alternator Drive Belts..............................................494 Alternator Drive Pulley.............................................494 Alternator Bearings.................................................494 Alternator Will Not Charge (Charging Problem)...............................494 Probable Causes.........................................................494 Recommended Actions.....................................................494 Alternator Drive Belts..............................................494 Charging Circuit....................................................494 Alternator or Regulator.............................................494 Battery.....................................................................494 Probable Causes.........................................................494 Recommended Actions.....................................................494 Faulty Battery......................................................494 Auxiliary Device....................................................494 Cannot Reach Top Engine RPM.................................................494 Probable Causes.........................................................495 Recommended Actions.....................................................495 Diagnostic Codes....................................................495 Fuel Supply.........................................................495 Air Intake and Exhaust System.......................................495 Individual Malfunctioning Cylinders.................................495 Valve Lash..........................................................495 Check for Low Compression...........................................495 Check the Fuel Injection Nozzles....................................496 Check the Turbocharger..............................................496 ECM Parameters......................................................496 Check the Signal for the Throttle Position Sensor...................496 Coolant in Engine Oil.......................................................496 Probable Causes.........................................................496 Recommended Actions.....................................................496 Engine Oil Cooler Core..............................................496 Cylinder Head Gasket................................................496 Cylinder Head.......................................................497 Cylinder Block......................................................497 Coolant Temperature Is Too High.............................................497 Probable Causes.........................................................497 Recommended Actions.....................................................497 Radiator Fins.......................................................497 Coolant Level.......................................................497 Radiator Cap and/or Pressure Relief Valve...........................497 Combustion Gases in the Cooling System..............................497 Water Temperature Regulator.........................................497 Restriction in the Coolant System...................................497 Coolant Temperature Gauge...........................................497 Coolant Pump........................................................497 Excessive Load on the System........................................497 ECM Will Not Accept Factory Passwords.......................................498 Probable Causes.........................................................498 Recommended Actions.....................................................498 ECM Will Not Communicate With Other Systems or Display Modules..............498 Probable Causes.........................................................498 Recommended Actions.....................................................498 Electronic Service Tool Will Not Communicate With ECM.......................498 Probable Causes.........................................................498 Recommended Actions.....................................................498 Engine Cranks but Will Not Start............................................499 Probable Causes.........................................................499 Recommended Actions.....................................................499 Diagnostic Codes....................................................499 Visual Checks.......................................................499 Crank Without Injection.............................................499 Starting Motor Solenoid or Starting Circuit.........................499 Valve Lash..........................................................499 Fuel Injection Nozzles..............................................499 Air Inlet Heater Starting Aid.......................................500 Air Intake and Exhaust System.......................................500 Low Compression.....................................................500 Fuel Supply.........................................................500 Engine Has Early Wear.......................................................500 Probable Causes.........................................................500 Recommended Actions.....................................................500 Dirt in Engine Oil..................................................500 Leaks in Air Intake System..........................................500 Low Oil Pressure....................................................500 Engine Misfires, Runs Rough or Is Unstable..................................501 Probable Causes.........................................................501 Recommended Actions.....................................................501 Logged Codes........................................................501 Fuel Supply.........................................................501 Air Intake and Exhaust System.......................................501 Individual Malfunctioning Cylinders.................................501 Valve Lash..........................................................501 Check for Low Compression...........................................501 Check the Fuel Injection Nozzles....................................502 Check the Air Inlet Heater Starting Aid.............................502 Check the Engine Speed/Timing Sensors...............................502 Check the Signal for the Throttle Position Sensor...................502 Check the Fuel Injection Pump.......................................502 Engine Oil in Cooling System................................................502 Probable Causes.........................................................502 Recommended Actions.....................................................502 Engine Oil Cooler Core..............................................502 Cylinder Head Gasket................................................503 Cylinder Head.......................................................503 Engine Speed Does Not Change................................................503 Probable Causes.........................................................503 Recommended Repairs.....................................................503 Diagnostic Codes....................................................503 Engine Stalls at Low RPM....................................................503 Probable Causes.........................................................503 Recommended Actions.....................................................503 Diagnostic Codes....................................................503 Fuel Injection Nozzles..............................................503 Fuel Supply.........................................................503 Accessory Equipment.................................................504 Power Mode Control..................................................504 Engine Vibration............................................................504 Probable Causes.........................................................504 Recommended Actions.....................................................504 Engine Supports.....................................................504 Malfunctioning Individual Cylinder..................................504 Valve Lash..........................................................504 Check for Low Compression (cylinder pressure).......................504 Check the Fuel Injection Nozzles....................................504 Turbocharger........................................................505 Engine Will Not Crank.......................................................505 Probable Causes.........................................................505 Recommended Repairs.....................................................505 Machine Security System.............................................505 Battery Cables and/or Batteries.....................................505 Starting Motor Solenoid or Starting Circuit.........................505 Starting Motor and/or Flywheel Ring Gear............................505 Electrical Power Supply.............................................505 Internal Engine Problem.............................................505 Excessive Black Smoke.......................................................505 Probable Causes.........................................................505 Recommended Actions.....................................................506 Air Intake System or Exhaust System.................................506 Individual Malfunctioning Cylinder..................................506 Valve Lash..........................................................506 Low Compression (cylinder pressure).................................506 Check the Fuel Injection Nozzles....................................506 Check the Turbocharger..............................................506 Broken 5-Volt Supply Wire...........................................507 Verifying the ECM Software..........................................507 Excessive Engine Oil Consumption............................................507 Probable Causes.........................................................507 Recommended Actions.....................................................507 Oil Level...........................................................507 Engine Crankcase Breather...........................................507 Air Intake and Exhaust System.......................................507 Turbocharger........................................................507 Low Compression (cylinder pressure).................................507 Excessive Valve Lash........................................................508 Probable Causes.........................................................508 Recommended Actions.....................................................508 Lubrication.........................................................508 Valve Lash..........................................................508 Valve Train Components..............................................508 Excessive White Smoke.......................................................508 Probable Causes.........................................................508 Recommended Actions.....................................................508 Fuel Supply.........................................................508 Individual Malfunctioning Cylinder..................................509 Valve Lash..........................................................509 Low Compression (cylinder pressure).................................509 Air Inlet Heater Starting Aid.......................................509 Fuel Injection Nozzles..............................................509 Coolant Temperature Sensor Circuit..................................509 Engine Pressure Sensors.............................................509 Intake Air Temperature Is Too High..........................................509 Probable Causes.........................................................509 Recommended Repairs.....................................................509 High Ambient Air Temperature........................................509 Coolant Temperature.................................................509 Check for High Intake Air Restriction and/or High Altitude..........510 Intake Air Restriction..............................................510 High Altitude.......................................................510 Check the Intake Manifold Air Temperature Sensor and/or the Circ....510 Check for Sufficient Coolant Flow Through the Aftercooler (if eq....510 Check for Sufficient Flow of Air Through the Aftercooler (if equ....510 Intermittent Engine Shutdown................................................510 Probable Causes.........................................................510 Recommended Actions.....................................................510 Logged Codes........................................................510 Fuel Supply.........................................................510 Engine Protection Device............................................510 Electrical Connectors...............................................511 Intermittent Low Power or Power Cutout......................................511 Probable Causes.........................................................511 Recommended Repairs.....................................................511 Diagnostic Codes....................................................511 Electrical Connectors...............................................511 Fuel Supply.........................................................511 Check the Intake Manifold Pressure..................................512 Air Intake and Exhaust System.......................................512 Individual Malfunctioning Cylinders.................................512 Valve Lash..........................................................512 Check for Low Compression...........................................512 Check the Fuel Injection Nozzles....................................512 Check the Turbocharger..............................................512 ECM Parameters......................................................513 Electronic System Problem...........................................513 Low Engine Oil Pressure.....................................................513 Probable Causes.........................................................513 Recommended Actions.....................................................513 Engine Oil Level....................................................513 Engine Oil Pressure Gauge...........................................513 Engine Oil Bypass Valves............................................513 Piston Cooling Jets ................................................514 Engine Oil Suction Tube.............................................514 Engine Oil Pump.....................................................514 Bearing Clearance...................................................514 Low Power/Poor or No Response to Throttle...................................514 Probable Causes.........................................................514 Recommended Actions.....................................................514 Diagnostic Codes....................................................514 Fuel Supply.........................................................514 Air Intake and Exhaust System.......................................514 Individual Malfunctioning Cylinders.................................515 Valve Lash..........................................................515 Check for Low Compression...........................................515 Check the Fuel Injection Nozzles....................................515 Check the Turbocharger..............................................515 ECM Parameters......................................................515 Electronic System Problem...........................................516 Mechanical Noise (Knock) in Engine..........................................516 Probable Causes.........................................................516 Recommended Actions.....................................................516 Accessory Equipment.................................................516 Valve Train Components..............................................516 Connecting Rod and Main Bearings....................................516 Noise Coming from Cylinder..................................................516 Probable Causes.........................................................516 Recommended Actions.....................................................516 Fuel Quality........................................................516 Fuel Injection Nozzles..............................................516 Valve Lash..........................................................516 Poor Acceleration or Response...............................................517 Probable Causes.........................................................517 Recommended Repairs.....................................................517 Diagnostic Codes....................................................517 Fuel Supply.........................................................517 Individual Malfunctioning Cylinder..................................517 Valve Lash..........................................................517 Check for Low Compression...........................................517 Check the Fuel Injection Nozzles....................................517 Check the Turbocharger..............................................518 ECM Parameters......................................................518 Check Intake Manifold Pressure......................................518 Troubleshooting With a Diagnostic Code..........................................518 CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal............518 Conditions Which Generate This Code.....................................518 System Response.........................................................518 Possible Performance Effect.............................................518 Troubleshooting.........................................................518 Results.................................................................518 CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent............518 Conditions Which Generate This Code.....................................518 System Response.........................................................519 Possible Performance Effect.............................................519 Troubleshooting.........................................................519 Test Step 1.............................................................519 Results.................................................................519 CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted............519 Conditions Which Generate This Code.....................................519 System Response.........................................................519 Possible Performance Effect.............................................519 CID 0091 FMI 04 Throttle Position Sensor Shorted Low........................519 Conditions Which Generate This Code.....................................519 System Response.........................................................519 Possible Performance Effect.............................................519 Troubleshooting.........................................................519 Results.................................................................519 CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal....................519 Conditions Which Generate This Code.....................................519 System Response.........................................................519 Troubleshooting.........................................................520 Results.................................................................520 CID 0091 FMI 12 Throttle Position Sensor Out of Calibration.................520 Conditions Which Generate This Code.....................................520 Possible Performance Effect.............................................520 Troubleshooting.........................................................520 Results.................................................................520 CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short............520 Conditions Which Generate This Code.....................................520 System Response.........................................................520 Troubleshooting.........................................................520 Results.................................................................520 CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low......................520 Conditions Which Generate This Code.....................................520 System Response.........................................................520 Troubleshooting.........................................................520 Results.................................................................520 CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci............521 Conditions Which Generate This Code.....................................521 System Response.........................................................521 Possible Performance Effect.............................................521 Results.................................................................521 CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or............521 Conditions Which Generate This Code.....................................521 System Response.........................................................521 Possible Performance Effect.............................................521 Results.................................................................521 CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low.................521 Conditions Which Generate This Code.....................................521 System Response.........................................................521 Possible Performance Effect.............................................521 Results.................................................................521 CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope............522 Conditions Which Generate This Code.....................................522 System Response.........................................................522 Results.................................................................522 CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ............522 Conditions Which Generate This Code.....................................522 System Response.........................................................522 Possible Performance Effect.............................................522 Troubleshooting.........................................................522 Results.................................................................522 CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low..............522 Conditions Which Generate This Code.....................................522 System Response.........................................................522 Possible Performance Effect.............................................522 Troubleshooting.........................................................522 Results.................................................................522 CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o............522 Conditions Which Generate This Code.....................................522 System Response.........................................................523 Possible Performance Effect.............................................523 Troubleshooting.........................................................523 Results.................................................................523 CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...............523 Conditions Which Generate This Code.....................................523 System Response.........................................................523 Possible Performance Effect.............................................523 Troubleshooting.........................................................523 Results.................................................................523 CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...............523 Conditions Which Generate This Code.....................................523 System Response.........................................................523 Possible Performance Effect.............................................523 Troubleshooting.........................................................523 Results.................................................................523 CID 0247 FMI 09 J1939 Datalink, Abnormal Update.............................524 Conditions Which Generate This Code.....................................524 System Response.........................................................524 Results.................................................................524 CID 0253 FMI 02 Incorrect ECM Software......................................524 Conditions Which Generate This Code.....................................524 System Response.........................................................524 Possible Performance Effect.............................................524 Troubleshooting.........................................................524 Expected Result.........................................................524 Results.................................................................524 CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal............524 Conditions Which Generate This Code.....................................524 System Response.........................................................524 Possible Performance Effect.............................................524 Troubleshooting.........................................................524 Results.................................................................524 CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal............525 Conditions Which Generate This Code.....................................525 System Response.........................................................525 Possible Performance Effect.............................................525 Troubleshooting.........................................................525 Results.................................................................525 CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs.......................525 Conditions Which Generate This Code.....................................525 System Response.........................................................525 Possible Performance Effect.............................................525 CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig............525 Conditions Which Generate This Code.....................................525 System Response.........................................................525 Possible Performance Effect.............................................525 Results.................................................................525 CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal......................525 Conditions Which Generate This Code.....................................525 System Response.........................................................525 Possible Performance Effect.............................................525 Results.................................................................526 CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa............526 Conditions Which Generate This Code.....................................526 System Response.........................................................526 Possible Performance Effect.............................................526 Test Step 1.............................................................526 Results.................................................................526 Test Step 2.............................................................526 Results.................................................................526 CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm............526 Conditions Which Generate This Code.....................................526 System Response.........................................................526 Possible Performance Effect.............................................526 Results.................................................................526 CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S............526 Conditions Which Generate This Code.....................................526 System Response.........................................................527 Possible Performance Effect.............................................527 Troubleshooting.........................................................527 Results.................................................................527 CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low..................527 Conditions Which Generate This Code.....................................527 System Response.........................................................527 Possible Performance Effect.............................................527 Troubleshooting.........................................................527 Results.................................................................527 CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal..............527 Conditions Which Generate This Code.....................................527 System Response.........................................................527 Possible Performance Effect.............................................527 Results.................................................................527 CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio............527 Conditions Which Generate This Code.....................................527 System Response.........................................................527 Possible Performance Effect.............................................527 Results.................................................................527 CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off..................528 Conditions Which Generate This Code.....................................528 System Response.........................................................528 Possible Performance Effect.............................................528 Results.................................................................528 CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ............528 Conditions Which Generate This Code.....................................528 System Response.........................................................528 Possible Performance Effect.............................................528 Test Step 1.............................................................528 Results.................................................................528 Test Step 2.............................................................528 Results.................................................................528 CID 1684 FMI 02 Fuel Injection Pump, Software Failure.......................528 Conditions Which Generate This Code.....................................528 System Response.........................................................528 Possible Performance Effect.............................................528 Troubleshooting.........................................................528 Results.................................................................529 CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault..........................529 Conditions Which Generate This Code.....................................529 System Response.........................................................529 Possible Performance Effect.............................................529 Troubleshooting.........................................................529 Results.................................................................529 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...................529 Conditions Which Generate This Code.....................................529 System Response.........................................................529 Possible Performance Effect.............................................529 Troubleshooting.........................................................529 Results.................................................................529 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width....................529 Conditions Which Generate This Code.....................................529 Troubleshooting.........................................................529 Results.................................................................530 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault.......................530 Conditions Which Generate This Code.....................................530 System Response.........................................................530 Possible Performance Effect.............................................530 Troubleshooting.........................................................530 Results.................................................................530 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault.............530 Conditions Which Generate This Code.....................................530 System Response.........................................................530 Possible Performance Effect.............................................530 Troubleshooting.........................................................530 Test Step 1.............................................................530 Results.................................................................530 Test Step 2.............................................................530 Results.................................................................530 Test Step 3.............................................................530 Results.................................................................531 Test Step 4.............................................................531 Expected Result.........................................................531 Results.................................................................531 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault..............................531 Conditions Which Generate This Code.....................................531 System Response.........................................................531 Possible Performance Effect.............................................531 Troubleshooting.........................................................531 Expected Result.........................................................531 Results.................................................................531 CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error..............531 Conditions Which Generate This Code.....................................531 System Response.........................................................531 Troubleshooting.........................................................531 Test Step 1.............................................................531 Results.................................................................532 Test Step 2.............................................................532 Results.................................................................532 Test Step 3.............................................................532 Results.................................................................532 CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault..................532 Conditions Which Generate This Code.....................................532 System Response.........................................................532 Possible Performance Effect.............................................532 Troubleshooting.........................................................532 Test Step 1.............................................................532 Results.................................................................532 Test Step 2.............................................................532 Results.................................................................532 CID 1684 FMI 14 Fuel Injection Pump, No Communications......................532 Conditions Which Generate This Code.....................................532 System Response.........................................................532 Troubleshooting.........................................................532 Test Step 1.............................................................532 Results.................................................................532 Test Step 2.............................................................533 Results.................................................................533 Test Step 3.............................................................533 Results.................................................................533 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali............533 Conditions Which Generate This Code.....................................533 System Response.........................................................533 Possible Performance Effect.............................................533 Troubleshooting.........................................................533 Results.................................................................533 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali............533 Conditions Which Generate This Code.....................................533 System Response.........................................................533 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S............533 Conditions Which Generate This Code.....................................533 System Response.........................................................533 Troubleshooting With an Event Code..............................................534 Event Codes.................................................................534 Programmable Engine Parameters..............................................534 E015 High Engine Coolant Temperature Derate.................................534 Conditions Which Generate This Code.....................................534 System Response.........................................................534 Possible Performance Effect.............................................534 Troubleshooting.........................................................534 Results.................................................................534 E016 High Engine Coolant Temperature Shutdown...............................534 Conditions Which Generate This Code.....................................534 System Response.........................................................534 Possible Performance Effect.............................................534 Troubleshooting.........................................................534 Results.................................................................534 E017 High Engine Coolant Temperature Warning................................534 Conditions Which Generate This Code.....................................534 System Response.........................................................534 Possible Performance Effect.............................................534 Troubleshooting.........................................................534 Results.................................................................534 E025 High Intake Air Temperature Derate.....................................535 Conditions Which Generate This Code.....................................535 System Response.........................................................535 Possible Performance Effect.............................................535 Troubleshooting.........................................................535 Results.................................................................535 E027 High Intake Air Temperature Warning....................................535 Conditions Which Generate This Code:....................................535 System Response.........................................................535 Possible Performance Effect.............................................535 Troubleshooting.........................................................535 Results.................................................................535 E040 Low Engine Oil Pressure Shutdown.......................................535 Conditions Which Generate This Code.....................................535 System Response.........................................................535 Possible Performance Effect.............................................535 Troubleshooting.........................................................535 Results.................................................................535 E054 High Fuel Temperature Derate...........................................536 Conditions Which Generate This Code.....................................536 System Response.........................................................536 Troubleshooting.........................................................536 Test Step 1 - Check for Diagnostic Codes................................536 Expected Result.........................................................536 Results.................................................................536 Test Step 2 - Perform a Check of the Fuel System........................536 Expected Result.........................................................536 Results.................................................................536 E056 High Fuel Temperature Warning..........................................536 Conditions Which Generate This Code.....................................536 System Response.........................................................536 Troubleshooting.........................................................536 Test Step 1 - Check for Diagnostic Codes................................536 Expected Result.........................................................536 Results.................................................................537 Test Step 2 - Perform a Check of the Fuel System........................537 Expected Result.........................................................537 Results.................................................................537 E100 Low Engine Oil Pressure Warning........................................537 Conditions Which Generate This Code.....................................537 System Response.........................................................537 Possible Performance Effect.............................................537 Troubleshooting.........................................................537 Test Step 1 - Check for Active Diagnostic Codes.........................537 Expected Result.........................................................537 Results.................................................................537 Test Step 2 - Perform a Check of the Engine Lubrication System..........537 Expected Result.........................................................537 Results.................................................................537 E190 Engine Overspeed Warning...............................................538 Conditions Which Generate This Code.....................................538 System Response.........................................................538 Possible Performance Effect.............................................538 Troubleshooting.........................................................538 Engine Overspeed Warning................................................538 Expected Result.........................................................538 Results.................................................................538 E442 Engine Failed to Stop With a No-Fuel Command...........................538 Conditions Which Generate This Code.....................................538 System Response.........................................................538 Possible Performance Effect.............................................538 Troubleshooting.........................................................538 Test Step 1.............................................................538 Results.................................................................538 Test Step 2.............................................................538 Results.................................................................538 E883 Engine Failed to Stop When Fuel Solenoid Disengaged....................538 Conditions Which Generate This Code.....................................538 System Response.........................................................538 Possible Performance Effect.............................................539 Troubleshooting.........................................................539 Test Step 1.............................................................539 Results.................................................................539 Test Step 2.............................................................539 Results.................................................................539 Test Step 3.............................................................539 Results.................................................................539 Diagnostic Function Tests.......................................................539 5-Volt Engine Pressure Sensor Supply Circuit - Test.........................539 System Operation Description............................................539 Background Information..................................................539 Test Step 1.............................................................540 Inspect Electrical Connectors and Wiring............................540 Expected Result.....................................................540 Results.............................................................541 Test Step 2.............................................................541 Check for Active Diagnostic Codes...................................541 Expected Result.....................................................541 Results.............................................................541 Test Step 3.............................................................541 Disconnect the ECM Engine Harness Connector From the ECM............541 Expected Result.....................................................542 Results.............................................................542 Test Step 4.............................................................542 Disconnect the +5V Sensors While Active Diagnostic Codes are Bei....542 Expected Result.....................................................543 Results.............................................................543 Test Step 5.............................................................543 Check the Engine Harness............................................543 Expected Result.....................................................543 Results.............................................................543 Air Inlet Heater Circuit - Test.............................................543 System Operation Description............................................543 Test Step 1.............................................................544 Inspect Electrical Connectors and Wiring............................544 Expected Result.....................................................544 Results.............................................................544 Test Step 2.............................................................544 Check the Supply to the Power Relay for the Air Inlet Heater Sta....544 Expected Result.....................................................545 Results.............................................................545 Test Step 3.............................................................545 Check the Output From the Power Relay for the Air Inlet Heater S....545 Expected Result.....................................................545 Results.............................................................545 Test Step 4.............................................................545 Ground the Input to the Power Relay at the MIC......................545 Expected Result.....................................................545 Results.............................................................545 Test Step 5.............................................................545 Ground the Input to the Power Relay at the ECM Connector............545 Expected Result.....................................................545 Results.............................................................545 Test Step 6.............................................................546 Override the Air Inlet Heater Starting Aid to Test the ECM..........546 Results.............................................................546 Checking Idle Validation Switching Point (Throttle Sensor) With ............546 Expected Result.........................................................546 Analog Throttle Position Sensor Circuit - Test..............................546 System Operation Description............................................546 Checking the Throttle Sensor With Unconnected Output C..................547 Expected Result.....................................................547 Test Step 1.............................................................547 Check for Connector Damage..........................................547 Expected Result.....................................................548 Results.............................................................548 Test Step 2.............................................................548 Check for Active Diagnostic Codes...................................548 Expected Result.....................................................548 Results.............................................................548 Test Step 3.............................................................548 Check the Throttle Position With the Electronic Service Tool........548 Expected Result.....................................................548 Results.............................................................548 Test Step 4.............................................................548 Check the Voltage at the Throttle Position Sensor...................548 Expected Result.....................................................548 Results.............................................................548 Test Step 5.............................................................549 Disconnect the Throttle Position Sensor and Check for Active Dia....549 Expected Result.....................................................549 Results.............................................................549 Test Step 6.............................................................549 Check the Throttle Selection Status With the Electronic Service ....549 Expected Result.....................................................549 Results.............................................................549 Test Step 7.............................................................550 Disconnect the Supply Terminals of the Throttle Position Sensor ....550 Expected Result.....................................................550 Results.............................................................550 Test Step 8.............................................................550 Check the Position of Throttle Position Sensor......................550 Expected Result.....................................................550 Results.............................................................551 Test Step 9.............................................................551 Check the Throttle Position Sensor at the ECM.......................551 Expected Result.....................................................551 Results.............................................................551 CAN Data Link Circuit - Test................................................551 System Operation Description............................................551 Test Step 1.............................................................552 Inspect Electrical Connectors and Wiring............................552 Expected Result.....................................................552 Results.............................................................552 Test Step 2.............................................................552 Check the CAN Data Link Between the ECM and P40 Fuel Injection P....552 Expected Result.....................................................552 Results.............................................................552 Test Step 3.............................................................552 Check the CAN Data Link Between the ECM and P40 Fuel Injection P....552 Expected Result.....................................................552 Results.............................................................553 Test Step 4.............................................................553 Verify the Supply Voltage at the Fuel Injection Pump................553 Expected Result.....................................................553 Results.............................................................553 Data Link Circuit - Test....................................................553 System Operation Description............................................553 Background Information..................................................554 Communication...........................................................554 Test Step 1.............................................................554 Inspect Electrical Connectors and Wiring............................554 Expected Result.....................................................554 Results.............................................................554 Test Step 2.............................................................554 Determine the Type of Problem With the Data Link....................554 Expected Result.....................................................554 Results.............................................................555 Test Step 3.............................................................555 Check the Battery Voltage at the ECM................................555 Expected Result.....................................................555 Results.............................................................555 Test Step 4.............................................................555 Check the Battery Voltage That is Coming to the Data Link Connec....555 Expected Result.....................................................556 Results.............................................................556 Test Step 5.............................................................556 Connect the Electronic Service Tool Directly to the ECM.............556 Expected Result.....................................................556 Results.............................................................556 Test Step 6.............................................................556 Change Electronic Service Tool Components...........................556 Expected Result.....................................................557 Results.............................................................557 Test Step 7.............................................................557 Connect an Electronic Service Tool and the ECM to Another Batter....557 Expected Result.....................................................557 Results.............................................................557 Electrical Connectors - Inspect.............................................557 System Operation Description............................................557 Background Information..................................................558 Test Step 1.............................................................561 Check the Locking of the DT Connector (Deutsch) and the Lock Rin....561 Expected Result.....................................................561 Results.............................................................561 Test Step 2.............................................................562 Check the Socket Head Screw on the Connector for the Electronic ....562 Expected Result.....................................................562 Results.............................................................562 Test Step 3.............................................................562 Perform a Pull Test on Each Wire Terminal Connection................562 Expected Result.....................................................562 Results.............................................................562 Test Step 4.............................................................562 Monitor the Electronic Service Tool While the Wiring and the Con....562 Expected Result.....................................................563 Results.............................................................563 Test Step 5.............................................................563 Check Wires for Nicks and/or Abrasions in the Insulation............563 Expected Result.....................................................563 Results.............................................................563 Test Step 6.............................................................563 Check Connectors for Moisture or Corrosion..........................563 Expected Result.....................................................564 Results.............................................................564 Test Step 7.............................................................564 Inspect the Connector Terminals.....................................564 Expected Result.....................................................564 Results.............................................................564 Test Step 8.............................................................564 Check Individual Pin Retention Into the Socket......................564 Expected Result.....................................................565 Results.............................................................565 Electrical Power Supply Circuit - Test......................................565 System Operation Description............................................565 Background Information..................................................565 Test Step 1.............................................................566 Check the Batteries.................................................566 Expected Result.....................................................566 Results.............................................................566 Test Step 2.............................................................567 Inspect Electrical Connectors and Wiring............................567 Expected Result.....................................................567 Results.............................................................567 Test Step 3.............................................................567 Check the Battery Voltage at the ECM................................567 Expected Result.....................................................567 Results.............................................................568 Test Step 4.............................................................568 Use the Bypass Harness for the Electronic Service Tool to Bypass....568 Expected Result.....................................................569 Results.............................................................569 Engine Pressure Sensor Open or Short Circuit - Test.........................569 System Operation Description............................................569 Background Information..................................................569 Test Step 1.............................................................569 Check for Active +5V Sensor Supply Diagnostic Codes.................569 Expected Result.....................................................570 Results.............................................................570 Test Step 2.............................................................570 Verify All Active Diagnostic Codes..................................570 Expected Result.....................................................570 Results.............................................................570 Test Step 3.............................................................570 Inspect Electrical Connectors And Wiring............................570 Expected Result.....................................................571 Results.............................................................571 Test Step 4.............................................................571 Verify That the Diagnostic Code is Still Active.....................571 Expected Result.....................................................571 Results.............................................................571 Test Step 5.............................................................571 Disconnect the Sensor to Create an Open Circuit.....................571 Expected Result.....................................................571 Results.............................................................571 Test Step 6.............................................................571 Measure the Sensor Supply Voltage...................................571 Expected Result.....................................................572 Results.............................................................572 Test Step 7.............................................................572 Determine if the Short Circuit is in the Connector or in the Sen....572 Expected Result.....................................................572 Results.............................................................572 Test Step 8.............................................................572 Create a Short Circuit Between the Signal and the Common Termina....572 Expected Result.....................................................573 Results.............................................................573 Test Step 9.............................................................573 Check the Operation of the ECM by Creating Open and Short Circui....573 Expected Result.....................................................573 Results.............................................................573 Test Step 10............................................................574 Bypass the Harness Wiring Between the ECM and the Sensor Connect....574 Expected Result.....................................................574 Results.............................................................574 Engine Speed/Timing Sensor Circuit - Test...................................574 System Operation Description............................................574 Test Step 1.............................................................575 Inspect the Electrical Connectors and Cables........................575 Expected Result.....................................................575 Results.............................................................575 Test Step 2.............................................................575 Check the Installation of the Engine Speed/Timing Sensors...........575 Expected Result.....................................................575 Results.............................................................575 Test Step 3.............................................................575 Measure the Sensor Resistance Through the Wiring Harness............575 Expected Result.....................................................576 Results.............................................................576 Test Step 4.............................................................576 Measure the Resistance of the Sensor................................576 Expected Result.....................................................576 Results.............................................................576 Test Step 5.............................................................577 Measure the Resistance of the Cables Between the Fuel Injection ....577 Expected Result.....................................................577 Results.............................................................577 Test Step 6.............................................................577 Check the Continuity of the Cables From the ECM to the Fuel Inje....577 Expected Result.....................................................577 Results.............................................................578 Engine Temperature Sensor Open or Short Circuit - Test......................578 System Operation Description............................................578 Background Information..................................................578 Test Step 1.............................................................579 Verify All Active Diagnostic Codes..................................579 Expected Result.....................................................579 Results.............................................................579 Test Step 2.............................................................579 Inspect Electrical Connectors and Wiring............................579 Expected Result.....................................................579 Results.............................................................580 Test Step 3.............................................................580 Verify That the Diagnostic Code is Still Active.....................580 Expected Result.....................................................580 Results.............................................................580 Test Step 4.............................................................580 Disconnect the Sensor to Create an Open Circuit.....................580 Expected Result.....................................................580 Results.............................................................580 Test Step 5.............................................................580 Create a Short Circuit Between the Signal and the Common Termina....580 Expected Result.....................................................581 Results.............................................................581 Test Step 6.............................................................581 Check the Operation of the ECM by Creating an Open and a Short C....581 Expected Result.....................................................581 Results.............................................................581 Test Step 7.............................................................581 Bypass the Harness Wiring Between the ECM and the Sensor Connect....581 Expected Result.....................................................582 Results.............................................................582 Fuel Injection Pump Circuit - Test..........................................582 System Operation Description............................................582 Background Information..................................................582 Test Step 1.............................................................582 Check the Batteries.................................................582 Expected Result.....................................................582 Results.............................................................583 Test Step 2.............................................................583 Inspect the Electrical Connectors and Wiring........................583 Expected Result.....................................................584 Results.............................................................584 Test Step 3.............................................................584 Check the Supply Voltage at the Machine Interface Connector.........584 Expected Result.....................................................584 Results.............................................................584 Test Step 4.............................................................584 Check the Supply Voltage at the Fuel Injection Pump.................584 Expected Result.....................................................584 Results.............................................................584 Test Step 5.............................................................585 Check the Supply to the Power Relay for the Fuel Injection Pump.....585 Expected Result.....................................................585 Results.............................................................585 Test Step 6.............................................................585 Check the Output of the Power Relay for the Fuel Injection Pump.....585 Expected Result.....................................................585 Results.............................................................585 Test Step 7.............................................................585 Check the Voltage at the Relay Coil for the Fuel Injection Pump.....585 Expected Result.....................................................585 Results.............................................................585 Test Step 8.............................................................586 Check the Output of the ECM Fuel Pump Power Control at the Machi....586 Expected Result.....................................................586 Results.............................................................586 Test Step 9.............................................................586 Check the Output of the Fuel Injection Pump Power Control at the....586 Expected Result.....................................................586 Results.............................................................586 Test Step 10............................................................586 Measure the Voltage at the Pump Power Supply........................586 Expected Result.....................................................587 Results.............................................................587 Test Step 11............................................................587 Check the Voltage Load Protection Module (VLPM).....................587 Expected Result.....................................................588 Results.............................................................588 Indicator Lamp Circuit - Test...............................................588 System Operation Description............................................588 Test Step 1.............................................................588 Inspect Electrical Connectors and Wiring............................588 Results.............................................................589 Test Step 2.............................................................589 Inspect the Lamp, the Fuse, and the Power Supply....................589 Expected Result.....................................................589 Results.............................................................589 Test Step 3.............................................................589 Inspect the Input to the Lamp at the ECM connector..................589 Expected Result.....................................................589 Results.............................................................590 Test Step 4.............................................................590 Test the Individual Lamp Circuits...................................590 Expected Result.....................................................590 Results.............................................................590 Test Step 5.............................................................590 Check the Voltage at the ECM........................................590 Expected Result.....................................................590 Results.............................................................590 Idle Validation Circuit - Test..............................................590 System Operation Description............................................590 Test Step 1.............................................................590 Expected Result.....................................................590 Results.............................................................591 tables..............................................................................439 Table 1. Electronic Service Tool................................................465 Table 2. Optional Service Tools.................................................466 Table 3. CID FMI Codes and J Code FMI Codes.....................................467 Table 4. Event Codes and CID FMI Codes..........................................469 Table 5. Diagnostics Supported Over J1939.......................................470 Table 6. Events Supported Over J1939............................................472 Table 7. Engine Connectors......................................................479 Table 8. Color Codes for the Harness Wire.......................................484 Table 9. Pin Connections for Perkins Deutsch Socket Connector...................486 Table 10. Suspect Parameter Numbers.............................................490 Table 11. Failure Mode Indicators (FMI) Codes...................................491 Table 12. Engine Oil Pressure Trip and Reset Points.............................535 TE10 Dana Spicer Manual.................................................................595
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