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Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD
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Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD
897108-1600SRM0326-(03-2007)-UK-EN.................................................................................................................................................................................................................................................... 1 toc............................................................................................................................................................................................................................................................................... 1 Steering Axle................................................................................................................................................................................................................................................................. 1 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 2 General....................................................................................................................................................................................................................................................................... 5 Description................................................................................................................................................................................................................................................................... 5 Steering Axle Assembly Repair................................................................................................................................................................................................................................................. 10 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70.......................................................................................................................................................................................................... 10 Remove................................................................................................................................................................................................................................................................ 10 Install............................................................................................................................................................................................................................................................... 10 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0.......................................................................................................................................................................................................... 11 Remove................................................................................................................................................................................................................................................................ 11 Install............................................................................................................................................................................................................................................................... 11 Wheels and Hubs Repair (All Units)............................................................................................................................................................................................................................................ 12 Remove and Disassemble.................................................................................................................................................................................................................................................... 12 Clean..................................................................................................................................................................................................................................................................... 12 Inspect................................................................................................................................................................................................................................................................... 12 Assemble and Install...................................................................................................................................................................................................................................................... 12 Spindles and Bearings Repair (All Units)...................................................................................................................................................................................................................................... 14 Remove.................................................................................................................................................................................................................................................................... 14 Clean..................................................................................................................................................................................................................................................................... 14 Assemble and Install...................................................................................................................................................................................................................................................... 15 Tie Rods Repair (All Units)................................................................................................................................................................................................................................................... 16 Remove.................................................................................................................................................................................................................................................................... 16 Clean..................................................................................................................................................................................................................................................................... 16 Install................................................................................................................................................................................................................................................................... 16 Steering Cylinder Repair...................................................................................................................................................................................................................................................... 19 Remove and Disassemble.................................................................................................................................................................................................................................................... 19 Clean and Inspect......................................................................................................................................................................................................................................................... 19 Assemble and Install...................................................................................................................................................................................................................................................... 19 Troubleshooting............................................................................................................................................................................................................................................................... 20 897934-0700SRM0626-(11-2001)-UK-EN.................................................................................................................................................................................................................................................... 25 toc............................................................................................................................................................................................................................................................................... 25 Cooling System................................................................................................................................................................................................................................................................ 25 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 26 General....................................................................................................................................................................................................................................................................... 29 Description................................................................................................................................................................................................................................................................... 30 Radiator.................................................................................................................................................................................................................................................................. 30 Radiator Cap.............................................................................................................................................................................................................................................................. 30 Thermostat................................................................................................................................................................................................................................................................ 30 Water Pump................................................................................................................................................................................................................................................................ 31 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 31 Cooling System Checks......................................................................................................................................................................................................................................................... 31 Radiator.................................................................................................................................................................................................................................................................. 31 Thermostat................................................................................................................................................................................................................................................................ 31 Water Pump................................................................................................................................................................................................................................................................ 32 Exhaust Leaks............................................................................................................................................................................................................................................................. 32 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 32 Radiator Cleaning............................................................................................................................................................................................................................................................. 32 Drain..................................................................................................................................................................................................................................................................... 32 Clean..................................................................................................................................................................................................................................................................... 32 Fill...................................................................................................................................................................................................................................................................... 33 Troubleshooting............................................................................................................................................................................................................................................................... 34 899784-2200SRM0002-(10-2003)-UK-EN.................................................................................................................................................................................................................................................... 37 toc............................................................................................................................................................................................................................................................................... 37 Alternator with Regulator..................................................................................................................................................................................................................................................... 37 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 38 General....................................................................................................................................................................................................................................................................... 41 Description................................................................................................................................................................................................................................................................... 41 Alternator Repair............................................................................................................................................................................................................................................................. 43 Alternator Type A......................................................................................................................................................................................................................................................... 43 Remove and Disassemble................................................................................................................................................................................................................................................ 43 Clean................................................................................................................................................................................................................................................................. 44 Assemble.............................................................................................................................................................................................................................................................. 45 Install............................................................................................................................................................................................................................................................... 45 Alternator Type B......................................................................................................................................................................................................................................................... 48 Remove and Disassemble................................................................................................................................................................................................................................................ 48 Clean................................................................................................................................................................................................................................................................. 48 Assemble.............................................................................................................................................................................................................................................................. 49 Install............................................................................................................................................................................................................................................................... 50 General Check and Adjustment.................................................................................................................................................................................................................................................. 51 Low Output Check (Type A or Type B)........................................................................................................................................................................................................................................... 51 High Output Check (Type A or Type B).......................................................................................................................................................................................................................................... 53 Brushes Circuit Check......................................................................................................................................................................................................................................................... 54 Delco Alternators......................................................................................................................................................................................................................................................... 54 Motorola Alternators...................................................................................................................................................................................................................................................... 55 Diodes Check.................................................................................................................................................................................................................................................................. 56 Diode Bridge Check............................................................................................................................................................................................................................................................ 56 Delco and Leece-Neville Alternators....................................................................................................................................................................................................................................... 56 Motorola Alternators...................................................................................................................................................................................................................................................... 56 Rotor Field Winding Check..................................................................................................................................................................................................................................................... 57 Stator Windings Check......................................................................................................................................................................................................................................................... 58 Voltage Regulator Check....................................................................................................................................................................................................................................................... 58 Troubleshooting............................................................................................................................................................................................................................................................... 58 910072-1400SRM0046-(07-2007)-UK-EN.................................................................................................................................................................................................................................................... 63 toc............................................................................................................................................................................................................................................................................... 63 Differential.................................................................................................................................................................................................................................................................. 63 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 64 General....................................................................................................................................................................................................................................................................... 67 Description................................................................................................................................................................................................................................................................... 67 Differential Repair........................................................................................................................................................................................................................................................... 68 Remove.................................................................................................................................................................................................................................................................... 68 Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................ 68 Differential and Ring Gear From Differential Carrier, Remove.......................................................................................................................................................................................................... 70 Drive Pinion and Pinion Carrier From Differential Carrier, Remov...................................................................................................................................................................................................... 72 Disassemble............................................................................................................................................................................................................................................................... 73 Differential and Ring Gear Assembly, Disassemble...................................................................................................................................................................................................................... 73 Drive Pinion and Pinion Carrier, Disassemble.......................................................................................................................................................................................................................... 75 Clean and Inspect......................................................................................................................................................................................................................................................... 78 Assemble.................................................................................................................................................................................................................................................................. 79 Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................ 79 Pinion Bearings, Adjust Preload....................................................................................................................................................................................................................................... 79 Press Method...................................................................................................................................................................................................................................................... 79 Yoke or Flange Method............................................................................................................................................................................................................................................. 80 Triple-Lip Seal, Install.............................................................................................................................................................................................................................................. 81 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)........................................................................................................................................................................................................... 82 Differential and Ring Gear, Assemble.................................................................................................................................................................................................................................. 84 Differential Gears Rotating Torque, Check............................................................................................................................................................................................................................. 86 Differential and Ring Gear Assembly, Install.......................................................................................................................................................................................................................... 87 Differential Bearings, Preload Adjust................................................................................................................................................................................................................................. 89 Ring Gear, Runout Check............................................................................................................................................................................................................................................... 90 Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................ 90 Gear Set, Tooth Contact Pattern Check................................................................................................................................................................................................................................. 92 Thrust Screw, Install and Adjust...................................................................................................................................................................................................................................... 95 Install................................................................................................................................................................................................................................................................... 95 Differential Assembly Into Axle Housing, Install...................................................................................................................................................................................................................... 95 Specifications................................................................................................................................................................................................................................................................ 97 Troubleshooting............................................................................................................................................................................................................................................................... 102 tables............................................................................................................................................................................................................................................................................ 63 Table 1. Ring Gear Backlash Adjustment Specifications......................................................................................................................................................................................................................... 92 Table 2. Ring and Pinion Tooth Contact Adjustment............................................................................................................................................................................................................................. 93 Table 3. General Specifications............................................................................................................................................................................................................................................... 97 Table 4. Rivet Installation Pressure.......................................................................................................................................................................................................................................... 97 Table 5. Pinion Adjustment.................................................................................................................................................................................................................................................... 98 Table 6. Pinion Preload Pressure.............................................................................................................................................................................................................................................. 98 Table 7. Torque Specifications................................................................................................................................................................................................................................................ 99 Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................ 100 Table 9. Torque Specifications for Metric (Fine) Hardware..................................................................................................................................................................................................................... 101 910102-2100SRM0103-(03-2007)-UK-EN.................................................................................................................................................................................................................................................... 105 toc............................................................................................................................................................................................................................................................................... 105 Tilt Cylinders................................................................................................................................................................................................................................................................ 105 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 106 General....................................................................................................................................................................................................................................................................... 109 Description................................................................................................................................................................................................................................................................... 109 Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 109 Remove.................................................................................................................................................................................................................................................................... 109 Disassemble............................................................................................................................................................................................................................................................... 109 Clean..................................................................................................................................................................................................................................................................... 109 Assemble.................................................................................................................................................................................................................................................................. 109 Tilt Cylinders With O-Ring or Single-Lip Seals........................................................................................................................................................................................................................ 109 Tilt Cylinders for XM and XMS Models.................................................................................................................................................................................................................................. 111 Tilt Cylinders for XL, XLS, and XL 3 Models........................................................................................................................................................................................................................... 112 Tilt Cylinders for H700-800A and Early Model H700-920B................................................................................................................................................................................................................ 114 Install................................................................................................................................................................................................................................................................... 115 Tilt Cylinders Using Chevron Packing.................................................................................................................................................................................................................................. 115 Install........................................................................................................................................................................................................................................................... 116 Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 118 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 120 Torque Specifications......................................................................................................................................................................................................................................................... 120 Piston Rod Nut............................................................................................................................................................................................................................................................ 120 Retainer.................................................................................................................................................................................................................................................................. 121 Troubleshooting............................................................................................................................................................................................................................................................... 123 tables............................................................................................................................................................................................................................................................................ 105 Table 1. Movement Rates (Maximum) for Tilt Cylinders.......................................................................................................................................................................................................................... 119 910107-2200SRM0106-(02-2001)-UK-EN.................................................................................................................................................................................................................................................... 127 toc............................................................................................................................................................................................................................................................................... 127 Starter....................................................................................................................................................................................................................................................................... 127 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 128 General....................................................................................................................................................................................................................................................................... 131 Description and Operation..................................................................................................................................................................................................................................................... 131 Starter Repair................................................................................................................................................................................................................................................................ 133 Remove.................................................................................................................................................................................................................................................................... 133 Disassemble............................................................................................................................................................................................................................................................... 133 Clean..................................................................................................................................................................................................................................................................... 134 Assemble.................................................................................................................................................................................................................................................................. 134 Install................................................................................................................................................................................................................................................................... 135 General Checks and Adjustments................................................................................................................................................................................................................................................ 135 Troubleshooting............................................................................................................................................................................................................................................................... 138 910442-8000SRM0231-(12-2004)-UK-EN.................................................................................................................................................................................................................................................... 143 toc............................................................................................................................................................................................................................................................................... 143 Metric and Inch (SAE) Fasteners............................................................................................................................................................................................................................................... 143 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 144 General....................................................................................................................................................................................................................................................................... 147 Threaded Fasteners........................................................................................................................................................................................................................................................ 147 Nomenclature, Threads..................................................................................................................................................................................................................................................... 147 Strength Identification................................................................................................................................................................................................................................................... 148 Cotter (Split) Pins....................................................................................................................................................................................................................................................... 148 Fastener Torque Tables.................................................................................................................................................................................................................................................... 153 Conversion Table.......................................................................................................................................................................................................................................................... 155 tables............................................................................................................................................................................................................................................................................ 143 Table 1. Bolts and Screws..................................................................................................................................................................................................................................................... 149 Table 2. Studs and Nuts....................................................................................................................................................................................................................................................... 150 Table 3. Torque Nuts.......................................................................................................................................................................................................................................................... 151 Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................ 152 Table 5. Torque Values for Metric Fasteners*.................................................................................................................................................................................................................................. 153 Table 6. Torque Values for Inch Fasteners*.................................................................................................................................................................................................................................... 154 Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................ 155 Table 8. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 156 Table 9. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 157 Table 10. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 158 Table 11. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 160 1494123-0100SRM0927-(01-2006)-UK-EN................................................................................................................................................................................................................................................... 165 toc............................................................................................................................................................................................................................................................................... 165 Frame......................................................................................................................................................................................................................................................................... 165 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 166 General....................................................................................................................................................................................................................................................................... 169 Description................................................................................................................................................................................................................................................................... 169 Counterweight Repair.......................................................................................................................................................................................................................................................... 169 Remove.................................................................................................................................................................................................................................................................... 169 Install................................................................................................................................................................................................................................................................... 171 Fenders................................................................................................................................................................................................................................................................... 171 Remove................................................................................................................................................................................................................................................................ 171 Install............................................................................................................................................................................................................................................................... 171 Side Counterweights H13.00-16.00XM (H300-360HD)........................................................................................................................................................................................................................... 171 Side Counterweight, Replace............................................................................................................................................................................................................................................... 171 Hood and Air Cleaner Repair................................................................................................................................................................................................................................................... 172 Remove.................................................................................................................................................................................................................................................................... 172 Install................................................................................................................................................................................................................................................................... 174 Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 174 Remove.................................................................................................................................................................................................................................................................... 174 Repairs, All Units........................................................................................................................................................................................................................................................ 175 Small Leaks........................................................................................................................................................................................................................................................... 175 Large Leaks........................................................................................................................................................................................................................................................... 176 Clean..................................................................................................................................................................................................................................................................... 176 Steam Method.......................................................................................................................................................................................................................................................... 176 Chemical Solution Method.............................................................................................................................................................................................................................................. 177 Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 177 Install................................................................................................................................................................................................................................................................... 177 Fuel Tank Repair.............................................................................................................................................................................................................................................................. 178 Remove.................................................................................................................................................................................................................................................................... 178 Repairs................................................................................................................................................................................................................................................................... 178 Install................................................................................................................................................................................................................................................................... 178 Cooling System and Radiator Repair............................................................................................................................................................................................................................................ 180 Remove.................................................................................................................................................................................................................................................................... 180 Install................................................................................................................................................................................................................................................................... 181 Engine and Transmission Repair................................................................................................................................................................................................................................................ 182 Hyster T-50 Transmission, Remove.......................................................................................................................................................................................................................................... 182 Hyster T-50 Transmission, Install......................................................................................................................................................................................................................................... 183 TE-10 Transmission........................................................................................................................................................................................................................................................ 184 Remove................................................................................................................................................................................................................................................................ 184 Install............................................................................................................................................................................................................................................................... 187 Label Replacement............................................................................................................................................................................................................................................................. 189 1494140-1600SRM0936-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 197 toc............................................................................................................................................................................................................................................................................... 197 Steering System............................................................................................................................................................................................................................................................... 197 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 198 General....................................................................................................................................................................................................................................................................... 201 Description................................................................................................................................................................................................................................................................... 201 Steering Wheel and Column Assembly............................................................................................................................................................................................................................................ 203 General................................................................................................................................................................................................................................................................... 203 Steering Wheel and Horn................................................................................................................................................................................................................................................... 203 Remove................................................................................................................................................................................................................................................................ 203 Install............................................................................................................................................................................................................................................................... 203 Steering Control Unit Repair.................................................................................................................................................................................................................................................. 205 General................................................................................................................................................................................................................................................................... 205 Description............................................................................................................................................................................................................................................................... 205 Operation................................................................................................................................................................................................................................................................. 205 Remove.................................................................................................................................................................................................................................................................... 206 Disassemble............................................................................................................................................................................................................................................................... 206 Clean..................................................................................................................................................................................................................................................................... 209 Assemble and Install...................................................................................................................................................................................................................................................... 209 Steering System Air Removal................................................................................................................................................................................................................................................... 215 Steering Relief Pressure Check................................................................................................................................................................................................................................................ 216 Troubleshooting............................................................................................................................................................................................................................................................... 216 1494141-1800SRM0937-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 221 toc............................................................................................................................................................................................................................................................................... 221 Dry Brake System.............................................................................................................................................................................................................................................................. 221 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 222 General....................................................................................................................................................................................................................................................................... 225 Description................................................................................................................................................................................................................................................................... 225 Operation..................................................................................................................................................................................................................................................................... 226 Service Brakes............................................................................................................................................................................................................................................................ 226 Parking Brake............................................................................................................................................................................................................................................................. 228 Air Tank Repair............................................................................................................................................................................................................................................................... 229 Relief Valve.............................................................................................................................................................................................................................................................. 229 Drain Valve............................................................................................................................................................................................................................................................... 229 Brake Pedal Valve Repair...................................................................................................................................................................................................................................................... 230 Remove.................................................................................................................................................................................................................................................................... 230 Disassemble, Inspect, and Assemble........................................................................................................................................................................................................................................ 230 Install................................................................................................................................................................................................................................................................... 230 Air Chambers Repair........................................................................................................................................................................................................................................................... 231 Remove.................................................................................................................................................................................................................................................................... 231 Disassemble............................................................................................................................................................................................................................................................... 231 Inspect................................................................................................................................................................................................................................................................... 232 Assemble.................................................................................................................................................................................................................................................................. 233 Install................................................................................................................................................................................................................................................................... 233 Actuator Arms Repair.......................................................................................................................................................................................................................................................... 233 Remove.................................................................................................................................................................................................................................................................... 233 Inspect................................................................................................................................................................................................................................................................... 234 Install................................................................................................................................................................................................................................................................... 234 Brake Assemblies Repair....................................................................................................................................................................................................................................................... 235 Brake Shoe, Remove........................................................................................................................................................................................................................................................ 235 Camshaft, Remove.......................................................................................................................................................................................................................................................... 237 Clean..................................................................................................................................................................................................................................................................... 237 Inspect................................................................................................................................................................................................................................................................... 238 Camshaft, Install......................................................................................................................................................................................................................................................... 238 Brake Shoe, Install....................................................................................................................................................................................................................................................... 239 Air Dryer..................................................................................................................................................................................................................................................................... 240 Description............................................................................................................................................................................................................................................................... 240 Cartridge................................................................................................................................................................................................................................................................. 240 Remove................................................................................................................................................................................................................................................................ 240 Install............................................................................................................................................................................................................................................................... 240 Filter.................................................................................................................................................................................................................................................................... 240 Remove................................................................................................................................................................................................................................................................ 240 Install............................................................................................................................................................................................................................................................... 240 Quick-Release Valve........................................................................................................................................................................................................................................................... 242 Governor Check and Adjustment for Air Compressor.............................................................................................................................................................................................................................. 242 Brake Shoes Adjustment........................................................................................................................................................................................................................................................ 243 Specifications................................................................................................................................................................................................................................................................ 244 Troubleshooting............................................................................................................................................................................................................................................................... 244 Service Brakes............................................................................................................................................................................................................................................................ 244 Service Brakes, Park Function ............................................................................................................................................................................................................................................ 247 tables............................................................................................................................................................................................................................................................................ 221 Table 1. Air Chambers Operation............................................................................................................................................................................................................................................... 228 1494142-1900SRM0938-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 251 toc............................................................................................................................................................................................................................................................................... 251 Hydraulic System.............................................................................................................................................................................................................................................................. 251 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 252 General....................................................................................................................................................................................................................................................................... 255 Description and Operation..................................................................................................................................................................................................................................................... 255 Hydraulic Tank............................................................................................................................................................................................................................................................ 255 Hydraulic Pump............................................................................................................................................................................................................................................................ 256 Steering Priority Flow Valve.............................................................................................................................................................................................................................................. 256 Pilot Valve............................................................................................................................................................................................................................................................... 257 Main Control Valve........................................................................................................................................................................................................................................................ 259 Unloader Valve............................................................................................................................................................................................................................................................ 260 Hydraulic Operation....................................................................................................................................................................................................................................................... 261 Checks and Adjustments........................................................................................................................................................................................................................................................ 264 Quick Disconnect Fittings................................................................................................................................................................................................................................................. 264 Steering Priority Flow Valve.............................................................................................................................................................................................................................................. 264 Steering Relief Pressure.................................................................................................................................................................................................................................................. 264 Modulator Valve........................................................................................................................................................................................................................................................... 265 Pilot Valve and Pressure Reducing Valve................................................................................................................................................................................................................................... 265 Accumulator............................................................................................................................................................................................................................................................... 266 Filter.................................................................................................................................................................................................................................................................... 266 Main Control Valve........................................................................................................................................................................................................................................................ 266 Relief Pressure Check................................................................................................................................................................................................................................................. 266 Check Valves.............................................................................................................................................................................................................................................................. 267 Unloader Valve............................................................................................................................................................................................................................................................ 267 Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 268 Remove.................................................................................................................................................................................................................................................................... 268 Disassemble............................................................................................................................................................................................................................................................... 268 Clean and Inspect......................................................................................................................................................................................................................................................... 268 Assemble.................................................................................................................................................................................................................................................................. 269 Install................................................................................................................................................................................................................................................................... 270 Pilot Accumulator Replacement ................................................................................................................................................................................................................................................ 270 Remove.................................................................................................................................................................................................................................................................... 270 Install................................................................................................................................................................................................................................................................... 270 Pilot Valve Repair............................................................................................................................................................................................................................................................ 271 Remove.................................................................................................................................................................................................................................................................... 271 Disassemble............................................................................................................................................................................................................................................................... 272 Clean and Inspect......................................................................................................................................................................................................................................................... 272 Assemble.................................................................................................................................................................................................................................................................. 272 Install................................................................................................................................................................................................................................................................... 272 Control Levers and Joystick Repair............................................................................................................................................................................................................................................ 273 Remove.................................................................................................................................................................................................................................................................... 273 Install................................................................................................................................................................................................................................................................... 273 Calibration and Diagnostics................................................................................................................................................................................................................................................... 274 General................................................................................................................................................................................................................................................................... 274 Description............................................................................................................................................................................................................................................................... 274 Lever and Joystick Calibration........................................................................................................................................................................................................................................ 274 Flow Adjustment....................................................................................................................................................................................................................................................... 274 Dead Band Value Setting............................................................................................................................................................................................................................................... 275 Lowering Delay........................................................................................................................................................................................................................................................ 276 PWM and I/O Module Readouts........................................................................................................................................................................................................................................... 276 Function Disable...................................................................................................................................................................................................................................................... 277 General Startup........................................................................................................................................................................................................................................................... 277 Minimum system requirements........................................................................................................................................................................................................................................... 277 Install the Hydraulic Controls Program................................................................................................................................................................................................................................ 277 DelayTimeFile (Reset)................................................................................................................................................................................................................................................. 277 Select the Processor Speed............................................................................................................................................................................................................................................ 278 Hydraulic Controls Program................................................................................................................................................................................................................................................ 278 Calibration............................................................................................................................................................................................................................................................... 280 Joystick/Lever Calibration............................................................................................................................................................................................................................................ 280 Levers............................................................................................................................................................................................................................................................ 280 Joystick.......................................................................................................................................................................................................................................................... 280 Valve Flow Adjustment..................................................................................................................................................................................................................................................... 281 Diagnostics............................................................................................................................................................................................................................................................... 281 Calibration System Shutdown............................................................................................................................................................................................................................................... 281 LED Diagnostics............................................................................................................................................................................................................................................................... 282 Electrical Connections........................................................................................................................................................................................................................................................ 285 Specifications................................................................................................................................................................................................................................................................ 289 tables............................................................................................................................................................................................................................................................................ 251 Table 1. Main Control Valve Port Settings..................................................................................................................................................................................................................................... 257 Table 2. Processor Speed Settings............................................................................................................................................................................................................................................. 277 Table 3. PWM Board LED Error Codes............................................................................................................................................................................................................................................ 282 Table 4. Altering PT FLT I/O Board LED's (Old Logic).......................................................................................................................................................................................................................... 283 Table 5. Altering PT FLT I/O Board LED's (New Logic).......................................................................................................................................................................................................................... 283 Table 6. Fixed PT Logic I/O Boards LED's...................................................................................................................................................................................................................................... 284 Table 7. ECH.................................................................................................................................................................................................................................................................. 284 Table 8. PWM Driver Module.................................................................................................................................................................................................................................................... 285 Table 9. Input/Output Module 1................................................................................................................................................................................................................................................ 286 Table 10. Input/Output Module 2............................................................................................................................................................................................................................................... 287 Table 11. Altering PT FLT..................................................................................................................................................................................................................................................... 288 Table 12. Fixed PT FLT........................................................................................................................................................................................................................................................ 288 Table 13. ECH................................................................................................................................................................................................................................................................. 289 1494145-8000SRM0940-(03-2008)-UK-EN................................................................................................................................................................................................................................................... 293 toc............................................................................................................................................................................................................................................................................... 293 Capacities and Specifications................................................................................................................................................................................................................................................. 293 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 294 Lift Truck Weights............................................................................................................................................................................................................................................................ 297 Capacities.................................................................................................................................................................................................................................................................... 297 Engine Specifications......................................................................................................................................................................................................................................................... 298 Perkins Diesel............................................................................................................................................................................................................................................................ 298 Cummins Diesel/LPG........................................................................................................................................................................................................................................................ 299 Hydraulic System.............................................................................................................................................................................................................................................................. 300 Electrical System............................................................................................................................................................................................................................................................. 301 Tire Sizes.................................................................................................................................................................................................................................................................... 301 Mast Speeds................................................................................................................................................................................................................................................................... 301 Perkins Diesel............................................................................................................................................................................................................................................................ 301 Cummins Diesel/LPG........................................................................................................................................................................................................................................................ 302 Torque Specifications, Cummins Diesel......................................................................................................................................................................................................................................... 303 Lubrication System........................................................................................................................................................................................................................................................ 303 Torque Specifications, Perkins Diesel......................................................................................................................................................................................................................................... 303 Engine.................................................................................................................................................................................................................................................................... 303 Cylinder Head Assembly................................................................................................................................................................................................................................................ 303 Piston and Connecting Rod Assemblies.................................................................................................................................................................................................................................. 303 Crankshaft Assembly................................................................................................................................................................................................................................................... 303 Timing Case and Drive Assembly........................................................................................................................................................................................................................................ 304 Turbocharger.......................................................................................................................................................................................................................................................... 304 Lubrication System.................................................................................................................................................................................................................................................... 304 Fuel System........................................................................................................................................................................................................................................................... 304 Cooling System........................................................................................................................................................................................................................................................ 304 Flywheel and Housing.................................................................................................................................................................................................................................................. 304 Aspiration System..................................................................................................................................................................................................................................................... 305 Electrical Equipment.................................................................................................................................................................................................................................................. 305 Auxiliary Equipment................................................................................................................................................................................................................................................... 305 Torque Specifications - Perkins, Tier 2....................................................................................................................................................................................................................................... 305 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 305 Piston and Connecting Rod Assemblies...................................................................................................................................................................................................................................... 305 Crankshaft Assembly....................................................................................................................................................................................................................................................... 305 Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 305 Turbocharger.............................................................................................................................................................................................................................................................. 306 Lubrication System........................................................................................................................................................................................................................................................ 306 Fuel System............................................................................................................................................................................................................................................................... 306 Cooling System............................................................................................................................................................................................................................................................ 306 Flywheel.................................................................................................................................................................................................................................................................. 306 Auxiliary Equipment....................................................................................................................................................................................................................................................... 306 Torque Specifications, General................................................................................................................................................................................................................................................ 307 Transmission.............................................................................................................................................................................................................................................................. 307 Driveline and Axle........................................................................................................................................................................................................................................................ 307 Differential.............................................................................................................................................................................................................................................................. 307 Brakes - Wet.............................................................................................................................................................................................................................................................. 307 Brakes - Dry.............................................................................................................................................................................................................................................................. 307 Steering.................................................................................................................................................................................................................................................................. 307 Hydraulic System.......................................................................................................................................................................................................................................................... 308 Mast...................................................................................................................................................................................................................................................................... 308 Carriage.................................................................................................................................................................................................................................................................. 308 Tilt Cylinders............................................................................................................................................................................................................................................................ 308 Frame..................................................................................................................................................................................................................................................................... 308 Wiper Arms, Front......................................................................................................................................................................................................................................................... 308 Hyster T-50 Transmission Pressures (Powershift and Automatic)................................................................................................................................................................................................................. 309 TE-10 Transmission Specifications............................................................................................................................................................................................................................................. 310 Electrical................................................................................................................................................................................................................................................................ 310 Hydraulic Cooler Lines.................................................................................................................................................................................................................................................... 310 Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 311 tables............................................................................................................................................................................................................................................................................ 293 Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp.............................................................................................................................................................................................................. 310 Table 2. Grade 5.............................................................................................................................................................................................................................................................. 311 Table 3. Grade 8.............................................................................................................................................................................................................................................................. 311 Table 4. Grades 8.8, 10.9, and 12.9........................................................................................................................................................................................................................................... 311 Table 5. O-ring Port Plug Torque Chart........................................................................................................................................................................................................................................ 312 Table 6. Pipe Plug Torque Chart............................................................................................................................................................................................................................................... 312 1494953-1400SRM0944-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 315 toc............................................................................................................................................................................................................................................................................... 315 Planetary Drive Axle.......................................................................................................................................................................................................................................................... 315 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 316 General....................................................................................................................................................................................................................................................................... 319 Description................................................................................................................................................................................................................................................................... 319 Operation..................................................................................................................................................................................................................................................................... 321 Identification............................................................................................................................................................................................................................................................ 321 Removal....................................................................................................................................................................................................................................................................... 322 Disassembly................................................................................................................................................................................................................................................................... 322 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 322 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 324 Wheel End................................................................................................................................................................................................................................................................. 326 Spindle and Piston Housing................................................................................................................................................................................................................................................ 327 Cleaning...................................................................................................................................................................................................................................................................... 328 Clean Ground or Polished Parts............................................................................................................................................................................................................................................ 328 Clean Parts With Rough Finish............................................................................................................................................................................................................................................. 328 Clean Axle Assemblies..................................................................................................................................................................................................................................................... 328 Drying Cleaned Parts...................................................................................................................................................................................................................................................... 328 Corrosion Prevention.......................................................................................................................................................................................................................................................... 328 Parts Inspection.............................................................................................................................................................................................................................................................. 329 Tapered Roller Bearings................................................................................................................................................................................................................................................... 329 Bevel Pinion and Ring Gear Sets........................................................................................................................................................................................................................................... 330 Main Differential Assembly................................................................................................................................................................................................................................................ 330 Axle Shafts............................................................................................................................................................................................................................................................... 330 Yoke...................................................................................................................................................................................................................................................................... 330 Brakes.................................................................................................................................................................................................................................................................... 330 Repair or Replace Parts................................................................................................................................................................................................................................................... 330 Repair Welding............................................................................................................................................................................................................................................................ 330 Apply Silicone Gasket Material............................................................................................................................................................................................................................................ 331 Assembly...................................................................................................................................................................................................................................................................... 331 Spindle and Piston Housing to Axle Housing................................................................................................................................................................................................................................ 331 Wet Disc Brakes........................................................................................................................................................................................................................................................... 332 Adjust Wheel Bearing Preload.............................................................................................................................................................................................................................................. 333 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 334 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 335 Planetary Spider Assembly................................................................................................................................................................................................................................................. 335 Installation.................................................................................................................................................................................................................................................................. 336 Fill Wet Disc Brakes With Hydraulic Fluid................................................................................................................................................................................................................................. 336 Torque Specifications......................................................................................................................................................................................................................................................... 337 Lubrication Specification..................................................................................................................................................................................................................................................... 338 1494955-2000SRM0943-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 341 toc............................................................................................................................................................................................................................................................................... 341 Main Control Valve............................................................................................................................................................................................................................................................ 341 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 342 General....................................................................................................................................................................................................................................................................... 345 Description................................................................................................................................................................................................................................................................... 345 Operation..................................................................................................................................................................................................................................................................... 348 Lift Section.............................................................................................................................................................................................................................................................. 348 Tilt/Auxiliary Section.................................................................................................................................................................................................................................................... 348 Relief Valves............................................................................................................................................................................................................................................................. 348 Unloader Valve............................................................................................................................................................................................................................................................ 348 Main Control Valve Repair..................................................................................................................................................................................................................................................... 351 Remove.................................................................................................................................................................................................................................................................... 351 Disassemble............................................................................................................................................................................................................................................................... 351 Auxiliary Side........................................................................................................................................................................................................................................................ 351 Lift Side............................................................................................................................................................................................................................................................. 351 Clean and Inspect......................................................................................................................................................................................................................................................... 354 Assemble.................................................................................................................................................................................................................................................................. 354 Auxiliary Side........................................................................................................................................................................................................................................................ 354 Lift Side............................................................................................................................................................................................................................................................. 354 Install................................................................................................................................................................................................................................................................... 354 Pressure Relief Valve Check and Adjustment.................................................................................................................................................................................................................................... 355 Check and Adjust.......................................................................................................................................................................................................................................................... 355 Replace................................................................................................................................................................................................................................................................... 355 Specifications................................................................................................................................................................................................................................................................ 356 Troubleshooting............................................................................................................................................................................................................................................................... 356 1498445-1400SRM0945-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 361 toc............................................................................................................................................................................................................................................................................... 361 Planetary Drive Axle.......................................................................................................................................................................................................................................................... 361 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 362 General....................................................................................................................................................................................................................................................................... 365 Description................................................................................................................................................................................................................................................................... 365 Operation..................................................................................................................................................................................................................................................................... 367 Identification............................................................................................................................................................................................................................................................ 367 Removal....................................................................................................................................................................................................................................................................... 368 Disassembly................................................................................................................................................................................................................................................................... 368 Brake Drum................................................................................................................................................................................................................................................................ 368 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 369 Dry Brakes................................................................................................................................................................................................................................................................ 371 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 371 Spindle and Brake Spider.................................................................................................................................................................................................................................................. 373 Cleaning...................................................................................................................................................................................................................................................................... 374 Ground or Polished Parts.................................................................................................................................................................................................................................................. 374 Parts With Rough Finish................................................................................................................................................................................................................................................... 374 Axle Assemblies........................................................................................................................................................................................................................................................... 374 Drying Cleaned Parts...................................................................................................................................................................................................................................................... 374 Corrosion Prevention.......................................................................................................................................................................................................................................................... 374 Parts Inspection.............................................................................................................................................................................................................................................................. 375 Tapered Roller Bearings................................................................................................................................................................................................................................................... 375 Bevel Pinion and Ring Gear Sets........................................................................................................................................................................................................................................... 376 Main Differential Assembly................................................................................................................................................................................................................................................ 376 Axle Shafts............................................................................................................................................................................................................................................................... 376 Yoke...................................................................................................................................................................................................................................................................... 376 Brakes.................................................................................................................................................................................................................................................................... 376 Repair or Replace Parts................................................................................................................................................................................................................................................... 376 Repair Welding............................................................................................................................................................................................................................................................ 376 Apply Silicone Gasket Material............................................................................................................................................................................................................................................ 377 Assembly...................................................................................................................................................................................................................................................................... 377 Spindle, Brake Spider, and Brake.......................................................................................................................................................................................................................................... 377 Wheel End................................................................................................................................................................................................................................................................. 378 Adjust Wheel Bearing Preload.............................................................................................................................................................................................................................................. 379 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 380 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 381 Planetary Spider Assembly................................................................................................................................................................................................................................................. 381 Installation.................................................................................................................................................................................................................................................................. 382 Torque Specifications......................................................................................................................................................................................................................................................... 383 Lubrication Specification..................................................................................................................................................................................................................................................... 384 1498450-1800SRM0951-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 387 toc............................................................................................................................................................................................................................................................................... 387 Wet Brake System.............................................................................................................................................................................................................................................................. 387 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 388 General....................................................................................................................................................................................................................................................................... 391 Description and Operation..................................................................................................................................................................................................................................................... 391 Service Brakes............................................................................................................................................................................................................................................................ 391 Parking Brake............................................................................................................................................................................................................................................................. 391 Oil Cooler Circuit........................................................................................................................................................................................................................................................ 391 Pressure Switch Replacement................................................................................................................................................................................................................................................... 395 Accumulators Replacement...................................................................................................................................................................................................................................................... 395 Brake Treadle Valve Repair.................................................................................................................................................................................................................................................... 395 Remove and Disassemble.................................................................................................................................................................................................................................................... 395 Clean and Inspect......................................................................................................................................................................................................................................................... 396 Assemble and Install...................................................................................................................................................................................................................................................... 396 Parking Brake Valve Repair.................................................................................................................................................................................................................................................... 396 Remove.................................................................................................................................................................................................................................................................... 396 Clean and Inspect......................................................................................................................................................................................................................................................... 396 Repair.................................................................................................................................................................................................................................................................... 396 Install................................................................................................................................................................................................................................................................... 396 Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 397 Remove.................................................................................................................................................................................................................................................................... 397 Disassemble............................................................................................................................................................................................................................................................... 399 Inspect................................................................................................................................................................................................................................................................... 399 Install................................................................................................................................................................................................................................................................... 399 Adjust.................................................................................................................................................................................................................................................................... 399 Brake Pad Repair.............................................................................................................................................................................................................................................................. 400 Inspect................................................................................................................................................................................................................................................................... 400 Remove.................................................................................................................................................................................................................................................................... 400 Install................................................................................................................................................................................................................................................................... 400 Seals Repair.................................................................................................................................................................................................................................................................. 400 Remove.................................................................................................................................................................................................................................................................... 400 Install................................................................................................................................................................................................................................................................... 401 Service Brake Repair.......................................................................................................................................................................................................................................................... 401 Remove and Disassemble.................................................................................................................................................................................................................................................... 401 Drain Lubricating Oil................................................................................................................................................................................................................................................. 401 Drain Coolant Oil..................................................................................................................................................................................................................................................... 408 Disconnect Brake Lines................................................................................................................................................................................................................................................ 408 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14....................................................................................................................................................................................................... 408 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...................................................................................................................................................................................................... 409 Brake Disc Housing Assembly Wheel End................................................................................................................................................................................................................................. 410 Brake Piston Housing.................................................................................................................................................................................................................................................. 411 Brake Piston Housing and Wheel Spindle................................................................................................................................................................................................................................ 412 Inspect................................................................................................................................................................................................................................................................... 412 Clean..................................................................................................................................................................................................................................................................... 414 Assemble.................................................................................................................................................................................................................................................................. 415 Wheel Spindle......................................................................................................................................................................................................................................................... 415 Brake Piston Housing.................................................................................................................................................................................................................................................. 415 Piston Assembly....................................................................................................................................................................................................................................................... 417 Brake Disc Housing.................................................................................................................................................................................................................................................... 417 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub............................................................................................................................................................................................................... 419 Check for Correct Installation of Duo-Cone Seal....................................................................................................................................................................................................................... 420 Wheel Hub to Brake Disc Housing....................................................................................................................................................................................................................................... 421 Adjust.................................................................................................................................................................................................................................................................... 422 Fill Brake System With Coolant Oil.................................................................................................................................................................................................................................... 422 System Air Removal.................................................................................................................................................................................................................................................... 423 Adjust Brake With New Disc Pack....................................................................................................................................................................................................................................... 423 Coolant Change Intervals.............................................................................................................................................................................................................................................. 424 Coolant Draining and Filling.......................................................................................................................................................................................................................................... 424 Specifications................................................................................................................................................................................................................................................................ 426 Minimum Brake Disc Thickness.............................................................................................................................................................................................................................................. 429 Hydraulic Fluid for Brake Actuation....................................................................................................................................................................................................................................... 429 Brake Coolant Specifications.............................................................................................................................................................................................................................................. 429 Coolant Change Intervals.................................................................................................................................................................................................................................................. 429 Hydraulic Fluid Specifications............................................................................................................................................................................................................................................ 429 Troubleshooting............................................................................................................................................................................................................................................................... 429 Brake Does Not Apply...................................................................................................................................................................................................................................................... 429 Brake Does Not Release.................................................................................................................................................................................................................................................... 430 Brake Performance......................................................................................................................................................................................................................................................... 430 Brake Leaks Actuation Fluid............................................................................................................................................................................................................................................... 431 Brake Cooling Fluid Leakage............................................................................................................................................................................................................................................... 432 Brake Noise and Vibration................................................................................................................................................................................................................................................. 432 Brake Overheats........................................................................................................................................................................................................................................................... 432 tables............................................................................................................................................................................................................................................................................ 387 Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 399 Table 2. Minimum Brake Disc Thickness......................................................................................................................................................................................................................................... 413 Table 3. Formed Seal Wear Chart............................................................................................................................................................................................................................................... 413 1503241-5000SRM0969-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 437 toc............................................................................................................................................................................................................................................................................... 437 Empty Container Handling Attachment........................................................................................................................................................................................................................................... 437 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 438 General....................................................................................................................................................................................................................................................................... 441 Description................................................................................................................................................................................................................................................................... 441 Operation..................................................................................................................................................................................................................................................................... 446 General................................................................................................................................................................................................................................................................... 446 Selector Valves........................................................................................................................................................................................................................................................... 446 Sideshift Circuit......................................................................................................................................................................................................................................................... 446 Extend and Retract Circuit................................................................................................................................................................................................................................................ 446 Twist Lock Circuit and Control............................................................................................................................................................................................................................................ 447 Model 553 - Horizontally Mounted...................................................................................................................................................................................................................................... 447 Model 558 - Vertically Mounted........................................................................................................................................................................................................................................ 447 Lifting Hooks............................................................................................................................................................................................................................................................. 447 Model 555............................................................................................................................................................................................................................................................. 447 Indicator Lights and LEDs................................................................................................................................................................................................................................................. 447 Lift Interrupt and Override............................................................................................................................................................................................................................................... 448 Overlowering Interrupt and Override....................................................................................................................................................................................................................................... 448 Carriage and Attachment Repair................................................................................................................................................................................................................................................ 448 Remove.................................................................................................................................................................................................................................................................... 448 Attachment Without Carriage Repair............................................................................................................................................................................................................................................ 449 Remove.................................................................................................................................................................................................................................................................... 449 Sideshift Cylinders Repair.................................................................................................................................................................................................................................................... 450 Remove.................................................................................................................................................................................................................................................................... 450 Disassemble............................................................................................................................................................................................................................................................... 450 Assemble.................................................................................................................................................................................................................................................................. 450 Extension Cylinders Repair.................................................................................................................................................................................................................................................... 451 Remove.................................................................................................................................................................................................................................................................... 451 Disassemble............................................................................................................................................................................................................................................................... 451 Clean and Inspect......................................................................................................................................................................................................................................................... 451 Assemble.................................................................................................................................................................................................................................................................. 451 Install................................................................................................................................................................................................................................................................... 451 Vertical End Beams Repair..................................................................................................................................................................................................................................................... 453 Remove.................................................................................................................................................................................................................................................................... 453 Install................................................................................................................................................................................................................................................................... 453 Hose Replacement in End Beams............................................................................................................................................................................................................................................. 453 Twist Locks Repair for Model 553.............................................................................................................................................................................................................................................. 454 Remove.................................................................................................................................................................................................................................................................... 454 Disassemble............................................................................................................................................................................................................................................................... 454 Clean and Inspect......................................................................................................................................................................................................................................................... 454 Assemble.................................................................................................................................................................................................................................................................. 454 Hooks Replacement for Model 555............................................................................................................................................................................................................................................... 455 Inspect................................................................................................................................................................................................................................................................... 455 Remove.................................................................................................................................................................................................................................................................... 455 Install................................................................................................................................................................................................................................................................... 455 Twist Locks Repair for Model 558.............................................................................................................................................................................................................................................. 456 Disassemble............................................................................................................................................................................................................................................................... 456 Clean and Inspect......................................................................................................................................................................................................................................................... 456 Assemble.................................................................................................................................................................................................................................................................. 456 Bleed the System.............................................................................................................................................................................................................................................................. 457 Valve Assembly................................................................................................................................................................................................................................................................ 457 Slide Pad Replacement......................................................................................................................................................................................................................................................... 458 Adjustments................................................................................................................................................................................................................................................................... 458 Twist Lock Angle Adjustment............................................................................................................................................................................................................................................... 458 Model 558 Only........................................................................................................................................................................................................................................................ 458 LOCKED/NOT LOCKED Sensors Adjustment...................................................................................................................................................................................................................................... 459 Model 553............................................................................................................................................................................................................................................................. 459 Model 558............................................................................................................................................................................................................................................................. 459 Seated Sensor Adjustment.................................................................................................................................................................................................................................................. 459 Model 553............................................................................................................................................................................................................................................................. 459 Model 558............................................................................................................................................................................................................................................................. 459 Overlowering Protection Sensor Adjustment (Models 553 and 558)............................................................................................................................................................................................................ 459 Torque Chart.............................................................................................................................................................................................................................................................. 460 Maintenance................................................................................................................................................................................................................................................................... 460 Additional Attachment Maintenance......................................................................................................................................................................................................................................... 462 Interface Boxes........................................................................................................................................................................................................................................................... 463 Model 555............................................................................................................................................................................................................................................................. 463 Models 553 and 558.................................................................................................................................................................................................................................................... 463 Troubleshooting............................................................................................................................................................................................................................................................... 465 tables............................................................................................................................................................................................................................................................................ 437 Table 1. Torque Chart......................................................................................................................................................................................................................................................... 460 Table 2. Inspect and Adjust (See Figure 14 ).................................................................................................................................................................................................................................. 461 Table 3. Lubricate (See Figure 14 )........................................................................................................................................................................................................................................... 462 Table 4. Replace (See Figure 14 )............................................................................................................................................................................................................................................. 462 1541323-0600SRM1068-(05-2004)-UK-EN................................................................................................................................................................................................................................................... 483 toc............................................................................................................................................................................................................................................................................... 483 Perkins Tier 2 Diesel Engines................................................................................................................................................................................................................................................. 483 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 484 General....................................................................................................................................................................................................................................................................... 491 General Safety Rules...................................................................................................................................................................................................................................................... 491 Description................................................................................................................................................................................................................................................................... 492 Engine Serial Number Codes................................................................................................................................................................................................................................................ 494 Engine Data............................................................................................................................................................................................................................................................... 494 Engine Removal and Installation............................................................................................................................................................................................................................................... 495 Cylinder Head Assembly Repair................................................................................................................................................................................................................................................. 495 Valve Cover............................................................................................................................................................................................................................................................... 495 Remove................................................................................................................................................................................................................................................................ 495 Install............................................................................................................................................................................................................................................................... 496 Rocker Arm Assembly....................................................................................................................................................................................................................................................... 496 Remove................................................................................................................................................................................................................................................................ 496 Disassemble........................................................................................................................................................................................................................................................... 496 Inspect............................................................................................................................................................................................................................................................... 496 Assemble.............................................................................................................................................................................................................................................................. 496 Install............................................................................................................................................................................................................................................................... 496 Valve Clearance Adjustments............................................................................................................................................................................................................................................... 497 Valve Springs............................................................................................................................................................................................................................................................. 498 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 499 Remove................................................................................................................................................................................................................................................................ 499 Install............................................................................................................................................................................................................................................................... 501 Valves and Valve Springs.................................................................................................................................................................................................................................................. 504 Remove................................................................................................................................................................................................................................................................ 504 Inspect............................................................................................................................................................................................................................................................... 504 Install............................................................................................................................................................................................................................................................... 505 Valve Guides.............................................................................................................................................................................................................................................................. 505 Inspect............................................................................................................................................................................................................................................................... 505 Remove................................................................................................................................................................................................................................................................ 505 Install............................................................................................................................................................................................................................................................... 505 Cylinder Head and Valve Seats............................................................................................................................................................................................................................................. 506 Inspect............................................................................................................................................................................................................................................................... 506 Repair................................................................................................................................................................................................................................................................ 507 New Valve Seats, Install.............................................................................................................................................................................................................................................. 507 Piston and Connecting Rod Assemblies Repair................................................................................................................................................................................................................................... 507 Rod Bearings.............................................................................................................................................................................................................................................................. 508 Remove................................................................................................................................................................................................................................................................ 508 Install............................................................................................................................................................................................................................................................... 508 Piston and Connecting Rod Assembly........................................................................................................................................................................................................................................ 509 Service Note.......................................................................................................................................................................................................................................................... 509 Remove................................................................................................................................................................................................................................................................ 509 Install............................................................................................................................................................................................................................................................... 510 Piston Rings.............................................................................................................................................................................................................................................................. 511 Remove................................................................................................................................................................................................................................................................ 511 Inspect............................................................................................................................................................................................................................................................... 511 Install............................................................................................................................................................................................................................................................... 512 Piston and Connecting Rod................................................................................................................................................................................................................................................. 512 Disassemble........................................................................................................................................................................................................................................................... 512 Inspect............................................................................................................................................................................................................................................................... 512 How to Select Correct Replacements.................................................................................................................................................................................................................................... 513 Install............................................................................................................................................................................................................................................................... 514 Piston Cooling Jets....................................................................................................................................................................................................................................................... 514 Remove................................................................................................................................................................................................................................................................ 514 Install............................................................................................................................................................................................................................................................... 515 Crankshaft Assembly Repair.................................................................................................................................................................................................................................................... 515 General................................................................................................................................................................................................................................................................... 515 Crankshaft Pulley......................................................................................................................................................................................................................................................... 516 Remove................................................................................................................................................................................................................................................................ 516 Inspect............................................................................................................................................................................................................................................................... 516 Install............................................................................................................................................................................................................................................................... 516 Rear Oil Seal............................................................................................................................................................................................................................................................. 517 Remove................................................................................................................................................................................................................................................................ 517 Install............................................................................................................................................................................................................................................................... 517 Main Bearings............................................................................................................................................................................................................................................................. 518 Remove................................................................................................................................................................................................................................................................ 518 Inspect............................................................................................................................................................................................................................................................... 519 Install............................................................................................................................................................................................................................................................... 519 Thrust Washers............................................................................................................................................................................................................................................................ 519 Crankshaft Axial Movement, Check...................................................................................................................................................................................................................................... 519 Remove................................................................................................................................................................................................................................................................ 520 Install............................................................................................................................................................................................................................................................... 520 Crankshaft................................................................................................................................................................................................................................................................ 521 Remove................................................................................................................................................................................................................................................................ 521 Inspect............................................................................................................................................................................................................................................................... 521 Install............................................................................................................................................................................................................................................................... 522 Flywheel.................................................................................................................................................................................................................................................................. 523 Remove................................................................................................................................................................................................................................................................ 523 Ring Gear, Replace.................................................................................................................................................................................................................................................... 523 Install............................................................................................................................................................................................................................................................... 523 Flywheel Housing.......................................................................................................................................................................................................................................................... 524 Remove................................................................................................................................................................................................................................................................ 524 Install............................................................................................................................................................................................................................................................... 524 Timing Case and Timing Gears Repair........................................................................................................................................................................................................................................... 525 General................................................................................................................................................................................................................................................................... 525 Timing Case Cover......................................................................................................................................................................................................................................................... 525 Remove................................................................................................................................................................................................................................................................ 525 Install............................................................................................................................................................................................................................................................... 526 Front Oil Seal............................................................................................................................................................................................................................................................ 526 Remove................................................................................................................................................................................................................................................................ 526 Install............................................................................................................................................................................................................................................................... 526 Crankshaft Pulley Wear Sleeve............................................................................................................................................................................................................................................. 527 Install............................................................................................................................................................................................................................................................... 527 Idler Gear and Hub........................................................................................................................................................................................................................................................ 527 Remove................................................................................................................................................................................................................................................................ 527 Install............................................................................................................................................................................................................................................................... 528 Air Compressor Drive, Bendix.............................................................................................................................................................................................................................................. 529 Disassemble........................................................................................................................................................................................................................................................... 529 Assemble.............................................................................................................................................................................................................................................................. 529 Fuel Injection Pump Gear.................................................................................................................................................................................................................................................. 530 Remove................................................................................................................................................................................................................................................................ 530 Install............................................................................................................................................................................................................................................................... 531 Camshaft Gear............................................................................................................................................................................................................................................................. 531 Remove................................................................................................................................................................................................................................................................ 531 Install............................................................................................................................................................................................................................................................... 532 Crankshaft Gear........................................................................................................................................................................................................................................................... 532 Remove................................................................................................................................................................................................................................................................ 532 Install............................................................................................................................................................................................................................................................... 533 Timing Case............................................................................................................................................................................................................................................................... 533 Remove................................................................................................................................................................................................................................................................ 533 Install............................................................................................................................................................................................................................................................... 533 Camshaft and Tappets...................................................................................................................................................................................................................................................... 534 Remove................................................................................................................................................................................................................................................................ 534 Install............................................................................................................................................................................................................................................................... 535 Cylinder Block Assembly Repair................................................................................................................................................................................................................................................ 535 Description............................................................................................................................................................................................................................................................... 535 Cylinder Block............................................................................................................................................................................................................................................................ 535 Disassemble........................................................................................................................................................................................................................................................... 535 Inspect............................................................................................................................................................................................................................................................... 536 Assemble.............................................................................................................................................................................................................................................................. 536 Cylinder Liner............................................................................................................................................................................................................................................................ 537 Inspect............................................................................................................................................................................................................................................................... 537 Cylinder Liner Condition, Check....................................................................................................................................................................................................................................... 537 Remove................................................................................................................................................................................................................................................................ 538 Service Liner, Install................................................................................................................................................................................................................................................ 539 Partially Finished Liner, Install..................................................................................................................................................................................................................................... 540 Engine Timing................................................................................................................................................................................................................................................................. 541 Description............................................................................................................................................................................................................................................................... 541 How to Set Number One Piston to TDC on Compression Stroke............................................................................................................................................................................................................. 542 How to Set Number One Piston to TDC on Compression Stroke (Alter...................................................................................................................................................................................................... 543 How to Set Number One Piston to 4° After TDC on Compression Stro...................................................................................................................................................................................................... 544 Valve Timing, Check................................................................................................................................................................................................................................................... 545 Fuel Injection Pump Timing, Check..................................................................................................................................................................................................................................... 546 Turbocharger.................................................................................................................................................................................................................................................................. 546 General................................................................................................................................................................................................................................................................... 546 Remove.................................................................................................................................................................................................................................................................... 546 Install................................................................................................................................................................................................................................................................... 547 Impeller and Compressor Housing, Clean.................................................................................................................................................................................................................................... 547 Waste-Gate Valve Check.................................................................................................................................................................................................................................................... 548 Closed Circuit Breather System (CCB)...................................................................................................................................................................................................................................... 549 CCB Assembly, Remove.................................................................................................................................................................................................................................................. 549 Closed Circuit Drain Valve, Remove.................................................................................................................................................................................................................................... 549 CCB Assembly, Install................................................................................................................................................................................................................................................. 549 Closed Circuit Drain Valve, Install................................................................................................................................................................................................................................... 549 Lubrication System Repair..................................................................................................................................................................................................................................................... 550 General................................................................................................................................................................................................................................................................... 550 Oil Filter, Replace....................................................................................................................................................................................................................................................... 550 Oil Filter Head........................................................................................................................................................................................................................................................... 550 Remove................................................................................................................................................................................................................................................................ 550 Install............................................................................................................................................................................................................................................................... 550 Oil Filter Head Bypass Valve.............................................................................................................................................................................................................................................. 551 Remove and Install.................................................................................................................................................................................................................................................... 551 Oil Sump.................................................................................................................................................................................................................................................................. 551 Remove................................................................................................................................................................................................................................................................ 551 Install............................................................................................................................................................................................................................................................... 551 Oil Pump.................................................................................................................................................................................................................................................................. 552 Remove................................................................................................................................................................................................................................................................ 552 Inspect............................................................................................................................................................................................................................................................... 552 Install............................................................................................................................................................................................................................................................... 553 Relief Valve.............................................................................................................................................................................................................................................................. 554 Remove................................................................................................................................................................................................................................................................ 554 Disassemble........................................................................................................................................................................................................................................................... 554 Inspect............................................................................................................................................................................................................................................................... 554 Assemble.............................................................................................................................................................................................................................................................. 554 Install............................................................................................................................................................................................................................................................... 554 Idler Gear Shaft, Replace................................................................................................................................................................................................................................................. 554 Remove................................................................................................................................................................................................................................................................ 555 Remove (Alternative).................................................................................................................................................................................................................................................. 555 Install............................................................................................................................................................................................................................................................... 556 Install (Alternative)................................................................................................................................................................................................................................................. 556 Fuel System Repair............................................................................................................................................................................................................................................................ 557 Description............................................................................................................................................................................................................................................................... 557 Fuel Injection Pump....................................................................................................................................................................................................................................................... 559 Remove................................................................................................................................................................................................................................................................ 559 Install............................................................................................................................................................................................................................................................... 561 Fuel System Air Removal................................................................................................................................................................................................................................................... 562 Fuel Filter, Replace...................................................................................................................................................................................................................................................... 564 Fuel Injectors............................................................................................................................................................................................................................................................ 564 Remove................................................................................................................................................................................................................................................................ 565 Inspect............................................................................................................................................................................................................................................................... 565 Install............................................................................................................................................................................................................................................................... 565 Fuel Lift Pump............................................................................................................................................................................................................................................................ 566 Remove................................................................................................................................................................................................................................................................ 566 Disassemble........................................................................................................................................................................................................................................................... 566 Assemble.............................................................................................................................................................................................................................................................. 566 Install............................................................................................................................................................................................................................................................... 567 Test.................................................................................................................................................................................................................................................................. 567 Cooling System Repair......................................................................................................................................................................................................................................................... 568 General................................................................................................................................................................................................................................................................... 568 Thermostat................................................................................................................................................................................................................................................................ 568 Remove................................................................................................................................................................................................................................................................ 568 Install............................................................................................................................................................................................................................................................... 569 Test.................................................................................................................................................................................................................................................................. 569 Coolant Pump.............................................................................................................................................................................................................................................................. 569 Remove................................................................................................................................................................................................................................................................ 569 Disassemble........................................................................................................................................................................................................................................................... 570 Assemble.............................................................................................................................................................................................................................................................. 572 Install............................................................................................................................................................................................................................................................... 574 Fan and Fan Drive......................................................................................................................................................................................................................................................... 575 Remove................................................................................................................................................................................................................................................................ 575 Install............................................................................................................................................................................................................................................................... 575 Oil Cooler................................................................................................................................................................................................................................................................ 575 Remove................................................................................................................................................................................................................................................................ 575 Disassemble and Assemble.............................................................................................................................................................................................................................................. 576 Install............................................................................................................................................................................................................................................................... 576 Electrical Equipment Repair................................................................................................................................................................................................................................................... 577 Drive Belts............................................................................................................................................................................................................................................................... 577 Alternator................................................................................................................................................................................................................................................................ 577 Remove................................................................................................................................................................................................................................................................ 577 Install............................................................................................................................................................................................................................................................... 577 Electronic Control Module (ECM)........................................................................................................................................................................................................................................... 578 Remove................................................................................................................................................................................................................................................................ 578 Inspect............................................................................................................................................................................................................................................................... 578 Install............................................................................................................................................................................................................................................................... 578 Voltage Load and Protection Module (VLPM)................................................................................................................................................................................................................................. 579 Remove................................................................................................................................................................................................................................................................ 579 Install............................................................................................................................................................................................................................................................... 579 Engine Speed and Timing Sensor............................................................................................................................................................................................................................................ 579 Remove................................................................................................................................................................................................................................................................ 579 Install............................................................................................................................................................................................................................................................... 580 Pressure Sensors (Engine Oil and Air Intake).............................................................................................................................................................................................................................. 580 Remove................................................................................................................................................................................................................................................................ 580 Install............................................................................................................................................................................................................................................................... 581 Temperature Sensor........................................................................................................................................................................................................................................................ 581 Remove................................................................................................................................................................................................................................................................ 581 Install............................................................................................................................................................................................................................................................... 582 Starter Motor............................................................................................................................................................................................................................................................. 582 Remove................................................................................................................................................................................................................................................................ 582 Install............................................................................................................................................................................................................................................................... 582 Cold Start Aid............................................................................................................................................................................................................................................................ 582 Air Compressor................................................................................................................................................................................................................................................................ 582 General................................................................................................................................................................................................................................................................... 582 Repair.................................................................................................................................................................................................................................................................... 583 Remove................................................................................................................................................................................................................................................................ 583 Install............................................................................................................................................................................................................................................................... 583 Rotary Exhauster Replacement.................................................................................................................................................................................................................................................. 584 Remove.................................................................................................................................................................................................................................................................... 584 Clean..................................................................................................................................................................................................................................................................... 584 Install................................................................................................................................................................................................................................................................... 584 Engine Specifications......................................................................................................................................................................................................................................................... 585 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 585 Piston and Connecting Rods................................................................................................................................................................................................................................................ 588 Crankshaft Assembly....................................................................................................................................................................................................................................................... 589 Crankshaft Overhaul................................................................................................................................................................................................................................................... 590 Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 592 Engine Block Assembly..................................................................................................................................................................................................................................................... 593 Turbocharger.............................................................................................................................................................................................................................................................. 594 Lubrication System........................................................................................................................................................................................................................................................ 595 Cooling System............................................................................................................................................................................................................................................................ 597 Flywheel and Housing...................................................................................................................................................................................................................................................... 597 Electrical Equipment...................................................................................................................................................................................................................................................... 597 Torque Specifications......................................................................................................................................................................................................................................................... 598 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 598 Piston and Connecting Rod Assemblies...................................................................................................................................................................................................................................... 598 Crankshaft Assembly....................................................................................................................................................................................................................................................... 598 Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 598 Turbocharger.............................................................................................................................................................................................................................................................. 598 Lubrication System........................................................................................................................................................................................................................................................ 598 Fuel System............................................................................................................................................................................................................................................................... 598 Cooling System............................................................................................................................................................................................................................................................ 599 Flywheel.................................................................................................................................................................................................................................................................. 599 Auxiliary Equipment....................................................................................................................................................................................................................................................... 599 Special Torque Specifications................................................................................................................................................................................................................................................. 599 Flywheel and Housing...................................................................................................................................................................................................................................................... 599 Electrical Equipment...................................................................................................................................................................................................................................................... 599 Auxiliary Equipment....................................................................................................................................................................................................................................................... 599 Special Tools................................................................................................................................................................................................................................................................. 600 Troubleshooting............................................................................................................................................................................................................................................................... 605 Turbocharger Troubleshooting.................................................................................................................................................................................................................................................. 607 tables............................................................................................................................................................................................................................................................................ 483 Table 1. Cylinder Head........................................................................................................................................................................................................................................................ 585 Table 2. Valve Guides......................................................................................................................................................................................................................................................... 585 Table 3. Inlet Valves......................................................................................................................................................................................................................................................... 586 Table 4. Exhaust Valves....................................................................................................................................................................................................................................................... 586 Table 5. Valve Springs........................................................................................................................................................................................................................................................ 587 Table 6. Tappets.............................................................................................................................................................................................................................................................. 587 Table 7. Rocker Arm Shaft..................................................................................................................................................................................................................................................... 587 Table 8. Rocker Arms and Bushings............................................................................................................................................................................................................................................. 587 Table 9. Pistons.............................................................................................................................................................................................................................................................. 588 Table 10. Piston Rings........................................................................................................................................................................................................................................................ 588 Table 11. Piston Pins......................................................................................................................................................................................................................................................... 588 Table 12. Connecting Rods..................................................................................................................................................................................................................................................... 588 Table 13. Small End Bushings.................................................................................................................................................................................................................................................. 589 Table 14. Connecting Rod Bearings............................................................................................................................................................................................................................................. 589 Table 15. Piston Cooling Jets................................................................................................................................................................................................................................................. 589 Table 16. Crankshaft.......................................................................................................................................................................................................................................................... 589 Table 17. Main Bearings....................................................................................................................................................................................................................................................... 590 Table 18. Crankshaft Thrust Washers........................................................................................................................................................................................................................................... 590 Table 19. Crankshaft Heat Treatment........................................................................................................................................................................................................................................... 590 Table 20. Crankshaft Overhaul Specifications.................................................................................................................................................................................................................................. 590 Table 21. Maximum Variation (Run-Out)......................................................................................................................................................................................................................................... 592 Table 22. Camshaft............................................................................................................................................................................................................................................................ 592 Table 23. Camshaft Thrust Washer.............................................................................................................................................................................................................................................. 592 Table 24. Camshaft Gear....................................................................................................................................................................................................................................................... 592 Table 25. Gear for Fuel Injection Pump........................................................................................................................................................................................................................................ 592 Table 26. Crankshaft Gear..................................................................................................................................................................................................................................................... 593 Table 27. Idler Gear and Hub.................................................................................................................................................................................................................................................. 593 Table 28. Cylinder Block...................................................................................................................................................................................................................................................... 593 Table 29. Cylinder Liners..................................................................................................................................................................................................................................................... 593 Table 30. Cylinder Liner Specifications (Partially Finished).................................................................................................................................................................................................................. 594 Table 31. Oil Pump............................................................................................................................................................................................................................................................ 595 Table 32. Idler Gear for Oil Pump............................................................................................................................................................................................................................................. 595 Table 33. Relief Valve........................................................................................................................................................................................................................................................ 595 Table 34. Oil Filter.......................................................................................................................................................................................................................................................... 595 Table 35. Bosch Fuel Injection Pump........................................................................................................................................................................................................................................... 595 Table 36. Fuel Injector Codes................................................................................................................................................................................................................................................. 596 Table 37. Fuel Pump........................................................................................................................................................................................................................................................... 597 Table 38. Fuel Filter......................................................................................................................................................................................................................................................... 597 Table 39. Coolant Pump........................................................................................................................................................................................................................................................ 597 Table 40. Thermostat.......................................................................................................................................................................................................................................................... 597 Table 41. Fan Drive Housing................................................................................................................................................................................................................................................... 597 Table 42. Limits for Flywheel Run Out and Alignment (Total Indic.............................................................................................................................................................................................................. 597 Table 43. Alternator.......................................................................................................................................................................................................................................................... 597 Table 44. Starter Motor....................................................................................................................................................................................................................................................... 597 Table 45. Cold Start Aid...................................................................................................................................................................................................................................................... 597 Table 46. List of Possible Causes............................................................................................................................................................................................................................................. 605 Table 47. List of Possible Causes............................................................................................................................................................................................................................................. 607 1553599-4000SRM1062-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 611 toc............................................................................................................................................................................................................................................................................... 611 Masts and Carriages........................................................................................................................................................................................................................................................... 611 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 612 General....................................................................................................................................................................................................................................................................... 615 Description................................................................................................................................................................................................................................................................... 615 Operation..................................................................................................................................................................................................................................................................... 616 Two-Stage Mast............................................................................................................................................................................................................................................................ 616 Three-Stage Mast.......................................................................................................................................................................................................................................................... 617 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 618 Forks Repair.................................................................................................................................................................................................................................................................. 621 Remove.................................................................................................................................................................................................................................................................... 621 Inspect and Adjust........................................................................................................................................................................................................................................................ 621 Install................................................................................................................................................................................................................................................................... 621 Carriage Repair............................................................................................................................................................................................................................................................... 622 Description............................................................................................................................................................................................................................................................... 622 Three Function........................................................................................................................................................................................................................................................ 622 Four to Six Function.................................................................................................................................................................................................................................................. 622 Remove.................................................................................................................................................................................................................................................................... 622 Disassemble............................................................................................................................................................................................................................................................... 623 Clean and Inspect......................................................................................................................................................................................................................................................... 625 Assemble.................................................................................................................................................................................................................................................................. 625 Install................................................................................................................................................................................................................................................................... 625 Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 626 Remove.................................................................................................................................................................................................................................................................... 626 Disassemble............................................................................................................................................................................................................................................................... 626 Clean and Inspect......................................................................................................................................................................................................................................................... 626 Assemble.................................................................................................................................................................................................................................................................. 626 Install................................................................................................................................................................................................................................................................... 626 Fork Positioner Cylinders Repair.............................................................................................................................................................................................................................................. 630 Remove.................................................................................................................................................................................................................................................................... 630 Disassemble............................................................................................................................................................................................................................................................... 630 Clean and Inspect......................................................................................................................................................................................................................................................... 630 Assemble.................................................................................................................................................................................................................................................................. 630 Install................................................................................................................................................................................................................................................................... 630 Directional Control Valve Repair.............................................................................................................................................................................................................................................. 637 Remove.................................................................................................................................................................................................................................................................... 637 Disassemble............................................................................................................................................................................................................................................................... 637 Clean and Inspect......................................................................................................................................................................................................................................................... 637 Assemble.................................................................................................................................................................................................................................................................. 638 Install................................................................................................................................................................................................................................................................... 638 Mast Repair................................................................................................................................................................................................................................................................... 638 Two- and Three-Stage Mast................................................................................................................................................................................................................................................. 638 Remove................................................................................................................................................................................................................................................................ 638 Disassemble........................................................................................................................................................................................................................................................... 643 Clean and Inspect..................................................................................................................................................................................................................................................... 645 Assemble.............................................................................................................................................................................................................................................................. 646 Install............................................................................................................................................................................................................................................................... 647 Three-Stage Mast (Four Cylinders)......................................................................................................................................................................................................................................... 647 Remove................................................................................................................................................................................................................................................................ 647 Disassemble........................................................................................................................................................................................................................................................... 649 Clean and Inspect..................................................................................................................................................................................................................................................... 651 Assemble.............................................................................................................................................................................................................................................................. 651 Install............................................................................................................................................................................................................................................................... 651 Fork Carriage Chains...................................................................................................................................................................................................................................................... 653 Adjust................................................................................................................................................................................................................................................................ 653 Bearing Rollers........................................................................................................................................................................................................................................................... 655 Description........................................................................................................................................................................................................................................................... 655 Lubrication........................................................................................................................................................................................................................................................... 655 Clearance............................................................................................................................................................................................................................................................. 655 Remove and Disassemble................................................................................................................................................................................................................................................ 655 Assemble.............................................................................................................................................................................................................................................................. 656 Mast Profile.............................................................................................................................................................................................................................................................. 656 Lift Cylinders Description.................................................................................................................................................................................................................................................... 656 Piston-Type Cylinders..................................................................................................................................................................................................................................................... 656 Displacement-Type Cylinders............................................................................................................................................................................................................................................... 656 Lift Cylinders Repair......................................................................................................................................................................................................................................................... 657 Remove.................................................................................................................................................................................................................................................................... 657 Disassemble............................................................................................................................................................................................................................................................... 659 Clean and Inspect......................................................................................................................................................................................................................................................... 659 Assemble.................................................................................................................................................................................................................................................................. 659 Install................................................................................................................................................................................................................................................................... 660 Mast Operation Check.......................................................................................................................................................................................................................................................... 660 Lift and Tilt System Leak Checks.............................................................................................................................................................................................................................................. 661 Lift System............................................................................................................................................................................................................................................................... 661 Tilt System............................................................................................................................................................................................................................................................... 661 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment....................................................................................................................................................................................................................... 662 Lift Chain Adjustments........................................................................................................................................................................................................................................................ 662 Mast Adjustments.............................................................................................................................................................................................................................................................. 663 Bearing Blocks, Two-Stage Masts........................................................................................................................................................................................................................................... 663 Wear Plates............................................................................................................................................................................................................................................................... 663 Carriage Adjustment........................................................................................................................................................................................................................................................... 663 Troubleshooting............................................................................................................................................................................................................................................................... 665 tables............................................................................................................................................................................................................................................................................ 611 Table 1. Allowable Mast Movement from Internal Leakage........................................................................................................................................................................................................................ 661 1556599-0100SRM1100-(09-2008)-UK-EN................................................................................................................................................................................................................................................... 669 toc............................................................................................................................................................................................................................................................................... 669 Operator's Cab................................................................................................................................................................................................................................................................ 669 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 670 General....................................................................................................................................................................................................................................................................... 673 Cab Repair.................................................................................................................................................................................................................................................................... 674 Rear Cab Assembly......................................................................................................................................................................................................................................................... 674 Bottom Cab Assembly....................................................................................................................................................................................................................................................... 675 Raising and Lowering Cab.................................................................................................................................................................................................................................................. 675 Raise Cab............................................................................................................................................................................................................................................................. 675 Lower Cab............................................................................................................................................................................................................................................................. 676 Cab Repair................................................................................................................................................................................................................................................................ 676 Remove................................................................................................................................................................................................................................................................ 676 Install............................................................................................................................................................................................................................................................... 677 Oil Filling for Tilt System................................................................................................................................................................................................................................................... 678 Inching and Brake Pedals...................................................................................................................................................................................................................................................... 679 Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 679 Inching Pedal, Adjust..................................................................................................................................................................................................................................................... 679 Inching Pedal Sensor, Adjust.............................................................................................................................................................................................................................................. 679 Throttle Pedal Sensor......................................................................................................................................................................................................................................................... 680 Check..................................................................................................................................................................................................................................................................... 680 Adjust.................................................................................................................................................................................................................................................................... 680 Seat Assembly Removal......................................................................................................................................................................................................................................................... 681 Power Assist Armrest.......................................................................................................................................................................................................................................................... 681 Adjust.................................................................................................................................................................................................................................................................... 681 Steering Column Repair........................................................................................................................................................................................................................................................ 682 Remove.................................................................................................................................................................................................................................................................... 682 Install................................................................................................................................................................................................................................................................... 682 Window Wipers Replacement..................................................................................................................................................................................................................................................... 683 Window Wiper Assembly, Replace............................................................................................................................................................................................................................................ 683 Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................ 683 Rear Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................. 684 Top Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................. 684 Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 685 Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 685 Window Replacement............................................................................................................................................................................................................................................................ 686 Front Window, Replace..................................................................................................................................................................................................................................................... 687 Rear Window, Replace...................................................................................................................................................................................................................................................... 687 Top Window, Replace....................................................................................................................................................................................................................................................... 687 Door Window, Replace...................................................................................................................................................................................................................................................... 688 Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 689 Heater Parts, Replace..................................................................................................................................................................................................................................................... 690 Heat Control Knob/Switches................................................................................................................................................................................................................................................ 690 Heat Control Knob/Cable................................................................................................................................................................................................................................................... 690 Adjust................................................................................................................................................................................................................................................................ 690 Air Control Knob/Cable.................................................................................................................................................................................................................................................... 691 Adjust................................................................................................................................................................................................................................................................ 691 Air Filter, Replace....................................................................................................................................................................................................................................................... 691 Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 692 Remove................................................................................................................................................................................................................................................................ 692 Install............................................................................................................................................................................................................................................................... 692 Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 692 Switches.................................................................................................................................................................................................................................................................. 692 Controls.................................................................................................................................................................................................................................................................. 693 Fuses and Relays.............................................................................................................................................................................................................................................................. 694 Fuse Panel................................................................................................................................................................................................................................................................ 694 Fuses..................................................................................................................................................................................................................................................................... 694 Relays.................................................................................................................................................................................................................................................................... 695 Label Replacement............................................................................................................................................................................................................................................................. 696 Electrical Schematics......................................................................................................................................................................................................................................................... 696 1556600-1300SRM1082-(09-2008)-UK-EN................................................................................................................................................................................................................................................... 699 toc............................................................................................................................................................................................................................................................................... 699 Transmission.................................................................................................................................................................................................................................................................. 699 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 700 Description of Operation...................................................................................................................................................................................................................................................... 705 General................................................................................................................................................................................................................................................................... 705 Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 705 Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 705 Range Clutches............................................................................................................................................................................................................................................................ 707 Output Section............................................................................................................................................................................................................................................................ 707 Transmission Controls..................................................................................................................................................................................................................................................... 708 Operation of the Valve................................................................................................................................................................................................................................................ 709 Selection of Range.................................................................................................................................................................................................................................................... 713 Pressure Switch....................................................................................................................................................................................................................................................... 713 Electric Solenoid Controls................................................................................................................................................................................................................................................ 714 Transmission Specifications............................................................................................................................................................................................................................................... 730 Transmission Identification........................................................................................................................................................................................................................................... 730 Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 730 Transmission Repair........................................................................................................................................................................................................................................................... 732 Remove.................................................................................................................................................................................................................................................................... 732 Disassemble............................................................................................................................................................................................................................................................... 734 Transmission Case, Disassemble........................................................................................................................................................................................................................................ 735 Torque Converter Housing, Disassemble................................................................................................................................................................................................................................. 752 Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 757 First-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 759 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 764 Reverse Clutch, Disassemble....................................................................................................................................................................................................................................... 764 Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 769 Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 771 Third Clutch Shaft, Disassemble....................................................................................................................................................................................................................................... 773 Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 774 Output Shaft, Disassemble............................................................................................................................................................................................................................................. 775 Impeller, Disassemble................................................................................................................................................................................................................................................. 776 Turbine, Disassemble.................................................................................................................................................................................................................................................. 778 Clean and Inspect......................................................................................................................................................................................................................................................... 780 Housings.............................................................................................................................................................................................................................................................. 780 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 781 Bearings.............................................................................................................................................................................................................................................................. 781 Gears and Shafts...................................................................................................................................................................................................................................................... 781 Assemble.................................................................................................................................................................................................................................................................. 782 Turbine, Assemble..................................................................................................................................................................................................................................................... 782 Impeller, Assemble.................................................................................................................................................................................................................................................... 783 Output Shaft, Assemble................................................................................................................................................................................................................................................ 785 Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 787 Third Clutch Shaft, Assemble.......................................................................................................................................................................................................................................... 788 Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 789 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 792 Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 792 Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 795 First-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 799 Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 804 Torque Converter Housing, Assemble.................................................................................................................................................................................................................................... 807 Transmission Case, Assemble........................................................................................................................................................................................................................................... 812 Install................................................................................................................................................................................................................................................................... 833 Control Valve Repair.......................................................................................................................................................................................................................................................... 835 Remove.................................................................................................................................................................................................................................................................... 835 Disassemble and Assemble.................................................................................................................................................................................................................................................. 835 Clean and Inspect......................................................................................................................................................................................................................................................... 837 Housings.............................................................................................................................................................................................................................................................. 837 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 837 Install................................................................................................................................................................................................................................................................... 838 Stall Test.................................................................................................................................................................................................................................................................... 839 Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 840 Userlink®................................................................................................................................................................................................................................................................. 840 Connection................................................................................................................................................................................................................................................................ 840 Clutch Filling Calibration................................................................................................................................................................................................................................................ 840 Purpose............................................................................................................................................................................................................................................................... 840 Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 841 Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 841 Heat-up Mode.......................................................................................................................................................................................................................................................... 842 Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 842 Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 300.......................................................................................................................................................................................................... 843 Purpose............................................................................................................................................................................................................................................................... 843 Brake Pedal Adjustment................................................................................................................................................................................................................................................ 843 Dry Brake......................................................................................................................................................................................................................................................... 843 Wet Brake......................................................................................................................................................................................................................................................... 843 Inching Pedal Adjustment.............................................................................................................................................................................................................................................. 843 Inching Pedal Sensor Adjustment....................................................................................................................................................................................................................................... 844 Inching Pedal Calibration Procedure................................................................................................................................................................................................................................... 844 Verification/Adjustment of Inching Pedal Sensor When the Pedal i...................................................................................................................................................................................................... 844 Manual Inching Pedal Sensor Calibration Procedure..................................................................................................................................................................................................................... 845 Inching Pedal Calibration [S/N 2326 and Up (F019)], [S/N 3002 an.......................................................................................................................................................................................................... 845 Purpose............................................................................................................................................................................................................................................................... 845 Brake Pedal Adjustment................................................................................................................................................................................................................................................ 845 Dry Brake......................................................................................................................................................................................................................................................... 845 Wet Brake......................................................................................................................................................................................................................................................... 845 Inching Pedal Adjustment.............................................................................................................................................................................................................................................. 846 Dry Brake......................................................................................................................................................................................................................................................... 846 Wet Brake......................................................................................................................................................................................................................................................... 846 Inching Pedal Sensor Adjustment Using Userlink® Program............................................................................................................................................................................................................... 846 Inching Pedal Sensor Calibration Procedure Using Userlink® Progr...................................................................................................................................................................................................... 847 Inching Pedal Sensor Adjustment Using the APC200...................................................................................................................................................................................................................... 847 Inching Pedal Sensor Calibration Procedure Using the APC200........................................................................................................................................................................................................... 848 Troubleshooting........................................................................................................................................................................................................................................................... 848 Transmission Display Warning Codes........................................................................................................................................................................................................................................ 848 Access................................................................................................................................................................................................................................................................ 848 Clear................................................................................................................................................................................................................................................................. 849 Exit.................................................................................................................................................................................................................................................................. 849 Limp Home Mode........................................................................................................................................................................................................................................................ 884 Shutdown Mode......................................................................................................................................................................................................................................................... 885 Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 885 Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 885 Pressure and Temperature Specifications................................................................................................................................................................................................................................... 885 Electrical Specifications..................................................................................................................................................................................................................................................... 890 Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 890 Torque Specifications......................................................................................................................................................................................................................................................... 890 Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 890 Troubleshooting............................................................................................................................................................................................................................................................... 893 tables............................................................................................................................................................................................................................................................................ 699 Table 1. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 849 Table 2. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 850 Table 3. Common Calibration Condition Messages................................................................................................................................................................................................................................ 852 Table 4. Calibration Codes During Calibration................................................................................................................................................................................................................................. 853 Table 5. Error Codes During Calibration....................................................................................................................................................................................................................................... 853 Table 6. Display Warning Codes................................................................................................................................................................................................................................................ 854 Table 7. Display Warning Exceed Codes......................................................................................................................................................................................................................................... 883 Table 8. Type of Warning Codes................................................................................................................................................................................................................................................ 884 Table 9. Temperature Sensor (In Speed Sensor) Resistance Versus .............................................................................................................................................................................................................. 890 Table 10. Grade 5............................................................................................................................................................................................................................................................. 890 Table 11. Grade 8............................................................................................................................................................................................................................................................. 891 Table 12. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 892 Table 13. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 892 Table 14. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 893 1556602-8000SRM1099-(06-2006)-UK-EN................................................................................................................................................................................................................................................... 901 toc............................................................................................................................................................................................................................................................................... 901 Periodic Maintenance.......................................................................................................................................................................................................................................................... 901 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 902 General....................................................................................................................................................................................................................................................................... 907 How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 907 How to Tow Lift Truck................................................................................................................................................................................................................................................. 907 How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 908 How to Raise Drive Tires.............................................................................................................................................................................................................................................. 908 How to Raise Steering Tires........................................................................................................................................................................................................................................... 908 Maintenance Schedule.......................................................................................................................................................................................................................................................... 910 Empty Container Attachment Maintenance.................................................................................................................................................................................................................................... 922 Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 924 How to Make Checks With Engine Stopped.................................................................................................................................................................................................................................... 924 Safety Labels......................................................................................................................................................................................................................................................... 924 Forks................................................................................................................................................................................................................................................................. 924 Adjust............................................................................................................................................................................................................................................................ 924 Remove............................................................................................................................................................................................................................................................ 924 Install........................................................................................................................................................................................................................................................... 924 Forks, Mast, and Lift Chains, Inspect................................................................................................................................................................................................................................. 925 Operator Restraint System............................................................................................................................................................................................................................................. 926 Steering Column Latch................................................................................................................................................................................................................................................. 927 Tires and Wheels...................................................................................................................................................................................................................................................... 927 Fuel, Oil, or Coolant Leaks, Check.................................................................................................................................................................................................................................... 928 Air Intake Piping..................................................................................................................................................................................................................................................... 928 Cooling Fan........................................................................................................................................................................................................................................................... 928 Crankcase Breather Tube............................................................................................................................................................................................................................................... 928 Drive Belts........................................................................................................................................................................................................................................................... 929 Hydraulic System Oil.................................................................................................................................................................................................................................................. 929 Cab Hydraulic System.................................................................................................................................................................................................................................................. 930 Engine Oil............................................................................................................................................................................................................................................................ 930 Cooling System........................................................................................................................................................................................................................................................ 932 Battery............................................................................................................................................................................................................................................................... 933 Fuel System (Diesel Engines Only)..................................................................................................................................................................................................................................... 933 Water Separator/Fuel Filter (Diesel Engines Only)..................................................................................................................................................................................................................... 933 How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 934 Fault Codes........................................................................................................................................................................................................................................................... 934 Access............................................................................................................................................................................................................................................................ 934 Exit.............................................................................................................................................................................................................................................................. 934 Clear............................................................................................................................................................................................................................................................. 934 Gauges, Lights, Horn and Fuses........................................................................................................................................................................................................................................ 934 Control Levers and Pedals............................................................................................................................................................................................................................................. 937 Steering System....................................................................................................................................................................................................................................................... 937 Air Filters........................................................................................................................................................................................................................................................... 938 Transmission Oil...................................................................................................................................................................................................................................................... 938 Brakes................................................................................................................................................................................................................................................................ 938 Lift System Operation................................................................................................................................................................................................................................................. 938 Attachments........................................................................................................................................................................................................................................................... 938 Maintenance Procedures Every 250 Hours or Every 2 Months...................................................................................................................................................................................................................... 939 Empty Container Handler................................................................................................................................................................................................................................................... 939 Maintenance Procedures Every 500 Hours or Every 3 Months...................................................................................................................................................................................................................... 939 Lift Chains............................................................................................................................................................................................................................................................... 939 Lubrication........................................................................................................................................................................................................................................................... 939 Adjust................................................................................................................................................................................................................................................................ 939 Drive Shaft............................................................................................................................................................................................................................................................... 939 Steering Axle............................................................................................................................................................................................................................................................. 940 Wheel Nuts................................................................................................................................................................................................................................................................ 940 Shafts for Brake Actuators................................................................................................................................................................................................................................................ 940 Drive Axle and Differential............................................................................................................................................................................................................................................... 940 Hydraulic Tank Breather................................................................................................................................................................................................................................................... 940 Cabin Air Filter, Heater.................................................................................................................................................................................................................................................. 940 Air Filter, Engine........................................................................................................................................................................................................................................................ 940 Engine Oil and Filter..................................................................................................................................................................................................................................................... 940 Drive Belts............................................................................................................................................................................................................................................................... 941 Perkins............................................................................................................................................................................................................................................................... 941 Cummins............................................................................................................................................................................................................................................................... 941 Mast...................................................................................................................................................................................................................................................................... 942 Bearing Rollers (Three-Stage Only).................................................................................................................................................................................................................................... 943 Lubrication....................................................................................................................................................................................................................................................... 943 Clearance......................................................................................................................................................................................................................................................... 943 General Lubrication....................................................................................................................................................................................................................................................... 943 Fork Wear and Damage Check................................................................................................................................................................................................................................................ 943 Lift Chains Wear Check.................................................................................................................................................................................................................................................... 944 Empty Container Handler................................................................................................................................................................................................................................................... 944 Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 944 Charge Air Cooler......................................................................................................................................................................................................................................................... 944 Dry Brakes Air Compressor (Cummins)....................................................................................................................................................................................................................................... 944 Fuel Pump (Cummins)....................................................................................................................................................................................................................................................... 945 Fuel Filter............................................................................................................................................................................................................................................................... 945 Perkins............................................................................................................................................................................................................................................................... 945 Remove............................................................................................................................................................................................................................................................ 945 Install........................................................................................................................................................................................................................................................... 945 Cummins............................................................................................................................................................................................................................................................... 946 Remove............................................................................................................................................................................................................................................................ 946 Install........................................................................................................................................................................................................................................................... 946 Fuel System Air Removal (Perkins)..................................................................................................................................................................................................................................... 946 Fuel System Air Removal (Cummins)..................................................................................................................................................................................................................................... 946 Fuel Injection Pump Without Vent Tube................................................................................................................................................................................................................................. 946 Coolant................................................................................................................................................................................................................................................................... 948 Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 948 Transmission Oil and Filter, Change....................................................................................................................................................................................................................................... 948 Fuel Injection Pump Timing (Perkins Only)................................................................................................................................................................................................................................. 948 Valve Adjustment.......................................................................................................................................................................................................................................................... 948 Perkins............................................................................................................................................................................................................................................................... 948 Differential and Drive Axle............................................................................................................................................................................................................................................... 948 Pilot Accumulator Pressure Charge Check................................................................................................................................................................................................................................... 949 Maintenance Procedures Every 1000 Hours or Yearly............................................................................................................................................................................................................................. 949 Coolant Fan Belt Tensioner................................................................................................................................................................................................................................................ 949 Belt Driven Fan Hub....................................................................................................................................................................................................................................................... 951 Valve Adjustment.......................................................................................................................................................................................................................................................... 951 Cummins............................................................................................................................................................................................................................................................... 951 Accumulator and Wet Brakes................................................................................................................................................................................................................................................ 952 Wet Brake Oil Filter...................................................................................................................................................................................................................................................... 952 Air Dryer Cartridge (Dry Brakes).......................................................................................................................................................................................................................................... 952 Air Compressor Air Filter (Dry Brakes).................................................................................................................................................................................................................................... 952 Maintenance Procedures Every 2000 Hours or Yearly............................................................................................................................................................................................................................. 953 Hydraulic System.......................................................................................................................................................................................................................................................... 953 Hydraulic Oil Filter, Change.......................................................................................................................................................................................................................................... 953 Hydraulic Oil, Change................................................................................................................................................................................................................................................. 953 Hydraulic Pilot Valve Filter, Change.................................................................................................................................................................................................................................. 953 Transmission Calibration.................................................................................................................................................................................................................................................. 954 Wheel Bearings............................................................................................................................................................................................................................................................ 954 Steer Wheels.......................................................................................................................................................................................................................................................... 954 Drive Wheels.......................................................................................................................................................................................................................................................... 954 Service Brakes............................................................................................................................................................................................................................................................ 954 Cleaning Procedures (Dry Brake Axle).................................................................................................................................................................................................................................. 954 Maintenance Procedures Every 2000 Hours or 2 Years............................................................................................................................................................................................................................ 955 Air Compressor Discharge Lines............................................................................................................................................................................................................................................ 955 Rubber Vibration Damper................................................................................................................................................................................................................................................... 956 Engine Coolant............................................................................................................................................................................................................................................................ 956 Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 956 Empty Container Handler................................................................................................................................................................................................................................................... 956 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 957 Fuel Injectors Check.......................................................................................................................................................................................................................................................... 957 Perkins................................................................................................................................................................................................................................................................... 957 Lift and Tilt System Leak Check............................................................................................................................................................................................................................................... 958 Lift System............................................................................................................................................................................................................................................................... 958 Tilt System............................................................................................................................................................................................................................................................... 959 Welding Repairs............................................................................................................................................................................................................................................................... 960 Wheel and Tire Replacement.................................................................................................................................................................................................................................................... 960 Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 960 Pneumatic Tires........................................................................................................................................................................................................................................................... 961 Remove Tire From Wheel................................................................................................................................................................................................................................................ 961 Remove Tire From Three- and Four-Piece Wheel...................................................................................................................................................................................................................... 961 Install Tire on Wheel................................................................................................................................................................................................................................................. 962 Install Three- or Four-Piece Wheel in Tire........................................................................................................................................................................................................................ 963 Add Air to Tires.......................................................................................................................................................................................................................................................... 964 Solid Rubber Tires........................................................................................................................................................................................................................................................ 964 Remove Tire From Wheel................................................................................................................................................................................................................................................ 964 Install Tire on Wheel................................................................................................................................................................................................................................................. 966 Wheels, Install........................................................................................................................................................................................................................................................... 967 tables............................................................................................................................................................................................................................................................................ 901 Table 1. Daily Inspections − Condition Check.................................................................................................................................................................................................................................. 911 Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 912 Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 913 Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 914 Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 914 Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 917 Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 918 Table 8. Empty Container Attachment Maintenance − Inspect and ................................................................................................................................................................................................................ 922 Table 9. Empty Container Attachment Maintenance − Lubricate................................................................................................................................................................................................................... 923 Table 10. Empty Container Attachment Maintenance − Replace.................................................................................................................................................................................................................... 923 Table 11. Nominal Valve Clearance............................................................................................................................................................................................................................................. 952 Table 12. Allowable Mast Movement from Internal Leakage....................................................................................................................................................................................................................... 959 1556604-8000SRM1103-(11-2006)-UK-EN................................................................................................................................................................................................................................................... 971 toc............................................................................................................................................................................................................................................................................... 971 Diagrams...................................................................................................................................................................................................................................................................... 971 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 972 1556871-2200SRM1105-(03-2007)-UK-EN...................................................................................................................................................................................................................................................1059 toc...............................................................................................................................................................................................................................................................................1059 Instrument Panel Indicators and Senders.......................................................................................................................................................................................................................................1059 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1060 General.......................................................................................................................................................................................................................................................................1063 Description...................................................................................................................................................................................................................................................................1063 General...................................................................................................................................................................................................................................................................1063 Instrument Panel Meters, Indicators, and LCD Display......................................................................................................................................................................................................................1063 Connector.................................................................................................................................................................................................................................................................1069 Seat Switch Logic.........................................................................................................................................................................................................................................................1070 Central Warning Light Output..............................................................................................................................................................................................................................................1070 Buzzer Output.............................................................................................................................................................................................................................................................1070 Instrument Panel..............................................................................................................................................................................................................................................................1072 Remove....................................................................................................................................................................................................................................................................1072 Sender Replacement............................................................................................................................................................................................................................................................1073 Fuel Level Sender (Diesel Engine Only)....................................................................................................................................................................................................................................1073 Engine Oil Pressure Sender................................................................................................................................................................................................................................................1074 Brake Pressure Sender.....................................................................................................................................................................................................................................................1074 Low Coolant Sender........................................................................................................................................................................................................................................................1074 Vacuum Switch.............................................................................................................................................................................................................................................................1074 Specifications................................................................................................................................................................................................................................................................1075 Troubleshooting...............................................................................................................................................................................................................................................................1076 tables............................................................................................................................................................................................................................................................................1059 Table 1. Instrument Panel and Indicators......................................................................................................................................................................................................................................1064 Table 2. Pin Description......................................................................................................................................................................................................................................................1069 Table 3. Sender Description...................................................................................................................................................................................................................................................1070 1564053-0600SRM1101-(11-2007)-UK-EN...................................................................................................................................................................................................................................................1081 toc...............................................................................................................................................................................................................................................................................1081 Cummins Diesel/LPG Engine Fault Code Guide....................................................................................................................................................................................................................................1081 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1082 General.......................................................................................................................................................................................................................................................................1085 Fault Codes...................................................................................................................................................................................................................................................................1085 Normal Mode...............................................................................................................................................................................................................................................................1085 Fault Log Mode............................................................................................................................................................................................................................................................1085 Access................................................................................................................................................................................................................................................................1085 Exit..................................................................................................................................................................................................................................................................1086 Clear.................................................................................................................................................................................................................................................................1086 Electronic Throttle Calibration...........................................................................................................................................................................................................................................1086 Electronic Throttle Calibration Procedure.............................................................................................................................................................................................................................1086 tables............................................................................................................................................................................................................................................................................1081 Table 1. Error Code Descriptions..............................................................................................................................................................................................................................................1087 1566673-0600SRM1158-(06-2005)-UK-EN...................................................................................................................................................................................................................................................1103 toc...............................................................................................................................................................................................................................................................................1103 Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide.................................................................................................................................................................................................................1103 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1104 Electronic Troubleshooting....................................................................................................................................................................................................................................................1127 System Operation..........................................................................................................................................................................................................................................................1127 Electronic Controls.......................................................................................................................................................................................................................................................1127 Engine Governor...........................................................................................................................................................................................................................................................1128 Timing Considerations.....................................................................................................................................................................................................................................................1128 Fuel Injection............................................................................................................................................................................................................................................................1128 Diagnostic Codes..........................................................................................................................................................................................................................................................1128 Diagnostic Fault Codes....................................................................................................................................................................................................................................................1128 Diagnostic Event Codes....................................................................................................................................................................................................................................................1128 Programmable Parameters...................................................................................................................................................................................................................................................1129 Passwords.................................................................................................................................................................................................................................................................1129 Electronic Service Tools..................................................................................................................................................................................................................................................1129 Electronic Service Tool (EST).............................................................................................................................................................................................................................................1129 Connecting the Electronic Service Tool and the Communication Ada......................................................................................................................................................................................................1129 Support for the Electronic Service Tool...............................................................................................................................................................................................................................1130 Optional Service Tools................................................................................................................................................................................................................................................1130 Diagnostic Codes..........................................................................................................................................................................................................................................................1130 Engine Display Warning Codes..............................................................................................................................................................................................................................................1134 Access................................................................................................................................................................................................................................................................1134 Exit..................................................................................................................................................................................................................................................................1134 Clear.................................................................................................................................................................................................................................................................1134 Replacing the ECM.........................................................................................................................................................................................................................................................1136 Self Diagnostics..........................................................................................................................................................................................................................................................1137 Glossary......................................................................................................................................................................................................................................................................1138 Sensors and Electrical Connectors.............................................................................................................................................................................................................................................1141 Engine Wiring Information.....................................................................................................................................................................................................................................................1144 Harness Wire Identification...............................................................................................................................................................................................................................................1148 Diagnostic Code Reader........................................................................................................................................................................................................................................................1148 General...................................................................................................................................................................................................................................................................1148 Reference Documents.......................................................................................................................................................................................................................................................1148 Abbreviations.............................................................................................................................................................................................................................................................1148 Environmental Specification...............................................................................................................................................................................................................................................1148 Hardware..................................................................................................................................................................................................................................................................1149 Connection Cable......................................................................................................................................................................................................................................................1150 Software..................................................................................................................................................................................................................................................................1150 Engine Communication..................................................................................................................................................................................................................................................1150 User Controls.............................................................................................................................................................................................................................................................1150 Power Supply..........................................................................................................................................................................................................................................................1150 Display Screen........................................................................................................................................................................................................................................................1150 Operation Controls....................................................................................................................................................................................................................................................1150 Audible Warning.......................................................................................................................................................................................................................................................1151 Operation Instructions....................................................................................................................................................................................................................................................1151 How to Connect the Diagnostic Code Reader to the Engine...............................................................................................................................................................................................................1151 How to Turn ON the Diagnostic Code Reader.............................................................................................................................................................................................................................1151 How to use the Display Screen.........................................................................................................................................................................................................................................1151 How to Operate the Diagnostic Code Reader.............................................................................................................................................................................................................................1152 Main Menu.........................................................................................................................................................................................................................................................1152 Active Codes......................................................................................................................................................................................................................................................1152 Inactive Codes....................................................................................................................................................................................................................................................1152 How to Clear Codes................................................................................................................................................................................................................................................1153 Status Lamp.......................................................................................................................................................................................................................................................1153 Data List.........................................................................................................................................................................................................................................................1154 Diagnostics...............................................................................................................................................................................................................................................................1154 Programming Parameters........................................................................................................................................................................................................................................................1155 Passwords.................................................................................................................................................................................................................................................................1155 Factory Passwords.........................................................................................................................................................................................................................................................1155 Customer Passwords........................................................................................................................................................................................................................................................1156 Flash Programming.........................................................................................................................................................................................................................................................1156 Flash Programming a Personality Module....................................................................................................................................................................................................................................1156 WinFlash Error Messages...................................................................................................................................................................................................................................................1156 System Configuration Parameters...............................................................................................................................................................................................................................................1157 Full Load Setting.........................................................................................................................................................................................................................................................1157 Full Torque Setting.......................................................................................................................................................................................................................................................1157 Rating Interlock..........................................................................................................................................................................................................................................................1157 Engine Serial Number......................................................................................................................................................................................................................................................1157 ECM Software Release Date.................................................................................................................................................................................................................................................1157 Troubleshooting Without A Diagnostic Code.....................................................................................................................................................................................................................................1158 Alternator Noise (Noisy Operation)........................................................................................................................................................................................................................................1158 Probable Causes.......................................................................................................................................................................................................................................................1158 Recommended Actions...................................................................................................................................................................................................................................................1158 Alternator Drive Belts............................................................................................................................................................................................................................................1158 Alternator Drive Pulley...........................................................................................................................................................................................................................................1158 Alternator Bearings...............................................................................................................................................................................................................................................1158 Alternator Will Not Charge (Charging Problem).............................................................................................................................................................................................................................1158 Probable Causes.......................................................................................................................................................................................................................................................1158 Recommended Actions...................................................................................................................................................................................................................................................1158 Alternator Drive Belts............................................................................................................................................................................................................................................1158 Charging Circuit..................................................................................................................................................................................................................................................1158 Alternator or Regulator...........................................................................................................................................................................................................................................1158 Battery...................................................................................................................................................................................................................................................................1158 Probable Causes.......................................................................................................................................................................................................................................................1158 Recommended Actions...................................................................................................................................................................................................................................................1158 Faulty Battery....................................................................................................................................................................................................................................................1158 Auxiliary Device..................................................................................................................................................................................................................................................1158 Cannot Reach Top Engine RPM...............................................................................................................................................................................................................................................1158 Probable Causes.......................................................................................................................................................................................................................................................1159 Recommended Actions...................................................................................................................................................................................................................................................1159 Diagnostic Codes..................................................................................................................................................................................................................................................1159 Fuel Supply.......................................................................................................................................................................................................................................................1159 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1159 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1159 Valve Lash........................................................................................................................................................................................................................................................1159 Check for Low Compression.........................................................................................................................................................................................................................................1159 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1160 Check the Turbocharger............................................................................................................................................................................................................................................1160 ECM Parameters....................................................................................................................................................................................................................................................1160 Check the Signal for the Throttle Position Sensor.................................................................................................................................................................................................................1160 Coolant in Engine Oil.....................................................................................................................................................................................................................................................1160 Probable Causes.......................................................................................................................................................................................................................................................1160 Recommended Actions...................................................................................................................................................................................................................................................1160 Engine Oil Cooler Core............................................................................................................................................................................................................................................1160 Cylinder Head Gasket..............................................................................................................................................................................................................................................1160 Cylinder Head.....................................................................................................................................................................................................................................................1161 Cylinder Block....................................................................................................................................................................................................................................................1161 Coolant Temperature Is Too High...........................................................................................................................................................................................................................................1161 Probable Causes.......................................................................................................................................................................................................................................................1161 Recommended Actions...................................................................................................................................................................................................................................................1161 Radiator Fins.....................................................................................................................................................................................................................................................1161 Coolant Level.....................................................................................................................................................................................................................................................1161 Radiator Cap and/or Pressure Relief Valve.........................................................................................................................................................................................................................1161 Combustion Gases in the Cooling System............................................................................................................................................................................................................................1161 Water Temperature Regulator.......................................................................................................................................................................................................................................1161 Restriction in the Coolant System.................................................................................................................................................................................................................................1161 Coolant Temperature Gauge.........................................................................................................................................................................................................................................1161 Coolant Pump......................................................................................................................................................................................................................................................1161 Excessive Load on the System......................................................................................................................................................................................................................................1161 ECM Will Not Accept Factory Passwords.....................................................................................................................................................................................................................................1162 Probable Causes.......................................................................................................................................................................................................................................................1162 Recommended Actions...................................................................................................................................................................................................................................................1162 ECM Will Not Communicate With Other Systems or Display Modules............................................................................................................................................................................................................1162 Probable Causes.......................................................................................................................................................................................................................................................1162 Recommended Actions...................................................................................................................................................................................................................................................1162 Electronic Service Tool Will Not Communicate With ECM.....................................................................................................................................................................................................................1162 Probable Causes.......................................................................................................................................................................................................................................................1162 Recommended Actions...................................................................................................................................................................................................................................................1162 Engine Cranks but Will Not Start..........................................................................................................................................................................................................................................1163 Probable Causes.......................................................................................................................................................................................................................................................1163 Recommended Actions...................................................................................................................................................................................................................................................1163 Diagnostic Codes..................................................................................................................................................................................................................................................1163 Visual Checks.....................................................................................................................................................................................................................................................1163 Crank Without Injection...........................................................................................................................................................................................................................................1163 Starting Motor Solenoid or Starting Circuit.......................................................................................................................................................................................................................1163 Valve Lash........................................................................................................................................................................................................................................................1163 Fuel Injection Nozzles............................................................................................................................................................................................................................................1163 Air Inlet Heater Starting Aid.....................................................................................................................................................................................................................................1164 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1164 Low Compression...................................................................................................................................................................................................................................................1164 Fuel Supply.......................................................................................................................................................................................................................................................1164 Engine Has Early Wear.....................................................................................................................................................................................................................................................1164 Probable Causes.......................................................................................................................................................................................................................................................1164 Recommended Actions...................................................................................................................................................................................................................................................1164 Dirt in Engine Oil................................................................................................................................................................................................................................................1164 Leaks in Air Intake System........................................................................................................................................................................................................................................1164 Low Oil Pressure..................................................................................................................................................................................................................................................1164 Engine Misfires, Runs Rough or Is Unstable................................................................................................................................................................................................................................1165 Probable Causes.......................................................................................................................................................................................................................................................1165 Recommended Actions...................................................................................................................................................................................................................................................1165 Logged Codes......................................................................................................................................................................................................................................................1165 Fuel Supply.......................................................................................................................................................................................................................................................1165 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1165 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1165 Valve Lash........................................................................................................................................................................................................................................................1165 Check for Low Compression.........................................................................................................................................................................................................................................1165 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1166 Check the Air Inlet Heater Starting Aid...........................................................................................................................................................................................................................1166 Check the Engine Speed/Timing Sensors.............................................................................................................................................................................................................................1166 Check the Signal for the Throttle Position Sensor.................................................................................................................................................................................................................1166 Check the Fuel Injection Pump.....................................................................................................................................................................................................................................1166 Engine Oil in Cooling System..............................................................................................................................................................................................................................................1166 Probable Causes.......................................................................................................................................................................................................................................................1166 Recommended Actions...................................................................................................................................................................................................................................................1166 Engine Oil Cooler Core............................................................................................................................................................................................................................................1166 Cylinder Head Gasket..............................................................................................................................................................................................................................................1167 Cylinder Head.....................................................................................................................................................................................................................................................1167 Engine Speed Does Not Change..............................................................................................................................................................................................................................................1167 Probable Causes.......................................................................................................................................................................................................................................................1167 Recommended Repairs...................................................................................................................................................................................................................................................1167 Diagnostic Codes..................................................................................................................................................................................................................................................1167 Engine Stalls at Low RPM..................................................................................................................................................................................................................................................1167 Probable Causes.......................................................................................................................................................................................................................................................1167 Recommended Actions...................................................................................................................................................................................................................................................1167 Diagnostic Codes..................................................................................................................................................................................................................................................1167 Fuel Injection Nozzles............................................................................................................................................................................................................................................1167 Fuel Supply.......................................................................................................................................................................................................................................................1167 Accessory Equipment...............................................................................................................................................................................................................................................1168 Power Mode Control................................................................................................................................................................................................................................................1168 Engine Vibration..........................................................................................................................................................................................................................................................1168 Probable Causes.......................................................................................................................................................................................................................................................1168 Recommended Actions...................................................................................................................................................................................................................................................1168 Engine Supports...................................................................................................................................................................................................................................................1168 Malfunctioning Individual Cylinder................................................................................................................................................................................................................................1168 Valve Lash........................................................................................................................................................................................................................................................1168 Check for Low Compression (cylinder pressure).....................................................................................................................................................................................................................1168 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1168 Turbocharger......................................................................................................................................................................................................................................................1169 Engine Will Not Crank.....................................................................................................................................................................................................................................................1169 Probable Causes.......................................................................................................................................................................................................................................................1169 Recommended Repairs...................................................................................................................................................................................................................................................1169 Machine Security System...........................................................................................................................................................................................................................................1169 Battery Cables and/or Batteries...................................................................................................................................................................................................................................1169 Starting Motor Solenoid or Starting Circuit.......................................................................................................................................................................................................................1169 Starting Motor and/or Flywheel Ring Gear..........................................................................................................................................................................................................................1169 Electrical Power Supply...........................................................................................................................................................................................................................................1169 Internal Engine Problem...........................................................................................................................................................................................................................................1169 Excessive Black Smoke.....................................................................................................................................................................................................................................................1169 Probable Causes.......................................................................................................................................................................................................................................................1169 Recommended Actions...................................................................................................................................................................................................................................................1170 Air Intake System or Exhaust System...............................................................................................................................................................................................................................1170 Individual Malfunctioning Cylinder................................................................................................................................................................................................................................1170 Valve Lash........................................................................................................................................................................................................................................................1170 Low Compression (cylinder pressure)...............................................................................................................................................................................................................................1170 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1170 Check the Turbocharger............................................................................................................................................................................................................................................1170 Broken 5-Volt Supply Wire.........................................................................................................................................................................................................................................1171 Verifying the ECM Software........................................................................................................................................................................................................................................1171 Excessive Engine Oil Consumption..........................................................................................................................................................................................................................................1171 Probable Causes.......................................................................................................................................................................................................................................................1171 Recommended Actions...................................................................................................................................................................................................................................................1171 Oil Level.........................................................................................................................................................................................................................................................1171 Engine Crankcase Breather.........................................................................................................................................................................................................................................1171 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1171 Turbocharger......................................................................................................................................................................................................................................................1171 Low Compression (cylinder pressure)...............................................................................................................................................................................................................................1171 Excessive Valve Lash......................................................................................................................................................................................................................................................1172 Probable Causes.......................................................................................................................................................................................................................................................1172 Recommended Actions...................................................................................................................................................................................................................................................1172 Lubrication.......................................................................................................................................................................................................................................................1172 Valve Lash........................................................................................................................................................................................................................................................1172 Valve Train Components............................................................................................................................................................................................................................................1172 Excessive White Smoke.....................................................................................................................................................................................................................................................1172 Probable Causes.......................................................................................................................................................................................................................................................1172 Recommended Actions...................................................................................................................................................................................................................................................1172 Fuel Supply.......................................................................................................................................................................................................................................................1172 Individual Malfunctioning Cylinder................................................................................................................................................................................................................................1173 Valve Lash........................................................................................................................................................................................................................................................1173 Low Compression (cylinder pressure)...............................................................................................................................................................................................................................1173 Air Inlet Heater Starting Aid.....................................................................................................................................................................................................................................1173 Fuel Injection Nozzles............................................................................................................................................................................................................................................1173 Coolant Temperature Sensor Circuit................................................................................................................................................................................................................................1173 Engine Pressure Sensors...........................................................................................................................................................................................................................................1173 Intake Air Temperature Is Too High........................................................................................................................................................................................................................................1173 Probable Causes.......................................................................................................................................................................................................................................................1173 Recommended Repairs...................................................................................................................................................................................................................................................1173 High Ambient Air Temperature......................................................................................................................................................................................................................................1173 Coolant Temperature...............................................................................................................................................................................................................................................1173 Check for High Intake Air Restriction and/or High Altitude........................................................................................................................................................................................................1174 Intake Air Restriction............................................................................................................................................................................................................................................1174 High Altitude.....................................................................................................................................................................................................................................................1174 Check the Intake Manifold Air Temperature Sensor and/or the Circ..................................................................................................................................................................................................1174 Check for Sufficient Coolant Flow Through the Aftercooler (if eq..................................................................................................................................................................................................1174 Check for Sufficient Flow of Air Through the Aftercooler (if equ..................................................................................................................................................................................................1174 Intermittent Engine Shutdown..............................................................................................................................................................................................................................................1174 Probable Causes.......................................................................................................................................................................................................................................................1174 Recommended Actions...................................................................................................................................................................................................................................................1174 Logged Codes......................................................................................................................................................................................................................................................1174 Fuel Supply.......................................................................................................................................................................................................................................................1174 Engine Protection Device..........................................................................................................................................................................................................................................1174 Electrical Connectors.............................................................................................................................................................................................................................................1175 Intermittent Low Power or Power Cutout....................................................................................................................................................................................................................................1175 Probable Causes.......................................................................................................................................................................................................................................................1175 Recommended Repairs...................................................................................................................................................................................................................................................1175 Diagnostic Codes..................................................................................................................................................................................................................................................1175 Electrical Connectors.............................................................................................................................................................................................................................................1175 Fuel Supply.......................................................................................................................................................................................................................................................1175 Check the Intake Manifold Pressure................................................................................................................................................................................................................................1176 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1176 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1176 Valve Lash........................................................................................................................................................................................................................................................1176 Check for Low Compression.........................................................................................................................................................................................................................................1176 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1176 Check the Turbocharger............................................................................................................................................................................................................................................1176 ECM Parameters....................................................................................................................................................................................................................................................1177 Electronic System Problem.........................................................................................................................................................................................................................................1177 Low Engine Oil Pressure...................................................................................................................................................................................................................................................1177 Probable Causes.......................................................................................................................................................................................................................................................1177 Recommended Actions...................................................................................................................................................................................................................................................1177 Engine Oil Level..................................................................................................................................................................................................................................................1177 Engine Oil Pressure Gauge.........................................................................................................................................................................................................................................1177 Engine Oil Bypass Valves..........................................................................................................................................................................................................................................1177 Piston Cooling Jets ..............................................................................................................................................................................................................................................1178 Engine Oil Suction Tube...........................................................................................................................................................................................................................................1178 Engine Oil Pump...................................................................................................................................................................................................................................................1178 Bearing Clearance.................................................................................................................................................................................................................................................1178 Low Power/Poor or No Response to Throttle.................................................................................................................................................................................................................................1178 Probable Causes.......................................................................................................................................................................................................................................................1178 Recommended Actions...................................................................................................................................................................................................................................................1178 Diagnostic Codes..................................................................................................................................................................................................................................................1178 Fuel Supply.......................................................................................................................................................................................................................................................1178 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1178 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1179 Valve Lash........................................................................................................................................................................................................................................................1179 Check for Low Compression.........................................................................................................................................................................................................................................1179 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1179 Check the Turbocharger............................................................................................................................................................................................................................................1179 ECM Parameters....................................................................................................................................................................................................................................................1179 Electronic System Problem.........................................................................................................................................................................................................................................1180 Mechanical Noise (Knock) in Engine........................................................................................................................................................................................................................................1180 Probable Causes.......................................................................................................................................................................................................................................................1180 Recommended Actions...................................................................................................................................................................................................................................................1180 Accessory Equipment...............................................................................................................................................................................................................................................1180 Valve Train Components............................................................................................................................................................................................................................................1180 Connecting Rod and Main Bearings..................................................................................................................................................................................................................................1180 Noise Coming from Cylinder................................................................................................................................................................................................................................................1180 Probable Causes.......................................................................................................................................................................................................................................................1180 Recommended Actions...................................................................................................................................................................................................................................................1180 Fuel Quality......................................................................................................................................................................................................................................................1180 Fuel Injection Nozzles............................................................................................................................................................................................................................................1180 Valve Lash........................................................................................................................................................................................................................................................1180 Poor Acceleration or Response.............................................................................................................................................................................................................................................1181 Probable Causes.......................................................................................................................................................................................................................................................1181 Recommended Repairs...................................................................................................................................................................................................................................................1181 Diagnostic Codes..................................................................................................................................................................................................................................................1181 Fuel Supply.......................................................................................................................................................................................................................................................1181 Individual Malfunctioning Cylinder................................................................................................................................................................................................................................1181 Valve Lash........................................................................................................................................................................................................................................................1181 Check for Low Compression.........................................................................................................................................................................................................................................1181 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1181 Check the Turbocharger............................................................................................................................................................................................................................................1182 ECM Parameters....................................................................................................................................................................................................................................................1182 Check Intake Manifold Pressure....................................................................................................................................................................................................................................1182 Troubleshooting With a Diagnostic Code........................................................................................................................................................................................................................................1182 CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal..........................................................................................................................................................................................................1182 Conditions Which Generate This Code...................................................................................................................................................................................................................................1182 System Response.......................................................................................................................................................................................................................................................1182 Possible Performance Effect...........................................................................................................................................................................................................................................1182 Troubleshooting.......................................................................................................................................................................................................................................................1182 Results...............................................................................................................................................................................................................................................................1182 CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent..........................................................................................................................................................................................................1182 Conditions Which Generate This Code...................................................................................................................................................................................................................................1182 System Response.......................................................................................................................................................................................................................................................1183 Possible Performance Effect...........................................................................................................................................................................................................................................1183 Troubleshooting.......................................................................................................................................................................................................................................................1183 Test Step 1...........................................................................................................................................................................................................................................................1183 Results...............................................................................................................................................................................................................................................................1183 CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted..........................................................................................................................................................................................................1183 Conditions Which Generate This Code...................................................................................................................................................................................................................................1183 System Response.......................................................................................................................................................................................................................................................1183 Possible Performance Effect...........................................................................................................................................................................................................................................1183 CID 0091 FMI 04 Throttle Position Sensor Shorted Low......................................................................................................................................................................................................................1183 Conditions Which Generate This Code...................................................................................................................................................................................................................................1183 System Response.......................................................................................................................................................................................................................................................1183 Possible Performance Effect...........................................................................................................................................................................................................................................1183 Troubleshooting.......................................................................................................................................................................................................................................................1183 Results...............................................................................................................................................................................................................................................................1183 CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal..................................................................................................................................................................................................................1183 Conditions Which Generate This Code...................................................................................................................................................................................................................................1183 System Response.......................................................................................................................................................................................................................................................1183 Troubleshooting.......................................................................................................................................................................................................................................................1184 Results...............................................................................................................................................................................................................................................................1184 CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...............................................................................................................................................................................................................1184 Conditions Which Generate This Code...................................................................................................................................................................................................................................1184 Possible Performance Effect...........................................................................................................................................................................................................................................1184 Troubleshooting.......................................................................................................................................................................................................................................................1184 Results...............................................................................................................................................................................................................................................................1184 CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short..........................................................................................................................................................................................................1184 Conditions Which Generate This Code...................................................................................................................................................................................................................................1184 System Response.......................................................................................................................................................................................................................................................1184 Troubleshooting.......................................................................................................................................................................................................................................................1184 Results...............................................................................................................................................................................................................................................................1184 CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low....................................................................................................................................................................................................................1184 Conditions Which Generate This Code...................................................................................................................................................................................................................................1184 System Response.......................................................................................................................................................................................................................................................1184 Troubleshooting.......................................................................................................................................................................................................................................................1184 Results...............................................................................................................................................................................................................................................................1184 CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci..........................................................................................................................................................................................................1185 Conditions Which Generate This Code...................................................................................................................................................................................................................................1185 System Response.......................................................................................................................................................................................................................................................1185 Possible Performance Effect...........................................................................................................................................................................................................................................1185 Results...............................................................................................................................................................................................................................................................1185 CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or..........................................................................................................................................................................................................1185 Conditions Which Generate This Code...................................................................................................................................................................................................................................1185 System Response.......................................................................................................................................................................................................................................................1185 Possible Performance Effect...........................................................................................................................................................................................................................................1185 Results...............................................................................................................................................................................................................................................................1185 CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...............................................................................................................................................................................................................1185 Conditions Which Generate This Code...................................................................................................................................................................................................................................1185 System Response.......................................................................................................................................................................................................................................................1185 Possible Performance Effect...........................................................................................................................................................................................................................................1185 Results...............................................................................................................................................................................................................................................................1185 CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope..........................................................................................................................................................................................................1186 Conditions Which Generate This Code...................................................................................................................................................................................................................................1186 System Response.......................................................................................................................................................................................................................................................1186 Results...............................................................................................................................................................................................................................................................1186 CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ..........................................................................................................................................................................................................1186 Conditions Which Generate This Code...................................................................................................................................................................................................................................1186 System Response.......................................................................................................................................................................................................................................................1186 Possible Performance Effect...........................................................................................................................................................................................................................................1186 Troubleshooting.......................................................................................................................................................................................................................................................1186 Results...............................................................................................................................................................................................................................................................1186 CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low............................................................................................................................................................................................................1186 Conditions Which Generate This Code...................................................................................................................................................................................................................................1186 System Response.......................................................................................................................................................................................................................................................1186 Possible Performance Effect...........................................................................................................................................................................................................................................1186 Troubleshooting.......................................................................................................................................................................................................................................................1186 Results...............................................................................................................................................................................................................................................................1186 CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o..........................................................................................................................................................................................................1186 Conditions Which Generate This Code...................................................................................................................................................................................................................................1186 System Response.......................................................................................................................................................................................................................................................1187 Possible Performance Effect...........................................................................................................................................................................................................................................1187 Troubleshooting.......................................................................................................................................................................................................................................................1187 Results...............................................................................................................................................................................................................................................................1187 CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low.............................................................................................................................................................................................................1187 Conditions Which Generate This Code...................................................................................................................................................................................................................................1187 System Response.......................................................................................................................................................................................................................................................1187 Possible Performance Effect...........................................................................................................................................................................................................................................1187 Troubleshooting.......................................................................................................................................................................................................................................................1187 Results...............................................................................................................................................................................................................................................................1187 CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent.............................................................................................................................................................................................................1187 Conditions Which Generate This Code...................................................................................................................................................................................................................................1187 System Response.......................................................................................................................................................................................................................................................1187 Possible Performance Effect...........................................................................................................................................................................................................................................1187 Troubleshooting.......................................................................................................................................................................................................................................................1187 Results...............................................................................................................................................................................................................................................................1187 CID 0247 FMI 09 J1939 Datalink, Abnormal Update...........................................................................................................................................................................................................................1188 Conditions Which Generate This Code...................................................................................................................................................................................................................................1188 System Response.......................................................................................................................................................................................................................................................1188 Results...............................................................................................................................................................................................................................................................1188 CID 0253 FMI 02 Incorrect ECM Software....................................................................................................................................................................................................................................1188 Conditions Which Generate This Code...................................................................................................................................................................................................................................1188 System Response.......................................................................................................................................................................................................................................................1188 Possible Performance Effect...........................................................................................................................................................................................................................................1188 Troubleshooting.......................................................................................................................................................................................................................................................1188 Expected Result.......................................................................................................................................................................................................................................................1188 Results...............................................................................................................................................................................................................................................................1188 CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal..........................................................................................................................................................................................................1188 Conditions Which Generate This Code...................................................................................................................................................................................................................................1188 System Response.......................................................................................................................................................................................................................................................1188 Possible Performance Effect...........................................................................................................................................................................................................................................1188 Troubleshooting.......................................................................................................................................................................................................................................................1188 Results...............................................................................................................................................................................................................................................................1188 CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal..........................................................................................................................................................................................................1189 Conditions Which Generate This Code...................................................................................................................................................................................................................................1189 System Response.......................................................................................................................................................................................................................................................1189 Possible Performance Effect...........................................................................................................................................................................................................................................1189 Troubleshooting.......................................................................................................................................................................................................................................................1189 Results...............................................................................................................................................................................................................................................................1189 CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs.....................................................................................................................................................................................................................1189 Conditions Which Generate This Code...................................................................................................................................................................................................................................1189 System Response.......................................................................................................................................................................................................................................................1189 Possible Performance Effect...........................................................................................................................................................................................................................................1189 CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig..........................................................................................................................................................................................................1189 Conditions Which Generate This Code...................................................................................................................................................................................................................................1189 System Response.......................................................................................................................................................................................................................................................1189 Possible Performance Effect...........................................................................................................................................................................................................................................1189 Results...............................................................................................................................................................................................................................................................1189 CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal....................................................................................................................................................................................................................1189 Conditions Which Generate This Code...................................................................................................................................................................................................................................1189 System Response.......................................................................................................................................................................................................................................................1189 Possible Performance Effect...........................................................................................................................................................................................................................................1189 Results...............................................................................................................................................................................................................................................................1190 CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa..........................................................................................................................................................................................................1190 Conditions Which Generate This Code...................................................................................................................................................................................................................................1190 System Response.......................................................................................................................................................................................................................................................1190 Possible Performance Effect...........................................................................................................................................................................................................................................1190 Test Step 1...........................................................................................................................................................................................................................................................1190 Results...............................................................................................................................................................................................................................................................1190 Test Step 2...........................................................................................................................................................................................................................................................1190 Results...............................................................................................................................................................................................................................................................1190 CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm..........................................................................................................................................................................................................1190 Conditions Which Generate This Code...................................................................................................................................................................................................................................1190 System Response.......................................................................................................................................................................................................................................................1190 Possible Performance Effect...........................................................................................................................................................................................................................................1190 Results...............................................................................................................................................................................................................................................................1190 CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S..........................................................................................................................................................................................................1190 Conditions Which Generate This Code...................................................................................................................................................................................................................................1190 System Response.......................................................................................................................................................................................................................................................1191 Possible Performance Effect...........................................................................................................................................................................................................................................1191 Troubleshooting.......................................................................................................................................................................................................................................................1191 Results...............................................................................................................................................................................................................................................................1191 CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low................................................................................................................................................................................................................1191 Conditions Which Generate This Code...................................................................................................................................................................................................................................1191 System Response.......................................................................................................................................................................................................................................................1191 Possible Performance Effect...........................................................................................................................................................................................................................................1191 Troubleshooting.......................................................................................................................................................................................................................................................1191 Results...............................................................................................................................................................................................................................................................1191 CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal............................................................................................................................................................................................................1191 Conditions Which Generate This Code...................................................................................................................................................................................................................................1191 System Response.......................................................................................................................................................................................................................................................1191 Possible Performance Effect...........................................................................................................................................................................................................................................1191 Results...............................................................................................................................................................................................................................................................1191 CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio..........................................................................................................................................................................................................1191 Conditions Which Generate This Code...................................................................................................................................................................................................................................1191 System Response.......................................................................................................................................................................................................................................................1191 Possible Performance Effect...........................................................................................................................................................................................................................................1191 Results...............................................................................................................................................................................................................................................................1191 CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off................................................................................................................................................................................................................1192 Conditions Which Generate This Code...................................................................................................................................................................................................................................1192 System Response.......................................................................................................................................................................................................................................................1192 Possible Performance Effect...........................................................................................................................................................................................................................................1192 Results...............................................................................................................................................................................................................................................................1192 CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ..........................................................................................................................................................................................................1192 Conditions Which Generate This Code...................................................................................................................................................................................................................................1192 System Response.......................................................................................................................................................................................................................................................1192 Possible Performance Effect...........................................................................................................................................................................................................................................1192 Test Step 1...........................................................................................................................................................................................................................................................1192 Results...............................................................................................................................................................................................................................................................1192 Test Step 2...........................................................................................................................................................................................................................................................1192 Results...............................................................................................................................................................................................................................................................1192 CID 1684 FMI 02 Fuel Injection Pump, Software Failure.....................................................................................................................................................................................................................1192 Conditions Which Generate This Code...................................................................................................................................................................................................................................1192 System Response.......................................................................................................................................................................................................................................................1192 Possible Performance Effect...........................................................................................................................................................................................................................................1192 Troubleshooting.......................................................................................................................................................................................................................................................1192 Results...............................................................................................................................................................................................................................................................1193 CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault........................................................................................................................................................................................................................1193 Conditions Which Generate This Code...................................................................................................................................................................................................................................1193 System Response.......................................................................................................................................................................................................................................................1193 Possible Performance Effect...........................................................................................................................................................................................................................................1193 Troubleshooting.......................................................................................................................................................................................................................................................1193 Results...............................................................................................................................................................................................................................................................1193 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault.................................................................................................................................................................................................................1193 Conditions Which Generate This Code...................................................................................................................................................................................................................................1193 System Response.......................................................................................................................................................................................................................................................1193 Possible Performance Effect...........................................................................................................................................................................................................................................1193 Troubleshooting.......................................................................................................................................................................................................................................................1193 Results...............................................................................................................................................................................................................................................................1193 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width..................................................................................................................................................................................................................1193 Conditions Which Generate This Code...................................................................................................................................................................................................................................1193 Troubleshooting.......................................................................................................................................................................................................................................................1193 Results...............................................................................................................................................................................................................................................................1194 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault.....................................................................................................................................................................................................................1194 Conditions Which Generate This Code...................................................................................................................................................................................................................................1194 System Response.......................................................................................................................................................................................................................................................1194 Possible Performance Effect...........................................................................................................................................................................................................................................1194 Troubleshooting.......................................................................................................................................................................................................................................................1194 Results...............................................................................................................................................................................................................................................................1194 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...........................................................................................................................................................................................................1194 Conditions Which Generate This Code...................................................................................................................................................................................................................................1194 System Response.......................................................................................................................................................................................................................................................1194 Possible Performance Effect...........................................................................................................................................................................................................................................1194 Troubleshooting.......................................................................................................................................................................................................................................................1194 Test Step 1...........................................................................................................................................................................................................................................................1194 Results...............................................................................................................................................................................................................................................................1194 Test Step 2...........................................................................................................................................................................................................................................................1194 Results...............................................................................................................................................................................................................................................................1194 Test Step 3...........................................................................................................................................................................................................................................................1194 Results...............................................................................................................................................................................................................................................................1195 Test Step 4...........................................................................................................................................................................................................................................................1195 Expected Result.......................................................................................................................................................................................................................................................1195 Results...............................................................................................................................................................................................................................................................1195 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault............................................................................................................................................................................................................................1195 Conditions Which Generate This Code...................................................................................................................................................................................................................................1195 System Response.......................................................................................................................................................................................................................................................1195 Possible Performance Effect...........................................................................................................................................................................................................................................1195 Troubleshooting.......................................................................................................................................................................................................................................................1195 Expected Result.......................................................................................................................................................................................................................................................1195 Results...............................................................................................................................................................................................................................................................1195 CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error............................................................................................................................................................................................................1195 Conditions Which Generate This Code...................................................................................................................................................................................................................................1195 System Response.......................................................................................................................................................................................................................................................1195 Troubleshooting.......................................................................................................................................................................................................................................................1195 Test Step 1...........................................................................................................................................................................................................................................................1195 Results...............................................................................................................................................................................................................................................................1196 Test Step 2...........................................................................................................................................................................................................................................................1196 Results...............................................................................................................................................................................................................................................................1196 Test Step 3...........................................................................................................................................................................................................................................................1196 Results...............................................................................................................................................................................................................................................................1196 CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault................................................................................................................................................................................................................1196 Conditions Which Generate This Code...................................................................................................................................................................................................................................1196 System Response.......................................................................................................................................................................................................................................................1196 Possible Performance Effect...........................................................................................................................................................................................................................................1196 Troubleshooting.......................................................................................................................................................................................................................................................1196 Test Step 1...........................................................................................................................................................................................................................................................1196 Results...............................................................................................................................................................................................................................................................1196 Test Step 2...........................................................................................................................................................................................................................................................1196 Results...............................................................................................................................................................................................................................................................1196 CID 1684 FMI 14 Fuel Injection Pump, No Communications....................................................................................................................................................................................................................1196 Conditions Which Generate This Code...................................................................................................................................................................................................................................1196 System Response.......................................................................................................................................................................................................................................................1196 Troubleshooting.......................................................................................................................................................................................................................................................1196 Test Step 1...........................................................................................................................................................................................................................................................1196 Results...............................................................................................................................................................................................................................................................1196 Test Step 2...........................................................................................................................................................................................................................................................1197 Results...............................................................................................................................................................................................................................................................1197 Test Step 3...........................................................................................................................................................................................................................................................1197 Results...............................................................................................................................................................................................................................................................1197 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali..........................................................................................................................................................................................................1197 Conditions Which Generate This Code...................................................................................................................................................................................................................................1197 System Response.......................................................................................................................................................................................................................................................1197 Possible Performance Effect...........................................................................................................................................................................................................................................1197 Troubleshooting.......................................................................................................................................................................................................................................................1197 Results...............................................................................................................................................................................................................................................................1197 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali..........................................................................................................................................................................................................1197 Conditions Which Generate This Code...................................................................................................................................................................................................................................1197 System Response.......................................................................................................................................................................................................................................................1197 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S..........................................................................................................................................................................................................1197 Conditions Which Generate This Code...................................................................................................................................................................................................................................1197 System Response.......................................................................................................................................................................................................................................................1197 Troubleshooting With an Event Code............................................................................................................................................................................................................................................1198 Event Codes...............................................................................................................................................................................................................................................................1198 Programmable Engine Parameters............................................................................................................................................................................................................................................1198 E015 High Engine Coolant Temperature Derate...............................................................................................................................................................................................................................1198 Conditions Which Generate This Code...................................................................................................................................................................................................................................1198 System Response.......................................................................................................................................................................................................................................................1198 Possible Performance Effect...........................................................................................................................................................................................................................................1198 Troubleshooting.......................................................................................................................................................................................................................................................1198 Results...............................................................................................................................................................................................................................................................1198 E016 High Engine Coolant Temperature Shutdown.............................................................................................................................................................................................................................1198 Conditions Which Generate This Code...................................................................................................................................................................................................................................1198 System Response.......................................................................................................................................................................................................................................................1198 Possible Performance Effect...........................................................................................................................................................................................................................................1198 Troubleshooting.......................................................................................................................................................................................................................................................1198 Results...............................................................................................................................................................................................................................................................1198 E017 High Engine Coolant Temperature Warning..............................................................................................................................................................................................................................1198 Conditions Which Generate This Code...................................................................................................................................................................................................................................1198 System Response.......................................................................................................................................................................................................................................................1198 Possible Performance Effect...........................................................................................................................................................................................................................................1198 Troubleshooting.......................................................................................................................................................................................................................................................1198 Results...............................................................................................................................................................................................................................................................1198 E025 High Intake Air Temperature Derate...................................................................................................................................................................................................................................1199 Conditions Which Generate This Code...................................................................................................................................................................................................................................1199 System Response.......................................................................................................................................................................................................................................................1199 Possible Performance Effect...........................................................................................................................................................................................................................................1199 Troubleshooting.......................................................................................................................................................................................................................................................1199 Results...............................................................................................................................................................................................................................................................1199 E027 High Intake Air Temperature Warning..................................................................................................................................................................................................................................1199 Conditions Which Generate This Code:..................................................................................................................................................................................................................................1199 System Response.......................................................................................................................................................................................................................................................1199 Possible Performance Effect...........................................................................................................................................................................................................................................1199 Troubleshooting.......................................................................................................................................................................................................................................................1199 Results...............................................................................................................................................................................................................................................................1199 E040 Low Engine Oil Pressure Shutdown.....................................................................................................................................................................................................................................1199 Conditions Which Generate This Code...................................................................................................................................................................................................................................1199 System Response.......................................................................................................................................................................................................................................................1199 Possible Performance Effect...........................................................................................................................................................................................................................................1199 Troubleshooting.......................................................................................................................................................................................................................................................1199 Results...............................................................................................................................................................................................................................................................1199 E054 High Fuel Temperature Derate.........................................................................................................................................................................................................................................1200 Conditions Which Generate This Code...................................................................................................................................................................................................................................1200 System Response.......................................................................................................................................................................................................................................................1200 Troubleshooting.......................................................................................................................................................................................................................................................1200 Test Step 1 - Check for Diagnostic Codes..............................................................................................................................................................................................................................1200 Expected Result.......................................................................................................................................................................................................................................................1200 Results...............................................................................................................................................................................................................................................................1200 Test Step 2 - Perform a Check of the Fuel System......................................................................................................................................................................................................................1200 Expected Result.......................................................................................................................................................................................................................................................1200 Results...............................................................................................................................................................................................................................................................1200 E056 High Fuel Temperature Warning........................................................................................................................................................................................................................................1200 Conditions Which Generate This Code...................................................................................................................................................................................................................................1200 System Response.......................................................................................................................................................................................................................................................1200 Troubleshooting.......................................................................................................................................................................................................................................................1200 Test Step 1 - Check for Diagnostic Codes..............................................................................................................................................................................................................................1200 Expected Result.......................................................................................................................................................................................................................................................1200 Results...............................................................................................................................................................................................................................................................1201 Test Step 2 - Perform a Check of the Fuel System......................................................................................................................................................................................................................1201 Expected Result.......................................................................................................................................................................................................................................................1201 Results...............................................................................................................................................................................................................................................................1201 E100 Low Engine Oil Pressure Warning......................................................................................................................................................................................................................................1201 Conditions Which Generate This Code...................................................................................................................................................................................................................................1201 System Response.......................................................................................................................................................................................................................................................1201 Possible Performance Effect...........................................................................................................................................................................................................................................1201 Troubleshooting.......................................................................................................................................................................................................................................................1201 Test Step 1 - Check for Active Diagnostic Codes.......................................................................................................................................................................................................................1201 Expected Result.......................................................................................................................................................................................................................................................1201 Results...............................................................................................................................................................................................................................................................1201 Test Step 2 - Perform a Check of the Engine Lubrication System........................................................................................................................................................................................................1201 Expected Result.......................................................................................................................................................................................................................................................1201 Results...............................................................................................................................................................................................................................................................1201 E190 Engine Overspeed Warning.............................................................................................................................................................................................................................................1202 Conditions Which Generate This Code...................................................................................................................................................................................................................................1202 System Response.......................................................................................................................................................................................................................................................1202 Possible Performance Effect...........................................................................................................................................................................................................................................1202 Troubleshooting.......................................................................................................................................................................................................................................................1202 Engine Overspeed Warning..............................................................................................................................................................................................................................................1202 Expected Result.......................................................................................................................................................................................................................................................1202 Results...............................................................................................................................................................................................................................................................1202 E442 Engine Failed to Stop With a No-Fuel Command.........................................................................................................................................................................................................................1202 Conditions Which Generate This Code...................................................................................................................................................................................................................................1202 System Response.......................................................................................................................................................................................................................................................1202 Possible Performance Effect...........................................................................................................................................................................................................................................1202 Troubleshooting.......................................................................................................................................................................................................................................................1202 Test Step 1...........................................................................................................................................................................................................................................................1202 Results...............................................................................................................................................................................................................................................................1202 Test Step 2...........................................................................................................................................................................................................................................................1202 Results...............................................................................................................................................................................................................................................................1202 E883 Engine Failed to Stop When Fuel Solenoid Disengaged..................................................................................................................................................................................................................1202 Conditions Which Generate This Code...................................................................................................................................................................................................................................1202 System Response.......................................................................................................................................................................................................................................................1202 Possible Performance Effect...........................................................................................................................................................................................................................................1203 Troubleshooting.......................................................................................................................................................................................................................................................1203 Test Step 1...........................................................................................................................................................................................................................................................1203 Results...............................................................................................................................................................................................................................................................1203 Test Step 2...........................................................................................................................................................................................................................................................1203 Results...............................................................................................................................................................................................................................................................1203 Test Step 3...........................................................................................................................................................................................................................................................1203 Results...............................................................................................................................................................................................................................................................1203 Diagnostic Function Tests.....................................................................................................................................................................................................................................................1203 5-Volt Engine Pressure Sensor Supply Circuit - Test.......................................................................................................................................................................................................................1203 System Operation Description..........................................................................................................................................................................................................................................1203 Background Information................................................................................................................................................................................................................................................1203 Test Step 1...........................................................................................................................................................................................................................................................1204 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1204 Expected Result...................................................................................................................................................................................................................................................1204 Results...........................................................................................................................................................................................................................................................1205 Test Step 2...........................................................................................................................................................................................................................................................1205 Check for Active Diagnostic Codes.................................................................................................................................................................................................................................1205 Expected Result...................................................................................................................................................................................................................................................1205 Results...........................................................................................................................................................................................................................................................1205 Test Step 3...........................................................................................................................................................................................................................................................1205 Disconnect the ECM Engine Harness Connector From the ECM..........................................................................................................................................................................................................1205 Expected Result...................................................................................................................................................................................................................................................1206 Results...........................................................................................................................................................................................................................................................1206 Test Step 4...........................................................................................................................................................................................................................................................1206 Disconnect the +5V Sensors While Active Diagnostic Codes are Bei..................................................................................................................................................................................................1206 Expected Result...................................................................................................................................................................................................................................................1207 Results...........................................................................................................................................................................................................................................................1207 Test Step 5...........................................................................................................................................................................................................................................................1207 Check the Engine Harness..........................................................................................................................................................................................................................................1207 Expected Result...................................................................................................................................................................................................................................................1207 Results...........................................................................................................................................................................................................................................................1207 Air Inlet Heater Circuit - Test...........................................................................................................................................................................................................................................1207 System Operation Description..........................................................................................................................................................................................................................................1207 Test Step 1...........................................................................................................................................................................................................................................................1208 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1208 Expected Result...................................................................................................................................................................................................................................................1208 Results...........................................................................................................................................................................................................................................................1208 Test Step 2...........................................................................................................................................................................................................................................................1208 Check the Supply to the Power Relay for the Air Inlet Heater Sta..................................................................................................................................................................................................1208 Expected Result...................................................................................................................................................................................................................................................1209 Results...........................................................................................................................................................................................................................................................1209 Test Step 3...........................................................................................................................................................................................................................................................1209 Check the Output From the Power Relay for the Air Inlet Heater S..................................................................................................................................................................................................1209 Expected Result...................................................................................................................................................................................................................................................1209 Results...........................................................................................................................................................................................................................................................1209 Test Step 4...........................................................................................................................................................................................................................................................1209 Ground the Input to the Power Relay at the MIC....................................................................................................................................................................................................................1209 Expected Result...................................................................................................................................................................................................................................................1209 Results...........................................................................................................................................................................................................................................................1209 Test Step 5...........................................................................................................................................................................................................................................................1209 Ground the Input to the Power Relay at the ECM Connector..........................................................................................................................................................................................................1209 Expected Result...................................................................................................................................................................................................................................................1209 Results...........................................................................................................................................................................................................................................................1209 Test Step 6...........................................................................................................................................................................................................................................................1210 Override the Air Inlet Heater Starting Aid to Test the ECM........................................................................................................................................................................................................1210 Results...........................................................................................................................................................................................................................................................1210 Checking Idle Validation Switching Point (Throttle Sensor) With ..........................................................................................................................................................................................................1210 Expected Result.......................................................................................................................................................................................................................................................1210 Analog Throttle Position Sensor Circuit - Test............................................................................................................................................................................................................................1210 System Operation Description..........................................................................................................................................................................................................................................1210 Checking the Throttle Sensor With Unconnected Output C................................................................................................................................................................................................................1211 Expected Result...................................................................................................................................................................................................................................................1211 Test Step 1...........................................................................................................................................................................................................................................................1211 Check for Connector Damage........................................................................................................................................................................................................................................1211 Expected Result...................................................................................................................................................................................................................................................1212 Results...........................................................................................................................................................................................................................................................1212 Test Step 2...........................................................................................................................................................................................................................................................1212 Check for Active Diagnostic Codes.................................................................................................................................................................................................................................1212 Expected Result...................................................................................................................................................................................................................................................1212 Results...........................................................................................................................................................................................................................................................1212 Test Step 3...........................................................................................................................................................................................................................................................1212 Check the Throttle Position With the Electronic Service Tool......................................................................................................................................................................................................1212 Expected Result...................................................................................................................................................................................................................................................1212 Results...........................................................................................................................................................................................................................................................1212 Test Step 4...........................................................................................................................................................................................................................................................1212 Check the Voltage at the Throttle Position Sensor.................................................................................................................................................................................................................1212 Expected Result...................................................................................................................................................................................................................................................1212 Results...........................................................................................................................................................................................................................................................1212 Test Step 5...........................................................................................................................................................................................................................................................1213 Disconnect the Throttle Position Sensor and Check for Active Dia..................................................................................................................................................................................................1213 Expected Result...................................................................................................................................................................................................................................................1213 Results...........................................................................................................................................................................................................................................................1213 Test Step 6...........................................................................................................................................................................................................................................................1213 Check the Throttle Selection Status With the Electronic Service ..................................................................................................................................................................................................1213 Expected Result...................................................................................................................................................................................................................................................1213 Results...........................................................................................................................................................................................................................................................1213 Test Step 7...........................................................................................................................................................................................................................................................1214 Disconnect the Supply Terminals of the Throttle Position Sensor ..................................................................................................................................................................................................1214 Expected Result...................................................................................................................................................................................................................................................1214 Results...........................................................................................................................................................................................................................................................1214 Test Step 8...........................................................................................................................................................................................................................................................1214 Check the Position of Throttle Position Sensor....................................................................................................................................................................................................................1214 Expected Result...................................................................................................................................................................................................................................................1214 Results...........................................................................................................................................................................................................................................................1215 Test Step 9...........................................................................................................................................................................................................................................................1215 Check the Throttle Position Sensor at the ECM.....................................................................................................................................................................................................................1215 Expected Result...................................................................................................................................................................................................................................................1215 Results...........................................................................................................................................................................................................................................................1215 CAN Data Link Circuit - Test..............................................................................................................................................................................................................................................1215 System Operation Description..........................................................................................................................................................................................................................................1215 Test Step 1...........................................................................................................................................................................................................................................................1216 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1216 Expected Result...................................................................................................................................................................................................................................................1216 Results...........................................................................................................................................................................................................................................................1216 Test Step 2...........................................................................................................................................................................................................................................................1216 Check the CAN Data Link Between the ECM and P40 Fuel Injection P..................................................................................................................................................................................................1216 Expected Result...................................................................................................................................................................................................................................................1216 Results...........................................................................................................................................................................................................................................................1216 Test Step 3...........................................................................................................................................................................................................................................................1216 Check the CAN Data Link Between the ECM and P40 Fuel Injection P..................................................................................................................................................................................................1216 Expected Result...................................................................................................................................................................................................................................................1216 Results...........................................................................................................................................................................................................................................................1217 Test Step 4...........................................................................................................................................................................................................................................................1217 Verify the Supply Voltage at the Fuel Injection Pump..............................................................................................................................................................................................................1217 Expected Result...................................................................................................................................................................................................................................................1217 Results...........................................................................................................................................................................................................................................................1217 Data Link Circuit - Test..................................................................................................................................................................................................................................................1217 System Operation Description..........................................................................................................................................................................................................................................1217 Background Information................................................................................................................................................................................................................................................1218 Communication.........................................................................................................................................................................................................................................................1218 Test Step 1...........................................................................................................................................................................................................................................................1218 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1218 Expected Result...................................................................................................................................................................................................................................................1218 Results...........................................................................................................................................................................................................................................................1218 Test Step 2...........................................................................................................................................................................................................................................................1218 Determine the Type of Problem With the Data Link..................................................................................................................................................................................................................1218 Expected Result...................................................................................................................................................................................................................................................1218 Results...........................................................................................................................................................................................................................................................1219 Test Step 3...........................................................................................................................................................................................................................................................1219 Check the Battery Voltage at the ECM..............................................................................................................................................................................................................................1219 Expected Result...................................................................................................................................................................................................................................................1219 Results...........................................................................................................................................................................................................................................................1219 Test Step 4...........................................................................................................................................................................................................................................................1219 Check the Battery Voltage That is Coming to the Data Link Connec..................................................................................................................................................................................................1219 Expected Result...................................................................................................................................................................................................................................................1220 Results...........................................................................................................................................................................................................................................................1220 Test Step 5...........................................................................................................................................................................................................................................................1220 Connect the Electronic Service Tool Directly to the ECM...........................................................................................................................................................................................................1220 Expected Result...................................................................................................................................................................................................................................................1220 Results...........................................................................................................................................................................................................................................................1220 Test Step 6...........................................................................................................................................................................................................................................................1220 Change Electronic Service Tool Components.........................................................................................................................................................................................................................1220 Expected Result...................................................................................................................................................................................................................................................1221 Results...........................................................................................................................................................................................................................................................1221 Test Step 7...........................................................................................................................................................................................................................................................1221 Connect an Electronic Service Tool and the ECM to Another Batter..................................................................................................................................................................................................1221 Expected Result...................................................................................................................................................................................................................................................1221 Results...........................................................................................................................................................................................................................................................1221 Electrical Connectors - Inspect...........................................................................................................................................................................................................................................1221 System Operation Description..........................................................................................................................................................................................................................................1221 Background Information................................................................................................................................................................................................................................................1222 Test Step 1...........................................................................................................................................................................................................................................................1225 Check the Locking of the DT Connector (Deutsch) and the Lock Rin..................................................................................................................................................................................................1225 Expected Result...................................................................................................................................................................................................................................................1225 Results...........................................................................................................................................................................................................................................................1225 Test Step 2...........................................................................................................................................................................................................................................................1226 Check the Socket Head Screw on the Connector for the Electronic ..................................................................................................................................................................................................1226 Expected Result...................................................................................................................................................................................................................................................1226 Results...........................................................................................................................................................................................................................................................1226 Test Step 3...........................................................................................................................................................................................................................................................1226 Perform a Pull Test on Each Wire Terminal Connection..............................................................................................................................................................................................................1226 Expected Result...................................................................................................................................................................................................................................................1226 Results...........................................................................................................................................................................................................................................................1226 Test Step 4...........................................................................................................................................................................................................................................................1226 Monitor the Electronic Service Tool While the Wiring and the Con..................................................................................................................................................................................................1226 Expected Result...................................................................................................................................................................................................................................................1227 Results...........................................................................................................................................................................................................................................................1227 Test Step 5...........................................................................................................................................................................................................................................................1227 Check Wires for Nicks and/or Abrasions in the Insulation..........................................................................................................................................................................................................1227 Expected Result...................................................................................................................................................................................................................................................1227 Results...........................................................................................................................................................................................................................................................1227 Test Step 6...........................................................................................................................................................................................................................................................1227 Check Connectors for Moisture or Corrosion........................................................................................................................................................................................................................1227 Expected Result...................................................................................................................................................................................................................................................1228 Results...........................................................................................................................................................................................................................................................1228 Test Step 7...........................................................................................................................................................................................................................................................1228 Inspect the Connector Terminals...................................................................................................................................................................................................................................1228 Expected Result...................................................................................................................................................................................................................................................1228 Results...........................................................................................................................................................................................................................................................1228 Test Step 8...........................................................................................................................................................................................................................................................1228 Check Individual Pin Retention Into the Socket....................................................................................................................................................................................................................1228 Expected Result...................................................................................................................................................................................................................................................1229 Results...........................................................................................................................................................................................................................................................1229 Electrical Power Supply Circuit - Test....................................................................................................................................................................................................................................1229 System Operation Description..........................................................................................................................................................................................................................................1229 Background Information................................................................................................................................................................................................................................................1229 Test Step 1...........................................................................................................................................................................................................................................................1230 Check the Batteries...............................................................................................................................................................................................................................................1230 Expected Result...................................................................................................................................................................................................................................................1230 Results...........................................................................................................................................................................................................................................................1230 Test Step 2...........................................................................................................................................................................................................................................................1231 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1231 Expected Result...................................................................................................................................................................................................................................................1231 Results...........................................................................................................................................................................................................................................................1231 Test Step 3...........................................................................................................................................................................................................................................................1231 Check the Battery Voltage at the ECM..............................................................................................................................................................................................................................1231 Expected Result...................................................................................................................................................................................................................................................1231 Results...........................................................................................................................................................................................................................................................1232 Test Step 4...........................................................................................................................................................................................................................................................1232 Use the Bypass Harness for the Electronic Service Tool to Bypass..................................................................................................................................................................................................1232 Expected Result...................................................................................................................................................................................................................................................1233 Results...........................................................................................................................................................................................................................................................1233 Engine Pressure Sensor Open or Short Circuit - Test.......................................................................................................................................................................................................................1233 System Operation Description..........................................................................................................................................................................................................................................1233 Background Information................................................................................................................................................................................................................................................1233 Test Step 1...........................................................................................................................................................................................................................................................1233 Check for Active +5V Sensor Supply Diagnostic Codes...............................................................................................................................................................................................................1233 Expected Result...................................................................................................................................................................................................................................................1234 Results...........................................................................................................................................................................................................................................................1234 Test Step 2...........................................................................................................................................................................................................................................................1234 Verify All Active Diagnostic Codes................................................................................................................................................................................................................................1234 Expected Result...................................................................................................................................................................................................................................................1234 Results...........................................................................................................................................................................................................................................................1234 Test Step 3...........................................................................................................................................................................................................................................................1234 Inspect Electrical Connectors And Wiring..........................................................................................................................................................................................................................1234 Expected Result...................................................................................................................................................................................................................................................1235 Results...........................................................................................................................................................................................................................................................1235 Test Step 4...........................................................................................................................................................................................................................................................1235 Verify That the Diagnostic Code is Still Active...................................................................................................................................................................................................................1235 Expected Result...................................................................................................................................................................................................................................................1235 Results...........................................................................................................................................................................................................................................................1235 Test Step 5...........................................................................................................................................................................................................................................................1235 Disconnect the Sensor to Create an Open Circuit...................................................................................................................................................................................................................1235 Expected Result...................................................................................................................................................................................................................................................1235 Results...........................................................................................................................................................................................................................................................1235 Test Step 6...........................................................................................................................................................................................................................................................1235 Measure the Sensor Supply Voltage.................................................................................................................................................................................................................................1235 Expected Result...................................................................................................................................................................................................................................................1236 Results...........................................................................................................................................................................................................................................................1236 Test Step 7...........................................................................................................................................................................................................................................................1236 Determine if the Short Circuit is in the Connector or in the Sen..................................................................................................................................................................................................1236 Expected Result...................................................................................................................................................................................................................................................1236 Results...........................................................................................................................................................................................................................................................1236 Test Step 8...........................................................................................................................................................................................................................................................1236 Create a Short Circuit Between the Signal and the Common Termina..................................................................................................................................................................................................1236 Expected Result...................................................................................................................................................................................................................................................1237 Results...........................................................................................................................................................................................................................................................1237 Test Step 9...........................................................................................................................................................................................................................................................1237 Check the Operation of the ECM by Creating Open and Short Circui..................................................................................................................................................................................................1237 Expected Result...................................................................................................................................................................................................................................................1237 Results...........................................................................................................................................................................................................................................................1237 Test Step 10..........................................................................................................................................................................................................................................................1238 Bypass the Harness Wiring Between the ECM and the Sensor Connect..................................................................................................................................................................................................1238 Expected Result...................................................................................................................................................................................................................................................1238 Results...........................................................................................................................................................................................................................................................1238 Engine Speed/Timing Sensor Circuit - Test.................................................................................................................................................................................................................................1238 System Operation Description..........................................................................................................................................................................................................................................1238 Test Step 1...........................................................................................................................................................................................................................................................1239 Inspect the Electrical Connectors and Cables......................................................................................................................................................................................................................1239 Expected Result...................................................................................................................................................................................................................................................1239 Results...........................................................................................................................................................................................................................................................1239 Test Step 2...........................................................................................................................................................................................................................................................1239 Check the Installation of the Engine Speed/Timing Sensors.........................................................................................................................................................................................................1239 Expected Result...................................................................................................................................................................................................................................................1239 Results...........................................................................................................................................................................................................................................................1239 Test Step 3...........................................................................................................................................................................................................................................................1239 Measure the Sensor Resistance Through the Wiring Harness..........................................................................................................................................................................................................1239 Expected Result...................................................................................................................................................................................................................................................1240 Results...........................................................................................................................................................................................................................................................1240 Test Step 4...........................................................................................................................................................................................................................................................1240 Measure the Resistance of the Sensor..............................................................................................................................................................................................................................1240 Expected Result...................................................................................................................................................................................................................................................1240 Results...........................................................................................................................................................................................................................................................1240 Test Step 5...........................................................................................................................................................................................................................................................1241 Measure the Resistance of the Cables Between the Fuel Injection ..................................................................................................................................................................................................1241 Expected Result...................................................................................................................................................................................................................................................1241 Results...........................................................................................................................................................................................................................................................1241 Test Step 6...........................................................................................................................................................................................................................................................1241 Check the Continuity of the Cables From the ECM to the Fuel Inje..................................................................................................................................................................................................1241 Expected Result...................................................................................................................................................................................................................................................1241 Results...........................................................................................................................................................................................................................................................1242 Engine Temperature Sensor Open or Short Circuit - Test....................................................................................................................................................................................................................1242 System Operation Description..........................................................................................................................................................................................................................................1242 Background Information................................................................................................................................................................................................................................................1242 Test Step 1...........................................................................................................................................................................................................................................................1243 Verify All Active Diagnostic Codes................................................................................................................................................................................................................................1243 Expected Result...................................................................................................................................................................................................................................................1243 Results...........................................................................................................................................................................................................................................................1243 Test Step 2...........................................................................................................................................................................................................................................................1243 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1243 Expected Result...................................................................................................................................................................................................................................................1243 Results...........................................................................................................................................................................................................................................................1244 Test Step 3...........................................................................................................................................................................................................................................................1244 Verify That the Diagnostic Code is Still Active...................................................................................................................................................................................................................1244 Expected Result...................................................................................................................................................................................................................................................1244 Results...........................................................................................................................................................................................................................................................1244 Test Step 4...........................................................................................................................................................................................................................................................1244 Disconnect the Sensor to Create an Open Circuit...................................................................................................................................................................................................................1244 Expected Result...................................................................................................................................................................................................................................................1244 Results...........................................................................................................................................................................................................................................................1244 Test Step 5...........................................................................................................................................................................................................................................................1244 Create a Short Circuit Between the Signal and the Common Termina..................................................................................................................................................................................................1244 Expected Result...................................................................................................................................................................................................................................................1245 Results...........................................................................................................................................................................................................................................................1245 Test Step 6...........................................................................................................................................................................................................................................................1245 Check the Operation of the ECM by Creating an Open and a Short C..................................................................................................................................................................................................1245 Expected Result...................................................................................................................................................................................................................................................1245 Results...........................................................................................................................................................................................................................................................1245 Test Step 7...........................................................................................................................................................................................................................................................1245 Bypass the Harness Wiring Between the ECM and the Sensor Connect..................................................................................................................................................................................................1245 Expected Result...................................................................................................................................................................................................................................................1246 Results...........................................................................................................................................................................................................................................................1246 Fuel Injection Pump Circuit - Test........................................................................................................................................................................................................................................1246 System Operation Description..........................................................................................................................................................................................................................................1246 Background Information................................................................................................................................................................................................................................................1246 Test Step 1...........................................................................................................................................................................................................................................................1246 Check the Batteries...............................................................................................................................................................................................................................................1246 Expected Result...................................................................................................................................................................................................................................................1246 Results...........................................................................................................................................................................................................................................................1247 Test Step 2...........................................................................................................................................................................................................................................................1247 Inspect the Electrical Connectors and Wiring......................................................................................................................................................................................................................1247 Expected Result...................................................................................................................................................................................................................................................1248 Results...........................................................................................................................................................................................................................................................1248 Test Step 3...........................................................................................................................................................................................................................................................1248 Check the Supply Voltage at the Machine Interface Connector.......................................................................................................................................................................................................1248 Expected Result...................................................................................................................................................................................................................................................1248 Results...........................................................................................................................................................................................................................................................1248 Test Step 4...........................................................................................................................................................................................................................................................1248 Check the Supply Voltage at the Fuel Injection Pump...............................................................................................................................................................................................................1248 Expected Result...................................................................................................................................................................................................................................................1248 Results...........................................................................................................................................................................................................................................................1248 Test Step 5...........................................................................................................................................................................................................................................................1249 Check the Supply to the Power Relay for the Fuel Injection Pump...................................................................................................................................................................................................1249 Expected Result...................................................................................................................................................................................................................................................1249 Results...........................................................................................................................................................................................................................................................1249 Test Step 6...........................................................................................................................................................................................................................................................1249 Check the Output of the Power Relay for the Fuel Injection Pump...................................................................................................................................................................................................1249 Expected Result...................................................................................................................................................................................................................................................1249 Results...........................................................................................................................................................................................................................................................1249 Test Step 7...........................................................................................................................................................................................................................................................1249 Check the Voltage at the Relay Coil for the Fuel Injection Pump...................................................................................................................................................................................................1249 Expected Result...................................................................................................................................................................................................................................................1249 Results...........................................................................................................................................................................................................................................................1249 Test Step 8...........................................................................................................................................................................................................................................................1250 Check the Output of the ECM Fuel Pump Power Control at the Machi..................................................................................................................................................................................................1250 Expected Result...................................................................................................................................................................................................................................................1250 Results...........................................................................................................................................................................................................................................................1250 Test Step 9...........................................................................................................................................................................................................................................................1250 Check the Output of the Fuel Injection Pump Power Control at the..................................................................................................................................................................................................1250 Expected Result...................................................................................................................................................................................................................................................1250 Results...........................................................................................................................................................................................................................................................1250 Test Step 10..........................................................................................................................................................................................................................................................1250 Measure the Voltage at the Pump Power Supply......................................................................................................................................................................................................................1250 Expected Result...................................................................................................................................................................................................................................................1251 Results...........................................................................................................................................................................................................................................................1251 Test Step 11..........................................................................................................................................................................................................................................................1251 Check the Voltage Load Protection Module (VLPM)...................................................................................................................................................................................................................1251 Expected Result...................................................................................................................................................................................................................................................1252 Results...........................................................................................................................................................................................................................................................1252 Indicator Lamp Circuit - Test.............................................................................................................................................................................................................................................1252 System Operation Description..........................................................................................................................................................................................................................................1252 Test Step 1...........................................................................................................................................................................................................................................................1252 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1252 Results...........................................................................................................................................................................................................................................................1253 Test Step 2...........................................................................................................................................................................................................................................................1253 Inspect the Lamp, the Fuse, and the Power Supply..................................................................................................................................................................................................................1253 Expected Result...................................................................................................................................................................................................................................................1253 Results...........................................................................................................................................................................................................................................................1253 Test Step 3...........................................................................................................................................................................................................................................................1253 Inspect the Input to the Lamp at the ECM connector................................................................................................................................................................................................................1253 Expected Result...................................................................................................................................................................................................................................................1253 Results...........................................................................................................................................................................................................................................................1254 Test Step 4...........................................................................................................................................................................................................................................................1254 Test the Individual Lamp Circuits.................................................................................................................................................................................................................................1254 Expected Result...................................................................................................................................................................................................................................................1254 Results...........................................................................................................................................................................................................................................................1254 Test Step 5...........................................................................................................................................................................................................................................................1254 Check the Voltage at the ECM......................................................................................................................................................................................................................................1254 Expected Result...................................................................................................................................................................................................................................................1254 Results...........................................................................................................................................................................................................................................................1254 Idle Validation Circuit - Test............................................................................................................................................................................................................................................1254 System Operation Description..........................................................................................................................................................................................................................................1254 Test Step 1...........................................................................................................................................................................................................................................................1254 Expected Result...................................................................................................................................................................................................................................................1254 Results...........................................................................................................................................................................................................................................................1255 tables............................................................................................................................................................................................................................................................................1103 Table 1. Electronic Service Tool..............................................................................................................................................................................................................................................1129 Table 2. Optional Service Tools...............................................................................................................................................................................................................................................1130 Table 3. CID FMI Codes and J Code FMI Codes...................................................................................................................................................................................................................................1131 Table 4. Event Codes and CID FMI Codes........................................................................................................................................................................................................................................1133 Table 5. Diagnostics Supported Over J1939.....................................................................................................................................................................................................................................1134 Table 6. Events Supported Over J1939..........................................................................................................................................................................................................................................1136 Table 7. Engine Connectors....................................................................................................................................................................................................................................................1143 Table 8. Color Codes for the Harness Wire.....................................................................................................................................................................................................................................1148 Table 9. Pin Connections for Perkins Deutsch Socket Connector.................................................................................................................................................................................................................1150 Table 10. Suspect Parameter Numbers...........................................................................................................................................................................................................................................1154 Table 11. Failure Mode Indicators (FMI) Codes.................................................................................................................................................................................................................................1155 Table 12. Engine Oil Pressure Trip and Reset Points...........................................................................................................................................................................................................................1199 1586990-8000SRM1181-(03-2007)-UK-EN...................................................................................................................................................................................................................................................1259 toc...............................................................................................................................................................................................................................................................................1259 Assembly Guide................................................................................................................................................................................................................................................................1259 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1260 List of All Special Tools and Equipment Needed for the Assembly...............................................................................................................................................................................................................1263 General Considerations Before Starting the Job................................................................................................................................................................................................................................1263 Preparation of the Components Before Assembly.................................................................................................................................................................................................................................1264 Liquefied Petroleum Gas (LPG Engines Only)....................................................................................................................................................................................................................................1264 Remove....................................................................................................................................................................................................................................................................1264 Install...................................................................................................................................................................................................................................................................1265 Checking of the Wheels........................................................................................................................................................................................................................................................1265 Air Pressure..............................................................................................................................................................................................................................................................1265 Drive Wheels..............................................................................................................................................................................................................................................................1266 Steer Wheels..............................................................................................................................................................................................................................................................1270 Wheel Nut Torque..........................................................................................................................................................................................................................................................1273 Mast Label Placement..........................................................................................................................................................................................................................................................1274 Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................1275 Mast Installation.............................................................................................................................................................................................................................................................1277 Mast......................................................................................................................................................................................................................................................................1277 Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................1280 Lift Cylinder Hose Connection.............................................................................................................................................................................................................................................1281 Truck Header Hoses and Electrical Cable Connections.......................................................................................................................................................................................................................1282 Mast Light Connection.....................................................................................................................................................................................................................................................1284 Carriage Installation.....................................................................................................................................................................................................................................................1285 Carriage Header Hoses and Electrical Cable Connection.....................................................................................................................................................................................................................1286 Fork Installation.........................................................................................................................................................................................................................................................1289 Exhaust Extension Tube Installation...........................................................................................................................................................................................................................................1290 Lights Installation - Operator Compartment....................................................................................................................................................................................................................................1292 Hydraulic Oil Check...........................................................................................................................................................................................................................................................1293 Lubrication Points............................................................................................................................................................................................................................................................1294 Check Points..................................................................................................................................................................................................................................................................1295 Checkpoint 1..............................................................................................................................................................................................................................................................1295 Checkpoint 2..............................................................................................................................................................................................................................................................1295 Checkpoint 3..............................................................................................................................................................................................................................................................1295 Checkpoint 4..............................................................................................................................................................................................................................................................1295 Checkpoint 5..............................................................................................................................................................................................................................................................1295 General Truck Install Procedures..............................................................................................................................................................................................................................................1295 tables............................................................................................................................................................................................................................................................................1259 Table 1. Mast Hanger Pins Capscrew Torques....................................................................................................................................................................................................................................1280 1612615-5000SRM1221-(11-2006)-UK-EN...................................................................................................................................................................................................................................................1299 toc...............................................................................................................................................................................................................................................................................1299 Extendable Container Attachment (Elme)........................................................................................................................................................................................................................................1299 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1300 General.......................................................................................................................................................................................................................................................................1305 Description...................................................................................................................................................................................................................................................................1305 Operation.....................................................................................................................................................................................................................................................................1309 General...................................................................................................................................................................................................................................................................1309 Optional Powered Pile Slope...............................................................................................................................................................................................................................................1309 Sideshift.................................................................................................................................................................................................................................................................1310 Extend and Retract Circuit................................................................................................................................................................................................................................................1311 Container locking Model 582...............................................................................................................................................................................................................................................1313 Sequence Valve........................................................................................................................................................................................................................................................1313 Pilot Check Valve.....................................................................................................................................................................................................................................................1314 Container Locking Model 583...............................................................................................................................................................................................................................................1315 Container Locking Model 584...............................................................................................................................................................................................................................................1315 Container Locking Model 585...............................................................................................................................................................................................................................................1316 Container Locking Models 586, 588, and 589................................................................................................................................................................................................................................1316 Electrical System.........................................................................................................................................................................................................................................................1318 Indicator Lights..........................................................................................................................................................................................................................................................1318 Flashing Indicator Lights.................................................................................................................................................................................................................................................1319 Automatic Locking.........................................................................................................................................................................................................................................................1319 Lift Interrupt and Override...............................................................................................................................................................................................................................................1319 Overlowering Interrupt and Override.......................................................................................................................................................................................................................................1319 Second Container Detection Sensor (Model 582 Only)........................................................................................................................................................................................................................1320 Carriage and Attachment Removal...............................................................................................................................................................................................................................................1320 Carriage..................................................................................................................................................................................................................................................................1320 Spreader..................................................................................................................................................................................................................................................................1321 Sideshift Cylinder Removal and Installation...................................................................................................................................................................................................................................1321 Remove....................................................................................................................................................................................................................................................................1321 Install...................................................................................................................................................................................................................................................................1321 Extension Cylinder Removal and Installation...................................................................................................................................................................................................................................1322 Remove....................................................................................................................................................................................................................................................................1322 Upper, Right-Hand.....................................................................................................................................................................................................................................................1322 Lower, Left-Hand......................................................................................................................................................................................................................................................1322 Install...................................................................................................................................................................................................................................................................1322 Floating End Beams Repair.....................................................................................................................................................................................................................................................1323 Remove....................................................................................................................................................................................................................................................................1323 Install...................................................................................................................................................................................................................................................................1323 Hose, Replace.............................................................................................................................................................................................................................................................1324 Twist Lock Repair for Model 582...............................................................................................................................................................................................................................................1325 Remove....................................................................................................................................................................................................................................................................1325 Upper Twist Lock......................................................................................................................................................................................................................................................1325 Lower Twist Lock......................................................................................................................................................................................................................................................1325 Disassemble...............................................................................................................................................................................................................................................................1326 Clean and Inspect.........................................................................................................................................................................................................................................................1326 Assemble..................................................................................................................................................................................................................................................................1327 Install...................................................................................................................................................................................................................................................................1327 Hook Repair for Model 584 and 585.............................................................................................................................................................................................................................................1327 Remove....................................................................................................................................................................................................................................................................1327 Inspect...................................................................................................................................................................................................................................................................1327 Install...................................................................................................................................................................................................................................................................1327 Side Clamp Replacement for Model 584..........................................................................................................................................................................................................................................1328 Remove....................................................................................................................................................................................................................................................................1328 Install...................................................................................................................................................................................................................................................................1329 Twist Lock Repair for Models 586, 588, and 589................................................................................................................................................................................................................................1329 Disassemble...............................................................................................................................................................................................................................................................1329 Clean and Inspect.........................................................................................................................................................................................................................................................1329 Assemble..................................................................................................................................................................................................................................................................1330 Extension Beam Repair.........................................................................................................................................................................................................................................................1331 Remove....................................................................................................................................................................................................................................................................1331 Inspect...................................................................................................................................................................................................................................................................1331 Assemble..................................................................................................................................................................................................................................................................1332 Cylinder Repair...............................................................................................................................................................................................................................................................1333 Extension Cylinder........................................................................................................................................................................................................................................................1333 Disassemble...........................................................................................................................................................................................................................................................1333 Clean and Inspect.....................................................................................................................................................................................................................................................1333 Assemble..............................................................................................................................................................................................................................................................1333 Guide for Extension Cylinder..............................................................................................................................................................................................................................................1334 Remove................................................................................................................................................................................................................................................................1334 Install...............................................................................................................................................................................................................................................................1334 Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde..........................................................................................................................................................................................................1334 Disassemble...........................................................................................................................................................................................................................................................1334 Assemble..............................................................................................................................................................................................................................................................1334 Wear Pad Replacement..........................................................................................................................................................................................................................................................1335 General...................................................................................................................................................................................................................................................................1335 Floating End Beam Wear Pads...............................................................................................................................................................................................................................................1335 Upper Wear Pads.......................................................................................................................................................................................................................................................1335 Lower Wear Pads.......................................................................................................................................................................................................................................................1335 Main Frame Wear Pads at Large (Right-Hand) Extension Beam.................................................................................................................................................................................................................1335 Main Frame Wear Pads at Small (Left-Hand) Extension Beam..................................................................................................................................................................................................................1335 Guide for Extension Cylinder..............................................................................................................................................................................................................................................1336 Large Extension Beam Internal Wear Pads...................................................................................................................................................................................................................................1337 Spreader Frame............................................................................................................................................................................................................................................................1337 Upper Wear Pads.......................................................................................................................................................................................................................................................1337 Lower Wear Pads.......................................................................................................................................................................................................................................................1337 Powered Pile Slope Carriage...............................................................................................................................................................................................................................................1337 Upper Wear Pads.......................................................................................................................................................................................................................................................1337 Lower Wear Pads.......................................................................................................................................................................................................................................................1337 Adjustments...................................................................................................................................................................................................................................................................1337 Twist Lock Angle Adjustment...............................................................................................................................................................................................................................................1337 Model 586, 588 and 589................................................................................................................................................................................................................................................1337 LOCKED/NOT LOCKED Sensors Adjustment......................................................................................................................................................................................................................................1338 Model 582.............................................................................................................................................................................................................................................................1338 Model 586, 588 and 589................................................................................................................................................................................................................................................1338 Side Clamp Open/Closed Sensor Adjustment (Model 584)......................................................................................................................................................................................................................1338 Hook in Sensor Adjustment (Model 584).....................................................................................................................................................................................................................................1338 Seated Sensor Adjustment..................................................................................................................................................................................................................................................1339 Model 582.............................................................................................................................................................................................................................................................1339 Model 586, 588 and 589................................................................................................................................................................................................................................................1339 Overlowering Protection Sensor Adjustment (All 580 Models)................................................................................................................................................................................................................1339 Schematics....................................................................................................................................................................................................................................................................1340 tables............................................................................................................................................................................................................................................................................1299 Table 1. Elme Schematic Overview..............................................................................................................................................................................................................................................1340 Aurora_AC.............................................................................................................................................................................................................................................................................1427 912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................1428 Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................1428 ..........................................................................................................................................................................................................................................................................1434 Filling procedure for refrigerants....................................................................................................................................................................................................................................1434 Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................1434 Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................1434 Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................1434 The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................1434 Never put the safety switch out of action.........................................................................................................................................................................................................................1434 Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................1434 Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................1434 Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................1434 Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................1434 Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................1434 Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov....1434 Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri....1434 No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion...................1434 Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................1434 It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only.....................................................1434 4. Troubleshooting............................................................................................................................................................................................................................................................1435 ..........................................................................................................................................................................................................................................................................1435 ......................................................................................................................................................................................................................................................................1435 Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................1435 By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................1435 The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................1435 With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................1435 Faulty shaft seals: On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o....1435 Noises Mechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with.....1435 Electrical faults A 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click....1435 912-100-0007_e.pdf................................................................................................................................................................................................................................................................1436 Technical modifications reserved..............................................................................................................................................................................................................................................1436 912-100-0258_e.pdf................................................................................................................................................................................................................................................................1447 Condenser unit, 24V...........................................................................................................................................................................................................................................................1447 ..........................................................................................................................................................................................................................................................................1447 ......................................................................................................................................................................................................................................................................1447 ..................................................................................................................................................................................................................................................................1447 ..............................................................................................................................................................................................................................................................1447 part no.:175-FR2-0002.....................................................................................................................................................................................................................................1447 Safety advices................................................................................................................................................................................................................................................1447 - we reserve the right to make technical modifications -..................................................................................................................................................................................................................1447 1Safety advices...............................................................................................................................................................................................................................................................1448 Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................1448 ......................................................................................................................................................................................................................................................................1449 2.2Condenser blowers..............................................................................................................................................................................................................................................1449 5Electrical connection............................................................................................................................................................................................................................................1450 every six months – authorised workshop:...................................................................................................................................................................................................................................1451 ......................................................................................................................................................................................................................................................................1451 ..................................................................................................................................................................................................................................................................1451 ..............................................................................................................................................................................................................................................................1451 State of the refrigerant hoses............................................................................................................................................................................................................................1451 State of the condenser................................................................................................................................................................................................................................................1451 A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner).................................................................................................................1451 every month sight checks - Operator.......................................................................................................................................................................................................................................1452 ......................................................................................................................................................................................................................................................................1452 ..................................................................................................................................................................................................................................................................1452 ..............................................................................................................................................................................................................................................................1452 State of the refrigerant hoses............................................................................................................................................................................................................................1452 State of the condenser................................................................................................................................................................................................................................................1452 Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................1452 A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner).................................................................................................................1452 Installation of replacement parts.....................................................................................................................................................................................................................................1452 8Technical data...................................................................................................................................................................................................................................................1452 9Fault diagnosis..................................................................................................................................................................................................................................................1453
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