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Hyster F019 Service Manual – PDF DOWNLOAD
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Description
Hyster F019 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F019 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 Service Manual – PDF DOWNLOAD
897934-0700SRM0626-(11-2001)-US-EN.................................................................................................................................................................................................................................................... 1 toc............................................................................................................................................................................................................................................................................... 1 Cooling System................................................................................................................................................................................................................................................................ 1 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 2 General....................................................................................................................................................................................................................................................................... 5 Description................................................................................................................................................................................................................................................................... 6 Radiator.................................................................................................................................................................................................................................................................. 6 Radiator Cap.............................................................................................................................................................................................................................................................. 6 Thermostat................................................................................................................................................................................................................................................................ 6 Water Pump................................................................................................................................................................................................................................................................ 7 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 7 Cooling System Checks......................................................................................................................................................................................................................................................... 7 Radiator.................................................................................................................................................................................................................................................................. 7 Thermostat................................................................................................................................................................................................................................................................ 7 Water Pump................................................................................................................................................................................................................................................................ 8 Exhaust Leaks............................................................................................................................................................................................................................................................. 8 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 8 Radiator Cleaning............................................................................................................................................................................................................................................................. 8 Drain..................................................................................................................................................................................................................................................................... 8 Clean..................................................................................................................................................................................................................................................................... 8 Fill...................................................................................................................................................................................................................................................................... 9 Troubleshooting............................................................................................................................................................................................................................................................... 10 899784-2200SRM0002-(12-2004)-US-EN.................................................................................................................................................................................................................................................... 13 toc............................................................................................................................................................................................................................................................................... 13 Alternator with Regulator..................................................................................................................................................................................................................................................... 13 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 14 General....................................................................................................................................................................................................................................................................... 17 Description................................................................................................................................................................................................................................................................... 17 Alternator Repair............................................................................................................................................................................................................................................................. 19 Alternator Type A......................................................................................................................................................................................................................................................... 19 Remove and Disassemble................................................................................................................................................................................................................................................ 19 Clean................................................................................................................................................................................................................................................................. 20 Assemble.............................................................................................................................................................................................................................................................. 21 Install............................................................................................................................................................................................................................................................... 21 Alternator Type B......................................................................................................................................................................................................................................................... 24 Remove and Disassemble................................................................................................................................................................................................................................................ 24 Clean................................................................................................................................................................................................................................................................. 24 Assemble.............................................................................................................................................................................................................................................................. 25 Install............................................................................................................................................................................................................................................................... 26 General Check and Adjustment.................................................................................................................................................................................................................................................. 27 Low Output Check (Type A or Type B)........................................................................................................................................................................................................................................... 27 High Output Check (Type A or Type B).......................................................................................................................................................................................................................................... 29 Brushes Circuit Check......................................................................................................................................................................................................................................................... 30 Delco Alternators......................................................................................................................................................................................................................................................... 30 Motorola Alternators...................................................................................................................................................................................................................................................... 31 Diodes Check.................................................................................................................................................................................................................................................................. 32 Diode Bridge Check............................................................................................................................................................................................................................................................ 32 Delco and Leece-Neville Alternators....................................................................................................................................................................................................................................... 32 Motorola Alternators...................................................................................................................................................................................................................................................... 32 Rotor Field Winding Check..................................................................................................................................................................................................................................................... 33 Stator Windings Check......................................................................................................................................................................................................................................................... 34 Voltage Regulator Check....................................................................................................................................................................................................................................................... 34 Troubleshooting............................................................................................................................................................................................................................................................... 34 910107-2200SRM0106-(12-2004)-US-EN.................................................................................................................................................................................................................................................... 39 toc............................................................................................................................................................................................................................................................................... 39 Starter....................................................................................................................................................................................................................................................................... 39 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 40 General....................................................................................................................................................................................................................................................................... 43 Description and Operation..................................................................................................................................................................................................................................................... 43 Starter Repair................................................................................................................................................................................................................................................................ 45 Remove.................................................................................................................................................................................................................................................................... 45 Disassemble............................................................................................................................................................................................................................................................... 45 Clean..................................................................................................................................................................................................................................................................... 46 Assemble.................................................................................................................................................................................................................................................................. 46 Install................................................................................................................................................................................................................................................................... 47 General Checks and Adjustments................................................................................................................................................................................................................................................ 47 Troubleshooting............................................................................................................................................................................................................................................................... 50 1494123-0100SRM0927-(01-2006)-US-EN................................................................................................................................................................................................................................................... 55 toc............................................................................................................................................................................................................................................................................... 55 Frame......................................................................................................................................................................................................................................................................... 55 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 56 General....................................................................................................................................................................................................................................................................... 59 Description................................................................................................................................................................................................................................................................... 59 Counterweight Repair.......................................................................................................................................................................................................................................................... 59 Remove.................................................................................................................................................................................................................................................................... 59 Install................................................................................................................................................................................................................................................................... 61 Fenders................................................................................................................................................................................................................................................................... 61 Remove................................................................................................................................................................................................................................................................ 61 Install............................................................................................................................................................................................................................................................... 61 Side Counterweights H13.00-16.00XM (H300-360HD)........................................................................................................................................................................................................................... 61 Side Counterweight, Replace............................................................................................................................................................................................................................................... 61 Hood and Air Cleaner Repair................................................................................................................................................................................................................................................... 62 Remove.................................................................................................................................................................................................................................................................... 62 Install................................................................................................................................................................................................................................................................... 64 Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 64 Remove.................................................................................................................................................................................................................................................................... 64 Repairs, All Units........................................................................................................................................................................................................................................................ 65 Small Leaks........................................................................................................................................................................................................................................................... 65 Large Leaks........................................................................................................................................................................................................................................................... 66 Clean..................................................................................................................................................................................................................................................................... 66 Steam Method.......................................................................................................................................................................................................................................................... 66 Chemical Solution Method.............................................................................................................................................................................................................................................. 67 Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 67 Install................................................................................................................................................................................................................................................................... 67 Fuel Tank Repair.............................................................................................................................................................................................................................................................. 68 Remove.................................................................................................................................................................................................................................................................... 68 Repairs................................................................................................................................................................................................................................................................... 68 Install................................................................................................................................................................................................................................................................... 68 Cooling System and Radiator Repair............................................................................................................................................................................................................................................ 70 Remove.................................................................................................................................................................................................................................................................... 70 Install................................................................................................................................................................................................................................................................... 71 Engine and Transmission Repair................................................................................................................................................................................................................................................ 72 Hyster T-50 Transmission, Remove.......................................................................................................................................................................................................................................... 72 Hyster T-50 Transmission, Install......................................................................................................................................................................................................................................... 73 TE-10 Transmission........................................................................................................................................................................................................................................................ 74 Remove................................................................................................................................................................................................................................................................ 74 Install............................................................................................................................................................................................................................................................... 77 Label Replacement............................................................................................................................................................................................................................................................. 79 1494140-1600SRM0936-(03-2007)-US-EN................................................................................................................................................................................................................................................... 87 toc............................................................................................................................................................................................................................................................................... 87 Steering System............................................................................................................................................................................................................................................................... 87 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 88 General....................................................................................................................................................................................................................................................................... 91 Description................................................................................................................................................................................................................................................................... 91 Steering Wheel and Column Assembly............................................................................................................................................................................................................................................ 93 General................................................................................................................................................................................................................................................................... 93 Steering Wheel and Horn................................................................................................................................................................................................................................................... 93 Remove................................................................................................................................................................................................................................................................ 93 Install............................................................................................................................................................................................................................................................... 93 Steering Control Unit Repair.................................................................................................................................................................................................................................................. 95 General................................................................................................................................................................................................................................................................... 95 Description............................................................................................................................................................................................................................................................... 95 Operation................................................................................................................................................................................................................................................................. 95 Remove.................................................................................................................................................................................................................................................................... 96 Disassemble............................................................................................................................................................................................................................................................... 96 Clean..................................................................................................................................................................................................................................................................... 99 Assemble and Install...................................................................................................................................................................................................................................................... 99 Steering System Air Removal................................................................................................................................................................................................................................................... 105 Steering Relief Pressure Check................................................................................................................................................................................................................................................ 106 Troubleshooting............................................................................................................................................................................................................................................................... 106 1494141-1800SRM0937-(03-2007)-US-EN................................................................................................................................................................................................................................................... 111 toc............................................................................................................................................................................................................................................................................... 111 Dry Brake System.............................................................................................................................................................................................................................................................. 111 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 112 General....................................................................................................................................................................................................................................................................... 115 Description................................................................................................................................................................................................................................................................... 115 Operation..................................................................................................................................................................................................................................................................... 116 Service Brakes............................................................................................................................................................................................................................................................ 116 Parking Brake............................................................................................................................................................................................................................................................. 118 Air Tank Repair............................................................................................................................................................................................................................................................... 119 Relief Valve.............................................................................................................................................................................................................................................................. 119 Drain Valve............................................................................................................................................................................................................................................................... 119 Brake Pedal Valve Repair...................................................................................................................................................................................................................................................... 120 Remove.................................................................................................................................................................................................................................................................... 120 Disassemble, Inspect, and Assemble........................................................................................................................................................................................................................................ 120 Install................................................................................................................................................................................................................................................................... 120 Air Chambers Repair........................................................................................................................................................................................................................................................... 121 Remove.................................................................................................................................................................................................................................................................... 121 Disassemble............................................................................................................................................................................................................................................................... 121 Inspect................................................................................................................................................................................................................................................................... 122 Assemble.................................................................................................................................................................................................................................................................. 123 Install................................................................................................................................................................................................................................................................... 123 Actuator Arms Repair.......................................................................................................................................................................................................................................................... 123 Remove.................................................................................................................................................................................................................................................................... 123 Inspect................................................................................................................................................................................................................................................................... 124 Install................................................................................................................................................................................................................................................................... 124 Brake Assemblies Repair....................................................................................................................................................................................................................................................... 125 Brake Shoe, Remove........................................................................................................................................................................................................................................................ 125 Camshaft, Remove.......................................................................................................................................................................................................................................................... 127 Clean..................................................................................................................................................................................................................................................................... 127 Inspect................................................................................................................................................................................................................................................................... 128 Camshaft, Install......................................................................................................................................................................................................................................................... 128 Brake Shoe, Install....................................................................................................................................................................................................................................................... 129 Air Dryer..................................................................................................................................................................................................................................................................... 130 Description............................................................................................................................................................................................................................................................... 130 Cartridge................................................................................................................................................................................................................................................................. 130 Remove................................................................................................................................................................................................................................................................ 130 Install............................................................................................................................................................................................................................................................... 130 Filter.................................................................................................................................................................................................................................................................... 130 Remove................................................................................................................................................................................................................................................................ 130 Install............................................................................................................................................................................................................................................................... 130 Quick-Release Valve........................................................................................................................................................................................................................................................... 132 Governor Check and Adjustment for Air Compressor.............................................................................................................................................................................................................................. 132 Brake Shoes Adjustment........................................................................................................................................................................................................................................................ 133 Specifications................................................................................................................................................................................................................................................................ 134 Troubleshooting............................................................................................................................................................................................................................................................... 134 Service Brakes............................................................................................................................................................................................................................................................ 134 Service Brakes, Park Function ............................................................................................................................................................................................................................................ 137 tables............................................................................................................................................................................................................................................................................ 111 Table 1. Air Chambers Operation............................................................................................................................................................................................................................................... 118 1494142-1900SRM0938-(03-2007)-US-EN................................................................................................................................................................................................................................................... 141 toc............................................................................................................................................................................................................................................................................... 141 Hydraulic System.............................................................................................................................................................................................................................................................. 141 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 142 General....................................................................................................................................................................................................................................................................... 145 Description and Operation..................................................................................................................................................................................................................................................... 145 Hydraulic Tank............................................................................................................................................................................................................................................................ 145 Hydraulic Pump............................................................................................................................................................................................................................................................ 146 Steering Priority Flow Valve.............................................................................................................................................................................................................................................. 146 Pilot Valve............................................................................................................................................................................................................................................................... 147 Main Control Valve........................................................................................................................................................................................................................................................ 149 Unloader Valve............................................................................................................................................................................................................................................................ 150 Hydraulic Operation....................................................................................................................................................................................................................................................... 151 Checks and Adjustments........................................................................................................................................................................................................................................................ 154 Quick Disconnect Fittings................................................................................................................................................................................................................................................. 154 Steering Priority Flow Valve.............................................................................................................................................................................................................................................. 154 Steering Relief Pressure.................................................................................................................................................................................................................................................. 154 Modulator Valve........................................................................................................................................................................................................................................................... 155 Pilot Valve and Pressure Reducing Valve................................................................................................................................................................................................................................... 155 Accumulator............................................................................................................................................................................................................................................................... 156 Filter.................................................................................................................................................................................................................................................................... 156 Main Control Valve........................................................................................................................................................................................................................................................ 156 Relief Pressure Check................................................................................................................................................................................................................................................. 156 Check Valves.............................................................................................................................................................................................................................................................. 157 Unloader Valve............................................................................................................................................................................................................................................................ 157 Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 158 Remove.................................................................................................................................................................................................................................................................... 158 Disassemble............................................................................................................................................................................................................................................................... 158 Clean and Inspect......................................................................................................................................................................................................................................................... 158 Assemble.................................................................................................................................................................................................................................................................. 159 Install................................................................................................................................................................................................................................................................... 160 Pilot Accumulator Replacement ................................................................................................................................................................................................................................................ 160 Remove.................................................................................................................................................................................................................................................................... 160 Install................................................................................................................................................................................................................................................................... 160 Pilot Valve Repair............................................................................................................................................................................................................................................................ 161 Remove.................................................................................................................................................................................................................................................................... 161 Disassemble............................................................................................................................................................................................................................................................... 162 Clean and Inspect......................................................................................................................................................................................................................................................... 162 Assemble.................................................................................................................................................................................................................................................................. 162 Install................................................................................................................................................................................................................................................................... 162 Control Levers and Joystick Repair............................................................................................................................................................................................................................................ 163 Remove.................................................................................................................................................................................................................................................................... 163 Install................................................................................................................................................................................................................................................................... 163 Calibration and Diagnostics................................................................................................................................................................................................................................................... 164 General................................................................................................................................................................................................................................................................... 164 Description............................................................................................................................................................................................................................................................... 164 Lever and Joystick Calibration........................................................................................................................................................................................................................................ 164 Flow Adjustment....................................................................................................................................................................................................................................................... 164 Dead Band Value Setting............................................................................................................................................................................................................................................... 165 Lowering Delay........................................................................................................................................................................................................................................................ 166 PWM and I/O Module Readouts........................................................................................................................................................................................................................................... 166 Function Disable...................................................................................................................................................................................................................................................... 167 General Startup........................................................................................................................................................................................................................................................... 167 Minimum system requirements........................................................................................................................................................................................................................................... 167 Install the Hydraulic Controls Program................................................................................................................................................................................................................................ 167 DelayTimeFile (Reset)................................................................................................................................................................................................................................................. 167 Select the Processor Speed............................................................................................................................................................................................................................................ 168 Hydraulic Controls Program................................................................................................................................................................................................................................................ 168 Calibration............................................................................................................................................................................................................................................................... 170 Joystick/Lever Calibration............................................................................................................................................................................................................................................ 170 Levers............................................................................................................................................................................................................................................................ 170 Joystick.......................................................................................................................................................................................................................................................... 170 Valve Flow Adjustment..................................................................................................................................................................................................................................................... 171 Diagnostics............................................................................................................................................................................................................................................................... 171 Calibration System Shutdown............................................................................................................................................................................................................................................... 171 LED Diagnostics............................................................................................................................................................................................................................................................... 172 Electrical Connections........................................................................................................................................................................................................................................................ 175 Specifications................................................................................................................................................................................................................................................................ 179 tables............................................................................................................................................................................................................................................................................ 141 Table 1. Main Control Valve Port Settings..................................................................................................................................................................................................................................... 147 Table 2. Processor Speed Settings............................................................................................................................................................................................................................................. 167 Table 3. PWM Board LED Error Codes............................................................................................................................................................................................................................................ 172 Table 4. Altering PT FLT I/O Board LED's (Old Logic).......................................................................................................................................................................................................................... 173 Table 5. Altering PT FLT I/O Board LED's (New Logic).......................................................................................................................................................................................................................... 173 Table 6. Fixed PT Logic I/O Boards LED's...................................................................................................................................................................................................................................... 174 Table 7. ECH.................................................................................................................................................................................................................................................................. 174 Table 8. PWM Driver Module.................................................................................................................................................................................................................................................... 175 Table 9. Input/Output Module 1................................................................................................................................................................................................................................................ 176 Table 10. Input/Output Module 2............................................................................................................................................................................................................................................... 177 Table 11. Altering PT FLT..................................................................................................................................................................................................................................................... 178 Table 12. Fixed PT FLT........................................................................................................................................................................................................................................................ 178 Table 13. ECH................................................................................................................................................................................................................................................................. 179 1494145-8000SRM0940-(01-2006)-US-EN................................................................................................................................................................................................................................................... 183 toc............................................................................................................................................................................................................................................................................... 183 Capacities and Specifications................................................................................................................................................................................................................................................. 183 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 184 Lift Truck Weights............................................................................................................................................................................................................................................................ 187 Capacities.................................................................................................................................................................................................................................................................... 187 Engine Specifications......................................................................................................................................................................................................................................................... 188 Perkins Diesel............................................................................................................................................................................................................................................................ 188 Cummins Diesel/LPG........................................................................................................................................................................................................................................................ 189 Hydraulic System.............................................................................................................................................................................................................................................................. 190 Electrical System............................................................................................................................................................................................................................................................. 191 Tire Sizes.................................................................................................................................................................................................................................................................... 191 Mast Speeds................................................................................................................................................................................................................................................................... 191 Perkins Diesel............................................................................................................................................................................................................................................................ 191 Cummins Diesel/LPG........................................................................................................................................................................................................................................................ 192 Torque Specifications, Cummins Diesel......................................................................................................................................................................................................................................... 193 Lubrication System........................................................................................................................................................................................................................................................ 193 Torque Specifications, Perkins Diesel......................................................................................................................................................................................................................................... 193 Engine.................................................................................................................................................................................................................................................................... 193 Cylinder Head Assembly................................................................................................................................................................................................................................................ 193 Piston and Connecting Rod Assemblies.................................................................................................................................................................................................................................. 193 Crankshaft Assembly................................................................................................................................................................................................................................................... 193 Timing Case and Drive Assembly........................................................................................................................................................................................................................................ 194 Turbocharger.......................................................................................................................................................................................................................................................... 194 Lubrication System.................................................................................................................................................................................................................................................... 194 Fuel System........................................................................................................................................................................................................................................................... 194 Cooling System........................................................................................................................................................................................................................................................ 194 Flywheel and Housing.................................................................................................................................................................................................................................................. 194 Aspiration System..................................................................................................................................................................................................................................................... 195 Electrical Equipment.................................................................................................................................................................................................................................................. 195 Auxiliary Equipment................................................................................................................................................................................................................................................... 195 Torque Specifications - Perkins, Tier 2....................................................................................................................................................................................................................................... 195 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 195 Piston and Connecting Rod Assemblies...................................................................................................................................................................................................................................... 195 Crankshaft Assembly....................................................................................................................................................................................................................................................... 195 Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 195 Turbocharger.............................................................................................................................................................................................................................................................. 196 Lubrication System........................................................................................................................................................................................................................................................ 196 Fuel System............................................................................................................................................................................................................................................................... 196 Cooling System............................................................................................................................................................................................................................................................ 196 Flywheel.................................................................................................................................................................................................................................................................. 196 Auxiliary Equipment....................................................................................................................................................................................................................................................... 196 Torque Specifications, General................................................................................................................................................................................................................................................ 197 Transmission.............................................................................................................................................................................................................................................................. 197 Driveline and Axle........................................................................................................................................................................................................................................................ 197 Differential.............................................................................................................................................................................................................................................................. 197 Brakes - Wet.............................................................................................................................................................................................................................................................. 197 Brakes - Dry.............................................................................................................................................................................................................................................................. 197 Steering.................................................................................................................................................................................................................................................................. 197 Hydraulic System.......................................................................................................................................................................................................................................................... 198 Mast...................................................................................................................................................................................................................................................................... 198 Carriage.................................................................................................................................................................................................................................................................. 198 Tilt Cylinders............................................................................................................................................................................................................................................................ 198 Frame..................................................................................................................................................................................................................................................................... 198 Wiper Arms, Front......................................................................................................................................................................................................................................................... 198 Hyster T-50 Transmission Pressures (Powershift and Automatic)................................................................................................................................................................................................................. 199 TE-10 Transmission Specifications............................................................................................................................................................................................................................................. 200 Electrical................................................................................................................................................................................................................................................................ 200 Hydraulic Cooler Lines.................................................................................................................................................................................................................................................... 200 Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 201 tables............................................................................................................................................................................................................................................................................ 183 Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp.............................................................................................................................................................................................................. 200 Table 2. Grade 5.............................................................................................................................................................................................................................................................. 201 Table 3. Grade 8.............................................................................................................................................................................................................................................................. 201 Table 4. Grades 8.8, 10.9, and 12.9........................................................................................................................................................................................................................................... 201 Table 5. O-ring Port Plug Torque Chart........................................................................................................................................................................................................................................ 202 Table 6. Pipe Plug Torque Chart............................................................................................................................................................................................................................................... 202 1494953-1400SRM0944-(03-2007)-US-EN................................................................................................................................................................................................................................................... 205 toc............................................................................................................................................................................................................................................................................... 205 Planetary Drive Axle.......................................................................................................................................................................................................................................................... 205 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 206 General....................................................................................................................................................................................................................................................................... 209 Description................................................................................................................................................................................................................................................................... 209 Operation..................................................................................................................................................................................................................................................................... 211 Identification............................................................................................................................................................................................................................................................ 211 Removal....................................................................................................................................................................................................................................................................... 212 Disassembly................................................................................................................................................................................................................................................................... 212 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 212 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 214 Wheel End................................................................................................................................................................................................................................................................. 216 Spindle and Piston Housing................................................................................................................................................................................................................................................ 217 Cleaning...................................................................................................................................................................................................................................................................... 218 Clean Ground or Polished Parts............................................................................................................................................................................................................................................ 218 Clean Parts With Rough Finish............................................................................................................................................................................................................................................. 218 Clean Axle Assemblies..................................................................................................................................................................................................................................................... 218 Drying Cleaned Parts...................................................................................................................................................................................................................................................... 218 Corrosion Prevention.......................................................................................................................................................................................................................................................... 218 Parts Inspection.............................................................................................................................................................................................................................................................. 219 Tapered Roller Bearings................................................................................................................................................................................................................................................... 219 Bevel Pinion and Ring Gear Sets........................................................................................................................................................................................................................................... 220 Main Differential Assembly................................................................................................................................................................................................................................................ 220 Axle Shafts............................................................................................................................................................................................................................................................... 220 Yoke...................................................................................................................................................................................................................................................................... 220 Brakes.................................................................................................................................................................................................................................................................... 220 Repair or Replace Parts................................................................................................................................................................................................................................................... 220 Repair Welding............................................................................................................................................................................................................................................................ 220 Apply Silicone Gasket Material............................................................................................................................................................................................................................................ 221 Assembly...................................................................................................................................................................................................................................................................... 221 Spindle and Piston Housing to Axle Housing................................................................................................................................................................................................................................ 221 Wet Disc Brakes........................................................................................................................................................................................................................................................... 222 Adjust Wheel Bearing Preload.............................................................................................................................................................................................................................................. 223 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 224 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 225 Planetary Spider Assembly................................................................................................................................................................................................................................................. 225 Installation.................................................................................................................................................................................................................................................................. 226 Fill Wet Disc Brakes With Hydraulic Fluid................................................................................................................................................................................................................................. 226 Torque Specifications......................................................................................................................................................................................................................................................... 227 Lubrication Specification..................................................................................................................................................................................................................................................... 228 1494955-2000SRM0943-(03-2007)-US-EN................................................................................................................................................................................................................................................... 231 toc............................................................................................................................................................................................................................................................................... 231 Main Control Valve............................................................................................................................................................................................................................................................ 231 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 232 General....................................................................................................................................................................................................................................................................... 235 Description................................................................................................................................................................................................................................................................... 235 Operation..................................................................................................................................................................................................................................................................... 238 Lift Section.............................................................................................................................................................................................................................................................. 238 Tilt/Auxiliary Section.................................................................................................................................................................................................................................................... 238 Relief Valves............................................................................................................................................................................................................................................................. 238 Unloader Valve............................................................................................................................................................................................................................................................ 238 Main Control Valve Repair..................................................................................................................................................................................................................................................... 241 Remove.................................................................................................................................................................................................................................................................... 241 Disassemble............................................................................................................................................................................................................................................................... 241 Auxiliary Side........................................................................................................................................................................................................................................................ 241 Lift Side............................................................................................................................................................................................................................................................. 241 Clean and Inspect......................................................................................................................................................................................................................................................... 244 Assemble.................................................................................................................................................................................................................................................................. 244 Auxiliary Side........................................................................................................................................................................................................................................................ 244 Lift Side............................................................................................................................................................................................................................................................. 244 Install................................................................................................................................................................................................................................................................... 244 Pressure Relief Valve Check and Adjustment.................................................................................................................................................................................................................................... 245 Check and Adjust.......................................................................................................................................................................................................................................................... 245 Replace................................................................................................................................................................................................................................................................... 245 Specifications................................................................................................................................................................................................................................................................ 246 Troubleshooting............................................................................................................................................................................................................................................................... 246 1498445-1400SRM0945-(03-2007)-US-EN................................................................................................................................................................................................................................................... 251 toc............................................................................................................................................................................................................................................................................... 251 Planetary Drive Axle.......................................................................................................................................................................................................................................................... 251 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 252 General....................................................................................................................................................................................................................................................................... 255 Description................................................................................................................................................................................................................................................................... 255 Operation..................................................................................................................................................................................................................................................................... 257 Identification............................................................................................................................................................................................................................................................ 257 Removal....................................................................................................................................................................................................................................................................... 258 Disassembly................................................................................................................................................................................................................................................................... 258 Brake Drum................................................................................................................................................................................................................................................................ 258 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 259 Dry Brakes................................................................................................................................................................................................................................................................ 261 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 261 Spindle and Brake Spider.................................................................................................................................................................................................................................................. 263 Cleaning...................................................................................................................................................................................................................................................................... 264 Ground or Polished Parts.................................................................................................................................................................................................................................................. 264 Parts With Rough Finish................................................................................................................................................................................................................................................... 264 Axle Assemblies........................................................................................................................................................................................................................................................... 264 Drying Cleaned Parts...................................................................................................................................................................................................................................................... 264 Corrosion Prevention.......................................................................................................................................................................................................................................................... 264 Parts Inspection.............................................................................................................................................................................................................................................................. 265 Tapered Roller Bearings................................................................................................................................................................................................................................................... 265 Bevel Pinion and Ring Gear Sets........................................................................................................................................................................................................................................... 266 Main Differential Assembly................................................................................................................................................................................................................................................ 266 Axle Shafts............................................................................................................................................................................................................................................................... 266 Yoke...................................................................................................................................................................................................................................................................... 266 Brakes.................................................................................................................................................................................................................................................................... 266 Repair or Replace Parts................................................................................................................................................................................................................................................... 266 Repair Welding............................................................................................................................................................................................................................................................ 266 Apply Silicone Gasket Material............................................................................................................................................................................................................................................ 267 Assembly...................................................................................................................................................................................................................................................................... 267 Spindle, Brake Spider, and Brake.......................................................................................................................................................................................................................................... 267 Wheel End................................................................................................................................................................................................................................................................. 268 Adjust Wheel Bearing Preload.............................................................................................................................................................................................................................................. 269 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 270 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 271 Planetary Spider Assembly................................................................................................................................................................................................................................................. 271 Installation.................................................................................................................................................................................................................................................................. 272 Torque Specifications......................................................................................................................................................................................................................................................... 273 Lubrication Specification..................................................................................................................................................................................................................................................... 274 1498450-1800SRM0951-(03-2007)-US-EN................................................................................................................................................................................................................................................... 277 toc............................................................................................................................................................................................................................................................................... 277 Wet Brake System.............................................................................................................................................................................................................................................................. 277 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 278 General....................................................................................................................................................................................................................................................................... 281 Description and Operation..................................................................................................................................................................................................................................................... 281 Service Brakes............................................................................................................................................................................................................................................................ 281 Parking Brake............................................................................................................................................................................................................................................................. 281 Oil Cooler Circuit........................................................................................................................................................................................................................................................ 281 Pressure Switch Replacement................................................................................................................................................................................................................................................... 285 Accumulators Replacement...................................................................................................................................................................................................................................................... 285 Brake Treadle Valve Repair.................................................................................................................................................................................................................................................... 285 Remove and Disassemble.................................................................................................................................................................................................................................................... 285 Clean and Inspect......................................................................................................................................................................................................................................................... 286 Assemble and Install...................................................................................................................................................................................................................................................... 286 Parking Brake Valve Repair.................................................................................................................................................................................................................................................... 286 Remove.................................................................................................................................................................................................................................................................... 286 Clean and Inspect......................................................................................................................................................................................................................................................... 286 Repair.................................................................................................................................................................................................................................................................... 286 Install................................................................................................................................................................................................................................................................... 286 Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 287 Remove.................................................................................................................................................................................................................................................................... 287 Disassemble............................................................................................................................................................................................................................................................... 289 Inspect................................................................................................................................................................................................................................................................... 289 Install................................................................................................................................................................................................................................................................... 289 Adjust.................................................................................................................................................................................................................................................................... 289 Brake Pad Repair.............................................................................................................................................................................................................................................................. 290 Inspect................................................................................................................................................................................................................................................................... 290 Remove.................................................................................................................................................................................................................................................................... 290 Install................................................................................................................................................................................................................................................................... 290 Seals Repair.................................................................................................................................................................................................................................................................. 290 Remove.................................................................................................................................................................................................................................................................... 290 Install................................................................................................................................................................................................................................................................... 291 Service Brake Repair.......................................................................................................................................................................................................................................................... 291 Remove and Disassemble.................................................................................................................................................................................................................................................... 291 Drain Lubricating Oil................................................................................................................................................................................................................................................. 291 Drain Coolant Oil..................................................................................................................................................................................................................................................... 298 Disconnect Brake Lines................................................................................................................................................................................................................................................ 298 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14....................................................................................................................................................................................................... 298 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...................................................................................................................................................................................................... 299 Brake Disc Housing Assembly Wheel End................................................................................................................................................................................................................................. 300 Brake Piston Housing.................................................................................................................................................................................................................................................. 301 Brake Piston Housing and Wheel Spindle................................................................................................................................................................................................................................ 302 Inspect................................................................................................................................................................................................................................................................... 302 Clean..................................................................................................................................................................................................................................................................... 304 Assemble.................................................................................................................................................................................................................................................................. 305 Wheel Spindle......................................................................................................................................................................................................................................................... 305 Brake Piston Housing.................................................................................................................................................................................................................................................. 305 Piston Assembly....................................................................................................................................................................................................................................................... 307 Brake Disc Housing.................................................................................................................................................................................................................................................... 307 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub............................................................................................................................................................................................................... 309 Check for Correct Installation of Duo-Cone Seal....................................................................................................................................................................................................................... 310 Wheel Hub to Brake Disc Housing....................................................................................................................................................................................................................................... 311 Adjust.................................................................................................................................................................................................................................................................... 312 Fill Brake System With Coolant Oil.................................................................................................................................................................................................................................... 312 System Air Removal.................................................................................................................................................................................................................................................... 313 Adjust Brake With New Disc Pack....................................................................................................................................................................................................................................... 313 Coolant Change Intervals.............................................................................................................................................................................................................................................. 314 Coolant Draining and Filling.......................................................................................................................................................................................................................................... 314 Specifications................................................................................................................................................................................................................................................................ 316 Minimum Brake Disc Thickness.............................................................................................................................................................................................................................................. 319 Hydraulic Fluid for Brake Actuation....................................................................................................................................................................................................................................... 319 Brake Coolant Specifications.............................................................................................................................................................................................................................................. 319 Coolant Change Intervals.................................................................................................................................................................................................................................................. 319 Hydraulic Fluid Specifications............................................................................................................................................................................................................................................ 319 Troubleshooting............................................................................................................................................................................................................................................................... 319 Brake Does Not Apply...................................................................................................................................................................................................................................................... 319 Brake Does Not Release.................................................................................................................................................................................................................................................... 320 Brake Performance......................................................................................................................................................................................................................................................... 320 Brake Leaks Actuation Fluid............................................................................................................................................................................................................................................... 321 Brake Cooling Fluid Leakage............................................................................................................................................................................................................................................... 322 Brake Noise and Vibration................................................................................................................................................................................................................................................. 322 Brake Overheats........................................................................................................................................................................................................................................................... 322 tables............................................................................................................................................................................................................................................................................ 277 Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 289 Table 2. Minimum Brake Disc Thickness......................................................................................................................................................................................................................................... 303 Table 3. Formed Seal Wear Chart............................................................................................................................................................................................................................................... 303 1503241-5000SRM0969-(03-2007)-US-EN................................................................................................................................................................................................................................................... 327 toc............................................................................................................................................................................................................................................................................... 327 Empty Container Handling Attachment........................................................................................................................................................................................................................................... 327 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 328 General....................................................................................................................................................................................................................................................................... 331 Description................................................................................................................................................................................................................................................................... 331 Operation..................................................................................................................................................................................................................................................................... 336 General................................................................................................................................................................................................................................................................... 336 Selector Valves........................................................................................................................................................................................................................................................... 336 Sideshift Circuit......................................................................................................................................................................................................................................................... 336 Extend and Retract Circuit................................................................................................................................................................................................................................................ 336 Twist Lock Circuit and Control............................................................................................................................................................................................................................................ 337 Model 553 - Horizontally Mounted...................................................................................................................................................................................................................................... 337 Model 558 - Vertically Mounted........................................................................................................................................................................................................................................ 337 Lifting Hooks............................................................................................................................................................................................................................................................. 337 Model 555............................................................................................................................................................................................................................................................. 337 Indicator Lights and LEDs................................................................................................................................................................................................................................................. 337 Lift Interrupt and Override............................................................................................................................................................................................................................................... 338 Overlowering Interrupt and Override....................................................................................................................................................................................................................................... 338 Carriage and Attachment Repair................................................................................................................................................................................................................................................ 338 Remove.................................................................................................................................................................................................................................................................... 338 Attachment Without Carriage Repair............................................................................................................................................................................................................................................ 339 Remove.................................................................................................................................................................................................................................................................... 339 Sideshift Cylinders Repair.................................................................................................................................................................................................................................................... 340 Remove.................................................................................................................................................................................................................................................................... 340 Disassemble............................................................................................................................................................................................................................................................... 340 Assemble.................................................................................................................................................................................................................................................................. 340 Extension Cylinders Repair.................................................................................................................................................................................................................................................... 341 Remove.................................................................................................................................................................................................................................................................... 341 Disassemble............................................................................................................................................................................................................................................................... 341 Clean and Inspect......................................................................................................................................................................................................................................................... 341 Assemble.................................................................................................................................................................................................................................................................. 341 Install................................................................................................................................................................................................................................................................... 341 Vertical End Beams Repair..................................................................................................................................................................................................................................................... 343 Remove.................................................................................................................................................................................................................................................................... 343 Install................................................................................................................................................................................................................................................................... 343 Hose Replacement in End Beams............................................................................................................................................................................................................................................. 343 Twist Locks Repair for Model 553.............................................................................................................................................................................................................................................. 344 Remove.................................................................................................................................................................................................................................................................... 344 Disassemble............................................................................................................................................................................................................................................................... 344 Clean and Inspect......................................................................................................................................................................................................................................................... 344 Assemble.................................................................................................................................................................................................................................................................. 344 Hooks Replacement for Model 555............................................................................................................................................................................................................................................... 345 Inspect................................................................................................................................................................................................................................................................... 345 Remove.................................................................................................................................................................................................................................................................... 345 Install................................................................................................................................................................................................................................................................... 345 Twist Locks Repair for Model 558.............................................................................................................................................................................................................................................. 346 Disassemble............................................................................................................................................................................................................................................................... 346 Clean and Inspect......................................................................................................................................................................................................................................................... 346 Assemble.................................................................................................................................................................................................................................................................. 346 Bleed the System.............................................................................................................................................................................................................................................................. 347 Valve Assembly................................................................................................................................................................................................................................................................ 347 Slide Pad Replacement......................................................................................................................................................................................................................................................... 348 Adjustments................................................................................................................................................................................................................................................................... 348 Twist Lock Angle Adjustment............................................................................................................................................................................................................................................... 348 Model 558 Only........................................................................................................................................................................................................................................................ 348 LOCKED/NOT LOCKED Sensors Adjustment...................................................................................................................................................................................................................................... 349 Model 553............................................................................................................................................................................................................................................................. 349 Model 558............................................................................................................................................................................................................................................................. 349 Seated Sensor Adjustment.................................................................................................................................................................................................................................................. 349 Model 553............................................................................................................................................................................................................................................................. 349 Model 558............................................................................................................................................................................................................................................................. 349 Overlowering Protection Sensor Adjustment (Models 553 and 558)............................................................................................................................................................................................................ 349 Torque Chart.............................................................................................................................................................................................................................................................. 350 Maintenance................................................................................................................................................................................................................................................................... 350 Additional Attachment Maintenance......................................................................................................................................................................................................................................... 352 Interface Boxes........................................................................................................................................................................................................................................................... 353 Model 555............................................................................................................................................................................................................................................................. 353 Models 553 and 558.................................................................................................................................................................................................................................................... 353 Troubleshooting............................................................................................................................................................................................................................................................... 355 tables............................................................................................................................................................................................................................................................................ 327 Table 1. Torque Chart......................................................................................................................................................................................................................................................... 350 Table 2. Inspect and Adjust (See Figure 14 ).................................................................................................................................................................................................................................. 351 Table 3. Lubricate (See Figure 14 )........................................................................................................................................................................................................................................... 352 Table 4. Replace (See Figure 14 )............................................................................................................................................................................................................................................. 352 1541323-0600SRM1068-(05-2004)-US-EN................................................................................................................................................................................................................................................... 373 toc............................................................................................................................................................................................................................................................................... 373 Perkins Tier 2 Diesel Engines................................................................................................................................................................................................................................................. 373 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 374 General....................................................................................................................................................................................................................................................................... 381 General Safety Rules...................................................................................................................................................................................................................................................... 381 Description................................................................................................................................................................................................................................................................... 382 Engine Serial Number Codes................................................................................................................................................................................................................................................ 384 Engine Data............................................................................................................................................................................................................................................................... 384 Engine Removal and Installation............................................................................................................................................................................................................................................... 385 Cylinder Head Assembly Repair................................................................................................................................................................................................................................................. 385 Valve Cover............................................................................................................................................................................................................................................................... 385 Remove................................................................................................................................................................................................................................................................ 385 Install............................................................................................................................................................................................................................................................... 386 Rocker Arm Assembly....................................................................................................................................................................................................................................................... 386 Remove................................................................................................................................................................................................................................................................ 386 Disassemble........................................................................................................................................................................................................................................................... 386 Inspect............................................................................................................................................................................................................................................................... 386 Assemble.............................................................................................................................................................................................................................................................. 386 Install............................................................................................................................................................................................................................................................... 386 Valve Clearance Adjustments............................................................................................................................................................................................................................................... 387 Valve Springs............................................................................................................................................................................................................................................................. 388 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 389 Remove................................................................................................................................................................................................................................................................ 389 Install............................................................................................................................................................................................................................................................... 391 Valves and Valve Springs.................................................................................................................................................................................................................................................. 394 Remove................................................................................................................................................................................................................................................................ 394 Inspect............................................................................................................................................................................................................................................................... 394 Install............................................................................................................................................................................................................................................................... 395 Valve Guides.............................................................................................................................................................................................................................................................. 395 Inspect............................................................................................................................................................................................................................................................... 395 Remove................................................................................................................................................................................................................................................................ 395 Install............................................................................................................................................................................................................................................................... 395 Cylinder Head and Valve Seats............................................................................................................................................................................................................................................. 396 Inspect............................................................................................................................................................................................................................................................... 396 Repair................................................................................................................................................................................................................................................................ 397 New Valve Seats, Install.............................................................................................................................................................................................................................................. 397 Piston and Connecting Rod Assemblies Repair................................................................................................................................................................................................................................... 397 Rod Bearings.............................................................................................................................................................................................................................................................. 398 Remove................................................................................................................................................................................................................................................................ 398 Install............................................................................................................................................................................................................................................................... 398 Piston and Connecting Rod Assembly........................................................................................................................................................................................................................................ 399 Service Note.......................................................................................................................................................................................................................................................... 399 Remove................................................................................................................................................................................................................................................................ 399 Install............................................................................................................................................................................................................................................................... 400 Piston Rings.............................................................................................................................................................................................................................................................. 401 Remove................................................................................................................................................................................................................................................................ 401 Inspect............................................................................................................................................................................................................................................................... 401 Install............................................................................................................................................................................................................................................................... 402 Piston and Connecting Rod................................................................................................................................................................................................................................................. 402 Disassemble........................................................................................................................................................................................................................................................... 402 Inspect............................................................................................................................................................................................................................................................... 402 How to Select Correct Replacements.................................................................................................................................................................................................................................... 403 Install............................................................................................................................................................................................................................................................... 404 Piston Cooling Jets....................................................................................................................................................................................................................................................... 404 Remove................................................................................................................................................................................................................................................................ 404 Install............................................................................................................................................................................................................................................................... 405 Crankshaft Assembly Repair.................................................................................................................................................................................................................................................... 405 General................................................................................................................................................................................................................................................................... 405 Crankshaft Pulley......................................................................................................................................................................................................................................................... 406 Remove................................................................................................................................................................................................................................................................ 406 Inspect............................................................................................................................................................................................................................................................... 406 Install............................................................................................................................................................................................................................................................... 406 Rear Oil Seal............................................................................................................................................................................................................................................................. 407 Remove................................................................................................................................................................................................................................................................ 407 Install............................................................................................................................................................................................................................................................... 407 Main Bearings............................................................................................................................................................................................................................................................. 408 Remove................................................................................................................................................................................................................................................................ 408 Inspect............................................................................................................................................................................................................................................................... 409 Install............................................................................................................................................................................................................................................................... 409 Thrust Washers............................................................................................................................................................................................................................................................ 409 Crankshaft Axial Movement, Check...................................................................................................................................................................................................................................... 409 Remove................................................................................................................................................................................................................................................................ 410 Install............................................................................................................................................................................................................................................................... 410 Crankshaft................................................................................................................................................................................................................................................................ 411 Remove................................................................................................................................................................................................................................................................ 411 Inspect............................................................................................................................................................................................................................................................... 411 Install............................................................................................................................................................................................................................................................... 412 Flywheel.................................................................................................................................................................................................................................................................. 413 Remove................................................................................................................................................................................................................................................................ 413 Ring Gear, Replace.................................................................................................................................................................................................................................................... 413 Install............................................................................................................................................................................................................................................................... 413 Flywheel Housing.......................................................................................................................................................................................................................................................... 414 Remove................................................................................................................................................................................................................................................................ 414 Install............................................................................................................................................................................................................................................................... 414 Timing Case and Timing Gears Repair........................................................................................................................................................................................................................................... 415 General................................................................................................................................................................................................................................................................... 415 Timing Case Cover......................................................................................................................................................................................................................................................... 415 Remove................................................................................................................................................................................................................................................................ 415 Install............................................................................................................................................................................................................................................................... 416 Front Oil Seal............................................................................................................................................................................................................................................................ 416 Remove................................................................................................................................................................................................................................................................ 416 Install............................................................................................................................................................................................................................................................... 416 Crankshaft Pulley Wear Sleeve............................................................................................................................................................................................................................................. 417 Install............................................................................................................................................................................................................................................................... 417 Idler Gear and Hub........................................................................................................................................................................................................................................................ 417 Remove................................................................................................................................................................................................................................................................ 417 Install............................................................................................................................................................................................................................................................... 418 Air Compressor Drive, Bendix.............................................................................................................................................................................................................................................. 419 Disassemble........................................................................................................................................................................................................................................................... 419 Assemble.............................................................................................................................................................................................................................................................. 419 Fuel Injection Pump Gear.................................................................................................................................................................................................................................................. 420 Remove................................................................................................................................................................................................................................................................ 420 Install............................................................................................................................................................................................................................................................... 421 Camshaft Gear............................................................................................................................................................................................................................................................. 421 Remove................................................................................................................................................................................................................................................................ 421 Install............................................................................................................................................................................................................................................................... 422 Crankshaft Gear........................................................................................................................................................................................................................................................... 422 Remove................................................................................................................................................................................................................................................................ 422 Install............................................................................................................................................................................................................................................................... 423 Timing Case............................................................................................................................................................................................................................................................... 423 Remove................................................................................................................................................................................................................................................................ 423 Install............................................................................................................................................................................................................................................................... 423 Camshaft and Tappets...................................................................................................................................................................................................................................................... 424 Remove................................................................................................................................................................................................................................................................ 424 Install............................................................................................................................................................................................................................................................... 425 Cylinder Block Assembly Repair................................................................................................................................................................................................................................................ 425 Description............................................................................................................................................................................................................................................................... 425 Cylinder Block............................................................................................................................................................................................................................................................ 425 Disassemble........................................................................................................................................................................................................................................................... 425 Inspect............................................................................................................................................................................................................................................................... 426 Assemble.............................................................................................................................................................................................................................................................. 426 Cylinder Liner............................................................................................................................................................................................................................................................ 427 Inspect............................................................................................................................................................................................................................................................... 427 Cylinder Liner Condition, Check....................................................................................................................................................................................................................................... 427 Remove................................................................................................................................................................................................................................................................ 428 Service Liner, Install................................................................................................................................................................................................................................................ 429 Partially Finished Liner, Install..................................................................................................................................................................................................................................... 430 Engine Timing................................................................................................................................................................................................................................................................. 431 Description............................................................................................................................................................................................................................................................... 431 How to Set Number One Piston to TDC on Compression Stroke............................................................................................................................................................................................................. 432 How to Set Number One Piston to TDC on Compression Stroke (Alter...................................................................................................................................................................................................... 433 How to Set Number One Piston to 4° After TDC on Compression Stro...................................................................................................................................................................................................... 434 Valve Timing, Check................................................................................................................................................................................................................................................... 435 Fuel Injection Pump Timing, Check..................................................................................................................................................................................................................................... 436 Turbocharger.................................................................................................................................................................................................................................................................. 436 General................................................................................................................................................................................................................................................................... 436 Remove.................................................................................................................................................................................................................................................................... 436 Install................................................................................................................................................................................................................................................................... 437 Impeller and Compressor Housing, Clean.................................................................................................................................................................................................................................... 437 Waste-Gate Valve Check.................................................................................................................................................................................................................................................... 438 Closed Circuit Breather System (CCB)...................................................................................................................................................................................................................................... 439 CCB Assembly, Remove.................................................................................................................................................................................................................................................. 439 Closed Circuit Drain Valve, Remove.................................................................................................................................................................................................................................... 439 CCB Assembly, Install................................................................................................................................................................................................................................................. 439 Closed Circuit Drain Valve, Install................................................................................................................................................................................................................................... 439 Lubrication System Repair..................................................................................................................................................................................................................................................... 440 General................................................................................................................................................................................................................................................................... 440 Oil Filter, Replace....................................................................................................................................................................................................................................................... 440 Oil Filter Head........................................................................................................................................................................................................................................................... 440 Remove................................................................................................................................................................................................................................................................ 440 Install............................................................................................................................................................................................................................................................... 440 Oil Filter Head Bypass Valve.............................................................................................................................................................................................................................................. 441 Remove and Install.................................................................................................................................................................................................................................................... 441 Oil Sump.................................................................................................................................................................................................................................................................. 441 Remove................................................................................................................................................................................................................................................................ 441 Install............................................................................................................................................................................................................................................................... 441 Oil Pump.................................................................................................................................................................................................................................................................. 442 Remove................................................................................................................................................................................................................................................................ 442 Inspect............................................................................................................................................................................................................................................................... 442 Install............................................................................................................................................................................................................................................................... 443 Relief Valve.............................................................................................................................................................................................................................................................. 444 Remove................................................................................................................................................................................................................................................................ 444 Disassemble........................................................................................................................................................................................................................................................... 444 Inspect............................................................................................................................................................................................................................................................... 444 Assemble.............................................................................................................................................................................................................................................................. 444 Install............................................................................................................................................................................................................................................................... 444 Idler Gear Shaft, Replace................................................................................................................................................................................................................................................. 444 Remove................................................................................................................................................................................................................................................................ 445 Remove (Alternative).................................................................................................................................................................................................................................................. 445 Install............................................................................................................................................................................................................................................................... 446 Install (Alternative)................................................................................................................................................................................................................................................. 446 Fuel System Repair............................................................................................................................................................................................................................................................ 447 Description............................................................................................................................................................................................................................................................... 447 Fuel Injection Pump....................................................................................................................................................................................................................................................... 449 Remove................................................................................................................................................................................................................................................................ 449 Install............................................................................................................................................................................................................................................................... 451 Fuel System Air Removal................................................................................................................................................................................................................................................... 452 Fuel Filter, Replace...................................................................................................................................................................................................................................................... 454 Fuel Injectors............................................................................................................................................................................................................................................................ 454 Remove................................................................................................................................................................................................................................................................ 455 Inspect............................................................................................................................................................................................................................................................... 455 Install............................................................................................................................................................................................................................................................... 455 Fuel Lift Pump............................................................................................................................................................................................................................................................ 456 Remove................................................................................................................................................................................................................................................................ 456 Disassemble........................................................................................................................................................................................................................................................... 456 Assemble.............................................................................................................................................................................................................................................................. 456 Install............................................................................................................................................................................................................................................................... 457 Test.................................................................................................................................................................................................................................................................. 457 Cooling System Repair......................................................................................................................................................................................................................................................... 458 General................................................................................................................................................................................................................................................................... 458 Thermostat................................................................................................................................................................................................................................................................ 458 Remove................................................................................................................................................................................................................................................................ 458 Install............................................................................................................................................................................................................................................................... 459 Test.................................................................................................................................................................................................................................................................. 459 Coolant Pump.............................................................................................................................................................................................................................................................. 459 Remove................................................................................................................................................................................................................................................................ 459 Disassemble........................................................................................................................................................................................................................................................... 460 Assemble.............................................................................................................................................................................................................................................................. 462 Install............................................................................................................................................................................................................................................................... 464 Fan and Fan Drive......................................................................................................................................................................................................................................................... 465 Remove................................................................................................................................................................................................................................................................ 465 Install............................................................................................................................................................................................................................................................... 465 Oil Cooler................................................................................................................................................................................................................................................................ 465 Remove................................................................................................................................................................................................................................................................ 465 Disassemble and Assemble.............................................................................................................................................................................................................................................. 466 Install............................................................................................................................................................................................................................................................... 466 Electrical Equipment Repair................................................................................................................................................................................................................................................... 467 Drive Belts............................................................................................................................................................................................................................................................... 467 Alternator................................................................................................................................................................................................................................................................ 467 Remove................................................................................................................................................................................................................................................................ 467 Install............................................................................................................................................................................................................................................................... 467 Electronic Control Module (ECM)........................................................................................................................................................................................................................................... 468 Remove................................................................................................................................................................................................................................................................ 468 Inspect............................................................................................................................................................................................................................................................... 468 Install............................................................................................................................................................................................................................................................... 468 Voltage Load and Protection Module (VLPM)................................................................................................................................................................................................................................. 469 Remove................................................................................................................................................................................................................................................................ 469 Install............................................................................................................................................................................................................................................................... 469 Engine Speed and Timing Sensor............................................................................................................................................................................................................................................ 469 Remove................................................................................................................................................................................................................................................................ 469 Install............................................................................................................................................................................................................................................................... 470 Pressure Sensors (Engine Oil and Air Intake).............................................................................................................................................................................................................................. 470 Remove................................................................................................................................................................................................................................................................ 470 Install............................................................................................................................................................................................................................................................... 471 Temperature Sensor........................................................................................................................................................................................................................................................ 471 Remove................................................................................................................................................................................................................................................................ 471 Install............................................................................................................................................................................................................................................................... 472 Starter Motor............................................................................................................................................................................................................................................................. 472 Remove................................................................................................................................................................................................................................................................ 472 Install............................................................................................................................................................................................................................................................... 472 Cold Start Aid............................................................................................................................................................................................................................................................ 472 Air Compressor................................................................................................................................................................................................................................................................ 472 General................................................................................................................................................................................................................................................................... 472 Repair.................................................................................................................................................................................................................................................................... 473 Remove................................................................................................................................................................................................................................................................ 473 Install............................................................................................................................................................................................................................................................... 473 Rotary Exhauster Replacement.................................................................................................................................................................................................................................................. 474 Remove.................................................................................................................................................................................................................................................................... 474 Clean..................................................................................................................................................................................................................................................................... 474 Install................................................................................................................................................................................................................................................................... 474 Engine Specifications......................................................................................................................................................................................................................................................... 475 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 475 Piston and Connecting Rods................................................................................................................................................................................................................................................ 478 Crankshaft Assembly....................................................................................................................................................................................................................................................... 479 Crankshaft Overhaul................................................................................................................................................................................................................................................... 480 Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 482 Engine Block Assembly..................................................................................................................................................................................................................................................... 483 Turbocharger.............................................................................................................................................................................................................................................................. 484 Lubrication System........................................................................................................................................................................................................................................................ 485 Cooling System............................................................................................................................................................................................................................................................ 487 Flywheel and Housing...................................................................................................................................................................................................................................................... 487 Electrical Equipment...................................................................................................................................................................................................................................................... 487 Torque Specifications......................................................................................................................................................................................................................................................... 488 Cylinder Head Assembly.................................................................................................................................................................................................................................................... 488 Piston and Connecting Rod Assemblies...................................................................................................................................................................................................................................... 488 Crankshaft Assembly....................................................................................................................................................................................................................................................... 488 Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 488 Turbocharger.............................................................................................................................................................................................................................................................. 488 Lubrication System........................................................................................................................................................................................................................................................ 488 Fuel System............................................................................................................................................................................................................................................................... 488 Cooling System............................................................................................................................................................................................................................................................ 489 Flywheel.................................................................................................................................................................................................................................................................. 489 Auxiliary Equipment....................................................................................................................................................................................................................................................... 489 Special Torque Specifications................................................................................................................................................................................................................................................. 489 Flywheel and Housing...................................................................................................................................................................................................................................................... 489 Electrical Equipment...................................................................................................................................................................................................................................................... 489 Auxiliary Equipment....................................................................................................................................................................................................................................................... 489 Special Tools................................................................................................................................................................................................................................................................. 490 Troubleshooting............................................................................................................................................................................................................................................................... 495 Turbocharger Troubleshooting.................................................................................................................................................................................................................................................. 497 tables............................................................................................................................................................................................................................................................................ 373 Table 1. Cylinder Head........................................................................................................................................................................................................................................................ 475 Table 2. Valve Guides......................................................................................................................................................................................................................................................... 475 Table 3. Inlet Valves......................................................................................................................................................................................................................................................... 476 Table 4. Exhaust Valves....................................................................................................................................................................................................................................................... 476 Table 5. Valve Springs........................................................................................................................................................................................................................................................ 477 Table 6. Tappets.............................................................................................................................................................................................................................................................. 477 Table 7. Rocker Arm Shaft..................................................................................................................................................................................................................................................... 477 Table 8. Rocker Arms and Bushings............................................................................................................................................................................................................................................. 477 Table 9. Pistons.............................................................................................................................................................................................................................................................. 478 Table 10. Piston Rings........................................................................................................................................................................................................................................................ 478 Table 11. Piston Pins......................................................................................................................................................................................................................................................... 478 Table 12. Connecting Rods..................................................................................................................................................................................................................................................... 478 Table 13. Small End Bushings.................................................................................................................................................................................................................................................. 479 Table 14. Connecting Rod Bearings............................................................................................................................................................................................................................................. 479 Table 15. Piston Cooling Jets................................................................................................................................................................................................................................................. 479 Table 16. Crankshaft.......................................................................................................................................................................................................................................................... 479 Table 17. Main Bearings....................................................................................................................................................................................................................................................... 480 Table 18. Crankshaft Thrust Washers........................................................................................................................................................................................................................................... 480 Table 19. Crankshaft Heat Treatment........................................................................................................................................................................................................................................... 480 Table 20. Crankshaft Overhaul Specifications.................................................................................................................................................................................................................................. 480 Table 21. Maximum Variation (Run-Out)......................................................................................................................................................................................................................................... 482 Table 22. Camshaft............................................................................................................................................................................................................................................................ 482 Table 23. Camshaft Thrust Washer.............................................................................................................................................................................................................................................. 482 Table 24. Camshaft Gear....................................................................................................................................................................................................................................................... 482 Table 25. Gear for Fuel Injection Pump........................................................................................................................................................................................................................................ 482 Table 26. Crankshaft Gear..................................................................................................................................................................................................................................................... 483 Table 27. Idler Gear and Hub.................................................................................................................................................................................................................................................. 483 Table 28. Cylinder Block...................................................................................................................................................................................................................................................... 483 Table 29. Cylinder Liners..................................................................................................................................................................................................................................................... 483 Table 30. Cylinder Liner Specifications (Partially Finished).................................................................................................................................................................................................................. 484 Table 31. Oil Pump............................................................................................................................................................................................................................................................ 485 Table 32. Idler Gear for Oil Pump............................................................................................................................................................................................................................................. 485 Table 33. Relief Valve........................................................................................................................................................................................................................................................ 485 Table 34. Oil Filter.......................................................................................................................................................................................................................................................... 485 Table 35. Bosch Fuel Injection Pump........................................................................................................................................................................................................................................... 485 Table 36. Fuel Injector Codes................................................................................................................................................................................................................................................. 486 Table 37. Fuel Pump........................................................................................................................................................................................................................................................... 487 Table 38. Fuel Filter......................................................................................................................................................................................................................................................... 487 Table 39. Coolant Pump........................................................................................................................................................................................................................................................ 487 Table 40. Thermostat.......................................................................................................................................................................................................................................................... 487 Table 41. Fan Drive Housing................................................................................................................................................................................................................................................... 487 Table 42. Limits for Flywheel Run Out and Alignment (Total Indic.............................................................................................................................................................................................................. 487 Table 43. Alternator.......................................................................................................................................................................................................................................................... 487 Table 44. Starter Motor....................................................................................................................................................................................................................................................... 487 Table 45. Cold Start Aid...................................................................................................................................................................................................................................................... 487 Table 46. List of Possible Causes............................................................................................................................................................................................................................................. 495 Table 47. List of Possible Causes............................................................................................................................................................................................................................................. 497 1553599-4000SRM1062-(03-2007)-US-EN................................................................................................................................................................................................................................................... 501 toc............................................................................................................................................................................................................................................................................... 501 Masts and Carriages........................................................................................................................................................................................................................................................... 501 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 502 General....................................................................................................................................................................................................................................................................... 505 Description................................................................................................................................................................................................................................................................... 505 Operation..................................................................................................................................................................................................................................................................... 506 Two-Stage Mast............................................................................................................................................................................................................................................................ 506 Three-Stage Mast.......................................................................................................................................................................................................................................................... 507 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 508 Forks Repair.................................................................................................................................................................................................................................................................. 511 Remove.................................................................................................................................................................................................................................................................... 511 Inspect and Adjust........................................................................................................................................................................................................................................................ 511 Install................................................................................................................................................................................................................................................................... 511 Carriage Repair............................................................................................................................................................................................................................................................... 512 Description............................................................................................................................................................................................................................................................... 512 Three Function........................................................................................................................................................................................................................................................ 512 Four to Six Function.................................................................................................................................................................................................................................................. 512 Remove.................................................................................................................................................................................................................................................................... 512 Disassemble............................................................................................................................................................................................................................................................... 513 Clean and Inspect......................................................................................................................................................................................................................................................... 515 Assemble.................................................................................................................................................................................................................................................................. 515 Install................................................................................................................................................................................................................................................................... 515 Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 516 Remove.................................................................................................................................................................................................................................................................... 516 Disassemble............................................................................................................................................................................................................................................................... 516 Clean and Inspect......................................................................................................................................................................................................................................................... 516 Assemble.................................................................................................................................................................................................................................................................. 516 Install................................................................................................................................................................................................................................................................... 516 Fork Positioner Cylinders Repair.............................................................................................................................................................................................................................................. 520 Remove.................................................................................................................................................................................................................................................................... 520 Disassemble............................................................................................................................................................................................................................................................... 520 Clean and Inspect......................................................................................................................................................................................................................................................... 520 Assemble.................................................................................................................................................................................................................................................................. 520 Install................................................................................................................................................................................................................................................................... 520 Directional Control Valve Repair.............................................................................................................................................................................................................................................. 527 Remove.................................................................................................................................................................................................................................................................... 527 Disassemble............................................................................................................................................................................................................................................................... 527 Clean and Inspect......................................................................................................................................................................................................................................................... 527 Assemble.................................................................................................................................................................................................................................................................. 528 Install................................................................................................................................................................................................................................................................... 528 Mast Repair................................................................................................................................................................................................................................................................... 528 Two- and Three-Stage Mast................................................................................................................................................................................................................................................. 528 Remove................................................................................................................................................................................................................................................................ 528 Disassemble........................................................................................................................................................................................................................................................... 533 Clean and Inspect..................................................................................................................................................................................................................................................... 535 Assemble.............................................................................................................................................................................................................................................................. 536 Install............................................................................................................................................................................................................................................................... 537 Three-Stage Mast (Four Cylinders)......................................................................................................................................................................................................................................... 537 Remove................................................................................................................................................................................................................................................................ 537 Disassemble........................................................................................................................................................................................................................................................... 539 Clean and Inspect..................................................................................................................................................................................................................................................... 541 Assemble.............................................................................................................................................................................................................................................................. 541 Install............................................................................................................................................................................................................................................................... 541 Fork Carriage Chains...................................................................................................................................................................................................................................................... 543 Adjust................................................................................................................................................................................................................................................................ 543 Bearing Rollers........................................................................................................................................................................................................................................................... 545 Description........................................................................................................................................................................................................................................................... 545 Lubrication........................................................................................................................................................................................................................................................... 545 Clearance............................................................................................................................................................................................................................................................. 545 Remove and Disassemble................................................................................................................................................................................................................................................ 545 Assemble.............................................................................................................................................................................................................................................................. 546 Mast Profile.............................................................................................................................................................................................................................................................. 546 Lift Cylinders Description.................................................................................................................................................................................................................................................... 546 Piston-Type Cylinders..................................................................................................................................................................................................................................................... 546 Displacement-Type Cylinders............................................................................................................................................................................................................................................... 546 Lift Cylinders Repair......................................................................................................................................................................................................................................................... 547 Remove.................................................................................................................................................................................................................................................................... 547 Disassemble............................................................................................................................................................................................................................................................... 549 Clean and Inspect......................................................................................................................................................................................................................................................... 549 Assemble.................................................................................................................................................................................................................................................................. 549 Install................................................................................................................................................................................................................................................................... 550 Mast Operation Check.......................................................................................................................................................................................................................................................... 550 Lift and Tilt System Leak Checks.............................................................................................................................................................................................................................................. 551 Lift System............................................................................................................................................................................................................................................................... 551 Tilt System............................................................................................................................................................................................................................................................... 551 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment....................................................................................................................................................................................................................... 552 Lift Chain Adjustments........................................................................................................................................................................................................................................................ 552 Mast Adjustments.............................................................................................................................................................................................................................................................. 553 Bearing Blocks, Two-Stage Masts........................................................................................................................................................................................................................................... 553 Wear Plates............................................................................................................................................................................................................................................................... 553 Carriage Adjustment........................................................................................................................................................................................................................................................... 553 Troubleshooting............................................................................................................................................................................................................................................................... 555 tables............................................................................................................................................................................................................................................................................ 501 Table 1. Allowable Mast Movement from Internal Leakage........................................................................................................................................................................................................................ 551 1556599-0100SRM1100-(03-2007)-US-EN................................................................................................................................................................................................................................................... 559 toc............................................................................................................................................................................................................................................................................... 559 Operator's Cab................................................................................................................................................................................................................................................................ 559 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 560 General....................................................................................................................................................................................................................................................................... 563 Cab Repair.................................................................................................................................................................................................................................................................... 564 Rear Cab Assembly......................................................................................................................................................................................................................................................... 564 Bottom Cab Assembly....................................................................................................................................................................................................................................................... 565 Raising and Lowering Cab.................................................................................................................................................................................................................................................. 565 Raise Cab............................................................................................................................................................................................................................................................. 565 Lower Cab............................................................................................................................................................................................................................................................. 566 Cab Repair................................................................................................................................................................................................................................................................ 566 Remove................................................................................................................................................................................................................................................................ 566 Install............................................................................................................................................................................................................................................................... 567 Oil Filling for Tilt System................................................................................................................................................................................................................................................... 568 Inching and Brake Pedals...................................................................................................................................................................................................................................................... 569 Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 569 Inching Pedal, Adjust..................................................................................................................................................................................................................................................... 569 Inching Pedal Sensor, Adjust.............................................................................................................................................................................................................................................. 569 Throttle Pedal Sensor......................................................................................................................................................................................................................................................... 570 Check..................................................................................................................................................................................................................................................................... 570 Adjust.................................................................................................................................................................................................................................................................... 570 Seat Assembly Removal......................................................................................................................................................................................................................................................... 570 Power Assist Armrest.......................................................................................................................................................................................................................................................... 571 Adjust.................................................................................................................................................................................................................................................................... 571 Steering Column Repair........................................................................................................................................................................................................................................................ 572 Remove.................................................................................................................................................................................................................................................................... 572 Install................................................................................................................................................................................................................................................................... 572 Window Wipers Replacement..................................................................................................................................................................................................................................................... 573 Window Wiper Assembly, Replace............................................................................................................................................................................................................................................ 573 Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................ 573 Rear Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................. 573 Top Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................. 574 Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 574 Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 575 Window Replacement............................................................................................................................................................................................................................................................ 576 Front Window, Replace..................................................................................................................................................................................................................................................... 577 Rear Window, Replace...................................................................................................................................................................................................................................................... 577 Top Window, Replace....................................................................................................................................................................................................................................................... 577 Door Window, Replace...................................................................................................................................................................................................................................................... 578 Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 579 Heater Parts, Replace..................................................................................................................................................................................................................................................... 580 Heat Control Knob/Switches................................................................................................................................................................................................................................................ 580 Heat Control Knob/Cable................................................................................................................................................................................................................................................... 580 Adjust................................................................................................................................................................................................................................................................ 580 Air Control Knob/Cable.................................................................................................................................................................................................................................................... 581 Adjust................................................................................................................................................................................................................................................................ 581 Air Filter, Replace....................................................................................................................................................................................................................................................... 582 Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 582 Remove................................................................................................................................................................................................................................................................ 582 Install............................................................................................................................................................................................................................................................... 582 Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 583 Switches.................................................................................................................................................................................................................................................................. 583 Controls.................................................................................................................................................................................................................................................................. 583 Fuses and Relays.............................................................................................................................................................................................................................................................. 584 Fuse Panel................................................................................................................................................................................................................................................................ 584 Fuses..................................................................................................................................................................................................................................................................... 585 Relays.................................................................................................................................................................................................................................................................... 587 Label Replacement............................................................................................................................................................................................................................................................. 588 Electrical Schematics......................................................................................................................................................................................................................................................... 588 1556600-1300SRM1082-(03-2007)-US-EN................................................................................................................................................................................................................................................... 591 toc............................................................................................................................................................................................................................................................................... 591 Transmission.................................................................................................................................................................................................................................................................. 591 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 592 Description of Operation...................................................................................................................................................................................................................................................... 597 General................................................................................................................................................................................................................................................................... 597 Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 597 Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 597 Range Clutches............................................................................................................................................................................................................................................................ 599 Output Section............................................................................................................................................................................................................................................................ 599 Transmission Controls..................................................................................................................................................................................................................................................... 600 Operation of the Valve................................................................................................................................................................................................................................................ 601 Selection of Range.................................................................................................................................................................................................................................................... 605 Pressure Switch....................................................................................................................................................................................................................................................... 605 Electric Solenoid Controls................................................................................................................................................................................................................................................ 606 Transmission Specifications............................................................................................................................................................................................................................................... 623 Transmission Identification........................................................................................................................................................................................................................................... 623 Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 623 Transmission Repair........................................................................................................................................................................................................................................................... 624 Remove.................................................................................................................................................................................................................................................................... 624 Disassemble............................................................................................................................................................................................................................................................... 627 Transmission Case, Disassemble........................................................................................................................................................................................................................................ 627 Torque Converter Housing, Disassemble................................................................................................................................................................................................................................. 644 Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 649 First-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 651 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 656 Reverse Clutch, Disassemble....................................................................................................................................................................................................................................... 656 Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 661 Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 663 Third Clutch Shaft, Disassemble....................................................................................................................................................................................................................................... 665 Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 666 Output Shaft, Disassemble............................................................................................................................................................................................................................................. 667 Impeller, Disassemble................................................................................................................................................................................................................................................. 668 Turbine, Disassemble.................................................................................................................................................................................................................................................. 670 Clean and Inspect......................................................................................................................................................................................................................................................... 672 Housings.............................................................................................................................................................................................................................................................. 672 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 673 Bearings.............................................................................................................................................................................................................................................................. 673 Gears and Shafts...................................................................................................................................................................................................................................................... 673 Assemble.................................................................................................................................................................................................................................................................. 673 Turbine, Assemble..................................................................................................................................................................................................................................................... 673 Impeller, Assemble.................................................................................................................................................................................................................................................... 675 Output Shaft, Assemble................................................................................................................................................................................................................................................ 677 Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 679 Third Clutch Shaft, Assemble.......................................................................................................................................................................................................................................... 680 Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 681 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 684 Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 684 Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 687 First-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 691 Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 696 Torque Converter Housing, Assemble.................................................................................................................................................................................................................................... 699 Transmission Case, Assemble........................................................................................................................................................................................................................................... 704 Install................................................................................................................................................................................................................................................................... 725 Control Valve Repair.......................................................................................................................................................................................................................................................... 728 Remove.................................................................................................................................................................................................................................................................... 728 Disassemble and Assemble.................................................................................................................................................................................................................................................. 728 Clean and Inspect......................................................................................................................................................................................................................................................... 730 Housings.............................................................................................................................................................................................................................................................. 730 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 730 Install................................................................................................................................................................................................................................................................... 730 Stall Test.................................................................................................................................................................................................................................................................... 732 Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 733 Userlink®................................................................................................................................................................................................................................................................. 733 Connection................................................................................................................................................................................................................................................................ 733 Clutch Filling Calibration................................................................................................................................................................................................................................................ 733 Purpose............................................................................................................................................................................................................................................................... 733 Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 734 Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 734 Heat-up Mode.......................................................................................................................................................................................................................................................... 735 Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 735 Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 300.......................................................................................................................................................................................................... 736 Purpose............................................................................................................................................................................................................................................................... 736 Brake Pedal Adjustment................................................................................................................................................................................................................................................ 736 Dry Brake......................................................................................................................................................................................................................................................... 736 Wet Brake......................................................................................................................................................................................................................................................... 736 Inching Pedal Adjustment.............................................................................................................................................................................................................................................. 736 Inching Pedal Sensor Adjustment....................................................................................................................................................................................................................................... 737 Inching Pedal Calibration Procedure................................................................................................................................................................................................................................... 737 Verification/Adjustment of Inching Pedal Sensor When the Pedal i...................................................................................................................................................................................................... 738 Manual Inching Pedal Sensor Calibration Procedure..................................................................................................................................................................................................................... 738 Inching Pedal Calibration [S/N 2326 and Up (F019)], [S/N 3002 an.......................................................................................................................................................................................................... 738 Purpose............................................................................................................................................................................................................................................................... 738 Brake Pedal Adjustment................................................................................................................................................................................................................................................ 738 Dry Brake......................................................................................................................................................................................................................................................... 738 Wet Brake......................................................................................................................................................................................................................................................... 738 Inching Pedal Adjustment.............................................................................................................................................................................................................................................. 739 Dry Brake......................................................................................................................................................................................................................................................... 739 Wet Brake......................................................................................................................................................................................................................................................... 739 Inching Pedal Sensor Adjustment Using Userlink® Program............................................................................................................................................................................................................... 740 Inching Pedal Sensor Calibration Procedure Using Userlink® Progr...................................................................................................................................................................................................... 740 Inching Pedal Sensor Adjustment Using the APC200...................................................................................................................................................................................................................... 740 Inching Pedal Sensor Calibration Procedure Using the APC200........................................................................................................................................................................................................... 741 Troubleshooting........................................................................................................................................................................................................................................................... 741 Transmission Display Warning Codes........................................................................................................................................................................................................................................ 742 Access................................................................................................................................................................................................................................................................ 742 Clear................................................................................................................................................................................................................................................................. 742 Exit.................................................................................................................................................................................................................................................................. 742 Limp Home Mode........................................................................................................................................................................................................................................................ 777 Shutdown Mode......................................................................................................................................................................................................................................................... 778 Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 778 Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 778 Pressure and Temperature Specifications................................................................................................................................................................................................................................... 778 Electrical Specifications..................................................................................................................................................................................................................................................... 783 Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 783 Torque Specifications......................................................................................................................................................................................................................................................... 784 Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 784 Troubleshooting............................................................................................................................................................................................................................................................... 786 tables............................................................................................................................................................................................................................................................................ 591 Table 1. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 743 Table 2. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 743 Table 3. Common Calibration Condition Messages................................................................................................................................................................................................................................ 745 Table 4. Calibration Codes During Calibration................................................................................................................................................................................................................................. 745 Table 5. Error Codes During Calibration....................................................................................................................................................................................................................................... 746 Table 6. Display Warning Codes................................................................................................................................................................................................................................................ 746 Table 7. Display Warning Exceed Codes......................................................................................................................................................................................................................................... 776 Table 8. Type of Warning Codes................................................................................................................................................................................................................................................ 777 Table 9. Temperature Sensor (In Speed Sensor) Resistance Versus .............................................................................................................................................................................................................. 783 Table 10. Grade 5............................................................................................................................................................................................................................................................. 784 Table 11. Grade 8............................................................................................................................................................................................................................................................. 784 Table 12. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 785 Table 13. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 785 Table 14. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 786 1556602-8000SRM1099-(06-2006)-US-EN................................................................................................................................................................................................................................................... 793 toc............................................................................................................................................................................................................................................................................... 793 Periodic Maintenance.......................................................................................................................................................................................................................................................... 793 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 794 General....................................................................................................................................................................................................................................................................... 799 How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 799 How to Tow Lift Truck................................................................................................................................................................................................................................................. 799 How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 800 How to Raise Drive Tires.............................................................................................................................................................................................................................................. 800 How to Raise Steering Tires........................................................................................................................................................................................................................................... 800 Maintenance Schedule.......................................................................................................................................................................................................................................................... 802 Empty Container Attachment Maintenance.................................................................................................................................................................................................................................... 814 Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 816 How to Make Checks With Engine Stopped.................................................................................................................................................................................................................................... 816 Safety Labels......................................................................................................................................................................................................................................................... 816 Forks................................................................................................................................................................................................................................................................. 816 Adjust............................................................................................................................................................................................................................................................ 816 Remove............................................................................................................................................................................................................................................................ 816 Install........................................................................................................................................................................................................................................................... 816 Forks, Mast, and Lift Chains, Inspect................................................................................................................................................................................................................................. 817 Operator Restraint System............................................................................................................................................................................................................................................. 818 Steering Column Latch................................................................................................................................................................................................................................................. 819 Tires and Wheels...................................................................................................................................................................................................................................................... 819 Fuel, Oil, or Coolant Leaks, Check.................................................................................................................................................................................................................................... 820 Air Intake Piping..................................................................................................................................................................................................................................................... 820 Cooling Fan........................................................................................................................................................................................................................................................... 820 Crankcase Breather Tube............................................................................................................................................................................................................................................... 820 Drive Belts........................................................................................................................................................................................................................................................... 821 Hydraulic System Oil.................................................................................................................................................................................................................................................. 821 Cab Hydraulic System.................................................................................................................................................................................................................................................. 822 Engine Oil............................................................................................................................................................................................................................................................ 822 Cooling System........................................................................................................................................................................................................................................................ 824 Battery............................................................................................................................................................................................................................................................... 825 Fuel System (Diesel Engines Only)..................................................................................................................................................................................................................................... 825 Water Separator/Fuel Filter (Diesel Engines Only)..................................................................................................................................................................................................................... 825 How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 826 Fault Codes........................................................................................................................................................................................................................................................... 826 Access............................................................................................................................................................................................................................................................ 826 Exit.............................................................................................................................................................................................................................................................. 826 Clear............................................................................................................................................................................................................................................................. 826 Gauges, Lights, Horn and Fuses........................................................................................................................................................................................................................................ 826 Control Levers and Pedals............................................................................................................................................................................................................................................. 829 Steering System....................................................................................................................................................................................................................................................... 829 Air Filters........................................................................................................................................................................................................................................................... 830 Transmission Oil...................................................................................................................................................................................................................................................... 830 Brakes................................................................................................................................................................................................................................................................ 830 Lift System Operation................................................................................................................................................................................................................................................. 830 Attachments........................................................................................................................................................................................................................................................... 830 Maintenance Procedures Every 250 Hours or Every 2 Months...................................................................................................................................................................................................................... 831 Empty Container Handler................................................................................................................................................................................................................................................... 831 Maintenance Procedures Every 500 Hours or Every 3 Months...................................................................................................................................................................................................................... 831 Lift Chains............................................................................................................................................................................................................................................................... 831 Lubrication........................................................................................................................................................................................................................................................... 831 Adjust................................................................................................................................................................................................................................................................ 831 Drive Shaft............................................................................................................................................................................................................................................................... 831 Steering Axle............................................................................................................................................................................................................................................................. 832 Wheel Nuts................................................................................................................................................................................................................................................................ 832 Shafts for Brake Actuators................................................................................................................................................................................................................................................ 832 Drive Axle and Differential............................................................................................................................................................................................................................................... 832 Hydraulic Tank Breather................................................................................................................................................................................................................................................... 832 Cabin Air Filter, Heater.................................................................................................................................................................................................................................................. 832 Air Filter, Engine........................................................................................................................................................................................................................................................ 832 Engine Oil and Filter..................................................................................................................................................................................................................................................... 832 Drive Belts............................................................................................................................................................................................................................................................... 833 Perkins............................................................................................................................................................................................................................................................... 833 Cummins............................................................................................................................................................................................................................................................... 833 Mast...................................................................................................................................................................................................................................................................... 834 Bearing Rollers (Three-Stage Only).................................................................................................................................................................................................................................... 835 Lubrication....................................................................................................................................................................................................................................................... 835 Clearance......................................................................................................................................................................................................................................................... 835 General Lubrication....................................................................................................................................................................................................................................................... 835 Fork Wear and Damage Check................................................................................................................................................................................................................................................ 835 Lift Chains Wear Check.................................................................................................................................................................................................................................................... 836 Empty Container Handler................................................................................................................................................................................................................................................... 836 Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 836 Charge Air Cooler......................................................................................................................................................................................................................................................... 836 Dry Brakes Air Compressor (Cummins)....................................................................................................................................................................................................................................... 836 Fuel Pump (Cummins)....................................................................................................................................................................................................................................................... 837 Fuel Filter............................................................................................................................................................................................................................................................... 837 Perkins............................................................................................................................................................................................................................................................... 837 Remove............................................................................................................................................................................................................................................................ 837 Install........................................................................................................................................................................................................................................................... 837 Cummins............................................................................................................................................................................................................................................................... 838 Remove............................................................................................................................................................................................................................................................ 838 Install........................................................................................................................................................................................................................................................... 838 Fuel System Air Removal (Perkins)..................................................................................................................................................................................................................................... 838 Fuel System Air Removal (Cummins)..................................................................................................................................................................................................................................... 838 Fuel Injection Pump Without Vent Tube................................................................................................................................................................................................................................. 838 Coolant................................................................................................................................................................................................................................................................... 840 Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 840 Transmission Oil and Filter, Change....................................................................................................................................................................................................................................... 840 Fuel Injection Pump Timing (Perkins Only)................................................................................................................................................................................................................................. 840 Valve Adjustment.......................................................................................................................................................................................................................................................... 840 Perkins............................................................................................................................................................................................................................................................... 840 Differential and Drive Axle............................................................................................................................................................................................................................................... 840 Pilot Accumulator Pressure Charge Check................................................................................................................................................................................................................................... 841 Maintenance Procedures Every 1000 Hours or Yearly............................................................................................................................................................................................................................. 841 Coolant Fan Belt Tensioner................................................................................................................................................................................................................................................ 841 Belt Driven Fan Hub....................................................................................................................................................................................................................................................... 843 Valve Adjustment.......................................................................................................................................................................................................................................................... 843 Cummins............................................................................................................................................................................................................................................................... 843 Accumulator and Wet Brakes................................................................................................................................................................................................................................................ 844 Wet Brake Oil Filter...................................................................................................................................................................................................................................................... 844 Air Dryer Cartridge (Dry Brakes).......................................................................................................................................................................................................................................... 844 Air Compressor Air Filter (Dry Brakes).................................................................................................................................................................................................................................... 844 Maintenance Procedures Every 2000 Hours or Yearly............................................................................................................................................................................................................................. 845 Hydraulic System.......................................................................................................................................................................................................................................................... 845 Hydraulic Oil Filter, Change.......................................................................................................................................................................................................................................... 845 Hydraulic Oil, Change................................................................................................................................................................................................................................................. 845 Hydraulic Pilot Valve Filter, Change.................................................................................................................................................................................................................................. 845 Transmission Calibration.................................................................................................................................................................................................................................................. 846 Wheel Bearings............................................................................................................................................................................................................................................................ 846 Steer Wheels.......................................................................................................................................................................................................................................................... 846 Drive Wheels.......................................................................................................................................................................................................................................................... 846 Service Brakes............................................................................................................................................................................................................................................................ 846 Cleaning Procedures (Dry Brake Axle).................................................................................................................................................................................................................................. 846 Maintenance Procedures Every 2000 Hours or 2 Years............................................................................................................................................................................................................................ 847 Air Compressor Discharge Lines............................................................................................................................................................................................................................................ 847 Rubber Vibration Damper................................................................................................................................................................................................................................................... 848 Engine Coolant............................................................................................................................................................................................................................................................ 848 Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 848 Empty Container Handler................................................................................................................................................................................................................................................... 848 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 849 Fuel Injectors Check.......................................................................................................................................................................................................................................................... 849 Perkins................................................................................................................................................................................................................................................................... 849 Lift and Tilt System Leak Check............................................................................................................................................................................................................................................... 850 Lift System............................................................................................................................................................................................................................................................... 850 Tilt System............................................................................................................................................................................................................................................................... 851 Welding Repairs............................................................................................................................................................................................................................................................... 852 Wheel and Tire Replacement.................................................................................................................................................................................................................................................... 852 Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 852 Pneumatic Tires........................................................................................................................................................................................................................................................... 853 Remove Tire From Wheel................................................................................................................................................................................................................................................ 853 Remove Tire From Three- and Four-Piece Wheel...................................................................................................................................................................................................................... 853 Install Tire on Wheel................................................................................................................................................................................................................................................. 854 Install Three- or Four-Piece Wheel in Tire........................................................................................................................................................................................................................ 855 Add Air to Tires.......................................................................................................................................................................................................................................................... 856 Solid Rubber Tires........................................................................................................................................................................................................................................................ 856 Remove Tire From Wheel................................................................................................................................................................................................................................................ 856 Install Tire on Wheel................................................................................................................................................................................................................................................. 858 Wheels, Install........................................................................................................................................................................................................................................................... 859 tables............................................................................................................................................................................................................................................................................ 793 Table 1. Daily Inspections − Condition Check.................................................................................................................................................................................................................................. 803 Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 804 Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 805 Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 806 Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 806 Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 809 Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 810 Table 8. Empty Container Attachment Maintenance − Inspect and ................................................................................................................................................................................................................ 814 Table 9. Empty Container Attachment Maintenance − Lubricate................................................................................................................................................................................................................... 815 Table 10. Empty Container Attachment Maintenance − Replace.................................................................................................................................................................................................................... 815 Table 11. Nominal Valve Clearance............................................................................................................................................................................................................................................. 844 Table 12. Allowable Mast Movement from Internal Leakage....................................................................................................................................................................................................................... 851 1556604-8000SRM1103-(07-2004)-US-EN................................................................................................................................................................................................................................................... 863 toc............................................................................................................................................................................................................................................................................... 863 Diagrams...................................................................................................................................................................................................................................................................... 863 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 864 1556604-8000SRM1103-(11-2006)-US-EN................................................................................................................................................................................................................................................... 903 toc............................................................................................................................................................................................................................................................................... 903 Diagrams...................................................................................................................................................................................................................................................................... 903 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 904 1556871-2200SRM1105-(03-2007)-US-EN................................................................................................................................................................................................................................................... 991 toc............................................................................................................................................................................................................................................................................... 991 Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 991 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 992 General....................................................................................................................................................................................................................................................................... 995 Description................................................................................................................................................................................................................................................................... 995 General................................................................................................................................................................................................................................................................... 995 Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 995 Connector.................................................................................................................................................................................................................................................................1001 Seat Switch Logic.........................................................................................................................................................................................................................................................1002 Central Warning Light Output..............................................................................................................................................................................................................................................1002 Buzzer Output.............................................................................................................................................................................................................................................................1002 Instrument Panel..............................................................................................................................................................................................................................................................1004 Remove....................................................................................................................................................................................................................................................................1004 Sender Replacement............................................................................................................................................................................................................................................................1005 Fuel Level Sender (Diesel Engine Only)....................................................................................................................................................................................................................................1005 Engine Oil Pressure Sender................................................................................................................................................................................................................................................1006 Brake Pressure Sender.....................................................................................................................................................................................................................................................1006 Low Coolant Sender........................................................................................................................................................................................................................................................1006 Vacuum Switch.............................................................................................................................................................................................................................................................1006 Specifications................................................................................................................................................................................................................................................................1007 Troubleshooting...............................................................................................................................................................................................................................................................1008 tables............................................................................................................................................................................................................................................................................ 991 Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 996 Table 2. Pin Description......................................................................................................................................................................................................................................................1001 Table 3. Sender Description...................................................................................................................................................................................................................................................1002 1564053-0600SRM1101-(03-2007)-US-EN...................................................................................................................................................................................................................................................1013 toc...............................................................................................................................................................................................................................................................................1013 Cummins Diesel/LPG Engine Fault Code Guide....................................................................................................................................................................................................................................1013 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1014 General.......................................................................................................................................................................................................................................................................1017 Fault Codes...................................................................................................................................................................................................................................................................1017 Normal Mode...............................................................................................................................................................................................................................................................1017 Fault Log Mode............................................................................................................................................................................................................................................................1017 Access................................................................................................................................................................................................................................................................1017 Exit......................................................................................................................................................................................................................................................................1017 Clear.....................................................................................................................................................................................................................................................................1018 Electronic Throttle Calibration...........................................................................................................................................................................................................................................1018 Electronic Throttle Calibration Procedure.............................................................................................................................................................................................................................1018 tables............................................................................................................................................................................................................................................................................1013 Table 1. Error Code Descriptions..............................................................................................................................................................................................................................................1019 1566673-0600SRM1158-(06-2005)-US-EN...................................................................................................................................................................................................................................................1035 toc...............................................................................................................................................................................................................................................................................1035 Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide.................................................................................................................................................................................................................1035 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1036 Electronic Troubleshooting....................................................................................................................................................................................................................................................1059 System Operation..........................................................................................................................................................................................................................................................1059 Electronic Controls.......................................................................................................................................................................................................................................................1059 Engine Governor...........................................................................................................................................................................................................................................................1060 Timing Considerations.....................................................................................................................................................................................................................................................1060 Fuel Injection............................................................................................................................................................................................................................................................1060 Diagnostic Codes..........................................................................................................................................................................................................................................................1060 Diagnostic Fault Codes....................................................................................................................................................................................................................................................1060 Diagnostic Event Codes....................................................................................................................................................................................................................................................1060 Programmable Parameters...................................................................................................................................................................................................................................................1061 Passwords.................................................................................................................................................................................................................................................................1061 Electronic Service Tools..................................................................................................................................................................................................................................................1061 Electronic Service Tool (EST).............................................................................................................................................................................................................................................1061 Connecting the Electronic Service Tool and the Communication Ada......................................................................................................................................................................................................1061 Support for the Electronic Service Tool...............................................................................................................................................................................................................................1062 Optional Service Tools................................................................................................................................................................................................................................................1062 Diagnostic Codes..........................................................................................................................................................................................................................................................1062 Engine Display Warning Codes..............................................................................................................................................................................................................................................1066 Access................................................................................................................................................................................................................................................................1066 Exit..................................................................................................................................................................................................................................................................1066 Clear.................................................................................................................................................................................................................................................................1066 Replacing the ECM.........................................................................................................................................................................................................................................................1068 Self Diagnostics..........................................................................................................................................................................................................................................................1069 Glossary......................................................................................................................................................................................................................................................................1070 Sensors and Electrical Connectors.............................................................................................................................................................................................................................................1073 Engine Wiring Information.....................................................................................................................................................................................................................................................1076 Harness Wire Identification...............................................................................................................................................................................................................................................1080 Diagnostic Code Reader........................................................................................................................................................................................................................................................1080 General...................................................................................................................................................................................................................................................................1080 Reference Documents.......................................................................................................................................................................................................................................................1080 Abbreviations.............................................................................................................................................................................................................................................................1080 Environmental Specification...............................................................................................................................................................................................................................................1080 Hardware..................................................................................................................................................................................................................................................................1081 Connection Cable......................................................................................................................................................................................................................................................1082 Software..................................................................................................................................................................................................................................................................1082 Engine Communication..................................................................................................................................................................................................................................................1082 User Controls.............................................................................................................................................................................................................................................................1082 Power Supply..........................................................................................................................................................................................................................................................1082 Display Screen........................................................................................................................................................................................................................................................1082 Operation Controls....................................................................................................................................................................................................................................................1082 Audible Warning.......................................................................................................................................................................................................................................................1083 Operation Instructions....................................................................................................................................................................................................................................................1083 How to Connect the Diagnostic Code Reader to the Engine...............................................................................................................................................................................................................1083 How to Turn ON the Diagnostic Code Reader.............................................................................................................................................................................................................................1083 How to use the Display Screen.........................................................................................................................................................................................................................................1083 How to Operate the Diagnostic Code Reader.............................................................................................................................................................................................................................1084 Main Menu.........................................................................................................................................................................................................................................................1084 Active Codes......................................................................................................................................................................................................................................................1084 Inactive Codes....................................................................................................................................................................................................................................................1084 How to Clear Codes................................................................................................................................................................................................................................................1085 Status Lamp.......................................................................................................................................................................................................................................................1085 Data List.........................................................................................................................................................................................................................................................1086 Diagnostics...............................................................................................................................................................................................................................................................1086 Programming Parameters........................................................................................................................................................................................................................................................1087 Passwords.................................................................................................................................................................................................................................................................1087 Factory Passwords.........................................................................................................................................................................................................................................................1087 Customer Passwords........................................................................................................................................................................................................................................................1088 Flash Programming.........................................................................................................................................................................................................................................................1088 Flash Programming a Personality Module....................................................................................................................................................................................................................................1088 WinFlash Error Messages...................................................................................................................................................................................................................................................1088 System Configuration Parameters...............................................................................................................................................................................................................................................1089 Full Load Setting.........................................................................................................................................................................................................................................................1089 Full Torque Setting.......................................................................................................................................................................................................................................................1089 Rating Interlock..........................................................................................................................................................................................................................................................1089 Engine Serial Number......................................................................................................................................................................................................................................................1089 ECM Software Release Date.................................................................................................................................................................................................................................................1089 Troubleshooting Without A Diagnostic Code.....................................................................................................................................................................................................................................1090 Alternator Noise (Noisy Operation)........................................................................................................................................................................................................................................1090 Probable Causes.......................................................................................................................................................................................................................................................1090 Recommended Actions...................................................................................................................................................................................................................................................1090 Alternator Drive Belts............................................................................................................................................................................................................................................1090 Alternator Drive Pulley...........................................................................................................................................................................................................................................1090 Alternator Bearings...............................................................................................................................................................................................................................................1090 Alternator Will Not Charge (Charging Problem).............................................................................................................................................................................................................................1090 Probable Causes.......................................................................................................................................................................................................................................................1090 Recommended Actions...................................................................................................................................................................................................................................................1090 Alternator Drive Belts............................................................................................................................................................................................................................................1090 Charging Circuit..................................................................................................................................................................................................................................................1090 Alternator or Regulator...........................................................................................................................................................................................................................................1090 Battery...................................................................................................................................................................................................................................................................1090 Probable Causes.......................................................................................................................................................................................................................................................1090 Recommended Actions...................................................................................................................................................................................................................................................1090 Faulty Battery....................................................................................................................................................................................................................................................1090 Auxiliary Device..................................................................................................................................................................................................................................................1090 Cannot Reach Top Engine RPM...............................................................................................................................................................................................................................................1090 Probable Causes.......................................................................................................................................................................................................................................................1091 Recommended Actions...................................................................................................................................................................................................................................................1091 Diagnostic Codes..................................................................................................................................................................................................................................................1091 Fuel Supply.......................................................................................................................................................................................................................................................1091 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1091 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1091 Valve Lash........................................................................................................................................................................................................................................................1091 Check for Low Compression.........................................................................................................................................................................................................................................1091 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1092 Check the Turbocharger............................................................................................................................................................................................................................................1092 ECM Parameters....................................................................................................................................................................................................................................................1092 Check the Signal for the Throttle Position Sensor.................................................................................................................................................................................................................1092 Coolant in Engine Oil.....................................................................................................................................................................................................................................................1092 Probable Causes.......................................................................................................................................................................................................................................................1092 Recommended Actions...................................................................................................................................................................................................................................................1092 Engine Oil Cooler Core............................................................................................................................................................................................................................................1092 Cylinder Head Gasket..............................................................................................................................................................................................................................................1092 Cylinder Head.....................................................................................................................................................................................................................................................1093 Cylinder Block....................................................................................................................................................................................................................................................1093 Coolant Temperature Is Too High...........................................................................................................................................................................................................................................1093 Probable Causes.......................................................................................................................................................................................................................................................1093 Recommended Actions...................................................................................................................................................................................................................................................1093 Radiator Fins.....................................................................................................................................................................................................................................................1093 Coolant Level.....................................................................................................................................................................................................................................................1093 Radiator Cap and/or Pressure Relief Valve.........................................................................................................................................................................................................................1093 Combustion Gases in the Cooling System............................................................................................................................................................................................................................1093 Water Temperature Regulator.......................................................................................................................................................................................................................................1093 Restriction in the Coolant System.................................................................................................................................................................................................................................1093 Coolant Temperature Gauge.........................................................................................................................................................................................................................................1093 Coolant Pump......................................................................................................................................................................................................................................................1093 Excessive Load on the System......................................................................................................................................................................................................................................1093 ECM Will Not Accept Factory Passwords.....................................................................................................................................................................................................................................1094 Probable Causes.......................................................................................................................................................................................................................................................1094 Recommended Actions...................................................................................................................................................................................................................................................1094 ECM Will Not Communicate With Other Systems or Display Modules............................................................................................................................................................................................................1094 Probable Causes.......................................................................................................................................................................................................................................................1094 Recommended Actions...................................................................................................................................................................................................................................................1094 Electronic Service Tool Will Not Communicate With ECM.....................................................................................................................................................................................................................1094 Probable Causes.......................................................................................................................................................................................................................................................1094 Recommended Actions...................................................................................................................................................................................................................................................1094 Engine Cranks but Will Not Start..........................................................................................................................................................................................................................................1095 Probable Causes.......................................................................................................................................................................................................................................................1095 Recommended Actions...................................................................................................................................................................................................................................................1095 Diagnostic Codes..................................................................................................................................................................................................................................................1095 Visual Checks.....................................................................................................................................................................................................................................................1095 Crank Without Injection...........................................................................................................................................................................................................................................1095 Starting Motor Solenoid or Starting Circuit.......................................................................................................................................................................................................................1095 Valve Lash........................................................................................................................................................................................................................................................1095 Fuel Injection Nozzles............................................................................................................................................................................................................................................1095 Air Inlet Heater Starting Aid.....................................................................................................................................................................................................................................1096 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1096 Low Compression...................................................................................................................................................................................................................................................1096 Fuel Supply.......................................................................................................................................................................................................................................................1096 Engine Has Early Wear.....................................................................................................................................................................................................................................................1096 Probable Causes.......................................................................................................................................................................................................................................................1096 Recommended Actions...................................................................................................................................................................................................................................................1096 Dirt in Engine Oil................................................................................................................................................................................................................................................1096 Leaks in Air Intake System........................................................................................................................................................................................................................................1096 Low Oil Pressure..................................................................................................................................................................................................................................................1096 Engine Misfires, Runs Rough or Is Unstable................................................................................................................................................................................................................................1097 Probable Causes.......................................................................................................................................................................................................................................................1097 Recommended Actions...................................................................................................................................................................................................................................................1097 Logged Codes......................................................................................................................................................................................................................................................1097 Fuel Supply.......................................................................................................................................................................................................................................................1097 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1097 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1097 Valve Lash........................................................................................................................................................................................................................................................1097 Check for Low Compression.........................................................................................................................................................................................................................................1097 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1098 Check the Air Inlet Heater Starting Aid...........................................................................................................................................................................................................................1098 Check the Engine Speed/Timing Sensors.............................................................................................................................................................................................................................1098 Check the Signal for the Throttle Position Sensor.................................................................................................................................................................................................................1098 Check the Fuel Injection Pump.....................................................................................................................................................................................................................................1098 Engine Oil in Cooling System..............................................................................................................................................................................................................................................1098 Probable Causes.......................................................................................................................................................................................................................................................1098 Recommended Actions...................................................................................................................................................................................................................................................1098 Engine Oil Cooler Core............................................................................................................................................................................................................................................1098 Cylinder Head Gasket..............................................................................................................................................................................................................................................1099 Cylinder Head.....................................................................................................................................................................................................................................................1099 Engine Speed Does Not Change..............................................................................................................................................................................................................................................1099 Probable Causes.......................................................................................................................................................................................................................................................1099 Recommended Repairs...................................................................................................................................................................................................................................................1099 Diagnostic Codes..................................................................................................................................................................................................................................................1099 Engine Stalls at Low RPM..................................................................................................................................................................................................................................................1099 Probable Causes.......................................................................................................................................................................................................................................................1099 Recommended Actions...................................................................................................................................................................................................................................................1099 Diagnostic Codes..................................................................................................................................................................................................................................................1099 Fuel Injection Nozzles............................................................................................................................................................................................................................................1099 Fuel Supply.......................................................................................................................................................................................................................................................1099 Accessory Equipment...............................................................................................................................................................................................................................................1100 Power Mode Control................................................................................................................................................................................................................................................1100 Engine Vibration..........................................................................................................................................................................................................................................................1100 Probable Causes.......................................................................................................................................................................................................................................................1100 Recommended Actions...................................................................................................................................................................................................................................................1100 Engine Supports...................................................................................................................................................................................................................................................1100 Malfunctioning Individual Cylinder................................................................................................................................................................................................................................1100 Valve Lash........................................................................................................................................................................................................................................................1100 Check for Low Compression (cylinder pressure).....................................................................................................................................................................................................................1100 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1100 Turbocharger......................................................................................................................................................................................................................................................1101 Engine Will Not Crank.....................................................................................................................................................................................................................................................1101 Probable Causes.......................................................................................................................................................................................................................................................1101 Recommended Repairs...................................................................................................................................................................................................................................................1101 Machine Security System...........................................................................................................................................................................................................................................1101 Battery Cables and/or Batteries...................................................................................................................................................................................................................................1101 Starting Motor Solenoid or Starting Circuit.......................................................................................................................................................................................................................1101 Starting Motor and/or Flywheel Ring Gear..........................................................................................................................................................................................................................1101 Electrical Power Supply...........................................................................................................................................................................................................................................1101 Internal Engine Problem...........................................................................................................................................................................................................................................1101 Excessive Black Smoke.....................................................................................................................................................................................................................................................1101 Probable Causes.......................................................................................................................................................................................................................................................1101 Recommended Actions...................................................................................................................................................................................................................................................1102 Air Intake System or Exhaust System...............................................................................................................................................................................................................................1102 Individual Malfunctioning Cylinder................................................................................................................................................................................................................................1102 Valve Lash........................................................................................................................................................................................................................................................1102 Low Compression (cylinder pressure)...............................................................................................................................................................................................................................1102 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1102 Check the Turbocharger............................................................................................................................................................................................................................................1102 Broken 5-Volt Supply Wire.........................................................................................................................................................................................................................................1103 Verifying the ECM Software........................................................................................................................................................................................................................................1103 Excessive Engine Oil Consumption..........................................................................................................................................................................................................................................1103 Probable Causes.......................................................................................................................................................................................................................................................1103 Recommended Actions...................................................................................................................................................................................................................................................1103 Oil Level.........................................................................................................................................................................................................................................................1103 Engine Crankcase Breather.........................................................................................................................................................................................................................................1103 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1103 Turbocharger......................................................................................................................................................................................................................................................1103 Low Compression (cylinder pressure)...............................................................................................................................................................................................................................1103 Excessive Valve Lash......................................................................................................................................................................................................................................................1104 Probable Causes.......................................................................................................................................................................................................................................................1104 Recommended Actions...................................................................................................................................................................................................................................................1104 Lubrication.......................................................................................................................................................................................................................................................1104 Valve Lash........................................................................................................................................................................................................................................................1104 Valve Train Components............................................................................................................................................................................................................................................1104 Excessive White Smoke.....................................................................................................................................................................................................................................................1104 Probable Causes.......................................................................................................................................................................................................................................................1104 Recommended Actions...................................................................................................................................................................................................................................................1104 Fuel Supply.......................................................................................................................................................................................................................................................1104 Individual Malfunctioning Cylinder................................................................................................................................................................................................................................1105 Valve Lash........................................................................................................................................................................................................................................................1105 Low Compression (cylinder pressure)...............................................................................................................................................................................................................................1105 Air Inlet Heater Starting Aid.....................................................................................................................................................................................................................................1105 Fuel Injection Nozzles............................................................................................................................................................................................................................................1105 Coolant Temperature Sensor Circuit................................................................................................................................................................................................................................1105 Engine Pressure Sensors...........................................................................................................................................................................................................................................1105 Intake Air Temperature Is Too High........................................................................................................................................................................................................................................1105 Probable Causes.......................................................................................................................................................................................................................................................1105 Recommended Repairs...................................................................................................................................................................................................................................................1105 High Ambient Air Temperature......................................................................................................................................................................................................................................1105 Coolant Temperature...............................................................................................................................................................................................................................................1105 Check for High Intake Air Restriction and/or High Altitude........................................................................................................................................................................................................1106 Intake Air Restriction............................................................................................................................................................................................................................................1106 High Altitude.....................................................................................................................................................................................................................................................1106 Check the Intake Manifold Air Temperature Sensor and/or the Circ..................................................................................................................................................................................................1106 Check for Sufficient Coolant Flow Through the Aftercooler (if eq..................................................................................................................................................................................................1106 Check for Sufficient Flow of Air Through the Aftercooler (if equ..................................................................................................................................................................................................1106 Intermittent Engine Shutdown..............................................................................................................................................................................................................................................1106 Probable Causes.......................................................................................................................................................................................................................................................1106 Recommended Actions...................................................................................................................................................................................................................................................1106 Logged Codes......................................................................................................................................................................................................................................................1106 Fuel Supply.......................................................................................................................................................................................................................................................1106 Engine Protection Device..........................................................................................................................................................................................................................................1106 Electrical Connectors.............................................................................................................................................................................................................................................1107 Intermittent Low Power or Power Cutout....................................................................................................................................................................................................................................1107 Probable Causes.......................................................................................................................................................................................................................................................1107 Recommended Repairs...................................................................................................................................................................................................................................................1107 Diagnostic Codes..................................................................................................................................................................................................................................................1107 Electrical Connectors.............................................................................................................................................................................................................................................1107 Fuel Supply.......................................................................................................................................................................................................................................................1107 Check the Intake Manifold Pressure................................................................................................................................................................................................................................1108 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1108 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1108 Valve Lash........................................................................................................................................................................................................................................................1108 Check for Low Compression.........................................................................................................................................................................................................................................1108 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1108 Check the Turbocharger............................................................................................................................................................................................................................................1108 ECM Parameters....................................................................................................................................................................................................................................................1109 Electronic System Problem.........................................................................................................................................................................................................................................1109 Low Engine Oil Pressure...................................................................................................................................................................................................................................................1109 Probable Causes.......................................................................................................................................................................................................................................................1109 Recommended Actions...................................................................................................................................................................................................................................................1109 Engine Oil Level..................................................................................................................................................................................................................................................1109 Engine Oil Pressure Gauge.........................................................................................................................................................................................................................................1109 Engine Oil Bypass Valves..........................................................................................................................................................................................................................................1109 Piston Cooling Jets ..............................................................................................................................................................................................................................................1110 Engine Oil Suction Tube...........................................................................................................................................................................................................................................1110 Engine Oil Pump...................................................................................................................................................................................................................................................1110 Bearing Clearance.................................................................................................................................................................................................................................................1110 Low Power/Poor or No Response to Throttle.................................................................................................................................................................................................................................1110 Probable Causes.......................................................................................................................................................................................................................................................1110 Recommended Actions...................................................................................................................................................................................................................................................1110 Diagnostic Codes..................................................................................................................................................................................................................................................1110 Fuel Supply.......................................................................................................................................................................................................................................................1110 Air Intake and Exhaust System.....................................................................................................................................................................................................................................1110 Individual Malfunctioning Cylinders...............................................................................................................................................................................................................................1111 Valve Lash........................................................................................................................................................................................................................................................1111 Check for Low Compression.........................................................................................................................................................................................................................................1111 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1111 Check the Turbocharger............................................................................................................................................................................................................................................1111 ECM Parameters....................................................................................................................................................................................................................................................1111 Electronic System Problem.........................................................................................................................................................................................................................................1112 Mechanical Noise (Knock) in Engine........................................................................................................................................................................................................................................1112 Probable Causes.......................................................................................................................................................................................................................................................1112 Recommended Actions...................................................................................................................................................................................................................................................1112 Accessory Equipment...............................................................................................................................................................................................................................................1112 Valve Train Components............................................................................................................................................................................................................................................1112 Connecting Rod and Main Bearings..................................................................................................................................................................................................................................1112 Noise Coming from Cylinder................................................................................................................................................................................................................................................1112 Probable Causes.......................................................................................................................................................................................................................................................1112 Recommended Actions...................................................................................................................................................................................................................................................1112 Fuel Quality......................................................................................................................................................................................................................................................1112 Fuel Injection Nozzles............................................................................................................................................................................................................................................1112 Valve Lash........................................................................................................................................................................................................................................................1112 Poor Acceleration or Response.............................................................................................................................................................................................................................................1113 Probable Causes.......................................................................................................................................................................................................................................................1113 Recommended Repairs...................................................................................................................................................................................................................................................1113 Diagnostic Codes..................................................................................................................................................................................................................................................1113 Fuel Supply.......................................................................................................................................................................................................................................................1113 Individual Malfunctioning Cylinder................................................................................................................................................................................................................................1113 Valve Lash........................................................................................................................................................................................................................................................1113 Check for Low Compression.........................................................................................................................................................................................................................................1113 Check the Fuel Injection Nozzles..................................................................................................................................................................................................................................1113 Check the Turbocharger............................................................................................................................................................................................................................................1114 ECM Parameters....................................................................................................................................................................................................................................................1114 Check Intake Manifold Pressure....................................................................................................................................................................................................................................1114 Troubleshooting With a Diagnostic Code........................................................................................................................................................................................................................................1114 CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal..........................................................................................................................................................................................................1114 Conditions Which Generate This Code...................................................................................................................................................................................................................................1114 System Response.......................................................................................................................................................................................................................................................1114 Possible Performance Effect...........................................................................................................................................................................................................................................1114 Troubleshooting.......................................................................................................................................................................................................................................................1114 Results...............................................................................................................................................................................................................................................................1114 CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent..........................................................................................................................................................................................................1114 Conditions Which Generate This Code...................................................................................................................................................................................................................................1114 System Response.......................................................................................................................................................................................................................................................1115 Possible Performance Effect...........................................................................................................................................................................................................................................1115 Troubleshooting.......................................................................................................................................................................................................................................................1115 Test Step 1...........................................................................................................................................................................................................................................................1115 Results...............................................................................................................................................................................................................................................................1115 CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted..........................................................................................................................................................................................................1115 Conditions Which Generate This Code...................................................................................................................................................................................................................................1115 System Response.......................................................................................................................................................................................................................................................1115 Possible Performance Effect...........................................................................................................................................................................................................................................1115 CID 0091 FMI 04 Throttle Position Sensor Shorted Low......................................................................................................................................................................................................................1115 Conditions Which Generate This Code...................................................................................................................................................................................................................................1115 System Response.......................................................................................................................................................................................................................................................1115 Possible Performance Effect...........................................................................................................................................................................................................................................1115 Troubleshooting.......................................................................................................................................................................................................................................................1115 Results...............................................................................................................................................................................................................................................................1115 CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal..................................................................................................................................................................................................................1115 Conditions Which Generate This Code...................................................................................................................................................................................................................................1115 System Response.......................................................................................................................................................................................................................................................1115 Troubleshooting.......................................................................................................................................................................................................................................................1116 Results...............................................................................................................................................................................................................................................................1116 CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...............................................................................................................................................................................................................1116 Conditions Which Generate This Code...................................................................................................................................................................................................................................1116 Possible Performance Effect...........................................................................................................................................................................................................................................1116 Troubleshooting.......................................................................................................................................................................................................................................................1116 Results...............................................................................................................................................................................................................................................................1116 CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short..........................................................................................................................................................................................................1116 Conditions Which Generate This Code...................................................................................................................................................................................................................................1116 System Response.......................................................................................................................................................................................................................................................1116 Troubleshooting.......................................................................................................................................................................................................................................................1116 Results...............................................................................................................................................................................................................................................................1116 CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low....................................................................................................................................................................................................................1116 Conditions Which Generate This Code...................................................................................................................................................................................................................................1116 System Response.......................................................................................................................................................................................................................................................1116 Troubleshooting.......................................................................................................................................................................................................................................................1116 Results...............................................................................................................................................................................................................................................................1116 CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci..........................................................................................................................................................................................................1117 Conditions Which Generate This Code...................................................................................................................................................................................................................................1117 System Response.......................................................................................................................................................................................................................................................1117 Possible Performance Effect...........................................................................................................................................................................................................................................1117 Results...............................................................................................................................................................................................................................................................1117 CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or..........................................................................................................................................................................................................1117 Conditions Which Generate This Code...................................................................................................................................................................................................................................1117 System Response.......................................................................................................................................................................................................................................................1117 Possible Performance Effect...........................................................................................................................................................................................................................................1117 Results...............................................................................................................................................................................................................................................................1117 CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...............................................................................................................................................................................................................1117 Conditions Which Generate This Code...................................................................................................................................................................................................................................1117 System Response.......................................................................................................................................................................................................................................................1117 Possible Performance Effect...........................................................................................................................................................................................................................................1117 Results...............................................................................................................................................................................................................................................................1117 CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope..........................................................................................................................................................................................................1118 Conditions Which Generate This Code...................................................................................................................................................................................................................................1118 System Response.......................................................................................................................................................................................................................................................1118 Results...............................................................................................................................................................................................................................................................1118 CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ..........................................................................................................................................................................................................1118 Conditions Which Generate This Code...................................................................................................................................................................................................................................1118 System Response.......................................................................................................................................................................................................................................................1118 Possible Performance Effect...........................................................................................................................................................................................................................................1118 Troubleshooting.......................................................................................................................................................................................................................................................1118 Results...............................................................................................................................................................................................................................................................1118 CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low............................................................................................................................................................................................................1118 Conditions Which Generate This Code...................................................................................................................................................................................................................................1118 System Response.......................................................................................................................................................................................................................................................1118 Possible Performance Effect...........................................................................................................................................................................................................................................1118 Troubleshooting.......................................................................................................................................................................................................................................................1118 Results...............................................................................................................................................................................................................................................................1118 CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o..........................................................................................................................................................................................................1118 Conditions Which Generate This Code...................................................................................................................................................................................................................................1118 System Response.......................................................................................................................................................................................................................................................1119 Possible Performance Effect...........................................................................................................................................................................................................................................1119 Troubleshooting.......................................................................................................................................................................................................................................................1119 Results...............................................................................................................................................................................................................................................................1119 CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low.............................................................................................................................................................................................................1119 Conditions Which Generate This Code...................................................................................................................................................................................................................................1119 System Response.......................................................................................................................................................................................................................................................1119 Possible Performance Effect...........................................................................................................................................................................................................................................1119 Troubleshooting.......................................................................................................................................................................................................................................................1119 Results...............................................................................................................................................................................................................................................................1119 CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent.............................................................................................................................................................................................................1119 Conditions Which Generate This Code...................................................................................................................................................................................................................................1119 System Response.......................................................................................................................................................................................................................................................1119 Possible Performance Effect...........................................................................................................................................................................................................................................1119 Troubleshooting.......................................................................................................................................................................................................................................................1119 Results...............................................................................................................................................................................................................................................................1119 CID 0247 FMI 09 J1939 Datalink, Abnormal Update...........................................................................................................................................................................................................................1120 Conditions Which Generate This Code...................................................................................................................................................................................................................................1120 System Response.......................................................................................................................................................................................................................................................1120 Results...............................................................................................................................................................................................................................................................1120 CID 0253 FMI 02 Incorrect ECM Software....................................................................................................................................................................................................................................1120 Conditions Which Generate This Code...................................................................................................................................................................................................................................1120 System Response.......................................................................................................................................................................................................................................................1120 Possible Performance Effect...........................................................................................................................................................................................................................................1120 Troubleshooting.......................................................................................................................................................................................................................................................1120 Expected Result.......................................................................................................................................................................................................................................................1120 Results...............................................................................................................................................................................................................................................................1120 CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal..........................................................................................................................................................................................................1120 Conditions Which Generate This Code...................................................................................................................................................................................................................................1120 System Response.......................................................................................................................................................................................................................................................1120 Possible Performance Effect...........................................................................................................................................................................................................................................1120 Troubleshooting.......................................................................................................................................................................................................................................................1120 Results...............................................................................................................................................................................................................................................................1120 CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal..........................................................................................................................................................................................................1121 Conditions Which Generate This Code...................................................................................................................................................................................................................................1121 System Response.......................................................................................................................................................................................................................................................1121 Possible Performance Effect...........................................................................................................................................................................................................................................1121 Troubleshooting.......................................................................................................................................................................................................................................................1121 Results...............................................................................................................................................................................................................................................................1121 CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs.....................................................................................................................................................................................................................1121 Conditions Which Generate This Code...................................................................................................................................................................................................................................1121 System Response.......................................................................................................................................................................................................................................................1121 Possible Performance Effect...........................................................................................................................................................................................................................................1121 CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig..........................................................................................................................................................................................................1121 Conditions Which Generate This Code...................................................................................................................................................................................................................................1121 System Response.......................................................................................................................................................................................................................................................1121 Possible Performance Effect...........................................................................................................................................................................................................................................1121 Results...............................................................................................................................................................................................................................................................1121 CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal....................................................................................................................................................................................................................1121 Conditions Which Generate This Code...................................................................................................................................................................................................................................1121 System Response.......................................................................................................................................................................................................................................................1121 Possible Performance Effect...........................................................................................................................................................................................................................................1121 Results...............................................................................................................................................................................................................................................................1122 CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa..........................................................................................................................................................................................................1122 Conditions Which Generate This Code...................................................................................................................................................................................................................................1122 System Response.......................................................................................................................................................................................................................................................1122 Possible Performance Effect...........................................................................................................................................................................................................................................1122 Test Step 1...........................................................................................................................................................................................................................................................1122 Results...............................................................................................................................................................................................................................................................1122 Test Step 2...........................................................................................................................................................................................................................................................1122 Results...............................................................................................................................................................................................................................................................1122 CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm..........................................................................................................................................................................................................1122 Conditions Which Generate This Code...................................................................................................................................................................................................................................1122 System Response.......................................................................................................................................................................................................................................................1122 Possible Performance Effect...........................................................................................................................................................................................................................................1122 Results...............................................................................................................................................................................................................................................................1122 CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S..........................................................................................................................................................................................................1122 Conditions Which Generate This Code...................................................................................................................................................................................................................................1122 System Response.......................................................................................................................................................................................................................................................1123 Possible Performance Effect...........................................................................................................................................................................................................................................1123 Troubleshooting.......................................................................................................................................................................................................................................................1123 Results...............................................................................................................................................................................................................................................................1123 CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low................................................................................................................................................................................................................1123 Conditions Which Generate This Code...................................................................................................................................................................................................................................1123 System Response.......................................................................................................................................................................................................................................................1123 Possible Performance Effect...........................................................................................................................................................................................................................................1123 Troubleshooting.......................................................................................................................................................................................................................................................1123 Results...............................................................................................................................................................................................................................................................1123 CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal............................................................................................................................................................................................................1123 Conditions Which Generate This Code...................................................................................................................................................................................................................................1123 System Response.......................................................................................................................................................................................................................................................1123 Possible Performance Effect...........................................................................................................................................................................................................................................1123 Results...............................................................................................................................................................................................................................................................1123 CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio..........................................................................................................................................................................................................1123 Conditions Which Generate This Code...................................................................................................................................................................................................................................1123 System Response.......................................................................................................................................................................................................................................................1123 Possible Performance Effect...........................................................................................................................................................................................................................................1123 Results...............................................................................................................................................................................................................................................................1123 CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off................................................................................................................................................................................................................1124 Conditions Which Generate This Code...................................................................................................................................................................................................................................1124 System Response.......................................................................................................................................................................................................................................................1124 Possible Performance Effect...........................................................................................................................................................................................................................................1124 Results...............................................................................................................................................................................................................................................................1124 CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ..........................................................................................................................................................................................................1124 Conditions Which Generate This Code...................................................................................................................................................................................................................................1124 System Response.......................................................................................................................................................................................................................................................1124 Possible Performance Effect...........................................................................................................................................................................................................................................1124 Test Step 1...........................................................................................................................................................................................................................................................1124 Results...............................................................................................................................................................................................................................................................1124 Test Step 2...........................................................................................................................................................................................................................................................1124 Results...............................................................................................................................................................................................................................................................1124 CID 1684 FMI 02 Fuel Injection Pump, Software Failure.....................................................................................................................................................................................................................1124 Conditions Which Generate This Code...................................................................................................................................................................................................................................1124 System Response.......................................................................................................................................................................................................................................................1124 Possible Performance Effect...........................................................................................................................................................................................................................................1124 Troubleshooting.......................................................................................................................................................................................................................................................1124 Results...............................................................................................................................................................................................................................................................1125 CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault........................................................................................................................................................................................................................1125 Conditions Which Generate This Code...................................................................................................................................................................................................................................1125 System Response.......................................................................................................................................................................................................................................................1125 Possible Performance Effect...........................................................................................................................................................................................................................................1125 Troubleshooting.......................................................................................................................................................................................................................................................1125 Results...............................................................................................................................................................................................................................................................1125 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault.................................................................................................................................................................................................................1125 Conditions Which Generate This Code...................................................................................................................................................................................................................................1125 System Response.......................................................................................................................................................................................................................................................1125 Possible Performance Effect...........................................................................................................................................................................................................................................1125 Troubleshooting.......................................................................................................................................................................................................................................................1125 Results...............................................................................................................................................................................................................................................................1125 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width..................................................................................................................................................................................................................1125 Conditions Which Generate This Code...................................................................................................................................................................................................................................1125 Troubleshooting.......................................................................................................................................................................................................................................................1125 Results...............................................................................................................................................................................................................................................................1126 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault.....................................................................................................................................................................................................................1126 Conditions Which Generate This Code...................................................................................................................................................................................................................................1126 System Response.......................................................................................................................................................................................................................................................1126 Possible Performance Effect...........................................................................................................................................................................................................................................1126 Troubleshooting.......................................................................................................................................................................................................................................................1126 Results...............................................................................................................................................................................................................................................................1126 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...........................................................................................................................................................................................................1126 Conditions Which Generate This Code...................................................................................................................................................................................................................................1126 System Response.......................................................................................................................................................................................................................................................1126 Possible Performance Effect...........................................................................................................................................................................................................................................1126 Troubleshooting.......................................................................................................................................................................................................................................................1126 Test Step 1...........................................................................................................................................................................................................................................................1126 Results...............................................................................................................................................................................................................................................................1126 Test Step 2...........................................................................................................................................................................................................................................................1126 Results...............................................................................................................................................................................................................................................................1126 Test Step 3...........................................................................................................................................................................................................................................................1126 Results...............................................................................................................................................................................................................................................................1127 Test Step 4...........................................................................................................................................................................................................................................................1127 Expected Result.......................................................................................................................................................................................................................................................1127 Results...............................................................................................................................................................................................................................................................1127 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault............................................................................................................................................................................................................................1127 Conditions Which Generate This Code...................................................................................................................................................................................................................................1127 System Response.......................................................................................................................................................................................................................................................1127 Possible Performance Effect...........................................................................................................................................................................................................................................1127 Troubleshooting.......................................................................................................................................................................................................................................................1127 Expected Result.......................................................................................................................................................................................................................................................1127 Results...............................................................................................................................................................................................................................................................1127 CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error............................................................................................................................................................................................................1127 Conditions Which Generate This Code...................................................................................................................................................................................................................................1127 System Response.......................................................................................................................................................................................................................................................1127 Troubleshooting.......................................................................................................................................................................................................................................................1127 Test Step 1...........................................................................................................................................................................................................................................................1127 Results...............................................................................................................................................................................................................................................................1128 Test Step 2...........................................................................................................................................................................................................................................................1128 Results...............................................................................................................................................................................................................................................................1128 Test Step 3...........................................................................................................................................................................................................................................................1128 Results...............................................................................................................................................................................................................................................................1128 CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault................................................................................................................................................................................................................1128 Conditions Which Generate This Code...................................................................................................................................................................................................................................1128 System Response.......................................................................................................................................................................................................................................................1128 Possible Performance Effect...........................................................................................................................................................................................................................................1128 Troubleshooting.......................................................................................................................................................................................................................................................1128 Test Step 1...........................................................................................................................................................................................................................................................1128 Results...............................................................................................................................................................................................................................................................1128 Test Step 2...........................................................................................................................................................................................................................................................1128 Results...............................................................................................................................................................................................................................................................1128 CID 1684 FMI 14 Fuel Injection Pump, No Communications....................................................................................................................................................................................................................1128 Conditions Which Generate This Code...................................................................................................................................................................................................................................1128 System Response.......................................................................................................................................................................................................................................................1128 Troubleshooting.......................................................................................................................................................................................................................................................1128 Test Step 1...........................................................................................................................................................................................................................................................1128 Results...............................................................................................................................................................................................................................................................1128 Test Step 2...........................................................................................................................................................................................................................................................1129 Results...............................................................................................................................................................................................................................................................1129 Test Step 3...........................................................................................................................................................................................................................................................1129 Results...............................................................................................................................................................................................................................................................1129 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali..........................................................................................................................................................................................................1129 Conditions Which Generate This Code...................................................................................................................................................................................................................................1129 System Response.......................................................................................................................................................................................................................................................1129 Possible Performance Effect...........................................................................................................................................................................................................................................1129 Troubleshooting.......................................................................................................................................................................................................................................................1129 Results...............................................................................................................................................................................................................................................................1129 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali..........................................................................................................................................................................................................1129 Conditions Which Generate This Code...................................................................................................................................................................................................................................1129 System Response.......................................................................................................................................................................................................................................................1129 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S..........................................................................................................................................................................................................1129 Conditions Which Generate This Code...................................................................................................................................................................................................................................1129 System Response.......................................................................................................................................................................................................................................................1129 Troubleshooting With an Event Code............................................................................................................................................................................................................................................1130 Event Codes...............................................................................................................................................................................................................................................................1130 Programmable Engine Parameters............................................................................................................................................................................................................................................1130 E015 High Engine Coolant Temperature Derate...............................................................................................................................................................................................................................1130 Conditions Which Generate This Code...................................................................................................................................................................................................................................1130 System Response.......................................................................................................................................................................................................................................................1130 Possible Performance Effect...........................................................................................................................................................................................................................................1130 Troubleshooting.......................................................................................................................................................................................................................................................1130 Results...............................................................................................................................................................................................................................................................1130 E016 High Engine Coolant Temperature Shutdown.............................................................................................................................................................................................................................1130 Conditions Which Generate This Code...................................................................................................................................................................................................................................1130 System Response.......................................................................................................................................................................................................................................................1130 Possible Performance Effect...........................................................................................................................................................................................................................................1130 Troubleshooting.......................................................................................................................................................................................................................................................1130 Results...............................................................................................................................................................................................................................................................1130 E017 High Engine Coolant Temperature Warning..............................................................................................................................................................................................................................1130 Conditions Which Generate This Code...................................................................................................................................................................................................................................1130 System Response.......................................................................................................................................................................................................................................................1130 Possible Performance Effect...........................................................................................................................................................................................................................................1130 Troubleshooting.......................................................................................................................................................................................................................................................1130 Results...............................................................................................................................................................................................................................................................1130 E025 High Intake Air Temperature Derate...................................................................................................................................................................................................................................1131 Conditions Which Generate This Code...................................................................................................................................................................................................................................1131 System Response.......................................................................................................................................................................................................................................................1131 Possible Performance Effect...........................................................................................................................................................................................................................................1131 Troubleshooting.......................................................................................................................................................................................................................................................1131 Results...............................................................................................................................................................................................................................................................1131 E027 High Intake Air Temperature Warning..................................................................................................................................................................................................................................1131 Conditions Which Generate This Code:..................................................................................................................................................................................................................................1131 System Response.......................................................................................................................................................................................................................................................1131 Possible Performance Effect...........................................................................................................................................................................................................................................1131 Troubleshooting.......................................................................................................................................................................................................................................................1131 Results...............................................................................................................................................................................................................................................................1131 E040 Low Engine Oil Pressure Shutdown.....................................................................................................................................................................................................................................1131 Conditions Which Generate This Code...................................................................................................................................................................................................................................1131 System Response.......................................................................................................................................................................................................................................................1131 Possible Performance Effect...........................................................................................................................................................................................................................................1131 Troubleshooting.......................................................................................................................................................................................................................................................1131 Results...............................................................................................................................................................................................................................................................1131 E054 High Fuel Temperature Derate.........................................................................................................................................................................................................................................1132 Conditions Which Generate This Code...................................................................................................................................................................................................................................1132 System Response.......................................................................................................................................................................................................................................................1132 Troubleshooting.......................................................................................................................................................................................................................................................1132 Test Step 1 - Check for Diagnostic Codes..............................................................................................................................................................................................................................1132 Expected Result.......................................................................................................................................................................................................................................................1132 Results...............................................................................................................................................................................................................................................................1132 Test Step 2 - Perform a Check of the Fuel System......................................................................................................................................................................................................................1132 Expected Result.......................................................................................................................................................................................................................................................1132 Results...............................................................................................................................................................................................................................................................1132 E056 High Fuel Temperature Warning........................................................................................................................................................................................................................................1132 Conditions Which Generate This Code...................................................................................................................................................................................................................................1132 System Response.......................................................................................................................................................................................................................................................1132 Troubleshooting.......................................................................................................................................................................................................................................................1132 Test Step 1 - Check for Diagnostic Codes..............................................................................................................................................................................................................................1132 Expected Result.......................................................................................................................................................................................................................................................1132 Results...............................................................................................................................................................................................................................................................1133 Test Step 2 - Perform a Check of the Fuel System......................................................................................................................................................................................................................1133 Expected Result.......................................................................................................................................................................................................................................................1133 Results...............................................................................................................................................................................................................................................................1133 E100 Low Engine Oil Pressure Warning......................................................................................................................................................................................................................................1133 Conditions Which Generate This Code...................................................................................................................................................................................................................................1133 System Response.......................................................................................................................................................................................................................................................1133 Possible Performance Effect...........................................................................................................................................................................................................................................1133 Troubleshooting.......................................................................................................................................................................................................................................................1133 Test Step 1 - Check for Active Diagnostic Codes.......................................................................................................................................................................................................................1133 Expected Result.......................................................................................................................................................................................................................................................1133 Results...............................................................................................................................................................................................................................................................1133 Test Step 2 - Perform a Check of the Engine Lubrication System........................................................................................................................................................................................................1133 Expected Result.......................................................................................................................................................................................................................................................1133 Results...............................................................................................................................................................................................................................................................1133 E190 Engine Overspeed Warning.............................................................................................................................................................................................................................................1134 Conditions Which Generate This Code...................................................................................................................................................................................................................................1134 System Response.......................................................................................................................................................................................................................................................1134 Possible Performance Effect...........................................................................................................................................................................................................................................1134 Troubleshooting.......................................................................................................................................................................................................................................................1134 Engine Overspeed Warning..............................................................................................................................................................................................................................................1134 Expected Result.......................................................................................................................................................................................................................................................1134 Results...............................................................................................................................................................................................................................................................1134 E442 Engine Failed to Stop With a No-Fuel Command.........................................................................................................................................................................................................................1134 Conditions Which Generate This Code...................................................................................................................................................................................................................................1134 System Response.......................................................................................................................................................................................................................................................1134 Possible Performance Effect...........................................................................................................................................................................................................................................1134 Troubleshooting.......................................................................................................................................................................................................................................................1134 Test Step 1...........................................................................................................................................................................................................................................................1134 Results...............................................................................................................................................................................................................................................................1134 Test Step 2...........................................................................................................................................................................................................................................................1134 Results...............................................................................................................................................................................................................................................................1134 E883 Engine Failed to Stop When Fuel Solenoid Disengaged..................................................................................................................................................................................................................1134 Conditions Which Generate This Code...................................................................................................................................................................................................................................1134 System Response.......................................................................................................................................................................................................................................................1134 Possible Performance Effect...........................................................................................................................................................................................................................................1135 Troubleshooting.......................................................................................................................................................................................................................................................1135 Test Step 1...........................................................................................................................................................................................................................................................1135 Results...............................................................................................................................................................................................................................................................1135 Test Step 2...........................................................................................................................................................................................................................................................1135 Results...............................................................................................................................................................................................................................................................1135 Test Step 3...........................................................................................................................................................................................................................................................1135 Results...............................................................................................................................................................................................................................................................1135 Diagnostic Function Tests.....................................................................................................................................................................................................................................................1135 5-Volt Engine Pressure Sensor Supply Circuit - Test.......................................................................................................................................................................................................................1135 System Operation Description..........................................................................................................................................................................................................................................1135 Background Information................................................................................................................................................................................................................................................1135 Test Step 1...........................................................................................................................................................................................................................................................1136 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1136 Expected Result...................................................................................................................................................................................................................................................1136 Results...........................................................................................................................................................................................................................................................1137 Test Step 2...........................................................................................................................................................................................................................................................1137 Check for Active Diagnostic Codes.................................................................................................................................................................................................................................1137 Expected Result...................................................................................................................................................................................................................................................1137 Results...........................................................................................................................................................................................................................................................1137 Test Step 3...........................................................................................................................................................................................................................................................1137 Disconnect the ECM Engine Harness Connector From the ECM..........................................................................................................................................................................................................1137 Expected Result...................................................................................................................................................................................................................................................1138 Results...........................................................................................................................................................................................................................................................1138 Test Step 4...........................................................................................................................................................................................................................................................1138 Disconnect the +5V Sensors While Active Diagnostic Codes are Bei..................................................................................................................................................................................................1138 Expected Result...................................................................................................................................................................................................................................................1139 Results...........................................................................................................................................................................................................................................................1139 Test Step 5...........................................................................................................................................................................................................................................................1139 Check the Engine Harness..........................................................................................................................................................................................................................................1139 Expected Result...................................................................................................................................................................................................................................................1139 Results...........................................................................................................................................................................................................................................................1139 Air Inlet Heater Circuit - Test...........................................................................................................................................................................................................................................1139 System Operation Description..........................................................................................................................................................................................................................................1139 Test Step 1...........................................................................................................................................................................................................................................................1140 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1140 Expected Result...................................................................................................................................................................................................................................................1140 Results...........................................................................................................................................................................................................................................................1140 Test Step 2...........................................................................................................................................................................................................................................................1140 Check the Supply to the Power Relay for the Air Inlet Heater Sta..................................................................................................................................................................................................1140 Expected Result...................................................................................................................................................................................................................................................1141 Results...........................................................................................................................................................................................................................................................1141 Test Step 3...........................................................................................................................................................................................................................................................1141 Check the Output From the Power Relay for the Air Inlet Heater S..................................................................................................................................................................................................1141 Expected Result...................................................................................................................................................................................................................................................1141 Results...........................................................................................................................................................................................................................................................1141 Test Step 4...........................................................................................................................................................................................................................................................1141 Ground the Input to the Power Relay at the MIC....................................................................................................................................................................................................................1141 Expected Result...................................................................................................................................................................................................................................................1141 Results...........................................................................................................................................................................................................................................................1141 Test Step 5...........................................................................................................................................................................................................................................................1141 Ground the Input to the Power Relay at the ECM Connector..........................................................................................................................................................................................................1141 Expected Result...................................................................................................................................................................................................................................................1141 Results...........................................................................................................................................................................................................................................................1141 Test Step 6...........................................................................................................................................................................................................................................................1142 Override the Air Inlet Heater Starting Aid to Test the ECM........................................................................................................................................................................................................1142 Results...........................................................................................................................................................................................................................................................1142 Checking Idle Validation Switching Point (Throttle Sensor) With ..........................................................................................................................................................................................................1142 Expected Result.......................................................................................................................................................................................................................................................1142 Analog Throttle Position Sensor Circuit - Test............................................................................................................................................................................................................................1142 System Operation Description..........................................................................................................................................................................................................................................1142 Checking the Throttle Sensor With Unconnected Output C................................................................................................................................................................................................................1143 Expected Result...................................................................................................................................................................................................................................................1143 Test Step 1...........................................................................................................................................................................................................................................................1143 Check for Connector Damage........................................................................................................................................................................................................................................1143 Expected Result...................................................................................................................................................................................................................................................1144 Results...........................................................................................................................................................................................................................................................1144 Test Step 2...........................................................................................................................................................................................................................................................1144 Check for Active Diagnostic Codes.................................................................................................................................................................................................................................1144 Expected Result...................................................................................................................................................................................................................................................1144 Results...........................................................................................................................................................................................................................................................1144 Test Step 3...........................................................................................................................................................................................................................................................1144 Check the Throttle Position With the Electronic Service Tool......................................................................................................................................................................................................1144 Expected Result...................................................................................................................................................................................................................................................1144 Results...........................................................................................................................................................................................................................................................1144 Test Step 4...........................................................................................................................................................................................................................................................1144 Check the Voltage at the Throttle Position Sensor.................................................................................................................................................................................................................1144 Expected Result...................................................................................................................................................................................................................................................1144 Results...........................................................................................................................................................................................................................................................1144 Test Step 5...........................................................................................................................................................................................................................................................1145 Disconnect the Throttle Position Sensor and Check for Active Dia..................................................................................................................................................................................................1145 Expected Result...................................................................................................................................................................................................................................................1145 Results...........................................................................................................................................................................................................................................................1145 Test Step 6...........................................................................................................................................................................................................................................................1145 Check the Throttle Selection Status With the Electronic Service ..................................................................................................................................................................................................1145 Expected Result...................................................................................................................................................................................................................................................1145 Results...........................................................................................................................................................................................................................................................1145 Test Step 7...........................................................................................................................................................................................................................................................1146 Disconnect the Supply Terminals of the Throttle Position Sensor ..................................................................................................................................................................................................1146 Expected Result...................................................................................................................................................................................................................................................1146 Results...........................................................................................................................................................................................................................................................1146 Test Step 8...........................................................................................................................................................................................................................................................1146 Check the Position of Throttle Position Sensor....................................................................................................................................................................................................................1146 Expected Result...................................................................................................................................................................................................................................................1146 Results...........................................................................................................................................................................................................................................................1147 Test Step 9...........................................................................................................................................................................................................................................................1147 Check the Throttle Position Sensor at the ECM.....................................................................................................................................................................................................................1147 Expected Result...................................................................................................................................................................................................................................................1147 Results...........................................................................................................................................................................................................................................................1147 CAN Data Link Circuit - Test..............................................................................................................................................................................................................................................1147 System Operation Description..........................................................................................................................................................................................................................................1147 Test Step 1...........................................................................................................................................................................................................................................................1148 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1148 Expected Result...................................................................................................................................................................................................................................................1148 Results...........................................................................................................................................................................................................................................................1148 Test Step 2...........................................................................................................................................................................................................................................................1148 Check the CAN Data Link Between the ECM and P40 Fuel Injection P..................................................................................................................................................................................................1148 Expected Result...................................................................................................................................................................................................................................................1148 Results...........................................................................................................................................................................................................................................................1148 Test Step 3...........................................................................................................................................................................................................................................................1148 Check the CAN Data Link Between the ECM and P40 Fuel Injection P..................................................................................................................................................................................................1148 Expected Result...................................................................................................................................................................................................................................................1148 Results...........................................................................................................................................................................................................................................................1149 Test Step 4...........................................................................................................................................................................................................................................................1149 Verify the Supply Voltage at the Fuel Injection Pump..............................................................................................................................................................................................................1149 Expected Result...................................................................................................................................................................................................................................................1149 Results...........................................................................................................................................................................................................................................................1149 Data Link Circuit - Test..................................................................................................................................................................................................................................................1149 System Operation Description..........................................................................................................................................................................................................................................1149 Background Information................................................................................................................................................................................................................................................1150 Communication.........................................................................................................................................................................................................................................................1150 Test Step 1...........................................................................................................................................................................................................................................................1150 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1150 Expected Result...................................................................................................................................................................................................................................................1150 Results...........................................................................................................................................................................................................................................................1150 Test Step 2...........................................................................................................................................................................................................................................................1150 Determine the Type of Problem With the Data Link..................................................................................................................................................................................................................1150 Expected Result...................................................................................................................................................................................................................................................1150 Results...........................................................................................................................................................................................................................................................1151 Test Step 3...........................................................................................................................................................................................................................................................1151 Check the Battery Voltage at the ECM..............................................................................................................................................................................................................................1151 Expected Result...................................................................................................................................................................................................................................................1151 Results...........................................................................................................................................................................................................................................................1151 Test Step 4...........................................................................................................................................................................................................................................................1151 Check the Battery Voltage That is Coming to the Data Link Connec..................................................................................................................................................................................................1151 Expected Result...................................................................................................................................................................................................................................................1152 Results...........................................................................................................................................................................................................................................................1152 Test Step 5...........................................................................................................................................................................................................................................................1152 Connect the Electronic Service Tool Directly to the ECM...........................................................................................................................................................................................................1152 Expected Result...................................................................................................................................................................................................................................................1152 Results...........................................................................................................................................................................................................................................................1152 Test Step 6...........................................................................................................................................................................................................................................................1152 Change Electronic Service Tool Components.........................................................................................................................................................................................................................1152 Expected Result...................................................................................................................................................................................................................................................1153 Results...........................................................................................................................................................................................................................................................1153 Test Step 7...........................................................................................................................................................................................................................................................1153 Connect an Electronic Service Tool and the ECM to Another Batter..................................................................................................................................................................................................1153 Expected Result...................................................................................................................................................................................................................................................1153 Results...........................................................................................................................................................................................................................................................1153 Electrical Connectors - Inspect...........................................................................................................................................................................................................................................1153 System Operation Description..........................................................................................................................................................................................................................................1153 Background Information................................................................................................................................................................................................................................................1154 Test Step 1...........................................................................................................................................................................................................................................................1157 Check the Locking of the DT Connector (Deutsch) and the Lock Rin..................................................................................................................................................................................................1157 Expected Result...................................................................................................................................................................................................................................................1157 Results...........................................................................................................................................................................................................................................................1157 Test Step 2...........................................................................................................................................................................................................................................................1158 Check the Socket Head Screw on the Connector for the Electronic ..................................................................................................................................................................................................1158 Expected Result...................................................................................................................................................................................................................................................1158 Results...........................................................................................................................................................................................................................................................1158 Test Step 3...........................................................................................................................................................................................................................................................1158 Perform a Pull Test on Each Wire Terminal Connection..............................................................................................................................................................................................................1158 Expected Result...................................................................................................................................................................................................................................................1158 Results...........................................................................................................................................................................................................................................................1158 Test Step 4...........................................................................................................................................................................................................................................................1158 Monitor the Electronic Service Tool While the Wiring and the Con..................................................................................................................................................................................................1158 Expected Result...................................................................................................................................................................................................................................................1159 Results...........................................................................................................................................................................................................................................................1159 Test Step 5...........................................................................................................................................................................................................................................................1159 Check Wires for Nicks and/or Abrasions in the Insulation..........................................................................................................................................................................................................1159 Expected Result...................................................................................................................................................................................................................................................1159 Results...........................................................................................................................................................................................................................................................1159 Test Step 6...........................................................................................................................................................................................................................................................1159 Check Connectors for Moisture or Corrosion........................................................................................................................................................................................................................1159 Expected Result...................................................................................................................................................................................................................................................1160 Results...........................................................................................................................................................................................................................................................1160 Test Step 7...........................................................................................................................................................................................................................................................1160 Inspect the Connector Terminals...................................................................................................................................................................................................................................1160 Expected Result...................................................................................................................................................................................................................................................1160 Results...........................................................................................................................................................................................................................................................1160 Test Step 8...........................................................................................................................................................................................................................................................1160 Check Individual Pin Retention Into the Socket....................................................................................................................................................................................................................1160 Expected Result...................................................................................................................................................................................................................................................1161 Results...........................................................................................................................................................................................................................................................1161 Electrical Power Supply Circuit - Test....................................................................................................................................................................................................................................1161 System Operation Description..........................................................................................................................................................................................................................................1161 Background Information................................................................................................................................................................................................................................................1161 Test Step 1...........................................................................................................................................................................................................................................................1162 Check the Batteries...............................................................................................................................................................................................................................................1162 Expected Result...................................................................................................................................................................................................................................................1162 Results...........................................................................................................................................................................................................................................................1162 Test Step 2...........................................................................................................................................................................................................................................................1163 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1163 Expected Result...................................................................................................................................................................................................................................................1163 Results...........................................................................................................................................................................................................................................................1163 Test Step 3...........................................................................................................................................................................................................................................................1163 Check the Battery Voltage at the ECM..............................................................................................................................................................................................................................1163 Expected Result...................................................................................................................................................................................................................................................1163 Results...........................................................................................................................................................................................................................................................1164 Test Step 4...........................................................................................................................................................................................................................................................1164 Use the Bypass Harness for the Electronic Service Tool to Bypass..................................................................................................................................................................................................1164 Expected Result...................................................................................................................................................................................................................................................1165 Results...........................................................................................................................................................................................................................................................1165 Engine Pressure Sensor Open or Short Circuit - Test.......................................................................................................................................................................................................................1165 System Operation Description..........................................................................................................................................................................................................................................1165 Background Information................................................................................................................................................................................................................................................1165 Test Step 1...........................................................................................................................................................................................................................................................1165 Check for Active +5V Sensor Supply Diagnostic Codes...............................................................................................................................................................................................................1165 Expected Result...................................................................................................................................................................................................................................................1166 Results...........................................................................................................................................................................................................................................................1166 Test Step 2...........................................................................................................................................................................................................................................................1166 Verify All Active Diagnostic Codes................................................................................................................................................................................................................................1166 Expected Result...................................................................................................................................................................................................................................................1166 Results...........................................................................................................................................................................................................................................................1166 Test Step 3...........................................................................................................................................................................................................................................................1166 Inspect Electrical Connectors And Wiring..........................................................................................................................................................................................................................1166 Expected Result...................................................................................................................................................................................................................................................1167 Results...........................................................................................................................................................................................................................................................1167 Test Step 4...........................................................................................................................................................................................................................................................1167 Verify That the Diagnostic Code is Still Active...................................................................................................................................................................................................................1167 Expected Result...................................................................................................................................................................................................................................................1167 Results...........................................................................................................................................................................................................................................................1167 Test Step 5...........................................................................................................................................................................................................................................................1167 Disconnect the Sensor to Create an Open Circuit...................................................................................................................................................................................................................1167 Expected Result...................................................................................................................................................................................................................................................1167 Results...........................................................................................................................................................................................................................................................1167 Test Step 6...........................................................................................................................................................................................................................................................1167 Measure the Sensor Supply Voltage.................................................................................................................................................................................................................................1167 Expected Result...................................................................................................................................................................................................................................................1168 Results...........................................................................................................................................................................................................................................................1168 Test Step 7...........................................................................................................................................................................................................................................................1168 Determine if the Short Circuit is in the Connector or in the Sen..................................................................................................................................................................................................1168 Expected Result...................................................................................................................................................................................................................................................1168 Results...........................................................................................................................................................................................................................................................1168 Test Step 8...........................................................................................................................................................................................................................................................1168 Create a Short Circuit Between the Signal and the Common Termina..................................................................................................................................................................................................1168 Expected Result...................................................................................................................................................................................................................................................1169 Results...........................................................................................................................................................................................................................................................1169 Test Step 9...........................................................................................................................................................................................................................................................1169 Check the Operation of the ECM by Creating Open and Short Circui..................................................................................................................................................................................................1169 Expected Result...................................................................................................................................................................................................................................................1169 Results...........................................................................................................................................................................................................................................................1169 Test Step 10..........................................................................................................................................................................................................................................................1170 Bypass the Harness Wiring Between the ECM and the Sensor Connect..................................................................................................................................................................................................1170 Expected Result...................................................................................................................................................................................................................................................1170 Results...........................................................................................................................................................................................................................................................1170 Engine Speed/Timing Sensor Circuit - Test.................................................................................................................................................................................................................................1170 System Operation Description..........................................................................................................................................................................................................................................1170 Test Step 1...........................................................................................................................................................................................................................................................1171 Inspect the Electrical Connectors and Cables......................................................................................................................................................................................................................1171 Expected Result...................................................................................................................................................................................................................................................1171 Results...........................................................................................................................................................................................................................................................1171 Test Step 2...........................................................................................................................................................................................................................................................1171 Check the Installation of the Engine Speed/Timing Sensors.........................................................................................................................................................................................................1171 Expected Result...................................................................................................................................................................................................................................................1171 Results...........................................................................................................................................................................................................................................................1171 Test Step 3...........................................................................................................................................................................................................................................................1171 Measure the Sensor Resistance Through the Wiring Harness..........................................................................................................................................................................................................1171 Expected Result...................................................................................................................................................................................................................................................1172 Results...........................................................................................................................................................................................................................................................1172 Test Step 4...........................................................................................................................................................................................................................................................1172 Measure the Resistance of the Sensor..............................................................................................................................................................................................................................1172 Expected Result...................................................................................................................................................................................................................................................1172 Results...........................................................................................................................................................................................................................................................1172 Test Step 5...........................................................................................................................................................................................................................................................1173 Measure the Resistance of the Cables Between the Fuel Injection ..................................................................................................................................................................................................1173 Expected Result...................................................................................................................................................................................................................................................1173 Results...........................................................................................................................................................................................................................................................1173 Test Step 6...........................................................................................................................................................................................................................................................1173 Check the Continuity of the Cables From the ECM to the Fuel Inje..................................................................................................................................................................................................1173 Expected Result...................................................................................................................................................................................................................................................1173 Results...........................................................................................................................................................................................................................................................1174 Engine Temperature Sensor Open or Short Circuit - Test....................................................................................................................................................................................................................1174 System Operation Description..........................................................................................................................................................................................................................................1174 Background Information................................................................................................................................................................................................................................................1174 Test Step 1...........................................................................................................................................................................................................................................................1175 Verify All Active Diagnostic Codes................................................................................................................................................................................................................................1175 Expected Result...................................................................................................................................................................................................................................................1175 Results...........................................................................................................................................................................................................................................................1175 Test Step 2...........................................................................................................................................................................................................................................................1175 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1175 Expected Result...................................................................................................................................................................................................................................................1175 Results...........................................................................................................................................................................................................................................................1176 Test Step 3...........................................................................................................................................................................................................................................................1176 Verify That the Diagnostic Code is Still Active...................................................................................................................................................................................................................1176 Expected Result...................................................................................................................................................................................................................................................1176 Results...........................................................................................................................................................................................................................................................1176 Test Step 4...........................................................................................................................................................................................................................................................1176 Disconnect the Sensor to Create an Open Circuit...................................................................................................................................................................................................................1176 Expected Result...................................................................................................................................................................................................................................................1176 Results...........................................................................................................................................................................................................................................................1176 Test Step 5...........................................................................................................................................................................................................................................................1176 Create a Short Circuit Between the Signal and the Common Termina..................................................................................................................................................................................................1176 Expected Result...................................................................................................................................................................................................................................................1177 Results...........................................................................................................................................................................................................................................................1177 Test Step 6...........................................................................................................................................................................................................................................................1177 Check the Operation of the ECM by Creating an Open and a Short C..................................................................................................................................................................................................1177 Expected Result...................................................................................................................................................................................................................................................1177 Results...........................................................................................................................................................................................................................................................1177 Test Step 7...........................................................................................................................................................................................................................................................1177 Bypass the Harness Wiring Between the ECM and the Sensor Connect..................................................................................................................................................................................................1177 Expected Result...................................................................................................................................................................................................................................................1178 Results...........................................................................................................................................................................................................................................................1178 Fuel Injection Pump Circuit - Test........................................................................................................................................................................................................................................1178 System Operation Description..........................................................................................................................................................................................................................................1178 Background Information................................................................................................................................................................................................................................................1178 Test Step 1...........................................................................................................................................................................................................................................................1178 Check the Batteries...............................................................................................................................................................................................................................................1178 Expected Result...................................................................................................................................................................................................................................................1178 Results...........................................................................................................................................................................................................................................................1179 Test Step 2...........................................................................................................................................................................................................................................................1179 Inspect the Electrical Connectors and Wiring......................................................................................................................................................................................................................1179 Expected Result...................................................................................................................................................................................................................................................1180 Results...........................................................................................................................................................................................................................................................1180 Test Step 3...........................................................................................................................................................................................................................................................1180 Check the Supply Voltage at the Machine Interface Connector.......................................................................................................................................................................................................1180 Expected Result...................................................................................................................................................................................................................................................1180 Results...........................................................................................................................................................................................................................................................1180 Test Step 4...........................................................................................................................................................................................................................................................1180 Check the Supply Voltage at the Fuel Injection Pump...............................................................................................................................................................................................................1180 Expected Result...................................................................................................................................................................................................................................................1180 Results...........................................................................................................................................................................................................................................................1180 Test Step 5...........................................................................................................................................................................................................................................................1181 Check the Supply to the Power Relay for the Fuel Injection Pump...................................................................................................................................................................................................1181 Expected Result...................................................................................................................................................................................................................................................1181 Results...........................................................................................................................................................................................................................................................1181 Test Step 6...........................................................................................................................................................................................................................................................1181 Check the Output of the Power Relay for the Fuel Injection Pump...................................................................................................................................................................................................1181 Expected Result...................................................................................................................................................................................................................................................1181 Results...........................................................................................................................................................................................................................................................1181 Test Step 7...........................................................................................................................................................................................................................................................1181 Check the Voltage at the Relay Coil for the Fuel Injection Pump...................................................................................................................................................................................................1181 Expected Result...................................................................................................................................................................................................................................................1181 Results...........................................................................................................................................................................................................................................................1181 Test Step 8...........................................................................................................................................................................................................................................................1182 Check the Output of the ECM Fuel Pump Power Control at the Machi..................................................................................................................................................................................................1182 Expected Result...................................................................................................................................................................................................................................................1182 Results...........................................................................................................................................................................................................................................................1182 Test Step 9...........................................................................................................................................................................................................................................................1182 Check the Output of the Fuel Injection Pump Power Control at the..................................................................................................................................................................................................1182 Expected Result...................................................................................................................................................................................................................................................1182 Results...........................................................................................................................................................................................................................................................1182 Test Step 10..........................................................................................................................................................................................................................................................1182 Measure the Voltage at the Pump Power Supply......................................................................................................................................................................................................................1182 Expected Result...................................................................................................................................................................................................................................................1183 Results...........................................................................................................................................................................................................................................................1183 Test Step 11..........................................................................................................................................................................................................................................................1183 Check the Voltage Load Protection Module (VLPM)...................................................................................................................................................................................................................1183 Expected Result...................................................................................................................................................................................................................................................1184 Results...........................................................................................................................................................................................................................................................1184 Indicator Lamp Circuit - Test.............................................................................................................................................................................................................................................1184 System Operation Description..........................................................................................................................................................................................................................................1184 Test Step 1...........................................................................................................................................................................................................................................................1184 Inspect Electrical Connectors and Wiring..........................................................................................................................................................................................................................1184 Results...........................................................................................................................................................................................................................................................1185 Test Step 2...........................................................................................................................................................................................................................................................1185 Inspect the Lamp, the Fuse, and the Power Supply..................................................................................................................................................................................................................1185 Expected Result...................................................................................................................................................................................................................................................1185 Results...........................................................................................................................................................................................................................................................1185 Test Step 3...........................................................................................................................................................................................................................................................1185 Inspect the Input to the Lamp at the ECM connector................................................................................................................................................................................................................1185 Expected Result...................................................................................................................................................................................................................................................1185 Results...........................................................................................................................................................................................................................................................1186 Test Step 4...........................................................................................................................................................................................................................................................1186 Test the Individual Lamp Circuits.................................................................................................................................................................................................................................1186 Expected Result...................................................................................................................................................................................................................................................1186 Results...........................................................................................................................................................................................................................................................1186 Test Step 5...........................................................................................................................................................................................................................................................1186 Check the Voltage at the ECM......................................................................................................................................................................................................................................1186 Expected Result...................................................................................................................................................................................................................................................1186 Results...........................................................................................................................................................................................................................................................1186 Idle Validation Circuit - Test............................................................................................................................................................................................................................................1186 System Operation Description..........................................................................................................................................................................................................................................1186 Test Step 1...........................................................................................................................................................................................................................................................1186 Expected Result...................................................................................................................................................................................................................................................1186 Results...........................................................................................................................................................................................................................................................1187 tables............................................................................................................................................................................................................................................................................1035 Table 1. Electronic Service Tool..............................................................................................................................................................................................................................................1061 Table 2. Optional Service Tools...............................................................................................................................................................................................................................................1062 Table 3. CID FMI Codes and J Code FMI Codes...................................................................................................................................................................................................................................1063 Table 4. Event Codes and CID FMI Codes........................................................................................................................................................................................................................................1065 Table 5. Diagnostics Supported Over J1939.....................................................................................................................................................................................................................................1066 Table 6. Events Supported Over J1939..........................................................................................................................................................................................................................................1068 Table 7. Engine Connectors....................................................................................................................................................................................................................................................1075 Table 8. Color Codes for the Harness Wire.....................................................................................................................................................................................................................................1080 Table 9. Pin Connections for Perkins Deutsch Socket Connector.................................................................................................................................................................................................................1082 Table 10. Suspect Parameter Numbers...........................................................................................................................................................................................................................................1086 Table 11. Failure Mode Indicators (FMI) Codes.................................................................................................................................................................................................................................1087 Table 12. Engine Oil Pressure Trip and Reset Points...........................................................................................................................................................................................................................1131 1586990-8000SRM1181-(03-2007)-US-EN...................................................................................................................................................................................................................................................1191 toc...............................................................................................................................................................................................................................................................................1191 Assembly Guide................................................................................................................................................................................................................................................................1191 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1192 List of All Special Tools and Equipment Needed for the Assembly...............................................................................................................................................................................................................1195 General Considerations Before Starting the Job................................................................................................................................................................................................................................1195 Preparation of the Components Before Assembly.................................................................................................................................................................................................................................1196 Liquefied Petroleum Gas (LPG Engines Only)....................................................................................................................................................................................................................................1196 Remove....................................................................................................................................................................................................................................................................1196 Install...................................................................................................................................................................................................................................................................1197 Checking of the Wheels........................................................................................................................................................................................................................................................1197 Air Pressure..............................................................................................................................................................................................................................................................1197 Drive Wheels..............................................................................................................................................................................................................................................................1198 Steer Wheels..............................................................................................................................................................................................................................................................1202 Wheel Nut Torque..........................................................................................................................................................................................................................................................1205 Mast Label Placement..........................................................................................................................................................................................................................................................1206 Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................1207 Mast Installation.............................................................................................................................................................................................................................................................1209 Mast......................................................................................................................................................................................................................................................................1209 Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................1212 Lift Cylinder Hose Connection.............................................................................................................................................................................................................................................1213 Truck Header Hoses and Electrical Cable Connections.......................................................................................................................................................................................................................1214 Mast Light Connection.....................................................................................................................................................................................................................................................1216 Carriage Installation.....................................................................................................................................................................................................................................................1217 Carriage Header Hoses and Electrical Cable Connection.....................................................................................................................................................................................................................1218 Fork Installation.........................................................................................................................................................................................................................................................1221 Exhaust Extension Tube Installation...........................................................................................................................................................................................................................................1222 Lights Installation - Operator Compartment....................................................................................................................................................................................................................................1224 Hydraulic Oil Check...........................................................................................................................................................................................................................................................1225 Lubrication Points............................................................................................................................................................................................................................................................1226 Check Points..................................................................................................................................................................................................................................................................1227 Checkpoint 1..............................................................................................................................................................................................................................................................1227 Checkpoint 2..............................................................................................................................................................................................................................................................1227 Checkpoint 3..............................................................................................................................................................................................................................................................1227 Checkpoint 4..............................................................................................................................................................................................................................................................1227 Checkpoint 5..............................................................................................................................................................................................................................................................1227 General Truck Install Procedures..............................................................................................................................................................................................................................................1227 tables............................................................................................................................................................................................................................................................................1191 Table 1. Mast Hanger Pins Capscrew Torques....................................................................................................................................................................................................................................1212 1612615-5000SRM1221-(11-2006)-US-EN...................................................................................................................................................................................................................................................1231 toc...............................................................................................................................................................................................................................................................................1231 Extendable Container Attachment (Elme)........................................................................................................................................................................................................................................1231 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1232 General.......................................................................................................................................................................................................................................................................1237 Description...................................................................................................................................................................................................................................................................1237 Operation.....................................................................................................................................................................................................................................................................1241 General...................................................................................................................................................................................................................................................................1241 Optional Powered Pile Slope...............................................................................................................................................................................................................................................1241 Sideshift.................................................................................................................................................................................................................................................................1242 Extend and Retract Circuit................................................................................................................................................................................................................................................1243 Container locking Model 582...............................................................................................................................................................................................................................................1245 Sequence Valve........................................................................................................................................................................................................................................................1245 Pilot Check Valve.....................................................................................................................................................................................................................................................1246 Container Locking Model 583...............................................................................................................................................................................................................................................1247 Container Locking Model 584...............................................................................................................................................................................................................................................1247 Container Locking Model 585...............................................................................................................................................................................................................................................1248 Container Locking Models 586, 588, and 589................................................................................................................................................................................................................................1248 Electrical System.........................................................................................................................................................................................................................................................1250 Indicator Lights..........................................................................................................................................................................................................................................................1250 Flashing Indicator Lights.................................................................................................................................................................................................................................................1251 Automatic Locking.........................................................................................................................................................................................................................................................1251 Lift Interrupt and Override...............................................................................................................................................................................................................................................1251 Overlowering Interrupt and Override.......................................................................................................................................................................................................................................1251 Second Container Detection Sensor (Model 582 Only)........................................................................................................................................................................................................................1252 Carriage and Attachment Removal...............................................................................................................................................................................................................................................1252 Carriage..................................................................................................................................................................................................................................................................1252 Spreader..................................................................................................................................................................................................................................................................1253 Sideshift Cylinder Removal and Installation...................................................................................................................................................................................................................................1253 Remove....................................................................................................................................................................................................................................................................1253 Install...................................................................................................................................................................................................................................................................1253 Extension Cylinder Removal and Installation...................................................................................................................................................................................................................................1254 Remove....................................................................................................................................................................................................................................................................1254 Upper, Right-Hand.....................................................................................................................................................................................................................................................1254 Lower, Left-Hand......................................................................................................................................................................................................................................................1254 Install...................................................................................................................................................................................................................................................................1254 Floating End Beams Repair.....................................................................................................................................................................................................................................................1255 Remove....................................................................................................................................................................................................................................................................1255 Install...................................................................................................................................................................................................................................................................1255 Hose, Replace.............................................................................................................................................................................................................................................................1256 Twist Lock Repair for Model 582...............................................................................................................................................................................................................................................1257 Remove....................................................................................................................................................................................................................................................................1257 Upper Twist Lock......................................................................................................................................................................................................................................................1257 Lower Twist Lock......................................................................................................................................................................................................................................................1257 Disassemble...............................................................................................................................................................................................................................................................1258 Clean and Inspect.........................................................................................................................................................................................................................................................1258 Assemble..................................................................................................................................................................................................................................................................1259 Install...................................................................................................................................................................................................................................................................1259 Hook Repair for Model 584 and 585.............................................................................................................................................................................................................................................1259 Remove....................................................................................................................................................................................................................................................................1259 Inspect...................................................................................................................................................................................................................................................................1259 Install...................................................................................................................................................................................................................................................................1259 Side Clamp Replacement for Model 584..........................................................................................................................................................................................................................................1260 Remove....................................................................................................................................................................................................................................................................1260 Install...................................................................................................................................................................................................................................................................1261 Twist Lock Repair for Models 586, 588, and 589................................................................................................................................................................................................................................1261 Disassemble...............................................................................................................................................................................................................................................................1261 Clean and Inspect.........................................................................................................................................................................................................................................................1261 Assemble..................................................................................................................................................................................................................................................................1262 Extension Beam Repair.........................................................................................................................................................................................................................................................1263 Remove....................................................................................................................................................................................................................................................................1263 Inspect...................................................................................................................................................................................................................................................................1263 Assemble..................................................................................................................................................................................................................................................................1264 Cylinder Repair...............................................................................................................................................................................................................................................................1265 Extension Cylinder........................................................................................................................................................................................................................................................1265 Disassemble...........................................................................................................................................................................................................................................................1265 Clean and Inspect.....................................................................................................................................................................................................................................................1265 Assemble..............................................................................................................................................................................................................................................................1265 Guide for Extension Cylinder..............................................................................................................................................................................................................................................1266 Remove................................................................................................................................................................................................................................................................1266 Install...............................................................................................................................................................................................................................................................1266 Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde..........................................................................................................................................................................................................1266 Disassemble...........................................................................................................................................................................................................................................................1266 Assemble..............................................................................................................................................................................................................................................................1266 Wear Pad Replacement..........................................................................................................................................................................................................................................................1267 General...................................................................................................................................................................................................................................................................1267 Floating End Beam Wear Pads...............................................................................................................................................................................................................................................1267 Upper Wear Pads.......................................................................................................................................................................................................................................................1267 Lower Wear Pads.......................................................................................................................................................................................................................................................1267 Main Frame Wear Pads at Large (Right-Hand) Extension Beam.................................................................................................................................................................................................................1267 Main Frame Wear Pads at Small (Left-Hand) Extension Beam..................................................................................................................................................................................................................1267 Guide for Extension Cylinder..............................................................................................................................................................................................................................................1268 Large Extension Beam Internal Wear Pads...................................................................................................................................................................................................................................1269 Spreader Frame............................................................................................................................................................................................................................................................1269 Upper Wear Pads.......................................................................................................................................................................................................................................................1269 Lower Wear Pads.......................................................................................................................................................................................................................................................1269 Powered Pile Slope Carriage...............................................................................................................................................................................................................................................1269 Upper Wear Pads.......................................................................................................................................................................................................................................................1269 Lower Wear Pads.......................................................................................................................................................................................................................................................1269 Adjustments...................................................................................................................................................................................................................................................................1269 Twist Lock Angle Adjustment...............................................................................................................................................................................................................................................1269 Model 586, 588 and 589................................................................................................................................................................................................................................................1269 LOCKED/NOT LOCKED Sensors Adjustment......................................................................................................................................................................................................................................1270 Model 582.............................................................................................................................................................................................................................................................1270 Model 586, 588 and 589................................................................................................................................................................................................................................................1270 Side Clamp Open/Closed Sensor Adjustment (Model 584)......................................................................................................................................................................................................................1270 Hook in Sensor Adjustment (Model 584).....................................................................................................................................................................................................................................1270 Seated Sensor Adjustment..................................................................................................................................................................................................................................................1271 Model 582.............................................................................................................................................................................................................................................................1271 Model 586, 588 and 589................................................................................................................................................................................................................................................1271 Overlowering Protection Sensor Adjustment (All 580 Models)................................................................................................................................................................................................................1271 Schematics....................................................................................................................................................................................................................................................................1272 tables............................................................................................................................................................................................................................................................................1231 Table 1. Elme Schematic Overview..............................................................................................................................................................................................................................................1272 Aurora_AC.............................................................................................................................................................................................................................................................................1359 912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................1360 Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................1360 ..........................................................................................................................................................................................................................................................................1366 Filling procedure for refrigerants....................................................................................................................................................................................................................................1366 Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................1366 Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................1366 Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................1366 The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................1366 Never put the safety switch out of action.........................................................................................................................................................................................................................1366 Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................1366 Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................1366 Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................1366 Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................1366 Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................1366 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....1366 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....1366 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...................1366 Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................1366 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.....................................................1366 4. Troubleshooting............................................................................................................................................................................................................................................................1367 ..........................................................................................................................................................................................................................................................................1367 ......................................................................................................................................................................................................................................................................1367 Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................1367 By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................1367 The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................1367 With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................1367 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....1367 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.....1367 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....1367 912-100-0007_e.pdf................................................................................................................................................................................................................................................................1368 Technical modifications reserved..............................................................................................................................................................................................................................................1368 912-100-0258_e.pdf................................................................................................................................................................................................................................................................1379 Condenser unit, 24V...........................................................................................................................................................................................................................................................1379 ..........................................................................................................................................................................................................................................................................1379 ......................................................................................................................................................................................................................................................................1379 ..................................................................................................................................................................................................................................................................1379 ..............................................................................................................................................................................................................................................................1379 part no.:175-FR2-0002.....................................................................................................................................................................................................................................1379 Safety advices................................................................................................................................................................................................................................................1379 - we reserve the right to make technical modifications -..................................................................................................................................................................................................................1379 1Safety advices...............................................................................................................................................................................................................................................................1380 Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................1380 ......................................................................................................................................................................................................................................................................1381 2.2Condenser blowers..............................................................................................................................................................................................................................................1381 5Electrical connection............................................................................................................................................................................................................................................1382 every six months – authorised workshop:...................................................................................................................................................................................................................................1383 ......................................................................................................................................................................................................................................................................1383 ..................................................................................................................................................................................................................................................................1383 ..............................................................................................................................................................................................................................................................1383 State of the refrigerant hoses............................................................................................................................................................................................................................1383 State of the condenser................................................................................................................................................................................................................................................1383 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).................................................................................................................1383 every month sight checks - Operator.......................................................................................................................................................................................................................................1384 ......................................................................................................................................................................................................................................................................1384 ..................................................................................................................................................................................................................................................................1384 ..............................................................................................................................................................................................................................................................1384 State of the refrigerant hoses............................................................................................................................................................................................................................1384 State of the condenser................................................................................................................................................................................................................................................1384 Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................1384 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).................................................................................................................1384 Installation of replacement parts.....................................................................................................................................................................................................................................1384 8Technical data...................................................................................................................................................................................................................................................1384 9Fault diagnosis..................................................................................................................................................................................................................................................1385
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