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Hyster G007 (H8.00-12.00XM) Service Manual – PDF DOWNLOAD
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Hyster G007 (H8.00-12.00XM) Service Manual – PDF DOWNLOAD
PART NO. 1494123
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Hyster G007 (H8.00-12.00XM) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster G007 (H8.00-12.00XM) Service Manual – PDF DOWNLOAD
PART NO. 1494123
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 G007 (H8.00-12.00XM) Service Manual – PDF DOWNLOAD
0100SRM927-1494123(12-2003)-EN.......................................................... 1 toc................................................................................. 1 Frame........................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Counterweight Repair............................................................ 5 Remove...................................................................... 5 Install..................................................................... 7 Fenders..................................................................... 7 Remove.................................................................. 7 Install................................................................. 7 Side Counterweights H13.00-16.00XM (H300-360HD)............................. 7 Side Counterweight, Replace................................................. 7 Hood and Air Cleaner Repair..................................................... 8 Remove...................................................................... 8 Install..................................................................... 9 Hydraulic Tank Repair........................................................... 10 Remove...................................................................... 10 Repairs, All Units.......................................................... 12 Small Leaks............................................................. 12 Large Leaks............................................................. 12 Clean....................................................................... 12 Steam Method............................................................ 12 Chemical Solution Method................................................ 13 Other Methods of Preparation for Repair..................................... 13 Install..................................................................... 13 Fuel Tank Repair................................................................ 14 Remove...................................................................... 14 Repairs..................................................................... 14 Install..................................................................... 14 Cooling System and Radiator Repair.............................................. 16 Remove...................................................................... 16 Install..................................................................... 16 Engine and Transmission Repair.................................................. 19 Hyster T-50 Transmission, Remove............................................ 19 Hyster T-50 Transmission, Install........................................... 20 TE-10 Transmission.......................................................... 21 Remove.................................................................. 21 Install................................................................. 24 Label Replacement............................................................... 26 0100SRM1100-1556599(09-2004)-EN......................................................... 31 toc................................................................................. 31 Operator's Cab.................................................................. 31 Safety Precautions Maintenance and Repair....................................... 32 General......................................................................... 35 Cab Repair...................................................................... 36 Rear Cab Assembly........................................................... 36 Bottom Cab Assembly......................................................... 37 Raising and Lowering Cab.................................................... 37 Raise Cab............................................................... 37 Lower Cab............................................................... 38 Cab Repair.................................................................. 38 Remove.................................................................. 38 Install................................................................. 39 Oil Filling for Tilt System..................................................... 40 Inching and Brake Pedals........................................................ 40 Pedal Adjustment............................................................ 40 Sensor Adjustment........................................................... 41 Throttle Pedal Sensor........................................................... 41 Check....................................................................... 41 Adjust...................................................................... 41 Seat Assembly Removal........................................................... 42 Power Assist Armrest............................................................ 43 Adjust...................................................................... 43 Steering Column Repair.......................................................... 43 Remove...................................................................... 43 Install..................................................................... 43 Window Wipers Replacement....................................................... 44 Window Wiper Assembly, Replace.............................................. 44 Front Window Wiper Motor Assembly, Replace.................................. 45 Rear Window Wiper Motor Assembly, Replace................................... 45 Top Window Wiper Motor Assembly, Replace.................................... 45 Window Washer Motors and Pumps.................................................. 46 Window Wiper and Washer Operating Switches.................................. 46 Window Replacement.............................................................. 46 Front Window, Replace....................................................... 47 Rear Window, Replace........................................................ 48 Top Window, Replace......................................................... 48 Door Window, Replace........................................................ 48 Heater and Air Conditioning Assembly............................................ 49 Heater Parts, Replace....................................................... 50 Heat Control Knob/Switches.................................................. 50 Heat Control Knob/Cable..................................................... 51 Adjust.................................................................. 51 Air Control Knob/Cable...................................................... 52 Adjust.................................................................. 52 Air Filter, Replace......................................................... 52 Air Conditioning Condenser Fan(s)........................................... 52 Remove.................................................................. 52 Install................................................................. 52 Instruments, Switches, and Controls............................................. 53 Switches.................................................................... 53 Controls.................................................................... 53 Fuses and Relays................................................................ 54 Fuse Panel.................................................................. 54 Fuses....................................................................... 55 Relays...................................................................... 56 Label Replacement............................................................... 56 Electrical Schematics........................................................... 56 0600SRM1068-1541323(05-2004)-EN......................................................... 59 toc................................................................................. 59 Perkins Tier 2 Diesel Engines................................................... 59 Safety Precautions Maintenance and Repair....................................... 60 General......................................................................... 67 General Safety Rules........................................................ 67 Description..................................................................... 68 Engine Serial Number Codes.................................................. 70 Engine Data................................................................. 70 Engine Removal and Installation................................................. 71 Cylinder Head Assembly Repair................................................... 71 Valve Cover................................................................. 71 Remove.................................................................. 71 Install................................................................. 72 Rocker Arm Assembly......................................................... 72 Remove.................................................................. 72 Disassemble............................................................. 72 Inspect................................................................. 72 Assemble................................................................ 72 Install................................................................. 72 Valve Clearance Adjustments................................................. 73 Valve Springs............................................................... 74 Cylinder Head Assembly...................................................... 75 Remove.................................................................. 75 Install................................................................. 77 Valves and Valve Springs.................................................... 80 Remove.................................................................. 80 Inspect................................................................. 80 Install................................................................. 81 Valve Guides................................................................ 81 Inspect................................................................. 81 Remove.................................................................. 81 Install................................................................. 81 Cylinder Head and Valve Seats............................................... 82 Inspect................................................................. 82 Repair.................................................................. 83 New Valve Seats, Install................................................ 83 Piston and Connecting Rod Assemblies Repair..................................... 83 Rod Bearings................................................................ 84 Remove.................................................................. 84 Install................................................................. 84 Piston and Connecting Rod Assembly.......................................... 85 Service Note............................................................ 85 Remove.................................................................. 85 Install................................................................. 86 Piston Rings................................................................ 87 Remove.................................................................. 87 Inspect................................................................. 87 Install................................................................. 88 Piston and Connecting Rod................................................... 88 Disassemble............................................................. 88 Inspect................................................................. 88 How to Select Correct Replacements...................................... 89 Install................................................................. 90 Piston Cooling Jets......................................................... 90 Remove.................................................................. 90 Install................................................................. 91 Crankshaft Assembly Repair...................................................... 91 General..................................................................... 91 Crankshaft Pulley........................................................... 92 Remove.................................................................. 92 Inspect................................................................. 92 Install................................................................. 92 Rear Oil Seal............................................................... 93 Remove.................................................................. 93 Install................................................................. 93 Main Bearings............................................................... 94 Remove.................................................................. 94 Inspect................................................................. 95 Install................................................................. 95 Thrust Washers.............................................................. 95 Crankshaft Axial Movement, Check........................................ 95 Remove.................................................................. 96 Install................................................................. 96 Crankshaft.................................................................. 97 Remove.................................................................. 97 Inspect................................................................. 97 Install................................................................. 98 Flywheel.................................................................... 99 Remove.................................................................. 99 Ring Gear, Replace...................................................... 99 Install................................................................. 99 Flywheel Housing............................................................ 100 Remove.................................................................. 100 Install................................................................. 100 Timing Case and Timing Gears Repair............................................. 101 General..................................................................... 101 Timing Case Cover........................................................... 101 Remove.................................................................. 101 Install................................................................. 102 Front Oil Seal.............................................................. 102 Remove.................................................................. 102 Install................................................................. 102 Crankshaft Pulley Wear Sleeve............................................... 103 Install................................................................. 103 Idler Gear and Hub.......................................................... 103 Remove.................................................................. 103 Install................................................................. 104 Air Compressor Drive, Bendix................................................ 105 Disassemble............................................................. 105 Assemble................................................................ 105 Fuel Injection Pump Gear.................................................... 106 Remove.................................................................. 106 Install................................................................. 107 Camshaft Gear............................................................... 107 Remove.................................................................. 107 Install................................................................. 108 Crankshaft Gear............................................................. 108 Remove.................................................................. 108 Install................................................................. 109 Timing Case................................................................. 109 Remove.................................................................. 109 Install................................................................. 109 Camshaft and Tappets........................................................ 110 Remove.................................................................. 110 Install................................................................. 111 Cylinder Block Assembly Repair.................................................. 111 Description................................................................. 111 Cylinder Block.............................................................. 111 Disassemble............................................................. 111 Inspect................................................................. 112 Assemble................................................................ 112 Cylinder Liner.............................................................. 113 Inspect................................................................. 113 Cylinder Liner Condition, Check......................................... 113 Remove.................................................................. 114 Service Liner, Install.................................................. 115 Partially Finished Liner, Install....................................... 116 Engine Timing................................................................... 117 Description................................................................. 117 How to Set Number One Piston to TDC on Compression Stroke............... 118 How to Set Number One Piston to TDC on Compression Stroke (Alter........ 119 How to Set Number One Piston to 4° After TDC on Compression Stro........ 120 Valve Timing, Check..................................................... 121 Fuel Injection Pump Timing, Check....................................... 122 Turbocharger.................................................................... 122 General..................................................................... 122 Remove...................................................................... 122 Install..................................................................... 123 Impeller and Compressor Housing, Clean...................................... 123 Waste-Gate Valve Check...................................................... 124 Closed Circuit Breather System (CCB)........................................ 125 CCB Assembly, Remove.................................................... 125 Closed Circuit Drain Valve, Remove...................................... 125 CCB Assembly, Install................................................... 125 Closed Circuit Drain Valve, Install..................................... 125 Lubrication System Repair....................................................... 126 General..................................................................... 126 Oil Filter, Replace......................................................... 126 Oil Filter Head............................................................. 126 Remove.................................................................. 126 Install................................................................. 126 Oil Filter Head Bypass Valve................................................ 127 Remove and Install...................................................... 127 Oil Sump.................................................................... 127 Remove.................................................................. 127 Install................................................................. 127 Oil Pump.................................................................... 128 Remove.................................................................. 128 Inspect................................................................. 128 Install................................................................. 129 Relief Valve................................................................ 130 Remove.................................................................. 130 Disassemble............................................................. 130 Inspect................................................................. 130 Assemble................................................................ 130 Install................................................................. 130 Idler Gear Shaft, Replace................................................... 130 Remove.................................................................. 131 Remove (Alternative).................................................... 131 Install................................................................. 132 Install (Alternative)................................................... 132 Fuel System Repair.............................................................. 133 Description................................................................. 133 Fuel Injection Pump......................................................... 135 Remove.................................................................. 135 Install................................................................. 137 Fuel System Air Removal..................................................... 138 Fuel Filter, Replace........................................................ 140 Fuel Injectors.............................................................. 140 Remove.................................................................. 141 Inspect................................................................. 141 Install................................................................. 141 Fuel Lift Pump.............................................................. 142 Remove.................................................................. 142 Disassemble............................................................. 142 Assemble................................................................ 142 Install................................................................. 143 Test.................................................................... 143 Cooling System Repair........................................................... 144 General..................................................................... 144 Thermostat.................................................................. 144 Remove.................................................................. 144 Install................................................................. 145 Test.................................................................... 145 Coolant Pump................................................................ 145 Remove.................................................................. 145 Disassemble............................................................. 146 Assemble................................................................ 148 Install................................................................. 150 Fan and Fan Drive........................................................... 151 Remove.................................................................. 151 Install................................................................. 151 Oil Cooler.................................................................. 151 Remove.................................................................. 151 Disassemble and Assemble................................................ 152 Install................................................................. 152 Electrical Equipment Repair..................................................... 153 Drive Belts................................................................. 153 Alternator.................................................................. 153 Remove.................................................................. 153 Install................................................................. 153 Electronic Control Module (ECM)............................................. 154 Remove.................................................................. 154 Inspect................................................................. 154 Install................................................................. 154 Voltage Load and Protection Module (VLPM)................................... 155 Remove.................................................................. 155 Install................................................................. 155 Engine Speed and Timing Sensor.............................................. 155 Remove.................................................................. 155 Install................................................................. 156 Pressure Sensors (Engine Oil and Air Intake)................................ 156 Remove.................................................................. 156 Install................................................................. 157 Temperature Sensor.......................................................... 157 Remove.................................................................. 157 Install................................................................. 158 Starter Motor............................................................... 158 Remove.................................................................. 158 Install................................................................. 158 Cold Start Aid.............................................................. 158 Air Compressor.................................................................. 158 General..................................................................... 158 Repair...................................................................... 159 Remove.................................................................. 159 Install................................................................. 159 Rotary Exhauster Replacement.................................................... 160 Remove...................................................................... 160 Clean....................................................................... 160 Install..................................................................... 160 Engine Specifications........................................................... 161 Cylinder Head Assembly...................................................... 161 Piston and Connecting Rods.................................................. 164 Crankshaft Assembly......................................................... 165 Crankshaft Overhaul..................................................... 166 Timing Case and Drive Assembly.............................................. 168 Engine Block Assembly....................................................... 169 Turbocharger................................................................ 170 Lubrication System.......................................................... 171 Cooling System.............................................................. 173 Flywheel and Housing........................................................ 173 Electrical Equipment........................................................ 173 Torque Specifications........................................................... 174 Cylinder Head Assembly...................................................... 174 Piston and Connecting Rod Assemblies........................................ 174 Crankshaft Assembly......................................................... 174 Timing Case and Drive Assembly.............................................. 174 Turbocharger................................................................ 174 Lubrication System.......................................................... 174 Fuel System................................................................. 174 Cooling System.............................................................. 175 Flywheel.................................................................... 175 Auxiliary Equipment......................................................... 175 Special Torque Specifications................................................... 175 Flywheel and Housing........................................................ 175 Electrical Equipment........................................................ 175 Auxiliary Equipment......................................................... 175 Special Tools................................................................... 176 Troubleshooting................................................................. 181 Turbocharger Troubleshooting.................................................... 183 tables.............................................................................. 59 Table 1. Cylinder Head.......................................................... 161 Table 2. Valve Guides........................................................... 161 Table 3. Inlet Valves........................................................... 162 Table 4. Exhaust Valves......................................................... 162 Table 5. Valve Springs.......................................................... 163 Table 6. Tappets................................................................ 163 Table 7. Rocker Arm Shaft....................................................... 163 Table 8. Rocker Arms and Bushings............................................... 163 Table 9. Pistons................................................................ 164 Table 10. Piston Rings.......................................................... 164 Table 11. Piston Pins........................................................... 164 Table 12. Connecting Rods....................................................... 164 Table 13. Small End Bushings.................................................... 165 Table 14. Connecting Rod Bearings............................................... 165 Table 15. Piston Cooling Jets................................................... 165 Table 16. Crankshaft............................................................ 165 Table 17. Main Bearings......................................................... 166 Table 18. Crankshaft Thrust Washers............................................. 166 Table 19. Crankshaft Heat Treatment............................................. 166 Table 20. Crankshaft Overhaul Specifications.................................... 166 Table 21. Maximum Variation (Run-Out)........................................... 168 Table 22. Camshaft.............................................................. 168 Table 23. Camshaft Thrust Washer................................................ 168 Table 24. Camshaft Gear......................................................... 168 Table 25. Gear for Fuel Injection Pump.......................................... 168 Table 26. Crankshaft Gear....................................................... 169 Table 27. Idler Gear and Hub.................................................... 169 Table 28. Cylinder Block........................................................ 169 Table 29. Cylinder Liners....................................................... 169 Table 30. Cylinder Liner Specifications (Partially Finished).................... 170 Table 31. Oil Pump.............................................................. 171 Table 32. Idler Gear for Oil Pump............................................... 171 Table 33. Relief Valve.......................................................... 171 Table 34. Oil Filter............................................................ 171 Table 35. Bosch Fuel Injection Pump............................................. 171 Table 36. Fuel Injector Codes................................................... 172 Table 37. Fuel Pump............................................................. 173 Table 38. Fuel Filter........................................................... 173 Table 39. Coolant Pump.......................................................... 173 Table 40. Thermostat............................................................ 173 Table 41. Fan Drive Housing..................................................... 173 Table 42. Limits for Flywheel Run Out and Alignment (Total Indic................ 173 Table 43. Alternator............................................................ 173 Table 44. Starter Motor......................................................... 173 Table 45. Cold Start Aid........................................................ 173 Table 46. List of Possible Causes............................................... 181 Table 47. List of Possible Causes............................................... 183 0600SRM1072-1553764(06-2005)-EN......................................................... 187 toc................................................................................. 187 Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide................... 187 Safety Precautions Maintenance and Repair....................................... 188 Electronic Troubleshooting...................................................... 211 System Operation............................................................ 211 Electronic Controls......................................................... 211 Engine Governor............................................................. 212 Timing Considerations....................................................... 212 Fuel Injection.............................................................. 212 Diagnostic Codes............................................................ 212 Diagnostic Fault Codes...................................................... 212 Diagnostic Event Codes...................................................... 212 Programmable Parameters..................................................... 213 Passwords................................................................... 213 Electronic Service Tools.................................................... 213 Electronic Service Tool (EST)............................................... 213 Connecting the Electronic Service Tool and the Communication Ada........ 213 Support for the Electronic Service Tool................................. 214 Optional Service Tools.................................................. 214 Diagnostic Codes............................................................ 214 Diagnostic Fault Code Access Via Indicator Lamps............................ 218 Replacing the ECM........................................................... 219 Self Diagnostics............................................................ 220 Glossary........................................................................ 221 Sensors and Electrical Connectors............................................... 224 Engine Wiring Information....................................................... 227 Harness Wire Identification................................................. 230 Diagnostic Code Reader.......................................................... 230 General..................................................................... 230 Reference Documents......................................................... 230 Abbreviations............................................................... 230 Environmental Specification................................................. 230 Hardware.................................................................... 231 Connection Cable........................................................ 232 Software.................................................................... 232 Engine Communication.................................................... 232 User Controls............................................................... 232 Power Supply............................................................ 232 Display Screen.......................................................... 233 Operation Controls...................................................... 233 Audible Warning......................................................... 233 Operation Instructions...................................................... 233 How to Connect the Diagnostic Code Reader to the Engine................. 233 How to Turn ON the Diagnostic Code Reader............................... 233 How to use the Display Screen........................................... 233 How to Operate the Diagnostic Code Reader............................... 234 Main Menu........................................................... 234 Active Codes........................................................ 234 Inactive Codes...................................................... 235 How to Clear Codes.................................................. 235 Status Lamp......................................................... 235 Data List........................................................... 236 Diagnostics................................................................. 236 Programming Parameters.......................................................... 237 Passwords................................................................... 237 Factory Passwords........................................................... 237 Customer Passwords.......................................................... 238 Flash Programming........................................................... 238 Flash Programming a Personality Module...................................... 238 WinFlash Error Messages..................................................... 238 System Configuration Parameters................................................. 239 Full Load Setting........................................................... 239 Full Torque Setting......................................................... 239 Rating Interlock............................................................ 239 Engine Serial Number........................................................ 239 ECM Software Release Date................................................... 239 Troubleshooting Without a Diagnostic Code....................................... 240 Alternator Noise (Noisy Operation).......................................... 240 Probable Causes......................................................... 240 Recommended Actions..................................................... 240 Alternator Drive Belts.............................................. 240 Alternator Drive Pulley............................................. 240 Alternator Bearings................................................. 240 Alternator Will Not Charge (Charging Problem)............................... 240 Probable Causes......................................................... 240 Recommended Actions..................................................... 240 Alternator Drive Belts.............................................. 240 Charging Circuit.................................................... 240 Alternator or Regulator............................................. 240 Battery..................................................................... 240 Probable Causes......................................................... 240 Recommended Actions..................................................... 240 Faulty Battery...................................................... 240 Auxiliary Device.................................................... 240 Cannot Reach Top Engine RPM................................................. 241 Probable Causes......................................................... 241 Recommended Actions..................................................... 241 Diagnostic Codes.................................................... 241 Fuel Supply......................................................... 241 Air Intake and Exhaust System....................................... 241 Individual Malfunctioning Cylinders................................. 241 Valve Lash.......................................................... 241 Check for Low Compression........................................... 241 Check the Fuel Injection Nozzles.................................... 242 Check the Turbocharger.............................................. 242 ECM Parameters...................................................... 242 Check the Signal for the Throttle Position Sensor................... 242 Coolant in Engine Oil....................................................... 242 Probable Causes......................................................... 242 Recommended Actions..................................................... 242 Engine Oil Cooler Core.............................................. 242 Cylinder Head Gasket................................................ 242 Cylinder Head....................................................... 243 Cylinder Block...................................................... 243 Coolant Temperature Is Too High............................................. 243 Probable Causes......................................................... 243 Recommended Actions..................................................... 243 Radiator Fins....................................................... 243 Coolant Level....................................................... 243 Radiator Cap and/or Pressure Relief Valve........................... 243 Combustion Gases in the Cooling System.............................. 243 Water Temperature Regulator......................................... 243 Restriction in the Coolant System................................... 243 Coolant Temperature Gauge........................................... 243 Coolant Pump........................................................ 243 Excessive Load on the System........................................ 244 ECM Will Not Accept Factory Passwords....................................... 244 Probable Causes......................................................... 244 Recommended Actions..................................................... 244 ECM Will Not Communicate With Other Systems or Display Modules.............. 244 Probable Causes......................................................... 244 Recommended Actions..................................................... 244 Electronic Service Tool Will Not Communicate With ECM....................... 244 Probable Causes......................................................... 244 Recommended Actions..................................................... 244 Engine Cranks but Will Not Start............................................ 245 Probable Causes......................................................... 245 Recommended Actions..................................................... 245 Diagnostic Codes.................................................... 245 Visual Checks....................................................... 245 Crank Without Injection............................................. 245 Starting Motor Solenoid or Starting Circuit......................... 245 Valve Lash.......................................................... 245 Fuel Injection Nozzles.............................................. 246 Air Inlet Heater Starting Aid....................................... 246 Air Intake and Exhaust System....................................... 246 Low Compression..................................................... 246 Fuel Supply......................................................... 246 Engine Has Early Wear....................................................... 246 Probable Causes......................................................... 246 Recommended Actions..................................................... 246 Dirt in Engine Oil.................................................. 246 Leaks in Air Intake System.......................................... 246 Low Oil Pressure.................................................... 247 Engine Misfires, Runs Rough or Is Unstable.................................. 247 Probable Causes......................................................... 247 Recommended Actions..................................................... 247 Logged Codes........................................................ 247 Fuel Supply......................................................... 247 Air Intake and Exhaust System....................................... 247 Individual Malfunctioning Cylinders................................. 247 Valve Lash.......................................................... 247 Check for Low Compression........................................... 248 Check the Fuel Injection Nozzles.................................... 248 Check the Air Inlet Heater Starting Aid............................. 248 Check the Engine Speed/Timing Sensors............................... 248 Check the Signal for the Throttle Position Sensor................... 248 Check the Fuel Injection Pump....................................... 248 Engine Oil in Cooling System................................................ 248 Probable Causes......................................................... 248 Recommended Actions..................................................... 249 Engine Oil Cooler Core.............................................. 249 Cylinder Head Gasket................................................ 249 Cylinder Head....................................................... 249 Engine Speed Does Not Change................................................ 249 Probable Causes......................................................... 249 Recommended Repairs..................................................... 249 Diagnostic Codes.................................................... 249 Engine Stalls at Low RPM.................................................... 249 Probable Causes......................................................... 249 Recommended Actions..................................................... 249 Diagnostic Codes.................................................... 249 Fuel Injection Nozzles.............................................. 249 Fuel Supply......................................................... 250 Accessory Equipment................................................. 250 Power Mode Control.................................................. 250 Engine Vibration............................................................ 250 Probable Causes......................................................... 250 Recommended Actions..................................................... 250 Engine Supports..................................................... 250 Malfunctioning Individual Cylinder.................................. 250 Valve Lash.......................................................... 250 Check for Low Compression (cylinder pressure)....................... 250 Check the Fuel Injection Nozzles.................................... 251 Turbocharger........................................................ 251 Engine Will Not Crank....................................................... 251 Probable Causes......................................................... 251 Recommended Repairs..................................................... 251 Machine Security System............................................. 251 Battery Cables and/or Batteries..................................... 251 Starting Motor Solenoid or Starting Circuit......................... 251 Starting Motor and/or Flywheel Ring Gear............................ 251 Electrical Power Supply............................................. 252 Internal Engine Problem............................................. 252 Excessive Black Smoke....................................................... 252 Probable Causes......................................................... 252 Recommended Actions..................................................... 252 Air Intake System or Exhaust System................................. 252 Individual Malfunctioning Cylinder.................................. 252 Valve Lash.......................................................... 252 Low Compression (cylinder pressure)................................. 252 Check the Fuel Injection Nozzles.................................... 252 Check the Turbocharger.............................................. 253 Broken 5-Volt Supply Wire........................................... 253 Verifying the ECM Software.......................................... 253 Excessive Engine Oil Consumption............................................ 253 Probable Causes......................................................... 253 Recommended Actions..................................................... 253 Oil Level........................................................... 253 Engine Crankcase Breather........................................... 253 Air Intake and Exhaust System....................................... 253 Turbocharger........................................................ 253 Low Compression (cylinder pressure)................................. 254 Excessive Valve Lash........................................................ 254 Probable Causes......................................................... 254 Recommended Actions..................................................... 254 Lubrication......................................................... 254 Valve Lash.......................................................... 254 Valve Train Components.............................................. 254 Excessive White Smoke....................................................... 254 Probable Causes......................................................... 254 Recommended Actions..................................................... 255 Fuel Supply......................................................... 255 Individual Malfunctioning Cylinder.................................. 255 Valve Lash.......................................................... 255 Low Compression (cylinder pressure)................................. 255 Air Inlet Heater Starting Aid....................................... 255 Fuel Injection Nozzles.............................................. 255 Coolant Temperature Sensor Circuit.................................. 255 Engine Pressure Sensors............................................. 255 Intake Air Temperature Is Too High.......................................... 256 Probable Causes......................................................... 256 Recommended Repairs..................................................... 256 High Ambient Air Temperature........................................ 256 Coolant Temperature................................................. 256 Check for High Intake Air Restriction and/or High Altitude.......... 256 Intake Air Restriction.............................................. 256 High Altitude....................................................... 256 Check the Intake Manifold Air Temperature Sensor and/or the Circ.... 256 Check for Sufficient Coolant Flow Through the Aftercooler (if eq.... 256 Check for Sufficient Flow of Air Through the Aftercooler (if equ.... 256 Intermittent Engine Shutdown................................................ 256 Probable Causes......................................................... 256 Recommended Actions..................................................... 256 Logged Codes........................................................ 256 Fuel Supply......................................................... 257 Engine Protection Device............................................ 257 Electrical Connectors............................................... 257 Intermittent Low Power or Power Cutout...................................... 257 Probable Causes......................................................... 257 Recommended Repairs..................................................... 257 Diagnostic Codes.................................................... 258 Electrical Connectors............................................... 258 Fuel Supply......................................................... 258 Check the Intake Manifold Pressure.................................. 258 Air Intake and Exhaust System....................................... 258 Individual Malfunctioning Cylinders................................. 258 Valve Lash.......................................................... 259 Check for Low Compression........................................... 259 Check the Fuel Injection Nozzles.................................... 259 Check the Turbocharger.............................................. 259 ECM Parameters...................................................... 259 Electronic System Problem........................................... 259 Low Engine Oil Pressure..................................................... 260 Probable Causes......................................................... 260 Recommended Actions..................................................... 260 Engine Oil Level.................................................... 260 Engine Oil Pressure Gauge........................................... 260 Engine Oil Bypass Valves............................................ 260 Piston Cooling Jets ................................................ 260 Engine Oil Suction Tube............................................. 260 Engine Oil Pump..................................................... 260 Bearing Clearance................................................... 260 Low Power/Poor or No Response to Throttle................................... 260 Probable Causes......................................................... 260 Recommended Actions..................................................... 261 Diagnostic Codes.................................................... 261 Fuel Supply......................................................... 261 Air Intake and Exhaust System....................................... 261 Individual Malfunctioning Cylinders................................. 261 Valve Lash.......................................................... 261 Check for Low Compression........................................... 261 Check the Fuel Injection Nozzles.................................... 262 Check the Turbocharger.............................................. 262 ECM Parameters...................................................... 262 Electronic System Problem........................................... 262 Mechanical Noise (Knock) in Engine.......................................... 262 Probable Causes......................................................... 262 Recommended Actions..................................................... 263 Accessory Equipment................................................. 263 Valve Train Components.............................................. 263 Connecting Rod and Main Bearings.................................... 263 Noise Coming from Cylinder.................................................. 263 Probable Causes......................................................... 263 Recommended Actions..................................................... 263 Fuel Quality........................................................ 263 Fuel Injection Nozzles.............................................. 263 Valve Lash.......................................................... 263 Poor Acceleration or Response............................................... 263 Probable Causes......................................................... 263 Recommended Repairs..................................................... 263 Diagnostic Codes.................................................... 263 Fuel Supply......................................................... 263 Individual Malfunctioning Cylinder.................................. 264 Valve Lash.......................................................... 264 Check for Low Compression........................................... 264 Check the Fuel Injection Nozzles.................................... 264 Check the Turbocharger.............................................. 264 ECM Parameters...................................................... 264 Check Intake Manifold Pressure...................................... 265 Troubleshooting With a Diagnostic Code.......................................... 265 CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal............ 265 Conditions Which Generate This Code..................................... 265 System Response......................................................... 265 Possible Performance Effect............................................. 265 Troubleshooting......................................................... 265 Results................................................................. 265 CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent............ 265 Conditions Which Generate This Code..................................... 265 System Response......................................................... 265 Possible Performance Effect............................................. 265 Troubleshooting......................................................... 265 Test Step 1............................................................. 265 Results................................................................. 265 CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted............ 265 Conditions Which Generate This Code..................................... 265 System Response......................................................... 265 Possible Performance Effect............................................. 266 CID 0091 FMI 04 Throttle Position Sensor Shorted Low........................ 266 Conditions Which Generate This Code..................................... 266 System Response......................................................... 266 Possible Performance Effect............................................. 266 Troubleshooting......................................................... 266 Results................................................................. 266 CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal.................... 266 Conditions Which Generate This Code..................................... 266 System Response......................................................... 266 Troubleshooting......................................................... 266 Results................................................................. 266 CID 0091 FMI 12 Throttle Position Sensor Out of Calibration................. 266 Conditions Which Generate This Code..................................... 266 Possible Performance Effect............................................. 266 Troubleshooting......................................................... 266 Results................................................................. 266 CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short............ 266 Conditions Which Generate This Code..................................... 266 System Response......................................................... 267 Troubleshooting......................................................... 267 Results................................................................. 267 CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...................... 267 Conditions Which Generate This Code..................................... 267 System Response......................................................... 267 Troubleshooting......................................................... 267 Results................................................................. 267 CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci............ 267 Conditions Which Generate This Code..................................... 267 System Response......................................................... 267 Possible Performance Effect............................................. 267 Results................................................................. 267 CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or............ 267 Conditions Which Generate This Code..................................... 267 System Response......................................................... 267 Possible Performance Effect............................................. 268 Results................................................................. 268 CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low................. 268 Conditions Which Generate This Code..................................... 268 System Response......................................................... 268 Possible Performance Effect............................................. 268 Results................................................................. 268 CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope............ 268 Conditions Which Generate This Code..................................... 268 System Response......................................................... 268 Results................................................................. 268 CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ............ 268 Conditions Which Generate This Code..................................... 268 System Response......................................................... 268 Possible Performance Effect............................................. 269 Troubleshooting......................................................... 269 Results................................................................. 269 CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low.............. 269 Conditions Which Generate This Code..................................... 269 System Response......................................................... 269 Possible Performance Effect............................................. 269 Troubleshooting......................................................... 269 Results................................................................. 269 CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o............ 269 Conditions Which Generate This Code..................................... 269 System Response......................................................... 269 Possible Performance Effect............................................. 269 Troubleshooting......................................................... 269 Results................................................................. 269 CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low............... 269 Conditions Which Generate This Code..................................... 269 System Response......................................................... 269 Possible Performance Effect............................................. 269 Troubleshooting......................................................... 270 Results................................................................. 270 CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent............... 270 Conditions Which Generate This Code..................................... 270 System Response......................................................... 270 Possible Performance Effect............................................. 270 Troubleshooting......................................................... 270 Results................................................................. 270 CID 0247 FMI 09 J1939 Datalink, Abnormal Update............................. 270 Conditions Which Generate This Code..................................... 270 System Response......................................................... 270 Results................................................................. 270 CID 0253 FMI 02 Incorrect ECM Software...................................... 270 Conditions Which Generate This Code..................................... 270 System Response......................................................... 270 Possible Performance Effect............................................. 270 Troubleshooting......................................................... 271 Expected Result......................................................... 271 Results................................................................. 271 CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal............ 271 Conditions Which Generate This Code..................................... 271 System Response......................................................... 271 Possible Performance Effect............................................. 271 Troubleshooting......................................................... 271 Results................................................................. 271 CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal............ 271 Conditions Which Generate This Code..................................... 271 System Response......................................................... 271 Possible Performance Effect............................................. 271 Troubleshooting......................................................... 271 Results................................................................. 271 CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs....................... 271 Conditions Which Generate This Code..................................... 271 System Response......................................................... 271 Possible Performance Effect............................................. 271 CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig............ 272 Conditions Which Generate This Code..................................... 272 System Response......................................................... 272 Possible Performance Effect............................................. 272 Results................................................................. 272 CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...................... 272 Conditions Which Generate This Code..................................... 272 System Response......................................................... 272 Possible Performance Effect............................................. 272 Results................................................................. 272 CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa............ 272 Conditions Which Generate This Code..................................... 272 System Response......................................................... 272 Possible Performance Effect............................................. 272 Test Step 1............................................................. 272 Results................................................................. 272 Test Step 2............................................................. 272 Results................................................................. 273 CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm............ 273 Conditions Which Generate This Code..................................... 273 System Response......................................................... 273 Possible Performance Effect............................................. 273 Results................................................................. 273 CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S............ 273 Conditions Which Generate This Code..................................... 273 System Response......................................................... 273 Possible Performance Effect............................................. 273 Troubleshooting......................................................... 273 Results................................................................. 273 CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low.................. 273 Conditions Which Generate This Code..................................... 273 System Response......................................................... 273 Possible Performance Effect............................................. 273 Troubleshooting......................................................... 273 Results................................................................. 273 CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal.............. 274 Conditions Which Generate This Code..................................... 274 System Response......................................................... 274 Possible Performance Effect............................................. 274 Results................................................................. 274 CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio............ 274 Conditions Which Generate This Code..................................... 274 System Response......................................................... 274 Possible Performance Effect............................................. 274 Results................................................................. 274 CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off.................. 274 Conditions Which Generate This Code..................................... 274 System Response......................................................... 274 Possible Performance Effect............................................. 274 Results................................................................. 274 CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ............ 274 Conditions Which Generate This Code..................................... 274 System Response......................................................... 274 Possible Performance Effect............................................. 275 Test Step 1............................................................. 275 Results................................................................. 275 Test Step 2............................................................. 275 Results................................................................. 275 CID 1684 FMI 02 Fuel Injection Pump, Software Failure....................... 275 Conditions Which Generate This Code..................................... 275 System Response......................................................... 275 Possible Performance Effect............................................. 275 Troubleshooting......................................................... 275 Results................................................................. 275 CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault.......................... 275 Conditions Which Generate This Code..................................... 275 System Response......................................................... 275 Possible Performance Effect............................................. 275 Troubleshooting......................................................... 275 Results................................................................. 275 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault................... 276 Conditions Which Generate This Code..................................... 276 System Response......................................................... 276 Possible Performance Effect............................................. 276 Troubleshooting......................................................... 276 Results................................................................. 276 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width.................... 276 Conditions Which Generate This Code..................................... 276 Troubleshooting......................................................... 276 Results................................................................. 276 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault....................... 276 Conditions Which Generate This Code..................................... 276 System Response......................................................... 276 Possible Performance Effect............................................. 276 Troubleshooting......................................................... 276 Results................................................................. 276 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault............. 276 Conditions Which Generate This Code..................................... 276 System Response......................................................... 277 Possible Performance Effect............................................. 277 Troubleshooting......................................................... 277 Test Step 1............................................................. 277 Results................................................................. 277 Test Step 2............................................................. 277 Results................................................................. 277 Test Step 3............................................................. 277 Results................................................................. 277 Test Step 4............................................................. 277 Expected Result......................................................... 277 Results................................................................. 277 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault.............................. 277 Conditions Which Generate This Code..................................... 277 System Response......................................................... 277 Possible Performance Effect............................................. 277 Troubleshooting......................................................... 277 Expected Result......................................................... 278 Results................................................................. 278 CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error.............. 278 Conditions Which Generate This Code..................................... 278 System Response......................................................... 278 Troubleshooting......................................................... 278 Test Step 1............................................................. 278 Results................................................................. 278 Test Step 2............................................................. 278 Results................................................................. 278 Test Step 3............................................................. 278 Results................................................................. 278 CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault.................. 278 Conditions Which Generate This Code..................................... 278 System Response......................................................... 278 Possible Performance Effect............................................. 279 Troubleshooting......................................................... 279 Test Step 1............................................................. 279 Results................................................................. 279 Test Step 2............................................................. 279 Results................................................................. 279 CID 1684 FMI 14 Fuel Injection Pump, No Communications...................... 279 Conditions Which Generate This Code..................................... 279 System Response......................................................... 279 Troubleshooting......................................................... 279 Test Step 1............................................................. 279 Results................................................................. 279 Test Step 2............................................................. 279 Results................................................................. 279 Test Step 3............................................................. 279 Results................................................................. 279 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali............ 279 Conditions Which Generate This Code..................................... 279 System Response......................................................... 279 Possible Performance Effect............................................. 280 Troubleshooting......................................................... 280 Results................................................................. 280 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali............ 280 Conditions Which Generate This Code..................................... 280 System Response......................................................... 280 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S............ 280 Conditions Which Generate This Code..................................... 280 System Response......................................................... 280 Troubleshooting With an Event Code.............................................. 280 Event Codes................................................................. 280 Programmable Engine Parameters.............................................. 280 E015 High Engine Coolant Temperature Derate................................. 280 Conditions Which Generate This Code..................................... 280 System Response......................................................... 280 Possible Performance Effect............................................. 280 Troubleshooting......................................................... 280 Results................................................................. 280 E016 High Engine Coolant Temperature Shutdown............................... 281 Conditions Which Generate This Code..................................... 281 System Response......................................................... 281 Possible Performance Effect............................................. 281 Troubleshooting......................................................... 281 Results................................................................. 281 E017 High Engine Coolant Temperature Warning................................ 281 Conditions Which Generate This Code..................................... 281 System Response......................................................... 281 Possible Performance Effect............................................. 281 Troubleshooting......................................................... 281 Results................................................................. 281 E025 High Intake Air Temperature Derate..................................... 281 Conditions Which Generate This Code..................................... 281 System Response......................................................... 281 Possible Performance Effect............................................. 281 Troubleshooting......................................................... 281 Results................................................................. 281 E027 High Intake Air Temperature Warning.................................... 281 Conditions Which Generate This Code:.................................... 281 System Response......................................................... 281 Possible Performance Effect............................................. 282 Troubleshooting......................................................... 282 Results................................................................. 282 E040 Low Engine Oil Pressure Shutdown....................................... 282 Conditions Which Generate This Code..................................... 282 System Response......................................................... 282 Possible Performance Effect............................................. 282 Troubleshooting......................................................... 282 Results................................................................. 282 E054 High Fuel Temperature Derate........................................... 282 Conditions Which Generate This Code..................................... 282 System Response......................................................... 282 Troubleshooting......................................................... 282 Test Step 1 - Check for Diagnostic Codes................................ 282 Expected Result......................................................... 282 Results................................................................. 282 Test Step 2 - Perform a Check of the Fuel System........................ 282 Expected Result......................................................... 283 Results................................................................. 283 E056 High Fuel Temperature Warning.......................................... 283 Conditions Which Generate This Code..................................... 283 System Response......................................................... 283 Troubleshooting......................................................... 283 Test Step 1 - Check for Diagnostic Codes................................ 283 Expected Result......................................................... 283 Results................................................................. 283 Test Step 2 - Perform a Check of the Fuel System........................ 283 Expected Result......................................................... 283 Results................................................................. 283 E100 Low Engine Oil Pressure Warning........................................ 283 Conditions Which Generate This Code..................................... 283 System Response......................................................... 283 Possible Performance Effect............................................. 283 Troubleshooting......................................................... 284 Test Step 1 - Check for Active Diagnostic Codes......................... 284 Expected Result......................................................... 284 Results................................................................. 284 Test Step 2 - Perform a Check of the Engine Lubrication System.......... 284 Expected Result......................................................... 284 Results................................................................. 284 E190 Engine Overspeed Warning............................................... 284 Conditions Which Generate This Code..................................... 284 System Response......................................................... 284 Possible Performance Effect............................................. 284 Troubleshooting......................................................... 284 Engine Overspeed Warning................................................ 284 Expected Result......................................................... 284 Results................................................................. 284 E442 Engine Failed to Stop With a No-Fuel Command........................... 284 Conditions Which Generate This Code..................................... 284 System Response......................................................... 284 Possible Performance Effect............................................. 285 Troubleshooting......................................................... 285 Test Step 1............................................................. 285 Results................................................................. 285 Test Step 2............................................................. 285 Results................................................................. 285 E883 Engine Failed to Stop When Fuel Solenoid Disengaged.................... 285 Conditions Which Generate This Code..................................... 285 System Response......................................................... 285 Possible Performance Effect............................................. 285 Troubleshooting......................................................... 285 Test Step 1............................................................. 285 Results................................................................. 285 Test Step 2............................................................. 285 Results................................................................. 285 Test Step 3............................................................. 285 Results................................................................. 285 Diagnostic Function Tests....................................................... 286 5-Volt Engine Pressure Sensor Supply Circuit - Test......................... 286 System Operation Description............................................ 286 Background Information.................................................. 286 Test Step 1............................................................. 287 Inspect Electrical Connectors and Wiring............................ 287 Expected Result..................................................... 287 Results............................................................. 287 Test Step 2............................................................. 288 Check for Active Diagnostic Codes................................... 288 Expected Result..................................................... 288 Results............................................................. 288 Test Step 3............................................................. 288 Disconnect the ECM Engine Harness Connector From the ECM............ 288 Expected Result..................................................... 289 Results............................................................. 289 Test Step 4............................................................. 289 Disconnect the +5V Sensors While Active Diagnostic Codes are Bei.... 289 Expected Result..................................................... 289 Results............................................................. 289 Test Step 5............................................................. 290 Check the Engine Harness............................................ 290 Expected Result..................................................... 290 Results............................................................. 290 Air Inlet Heater Circuit - Test............................................. 290 System Operation Description............................................ 290 Test Step 1............................................................. 290 Inspect Electrical Connectors and Wiring............................ 290 Expected Result..................................................... 291 Results............................................................. 291 Test Step 2............................................................. 291 Check the Supply to the Power Relay for the Air Inlet Heater Sta.... 291 Expected Result..................................................... 291 Results............................................................. 291 Test Step 3............................................................. 292 Check the Output From the Power Relay for the Air Inlet Heater S.... 292 Expected Result..................................................... 292 Results............................................................. 292 Test Step 4............................................................. 292 Ground the Input to the Power Relay at the MIC...................... 292 Expected Result..................................................... 292 Results............................................................. 292 Test Step 5............................................................. 292 Ground the Input to the Power Relay at the ECM Connector............ 292 Expected Result..................................................... 292 Results............................................................. 292 Test Step 6............................................................. 292 Override the Air Inlet Heater Starting Aid to Test the ECM.......... 292 Results............................................................. 293 Checking Idle Validation Switching Point (Throttle Sensor) With ............ 293 Expected Result......................................................... 293 Analog Throttle Position Sensor Circuit - Test.............................. 293 System Operation Description............................................ 293 Checking the Throttle Sensor With Unconnected Output C.................. 294 Expected Result..................................................... 294 Test Step 1............................................................. 294 Check for Connector Damage.......................................... 294 Expected Result..................................................... 294 Results............................................................. 294 Test Step 2............................................................. 295 Check for Active Diagnostic Codes................................... 295 Expected Result..................................................... 295 Results............................................................. 295 Test Step 3............................................................. 295 Check the Throttle Position With the Electronic Service Tool........ 295 Expected Result..................................................... 295 Results............................................................. 295 Test Step 4............................................................. 295 Check the Voltage at the Throttle Position Sensor................... 295 Expected Result..................................................... 295 Results............................................................. 295 Test Step 5............................................................. 296 Disconnect the Throttle Position Sensor and Check for Active Dia.... 296 Expected Result..................................................... 296 Results............................................................. 296 Test Step 6............................................................. 296 Check the Throttle Selection Status With the Electronic Service .... 296 Expected Result..................................................... 296 Results............................................................. 297 Test Step 7............................................................. 297 Disconnect the Supply Terminals of the Throttle Position Sensor .... 297 Expected Result..................................................... 297 Results............................................................. 297 Test Step 8............................................................. 297 Check the Position of Throttle Position Sensor...................... 297 Expected Result..................................................... 298 Results............................................................. 298 Test Step 9............................................................. 298 Check the Throttle Position Sensor at the ECM....................... 298 Expected Result..................................................... 298 Results............................................................. 298 CAN Data Link Circuit - Test................................................ 298 System Operation Description............................................ 298 Test Step 1............................................................. 299 Inspect Electrical Connectors and Wiring............................ 299 Expected Result..................................................... 299 Results............................................................. 299 Test Step 2............................................................. 299 Check the CAN Data Link Between the ECM and P40 Fuel Injection P.... 299 Expected Result..................................................... 299 Results............................................................. 299 Test Step 3............................................................. 299 Check the CAN Data Link Between the ECM and P40 Fuel Injection P.... 299 Expected Result..................................................... 300 Results............................................................. 300 Test Step 4............................................................. 300 Verify the Supply Voltage at the Fuel Injection Pump................ 300 Expected Result..................................................... 300 Results............................................................. 300 Data Link Circuit - Test.................................................... 300 System Operation Description............................................ 300 Background Information.................................................. 301 Communication........................................................... 301 Test Step 1............................................................. 301 Inspect Electrical Connectors and Wiring............................ 301 Expected Result..................................................... 301 Results............................................................. 301 Test Step 2............................................................. 301 Determine the Type of Problem With the Data Link.................... 301 Expected Result..................................................... 301 Results............................................................. 302 Test Step 3............................................................. 302 Check the Battery Voltage at the ECM................................ 302 Expected Result..................................................... 302 Results............................................................. 302 Test Step 4............................................................. 302 Check the Battery Voltage That is Coming to the Data Link Connec.... 302 Expected Result..................................................... 303 Results............................................................. 303 Test Step 5............................................................. 303 Connect the Electronic Service Tool Directly to the ECM............. 303 Expected Result..................................................... 303 Results............................................................. 303 Test Step 6............................................................. 303 Change Electronic Service Tool Components........................... 303 Expected Result..................................................... 304 Results............................................................. 304 Test Step 7............................................................. 304 Connect an Electronic Service Tool and the ECM to Another Batter.... 304 Expected Result..................................................... 304 Results............................................................. 304 Electrical Connectors - Inspect............................................. 304 System Operation Description............................................ 305 Background Information.................................................. 305 Test Step 1............................................................. 309 Check the Locking of the DT Connector (Deutsch) and the Lock Rin.... 309 Expected Result..................................................... 309 Results............................................................. 309 Test Step 2............................................................. 309 Check the Socket Head Screw on the Connector for the Electronic .... 309 Expected Result..................................................... 309 Results............................................................. 309 Test Step 3............................................................. 309 Perform a Pull Test on Each Wire Terminal Connection................ 309 Expected Result..................................................... 309 Results............................................................. 309 Test Step 4............................................................. 310 Monitor the Electronic Service Tool While the Wiring and the Con.... 310 Expected Result..................................................... 310 Results............................................................. 310 Test Step 5............................................................. 310 Check Wires for Nicks and/or Abrasions in the Insulation............ 310 Expected Result..................................................... 310 Results............................................................. 310 Test Step 6............................................................. 310 Check Connectors for Moisture or Corrosion.......................... 310 Expected Result..................................................... 311 Results............................................................. 311 Test Step 7............................................................. 311 Inspect the Connector Terminals..................................... 311 Expected Result..................................................... 311 Results............................................................. 311 Test Step 8............................................................. 312 Check Individual Pin Retention Into the Socket...................... 312 Expected Result..................................................... 312 Results............................................................. 312 Electrical Power Supply Circuit - Test...................................... 312 System Operation Description............................................ 312 Background Information.................................................. 312 Test Step 1............................................................. 314 Check the Batteries................................................. 314 Expected Result..................................................... 314 Results............................................................. 314 Test Step 2............................................................. 314 Inspect Electrical Connectors and Wiring............................ 314 Expected Result..................................................... 314 Results............................................................. 314 Test Step 3............................................................. 314 Check the Battery Voltage at the ECM................................ 314 Expected Result..................................................... 315 Results............................................................. 315 Test Step 4............................................................. 315 Use the Bypass Harness for the Electronic Service Tool to Bypass.... 315 Expected Result..................................................... 316 Results............................................................. 316 Engine Pressure Sensor Open or Short Circuit - Test......................... 316 System Operation Description............................................ 316 Background Information.................................................. 316 Test Step 1............................................................. 317 Check for Active +5V Sensor Supply Diagnostic Codes................. 317 Expected Result..................................................... 317 Results............................................................. 317 Test Step 2............................................................. 317 Verify All Active Diagnostic Codes.................................. 317 Expected Result..................................................... 317 Results............................................................. 317 Test Step 3............................................................. 317 Inspect Electrical Connectors And Wiring............................ 317 Expected Result..................................................... 318 Results............................................................. 318 Test Step 4............................................................. 318 Verify That the Diagnostic Code is Still Active..................... 318 Expected Result..................................................... 318 Results............................................................. 318 Test Step 5............................................................. 318 Disconnect the Sensor to Create an Open Circuit..................... 318 Expected Result..................................................... 319 Results............................................................. 319 Test Step 6............................................................. 319 Measure the Sensor Supply Voltage................................... 319 Expected Result..................................................... 319 Results............................................................. 319 Test Step 7............................................................. 320 Determine if the Short Circuit is in the Connector or in the Sen.... 320 Expected Result..................................................... 320 Results............................................................. 320 Test Step 8............................................................. 320 Create a Short Circuit Between the Signal and the Common Termina.... 320 Expected Result..................................................... 320 Results............................................................. 320 Test Step 9............................................................. 320 Check the Operation of the ECM by Creating Open and Short Circui.... 320 Expected Result..................................................... 321 Results............................................................. 321 Test Step 10............................................................ 321 Bypass the Harness Wiring Between the ECM and the Sensor Connect.... 321 Expected Result..................................................... 321 Results............................................................. 321 Engine Speed/Timing Sensor Circuit - Test................................... 322 System Operation Description............................................ 322 Test Step 1............................................................. 322 Inspect the Electrical Connectors and Cables........................ 322 Expected Result..................................................... 322 Results............................................................. 322 Test Step 2............................................................. 323 Check the Installation of the Engine Speed/Timing Sensors........... 323 Expected Result..................................................... 323 Results............................................................. 323 Test Step 3............................................................. 323 Measure the Sensor Resistance Through the Wiring Harness............ 323 Expected Result..................................................... 323 Results............................................................. 323 Test Step 4............................................................. 323 Measure the Resistance of the Sensor................................ 323 Expected Result..................................................... 324 Results............................................................. 324 Test Step 5............................................................. 324 Measure the Resistance of the Cables Between the Fuel Injection .... 324 Expected Result..................................................... 325 Results............................................................. 325 Test Step 6............................................................. 325 Check the Continuity of the Cables From the ECM to the Fuel Inje.... 325 Expected Result..................................................... 325 Results............................................................. 325 Engine Temperature Sensor Open or Short Circuit - Test...................... 325 System Operation Description............................................ 325 Background Information.................................................. 325 Test Step 1............................................................. 326 Verify All Active Diagnostic Codes.................................. 326 Expected Result..................................................... 326 Results............................................................. 326 Test Step 2............................................................. 327 Inspect Electrical Connectors and Wiring............................ 327 Expected Result..................................................... 327 Results............................................................. 327 Test Step 3............................................................. 327 Verify That the Diagnostic Code is Still Active..................... 327 Expected Result..................................................... 327 Results............................................................. 327 Test Step 4............................................................. 327 Disconnect the Sensor to Create an Open Circuit..................... 327 Expected Result..................................................... 328 Results............................................................. 328 Test Step 5............................................................. 328 Create a Short Circuit Between the Signal and the Common Termina.... 328 Expected Result..................................................... 328 Results............................................................. 328 Test Step 6............................................................. 328 Check the Operation of the ECM by Creating an Open and a Short C.... 328 Expected Result..................................................... 329 Results............................................................. 329 Test Step 7............................................................. 329 Bypass the Harness Wiring Between the ECM and the Sensor Connect.... 329 Expected Result..................................................... 329 Results............................................................. 329 Fuel Injection Pump Circuit - Test.......................................... 330 System Operation Description............................................ 330 Background Information.................................................. 330 Test Step 1............................................................. 330 Check the Batteries................................................. 330 Expected Result..................................................... 330 Results............................................................. 330 Test Step 2............................................................. 330 Inspect the Electrical Connectors and Wiring........................ 330 Expected Result..................................................... 331 Results............................................................. 331 Test Step 3............................................................. 331 Check the Supply Voltage at the Machine Interface Connector......... 331 Expected Result..................................................... 332 Results............................................................. 332 Test Step 4............................................................. 332 Check the Supply Voltage at the Fuel Injection Pump................. 332 Expected Result..................................................... 332 Results............................................................. 332 Test Step 5............................................................. 332 Check the Supply to the Power Relay for the Fuel Injection Pump..... 332 Expected Result..................................................... 332 Results............................................................. 332 Test Step 6............................................................. 333 Check the Output of the Power Relay for the Fuel Injection Pump..... 333 Expected Result..................................................... 333 Results............................................................. 333 Test Step 7............................................................. 333 Check the Voltage at the Relay Coil for the Fuel Injection Pump..... 333 Expected Result..................................................... 333 Results............................................................. 333 Test Step 8............................................................. 333 Check the Output of the ECM Fuel Pump Power Control at the Machi.... 333 Expected Result..................................................... 333 Results............................................................. 334 Test Step 9............................................................. 334 Check the Output of the Fuel Injection Pump Power Control at the.... 334 Expected Result..................................................... 334 Results............................................................. 334 Test Step 10............................................................ 334 Measure the Voltage at the Pump Power Supply........................ 334 Expected Result..................................................... 334 Results............................................................. 334 Test Step 11............................................................ 335 Check the Voltage Load Protection Module (VLPM)..................... 335 Expected Result..................................................... 335 Results............................................................. 335 Indicator Lamp Circuit - Test............................................... 335 System Operation Description............................................ 335 Test Step 1............................................................. 336 Inspect Electrical Connectors and Wiring............................ 336 Results............................................................. 337 Test Step 2............................................................. 337 Inspect the Lamp, the Fuse, and the Power Supply.................... 337 Expected Result..................................................... 337 Results............................................................. 337 Test Step 3............................................................. 337 Inspect the Input to the Lamp at the ECM connector.................. 337 Expected Result..................................................... 337 Results............................................................. 337 Test Step 4............................................................. 337 Test the Individual Lamp Circuits................................... 337 Expected Result..................................................... 337 Results............................................................. 337 Test Step 5............................................................. 338 Check the Voltage at the ECM........................................ 338 Expected Result..................................................... 338 Results............................................................. 338 Idle Validation Circuit - Test.............................................. 338 System Operation Description............................................ 338 Test Step 1............................................................. 338 Expected Result..................................................... 338 Results............................................................. 338 tables.............................................................................. 187 Table 1. Electronic Service Tool................................................ 213 Table 2. Optional Service Tools................................................. 214 Table 3. CID FMI Codes and J Code FMI Codes..................................... 215 Table 4. Event Codes and CID FMI Codes.......................................... 217 Table 5. CID Numbers and Flash Codes............................................ 218 Table 6. Engine Connectors...................................................... 226 Table 7. Color Codes for the Harness Wire....................................... 230 Table 8. Pin Connections for Perkins Deutsch Socket Connector................... 232 Table 9. Suspect Parameter Numbers.............................................. 236 Table 10. Failure Mode Indicators (FMI) Codes................................... 237 Table 11. Engine Oil Pressure Trip and Reset Points............................. 282 0600SRM1101-1564053(03-2004)-EN......................................................... 343 toc................................................................................. 343 Cummins Diesel Engine Fault Code Guide.......................................... 343 Safety Precautions Maintenance and Repair....................................... 344 General......................................................................... 347 Electronic Throttle Calibration................................................. 347 Electronic Throttle Calibration Procedure................................... 347 Fault Codes..................................................................... 347 Access...................................................................... 347 Exit........................................................................ 347 Clear....................................................................... 347 tables.............................................................................. 343 Table 1. Fault Code Descriptions................................................ 348 0600SRM1158-1566673(06-2005)-EN......................................................... 355 toc................................................................................. 355 Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide................... 355 Safety Precautions Maintenance and Repair....................................... 356 Electronic Troubleshooting...................................................... 379 System Operation............................................................ 379 Electronic Controls......................................................... 379 Engine Governor............................................................. 380 Timing Considerations....................................................... 380 Fuel Injection.............................................................. 380 Diagnostic Codes............................................................ 380 Diagnostic Fault Codes...................................................... 380 Diagnostic Event Codes...................................................... 380 Programmable Parameters..................................................... 381 Passwords................................................................... 381 Electronic Service Tools.................................................... 381 Electronic Service Tool (EST)............................................... 381 Connecting the Electronic Service Tool and the Communication Ada........ 381 Support for the Electronic Service Tool................................. 382 Optional Service Tools.................................................. 382 Diagnostic Codes............................................................ 382 Engine Display Warning Codes................................................ 386 Access.................................................................. 386 Exit.................................................................... 386 Clear................................................................... 386 Replacing the ECM........................................................... 388 Self Diagnostics............................................................ 389 Glossary........................................................................ 390 Sensors and Electrical Connectors............................................... 393 Engine Wiring Information....................................................... 396 Harness Wire Identification................................................. 400 Diagnostic Code Reader.......................................................... 400 General..................................................................... 400 Reference Documents......................................................... 400 Abbreviations............................................................... 400 Environmental Specification................................................. 400 Hardware.................................................................... 401 Connection Cable........................................................ 402 Software.................................................................... 402 Engine Communication.................................................... 402 User Controls............................................................... 402 Power Supply............................................................ 402 Display Screen.......................................................... 402 Operation Controls...................................................... 402 Audible Warning......................................................... 403 Operation Instructions...................................................... 403 How to Connect the Diagnostic Code Reader to the Engine................. 403 How to Turn ON the Diagnostic Code Reader............................... 403 How to use the Display Screen........................................... 403 How to Operate the Diagnostic Code Reader............................... 404 Main Menu........................................................... 404 Active Codes........................................................ 404 Inactive Codes...................................................... 404 How to Clear Codes.................................................. 405 Status Lamp......................................................... 405 Data List........................................................... 406 Diagnostics................................................................. 406 Programming Parameters.......................................................... 407 Passwords................................................................... 407 Factory Passwords........................................................... 407 Customer Passwords.......................................................... 408 Flash Programming........................................................... 408 Flash Programming a Personality Module...................................... 408 WinFlash Error Messages..................................................... 408 System Configuration Parameters................................................. 409 Full Load Setting........................................................... 409 Full Torque Setting......................................................... 409 Rating Interlock............................................................ 409 Engine Serial Number........................................................ 409 ECM Software Release Date................................................... 409 Troubleshooting Without A Diagnostic Code....................................... 410 Alternator Noise (Noisy Operation).......................................... 410 Probable Causes......................................................... 410 Recommended Actions..................................................... 410 Alternator Drive Belts.............................................. 410 Alternator Drive Pulley............................................. 410 Alternator Bearings................................................. 410 Alternator Will Not Charge (Charging Problem)............................... 410 Probable Causes......................................................... 410 Recommended Actions..................................................... 410 Alternator Drive Belts.............................................. 410 Charging Circuit.................................................... 410 Alternator or Regulator............................................. 410 Battery..................................................................... 410 Probable Causes......................................................... 410 Recommended Actions..................................................... 410 Faulty Battery...................................................... 410 Auxiliary Device.................................................... 410 Cannot Reach Top Engine RPM................................................. 410 Probable Causes......................................................... 411 Recommended Actions..................................................... 411 Diagnostic Codes.................................................... 411 Fuel Supply......................................................... 411 Air Intake and Exhaust System....................................... 411 Individual Malfunctioning Cylinders................................. 411 Valve Lash.......................................................... 411 Check for Low Compression........................................... 411 Check the Fuel Injection Nozzles.................................... 412 Check the Turbocharger.............................................. 412 ECM Parameters...................................................... 412 Check the Signal for the Throttle Position Sensor................... 412 Coolant in Engine Oil....................................................... 412 Probable Causes......................................................... 412 Recommended Actions..................................................... 412 Engine Oil Cooler Core.............................................. 412 Cylinder Head Gasket................................................ 412 Cylinder Head....................................................... 413 Cylinder Block...................................................... 413 Coolant Temperature Is Too High............................................. 413 Probable Causes......................................................... 413 Recommended Actions..................................................... 413 Radiator Fins....................................................... 413 Coolant Level....................................................... 413 Radiator Cap and/or Pressure Relief Valve........................... 413 Combustion Gases in the Cooling System.............................. 413 Water Temperature Regulator......................................... 413 Restriction in the Coolant System................................... 413 Coolant Temperature Gauge........................................... 413 Coolant Pump........................................................ 413 Excessive Load on the System........................................ 413 ECM Will Not Accept Factory Passwords....................................... 414 Probable Causes......................................................... 414 Recommended Actions..................................................... 414 ECM Will Not Communicate With Other Systems or Display Modules.............. 414 Probable Causes......................................................... 414 Recommended Actions..................................................... 414 Electronic Service Tool Will Not Communicate With ECM....................... 414 Probable Causes......................................................... 414 Recommended Actions..................................................... 414 Engine Cranks but Will Not Start............................................ 415 Probable Causes......................................................... 415 Recommended Actions..................................................... 415 Diagnostic Codes.................................................... 415 Visual Checks....................................................... 415 Crank Without Injection............................................. 415 Starting Motor Solenoid or Starting Circuit......................... 415 Valve Lash.......................................................... 415 Fuel Injection Nozzles.............................................. 415 Air Inlet Heater Starting Aid....................................... 416 Air Intake and Exhaust System....................................... 416 Low Compression..................................................... 416 Fuel Supply......................................................... 416 Engine Has Early Wear....................................................... 416 Probable Causes......................................................... 416 Recommended Actions..................................................... 416 Dirt in Engine Oil.................................................. 416 Leaks in Air Intake System.......................................... 416 Low Oil Pressure.................................................... 416 Engine Misfires, Runs Rough or Is Unstable.................................. 417 Probable Causes......................................................... 417 Recommended Actions..................................................... 417 Logged Codes........................................................ 417 Fuel Supply......................................................... 417 Air Intake and Exhaust System....................................... 417 Individual Malfunctioning Cylinders................................. 417 Valve Lash.......................................................... 417 Check for Low Compression........................................... 417 Check the Fuel Injection Nozzles.................................... 418 Check the Air Inlet Heater Starting Aid............................. 418 Check the Engine Speed/Timing Sensors............................... 418 Check the Signal for the Throttle Position Sensor................... 418 Check the Fuel Injection Pump....................................... 418 Engine Oil in Cooling System................................................ 418 Probable Causes......................................................... 418 Recommended Actions..................................................... 418 Engine Oil Cooler Core.............................................. 418 Cylinder Head Gasket................................................ 419 Cylinder Head....................................................... 419 Engine Speed Does Not Change................................................ 419 Probable Causes......................................................... 419 Recommended Repairs..................................................... 419 Diagnostic Codes.................................................... 419 Engine Stalls at Low RPM.................................................... 419 Probable Causes......................................................... 419 Recommended Actions..................................................... 419 Diagnostic Codes.................................................... 419 Fuel Injection Nozzles.............................................. 419 Fuel Supply......................................................... 419 Accessory Equipment................................................. 420 Power Mode Control.................................................. 420 Engine Vibration............................................................ 420 Probable Causes......................................................... 420 Recommended Actions..................................................... 420 Engine Supports..................................................... 420 Malfunctioning Individual Cylinder.................................. 420 Valve Lash.......................................................... 420 Check for Low Compression (cylinder pressure)....................... 420 Check the Fuel Injection Nozzles.................................... 420 Turbocharger........................................................ 421 Engine Will Not Crank....................................................... 421 Probable Causes......................................................... 421 Recommended Repairs..................................................... 421 Machine Security System............................................. 421 Battery Cables and/or Batteries..................................... 421 Starting Motor Solenoid or Starting Circuit......................... 421 Starting Motor and/or Flywheel Ring Gear............................ 421 Electrical Power Supply............................................. 421 Internal Engine Problem............................................. 421 Excessive Black Smoke....................................................... 421 Probable Causes......................................................... 421 Recommended Actions..................................................... 422 Air Intake System or Exhaust System................................. 422 Individual Malfunctioning Cylinder.................................. 422 Valve Lash.......................................................... 422 Low Compression (cylinder pressure)................................. 422 Check the Fuel Injection Nozzles.................................... 422 Check the Turbocharger.............................................. 422 Broken 5-Volt Supply Wire........................................... 423 Verifying the ECM Software.......................................... 423 Excessive Engine Oil Consumption............................................ 423 Probable Causes......................................................... 423 Recommended Actions..................................................... 423 Oil Level........................................................... 423 Engine Crankcase Breather........................................... 423 Air Intake and Exhaust System....................................... 423 Turbocharger........................................................ 423 Low Compression (cylinder pressure)................................. 423 Excessive Valve Lash........................................................ 424 Probable Causes......................................................... 424 Recommended Actions..................................................... 424 Lubrication......................................................... 424 Valve Lash.......................................................... 424 Valve Train Components.............................................. 424 Excessive White Smoke....................................................... 424 Probable Causes......................................................... 424 Recommended Actions..................................................... 424 Fuel Supply......................................................... 424 Individual Malfunctioning Cylinder.................................. 425 Valve Lash.......................................................... 425 Low Compression (cylinder pressure)................................. 425 Air Inlet Heater Starting Aid....................................... 425 Fuel Injection Nozzles.............................................. 425 Coolant Temperature Sensor Circuit.................................. 425 Engine Pressure Sensors............................................. 425 Intake Air Temperature Is Too High.......................................... 425 Probable Causes......................................................... 425 Recommended Repairs..................................................... 425 High Ambient Air Temperature........................................ 425 Coolant Temperature................................................. 425 Check for High Intake Air Restriction and/or High Altitude.......... 426 Intake Air Restriction.............................................. 426 High Altitude....................................................... 426 Check the Intake Manifold Air Temperature Sensor and/or the Circ.... 426 Check for Sufficient Coolant Flow Through the Aftercooler (if eq.... 426 Check for Sufficient Flow of Air Through the Aftercooler (if equ.... 426 Intermittent Engine Shutdown................................................ 426 Probable Causes......................................................... 426 Recommended Actions..................................................... 426 Logged Codes........................................................ 426 Fuel Supply......................................................... 426 Engine Protection Device............................................ 426 Electrical Connectors............................................... 427 Intermittent Low Power or Power Cutout...................................... 427 Probable Causes......................................................... 427 Recommended Repairs..................................................... 427 Diagnostic Codes.................................................... 427 Electrical Connectors............................................... 427 Fuel Supply......................................................... 427 Check the Intake Manifold Pressure.................................. 428 Air Intake and Exhaust System....................................... 428 Individual Malfunctioning Cylinders................................. 428 Valve Lash.......................................................... 428 Check for Low Compression........................................... 428 Check the Fuel Injection Nozzles.................................... 428 Check the Turbocharger.............................................. 428 ECM Parameters...................................................... 429 Electronic System Problem........................................... 429 Low Engine Oil Pressure..................................................... 429 Probable Causes......................................................... 429 Recommended Actions..................................................... 429 Engine Oil Level.................................................... 429 Engine Oil Pressure Gauge........................................... 429 Engine Oil Bypass Valves............................................ 429 Piston Cooling Jets ................................................ 430 Engine Oil Suction Tube............................................. 430 Engine Oil Pump..................................................... 430 Bearing Clearance................................................... 430 Low Power/Poor or No Response to Throttle................................... 430 Probable Causes......................................................... 430 Recommended Actions..................................................... 430 Diagnostic Codes.................................................... 430 Fuel Supply......................................................... 430 Air Intake and Exhaust System....................................... 430 Individual Malfunctioning Cylinders................................. 431 Valve Lash.......................................................... 431 Check for Low Compression........................................... 431 Check the Fuel Injection Nozzles.................................... 431 Check the Turbocharger.............................................. 431 ECM Parameters...................................................... 431 Electronic System Problem........................................... 432 Mechanical Noise (Knock) in Engine.......................................... 432 Probable Causes......................................................... 432 Recommended Actions..................................................... 432 Accessory Equipment................................................. 432 Valve Train Components.............................................. 432 Connecting Rod and Main Bearings.................................... 432 Noise Coming from Cylinder.................................................. 432 Probable Causes......................................................... 432 Recommended Actions..................................................... 432 Fuel Quality........................................................ 432 Fuel Injection Nozzles.............................................. 432 Valve Lash.......................................................... 432 Poor Acceleration or Response............................................... 433 Probable Causes......................................................... 433 Recommended Repairs..................................................... 433 Diagnostic Codes.................................................... 433 Fuel Supply......................................................... 433 Individual Malfunctioning Cylinder.................................. 433 Valve Lash.......................................................... 433 Check for Low Compression........................................... 433 Check the Fuel Injection Nozzles.................................... 433 Check the Turbocharger.............................................. 434 ECM Parameters...................................................... 434 Check Intake Manifold Pressure...................................... 434 Troubleshooting With a Diagnostic Code.......................................... 434 CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal............ 434 Conditions Which Generate This Code..................................... 434 System Response......................................................... 434 Possible Performance Effect............................................. 434 Troubleshooting......................................................... 434 Results................................................................. 434 CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent............ 434 Conditions Which Generate This Code..................................... 434 System Response......................................................... 435 Possible Performance Effect............................................. 435 Troubleshooting......................................................... 435 Test Step 1............................................................. 435 Results................................................................. 435 CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted............ 435 Conditions Which Generate This Code..................................... 435 System Response......................................................... 435 Possible Performance Effect............................................. 435 CID 0091 FMI 04 Throttle Position Sensor Shorted Low........................ 435 Conditions Which Generate This Code..................................... 435 System Response......................................................... 435 Possible Performance Effect............................................. 435 Troubleshooting......................................................... 435 Results................................................................. 435 CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal.................... 435 Conditions Which Generate This Code..................................... 435 System Response......................................................... 435 Troubleshooting......................................................... 436 Results................................................................. 436 CID 0091 FMI 12 Throttle Position Sensor Out of Calibration................. 436 Conditions Which Generate This Code..................................... 436 Possible Performance Effect............................................. 436 Troubleshooting......................................................... 436 Results................................................................. 436 CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short............ 436 Conditions Which Generate This Code..................................... 436 System Response......................................................... 436 Troubleshooting......................................................... 436 Results................................................................. 436 CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...................... 436 Conditions Which Generate This Code..................................... 436 System Response......................................................... 436 Troubleshooting......................................................... 436 Results................................................................. 436 CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci............ 437 Conditions Which Generate This Code..................................... 437 System Response......................................................... 437 Possible Performance Effect............................................. 437 Results................................................................. 437 CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or............ 437 Conditions Which Generate This Code..................................... 437 System Response......................................................... 437 Possible Performance Effect............................................. 437 Results................................................................. 437 CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low................. 437 Conditions Which Generate This Code..................................... 437 System Response......................................................... 437 Possible Performance Effect............................................. 437 Results................................................................. 437 CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope............ 438 Conditions Which Generate This Code..................................... 438 System Response......................................................... 438 Results................................................................. 438 CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ............ 438 Conditions Which Generate This Code..................................... 438 System Response......................................................... 438 Possible Performance Effect............................................. 438 Troubleshooting......................................................... 438 Results................................................................. 438 CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low.............. 438 Conditions Which Generate This Code..................................... 438 System Response......................................................... 438 Possible Performance Effect............................................. 438 Troubleshooting......................................................... 438 Results................................................................. 438 CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o............ 438 Conditions Which Generate This Code..................................... 438 System Response......................................................... 439 Possible Performance Effect............................................. 439 Troubleshooting......................................................... 439 Results................................................................. 439 CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low............... 439 Conditions Which Generate This Code..................................... 439 System Response......................................................... 439 Possible Performance Effect............................................. 439 Troubleshooting......................................................... 439 Results................................................................. 439 CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent............... 439 Conditions Which Generate This Code..................................... 439 System Response......................................................... 439 Possible Performance Effect............................................. 439 Troubleshooting......................................................... 439 Results................................................................. 439 CID 0247 FMI 09 J1939 Datalink, Abnormal Update............................. 440 Conditions Which Generate This Code..................................... 440 System Response......................................................... 440 Results................................................................. 440 CID 0253 FMI 02 Incorrect ECM Software...................................... 440 Conditions Which Generate This Code..................................... 440 System Response......................................................... 440 Possible Performance Effect............................................. 440 Troubleshooting......................................................... 440 Expected Result......................................................... 440 Results................................................................. 440 CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal............ 440 Conditions Which Generate This Code..................................... 440 System Response......................................................... 440 Possible Performance Effect............................................. 440 Troubleshooting......................................................... 440 Results................................................................. 440 CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal............ 441 Conditions Which Generate This Code..................................... 441 System Response......................................................... 441 Possible Performance Effect............................................. 441 Troubleshooting......................................................... 441 Results................................................................. 441 CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs....................... 441 Conditions Which Generate This Code..................................... 441 System Response......................................................... 441 Possible Performance Effect............................................. 441 CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig............ 441 Conditions Which Generate This Code..................................... 441 System Response......................................................... 441 Possible Performance Effect............................................. 441 Results................................................................. 441 CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...................... 441 Conditions Which Generate This Code..................................... 441 System Response......................................................... 441 Possible Performance Effect............................................. 441 Results................................................................. 442 CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa............ 442 Conditions Which Generate This Code..................................... 442 System Response......................................................... 442 Possible Performance Effect............................................. 442 Test Step 1............................................................. 442 Results................................................................. 442 Test Step 2............................................................. 442 Results................................................................. 442 CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm............ 442 Conditions Which Generate This Code..................................... 442 System Response......................................................... 442 Possible Performance Effect............................................. 442 Results................................................................. 442 CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S............ 442 Conditions Which Generate This Code..................................... 442 System Response......................................................... 443 Possible Performance Effect............................................. 443 Troubleshooting......................................................... 443 Results................................................................. 443 CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low.................. 443 Conditions Which Generate This Code..................................... 443 System Response......................................................... 443 Possible Performance Effect............................................. 443 Troubleshooting......................................................... 443 Results................................................................. 443 CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal.............. 443 Conditions Which Generate This Code..................................... 443 System Response......................................................... 443 Possible Performance Effect............................................. 443 Results................................................................. 443 CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio............ 443 Conditions Which Generate This Code..................................... 443 System Response......................................................... 443 Possible Performance Effect............................................. 443 Results................................................................. 443 CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off.................. 444 Conditions Which Generate This Code..................................... 444 System Response......................................................... 444 Possible Performance Effect............................................. 444 Results................................................................. 444 CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ............ 444 Conditions Which Generate This Code..................................... 444 System Response......................................................... 444 Possible Performance Effect............................................. 444 Test Step 1............................................................. 444 Results................................................................. 444 Test Step 2............................................................. 444 Results................................................................. 444 CID 1684 FMI 02 Fuel Injection Pump, Software Failure....................... 444 Conditions Which Generate This Code..................................... 444 System Response......................................................... 444 Possible Performance Effect............................................. 444 Troubleshooting......................................................... 444 Results................................................................. 445 CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault.......................... 445 Conditions Which Generate This Code..................................... 445 System Response......................................................... 445 Possible Performance Effect............................................. 445 Troubleshooting......................................................... 445 Results................................................................. 445 CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault................... 445 Conditions Which Generate This Code..................................... 445 System Response......................................................... 445 Possible Performance Effect............................................. 445 Troubleshooting......................................................... 445 Results................................................................. 445 CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width.................... 445 Conditions Which Generate This Code..................................... 445 Troubleshooting......................................................... 445 Results................................................................. 446 CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault....................... 446 Conditions Which Generate This Code..................................... 446 System Response......................................................... 446 Possible Performance Effect............................................. 446 Troubleshooting......................................................... 446 Results................................................................. 446 CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault............. 446 Conditions Which Generate This Code..................................... 446 System Response......................................................... 446 Possible Performance Effect............................................. 446 Troubleshooting......................................................... 446 Test Step 1............................................................. 446 Results................................................................. 446 Test Step 2............................................................. 446 Results................................................................. 446 Test Step 3............................................................. 446 Results................................................................. 447 Test Step 4............................................................. 447 Expected Result......................................................... 447 Results................................................................. 447 CID 1684 FMI 09 Fuel Injection Pump, CAN Fault.............................. 447 Conditions Which Generate This Code..................................... 447 System Response......................................................... 447 Possible Performance Effect............................................. 447 Troubleshooting......................................................... 447 Expected Result......................................................... 447 Results................................................................. 447 CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error.............. 447 Conditions Which Generate This Code..................................... 447 System Response......................................................... 447 Troubleshooting......................................................... 447 Test Step 1............................................................. 447 Results................................................................. 448 Test Step 2............................................................. 448 Results................................................................. 448 Test Step 3............................................................. 448 Results................................................................. 448 CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault.................. 448 Conditions Which Generate This Code..................................... 448 System Response......................................................... 448 Possible Performance Effect............................................. 448 Troubleshooting......................................................... 448 Test Step 1............................................................. 448 Results................................................................. 448 Test Step 2............................................................. 448 Results................................................................. 448 CID 1684 FMI 14 Fuel Injection Pump, No Communications...................... 448 Conditions Which Generate This Code..................................... 448 System Response......................................................... 448 Troubleshooting......................................................... 448 Test Step 1............................................................. 448 Results................................................................. 448 Test Step 2............................................................. 449 Results................................................................. 449 Test Step 3............................................................. 449 Results................................................................. 449 CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali............ 449 Conditions Which Generate This Code..................................... 449 System Response......................................................... 449 Possible Performance Effect............................................. 449 Troubleshooting......................................................... 449 Results................................................................. 449 CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali............ 449 Conditions Which Generate This Code..................................... 449 System Response......................................................... 449 CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S............ 449 Conditions Which Generate This Code..................................... 449 System Response......................................................... 449 Troubleshooting With an Event Code.............................................. 450 Event Codes................................................................. 450 Programmable Engine Parameters.............................................. 450 E015 High Engine Coolant Temperature Derate................................. 450 Conditions Which Generate This Code..................................... 450 System Response......................................................... 450 Possible Performance Effect............................................. 450 Troubleshooting......................................................... 450 Results................................................................. 450 E016 High Engine Coolant Temperature Shutdown............................... 450 Conditions Which Generate This Code..................................... 450 System Response......................................................... 450 Possible Performance Effect............................................. 450 Troubleshooting......................................................... 450 Results................................................................. 450 E017 High Engine Coolant Temperature Warning................................ 450 Conditions Which Generate This Code..................................... 450 System Response......................................................... 450 Possible Performance Effect............................................. 450 Troubleshooting......................................................... 450 Results................................................................. 450 E025 High Intake Air Temperature Derate..................................... 451 Conditions Which Generate This Code..................................... 451 System Response......................................................... 451 Possible Performance Effect............................................. 451 Troubleshooting......................................................... 451 Results................................................................. 451 E027 High Intake Air Temperature Warning.................................... 451 Conditions Which Generate This Code:.................................... 451 System Response......................................................... 451 Possible Performance Effect............................................. 451 Troubleshooting......................................................... 451 Results................................................................. 451 E040 Low Engine Oil Pressure Shutdown....................................... 451 Conditions Which Generate This Code..................................... 451 System Response......................................................... 451 Possible Performance Effect............................................. 451 Troubleshooting......................................................... 451 Results................................................................. 451 E054 High Fuel Temperature Derate........................................... 452 Conditions Which Generate This Code..................................... 452 System Response......................................................... 452 Troubleshooting......................................................... 452 Test Step 1 - Check for Diagnostic Codes................................ 452 Expected Result......................................................... 452 Results................................................................. 452 Test Step 2 - Perform a Check of the Fuel System........................ 452 Expected Result......................................................... 452 Results................................................................. 452 E056 High Fuel Temperature Warning.......................................... 452 Conditions Which Generate This Code..................................... 452 System Response......................................................... 452 Troubleshooting......................................................... 452 Test Step 1 - Check for Diagnostic Codes................................ 452 Expected Result......................................................... 452 Results................................................................. 453 Test Step 2 - Perform a Check of the Fuel System........................ 453 Expected Result......................................................... 453 Results................................................................. 453 E100 Low Engine Oil Pressure Warning........................................ 453 Conditions Which Generate This Code..................................... 453 System Response......................................................... 453 Possible Performance Effect............................................. 453 Troubleshooting......................................................... 453 Test Step 1 - Check for Active Diagnostic Codes......................... 453 Expected Result......................................................... 453 Results................................................................. 453 Test Step 2 - Perform a Check of the Engine Lubrication System.......... 453 Expected Result......................................................... 453 Results................................................................. 453 E190 Engine Overspeed Warning............................................... 454 Conditions Which Generate This Code..................................... 454 System Response......................................................... 454 Possible Performance Effect............................................. 454 Troubleshooting......................................................... 454 Engine Overspeed Warning................................................ 454 Expected Result......................................................... 454 Results................................................................. 454 E442 Engine Failed to Stop With a No-Fuel Command........................... 454 Conditions Which Generate This Code..................................... 454 System Response......................................................... 454 Possible Performance Effect............................................. 454 Troubleshooting......................................................... 454 Test Step 1............................................................. 454 Results................................................................. 454 Test Step 2............................................................. 454 Results................................................................. 454 E883 Engine Failed to Stop When Fuel Solenoid Disengaged.................... 454 Conditions Which Generate This Code..................................... 454 System Response......................................................... 454 Possible Performance Effect............................................. 455 Troubleshooting......................................................... 455 Test Step 1............................................................. 455 Results................................................................. 455 Test Step 2............................................................. 455 Results................................................................. 455 Test Step 3............................................................. 455 Results................................................................. 455 Diagnostic Function Tests....................................................... 455 5-Volt Engine Pressure Sensor Supply Circuit - Test......................... 455 System Operation Description............................................ 455 Background Information.................................................. 455 Test Step 1............................................................. 456 Inspect Electrical Connectors and Wiring............................ 456 Expected Result..................................................... 456 Results............................................................. 457 Test Step 2............................................................. 457 Check for Active Diagnostic Codes................................... 457 Expected Result..................................................... 457 Results............................................................. 457 Test Step 3............................................................. 457 Disconnect the ECM Engine Harness Connector From the ECM............ 457 Expected Result..................................................... 458 Results............................................................. 458 Test Step 4............................................................. 458 Disconnect the +5V Sensors While Active Diagnostic Codes are Bei.... 458 Expected Result..................................................... 459 Results............................................................. 459 Test Step 5............................................................. 459 Check the Engine Harness............................................ 459 Expected Result..................................................... 459 Results............................................................. 459 Air Inlet Heater Circuit - Test............................................. 459 System Operation Description............................................ 459 Test Step 1............................................................. 460 Inspect Electrical Connectors and Wiring............................ 460 Expected Result..................................................... 460 Results............................................................. 460 Test Step 2............................................................. 460 Check the Supply to the Power Relay for the Air Inlet Heater Sta.... 460 Expected Result..................................................... 461 Results............................................................. 461 Test Step 3............................................................. 461 Check the Output From the Power Relay for the Air Inlet Heater S.... 461 Expected Result..................................................... 461 Results............................................................. 461 Test Step 4............................................................. 461 Ground the Input to the Power Relay at the MIC...................... 461 Expected Result..................................................... 461 Results............................................................. 461 Test Step 5............................................................. 461 Ground the Input to the Power Relay at the ECM Connector............ 461 Expected Result..................................................... 461 Results............................................................. 461 Test Step 6............................................................. 462 Override the Air Inlet Heater Starting Aid to Test the ECM.......... 462 Results............................................................. 462 Checking Idle Validation Switching Point (Throttle Sensor) With ............ 462 Expected Result......................................................... 462 Analog Throttle Position Sensor Circuit - Test.............................. 462 System Operation Description............................................ 462 Checking the Throttle Sensor With Unconnected Output C.................. 463 Expected Result..................................................... 463 Test Step 1............................................................. 463 Check for Connector Damage.......................................... 463 Expected Result..................................................... 464 Results............................................................. 464 Test Step 2............................................................. 464 Check for Active Diagnostic Codes................................... 464 Expected Result..................................................... 464 Results............................................................. 464 Test Step 3............................................................. 464 Check the Throttle Position With the Electronic Service Tool........ 464 Expected Result..................................................... 464 Results............................................................. 464 Test Step 4............................................................. 464 Check the Voltage at the Throttle Position Sensor................... 464 Expected Result..................................................... 464 Results............................................................. 464 Test Step 5............................................................. 465 Disconnect the Throttle Position Sensor and Check for Active Dia.... 465 Expected Result..................................................... 465 Results............................................................. 465 Test Step 6............................................................. 465 Check the Throttle Selection Status With the Electronic Service .... 465 Expected Result..................................................... 465 Results............................................................. 465 Test Step 7............................................................. 466 Disconnect the Supply Terminals of the Throttle Position Sensor .... 466 Expected Result..................................................... 466 Results............................................................. 466 Test Step 8............................................................. 466 Check the Position of Throttle Position Sensor...................... 466 Expected Result..................................................... 466 Results............................................................. 467 Test Step 9............................................................. 467 Check the Throttle Position Sensor at the ECM....................... 467 Expected Result..................................................... 467 Results............................................................. 467 CAN Data Link Circuit - Test................................................ 467 System Operation Description............................................ 467 Test Step 1............................................................. 468 Inspect Electrical Connectors and Wiring............................ 468 Expected Result..................................................... 468 Results............................................................. 468 Test Step 2............................................................. 468 Check the CAN Data Link Between the ECM and P40 Fuel Injection P.... 468 Expected Result..................................................... 468 Results............................................................. 468 Test Step 3............................................................. 468 Check the CAN Data Link Between the ECM and P40 Fuel Injection P.... 468 Expected Result..................................................... 468 Results............................................................. 469 Test Step 4............................................................. 469 Verify the Supply Voltage at the Fuel Injection Pump................ 469 Expected Result..................................................... 469 Results............................................................. 469 Data Link Circuit - Test.................................................... 469 System Operation Description............................................ 469 Background Information.................................................. 470 Communication........................................................... 470 Test Step 1............................................................. 470 Inspect Electrical Connectors and Wiring............................ 470 Expected Result..................................................... 470 Results............................................................. 470 Test Step 2............................................................. 470 Determine the Type of Problem With the Data Link.................... 470 Expected Result..................................................... 470 Results............................................................. 471 Test Step 3............................................................. 471 Check the Battery Voltage at the ECM................................ 471 Expected Result..................................................... 471 Results............................................................. 471 Test Step 4............................................................. 471 Check the Battery Voltage That is Coming to the Data Link Connec.... 471 Expected Result..................................................... 472 Results............................................................. 472 Test Step 5............................................................. 472 Connect the Electronic Service Tool Directly to the ECM............. 472 Expected Result..................................................... 472 Results............................................................. 472 Test Step 6............................................................. 472 Change Electronic Service Tool Components........................... 472 Expected Result..................................................... 473 Results............................................................. 473 Test Step 7............................................................. 473 Connect an Electronic Service Tool and the ECM to Another Batter.... 473 Expected Result..................................................... 473 Results............................................................. 473 Electrical Connectors - Inspect............................................. 473 System Operation Description............................................ 473 Background Information.................................................. 474 Test Step 1............................................................. 477 Check the Locking of the DT Connector (Deutsch) and the Lock Rin.... 477 Expected Result..................................................... 477 Results............................................................. 477 Test Step 2............................................................. 478 Check the Socket Head Screw on the Connector for the Electronic .... 478 Expected Result..................................................... 478 Results............................................................. 478 Test Step 3............................................................. 478 Perform a Pull Test on Each Wire Terminal Connection................ 478 Expected Result..................................................... 478 Results............................................................. 478 Test Step 4............................................................. 478 Monitor the Electronic Service Tool While the Wiring and the Con.... 478 Expected Result..................................................... 479 Results............................................................. 479 Test Step 5............................................................. 479 Check Wires for Nicks and/or Abrasions in the Insulation............ 479 Expected Result..................................................... 479 Results............................................................. 479 Test Step 6............................................................. 479 Check Connectors for Moisture or Corrosion.......................... 479 Expected Result..................................................... 480 Results............................................................. 480 Test Step 7............................................................. 480 Inspect the Connector Terminals..................................... 480 Expected Result..................................................... 480 Results............................................................. 480 Test Step 8............................................................. 480 Check Individual Pin Retention Into the Socket...................... 480 Expected Result..................................................... 481 Results............................................................. 481 Electrical Power Supply Circuit - Test...................................... 481 System Operation Description............................................ 481 Background Information.................................................. 481 Test Step 1............................................................. 482 Check the Batteries................................................. 482 Expected Result..................................................... 482 Results............................................................. 482 Test Step 2............................................................. 483 Inspect Electrical Connectors and Wiring............................ 483 Expected Result..................................................... 483 Results............................................................. 483 Test Step 3............................................................. 483 Check the Battery Voltage at the ECM................................ 483 Expected Result..................................................... 483 Results............................................................. 484 Test Step 4............................................................. 484 Use the Bypass Harness for the Electronic Service Tool to Bypass.... 484 Expected Result..................................................... 485 Results............................................................. 485 Engine Pressure Sensor Open or Short Circuit - Test......................... 485 System Operation Description............................................ 485 Background Information.................................................. 485 Test Step 1............................................................. 485 Check for Active +5V Sensor Supply Diagnostic Codes................. 485 Expected Result..................................................... 486 Results............................................................. 486 Test Step 2............................................................. 486 Verify All Active Diagnostic Codes.................................. 486 Expected Result..................................................... 486 Results............................................................. 486 Test Step 3............................................................. 486 Inspect Electrical Connectors And Wiring............................ 486 Expected Result..................................................... 487 Results............................................................. 487 Test Step 4............................................................. 487 Verify That the Diagnostic Code is Still Active..................... 487 Expected Result..................................................... 487 Results............................................................. 487 Test Step 5............................................................. 487 Disconnect the Sensor to Create an Open Circuit..................... 487 Expected Result..................................................... 487 Results............................................................. 487 Test Step 6............................................................. 487 Measure the Sensor Supply Voltage................................... 487 Expected Result..................................................... 488 Results............................................................. 488 Test Step 7............................................................. 488 Determine if the Short Circuit is in the Connector or in the Sen.... 488 Expected Result..................................................... 488 Results............................................................. 488 Test Step 8............................................................. 488 Create a Short Circuit Between the Signal and the Common Termina.... 488 Expected Result..................................................... 489 Results............................................................. 489 Test Step 9............................................................. 489 Check the Operation of the ECM by Creating Open and Short Circui.... 489 Expected Result..................................................... 489 Results............................................................. 489 Test Step 10............................................................ 490 Bypass the Harness Wiring Between the ECM and the Sensor Connect.... 490 Expected Result..................................................... 490 Results............................................................. 490 Engine Speed/Timing Sensor Circuit - Test................................... 490 System Operation Description............................................ 490 Test Step 1............................................................. 491 Inspect the Electrical Connectors and Cables........................ 491 Expected Result..................................................... 491 Results............................................................. 491 Test Step 2............................................................. 491 Check the Installation of the Engine Speed/Timing Sensors........... 491 Expected Result..................................................... 491 Results............................................................. 491 Test Step 3............................................................. 491 Measure the Sensor Resistance Through the Wiring Harness............ 491 Expected Result..................................................... 492 Results............................................................. 492 Test Step 4............................................................. 492 Measure the Resistance of the Sensor................................ 492 Expected Result..................................................... 492 Results............................................................. 492 Test Step 5............................................................. 493 Measure the Resistance of the Cables Between the Fuel Injection .... 493 Expected Result..................................................... 493 Results............................................................. 493 Test Step 6............................................................. 493 Check the Continuity of the Cables From the ECM to the Fuel Inje.... 493 Expected Result..................................................... 493 Results............................................................. 494 Engine Temperature Sensor Open or Short Circuit - Test...................... 494 System Operation Description............................................ 494 Background Information.................................................. 494 Test Step 1............................................................. 495 Verify All Active Diagnostic Codes.................................. 495 Expected Result..................................................... 495 Results............................................................. 495 Test Step 2............................................................. 495 Inspect Electrical Connectors and Wiring............................ 495 Expected Result..................................................... 495 Results............................................................. 496 Test Step 3............................................................. 496 Verify That the Diagnostic Code is Still Active..................... 496 Expected Result..................................................... 496 Results............................................................. 496 Test Step 4............................................................. 496 Disconnect the Sensor to Create an Open Circuit..................... 496 Expected Result..................................................... 496 Results............................................................. 496 Test Step 5............................................................. 496 Create a Short Circuit Between the Signal and the Common Termina.... 496 Expected Result..................................................... 497 Results............................................................. 497 Test Step 6............................................................. 497 Check the Operation of the ECM by Creating an Open and a Short C.... 497 Expected Result..................................................... 497 Results............................................................. 497 Test Step 7............................................................. 497 Bypass the Harness Wiring Between the ECM and the Sensor Connect.... 497 Expected Result..................................................... 498 Results............................................................. 498 Fuel Injection Pump Circuit - Test.......................................... 498 System Operation Description............................................ 498 Background Information.................................................. 498 Test Step 1............................................................. 498 Check the Batteries................................................. 498 Expected Result..................................................... 498 Results............................................................. 499 Test Step 2............................................................. 499 Inspect the Electrical Connectors and Wiring........................ 499 Expected Result..................................................... 500 Results............................................................. 500 Test Step 3............................................................. 500 Check the Supply Voltage at the Machine Interface Connector......... 500 Expected Result..................................................... 500 Results............................................................. 500 Test Step 4............................................................. 500 Check the Supply Voltage at the Fuel Injection Pump................. 500 Expected Result..................................................... 500 Results............................................................. 500 Test Step 5............................................................. 501 Check the Supply to the Power Relay for the Fuel Injection Pump..... 501 Expected Result..................................................... 501 Results............................................................. 501 Test Step 6............................................................. 501 Check the Output of the Power Relay for the Fuel Injection Pump..... 501 Expected Result..................................................... 501 Results............................................................. 501 Test Step 7............................................................. 501 Check the Voltage at the Relay Coil for the Fuel Injection Pump..... 501 Expected Result..................................................... 501 Results............................................................. 501 Test Step 8............................................................. 502 Check the Output of the ECM Fuel Pump Power Control at the Machi.... 502 Expected Result..................................................... 502 Results............................................................. 502 Test Step 9............................................................. 502 Check the Output of the Fuel Injection Pump Power Control at the.... 502 Expected Result..................................................... 502 Results............................................................. 502 Test Step 10............................................................ 502 Measure the Voltage at the Pump Power Supply........................ 502 Expected Result..................................................... 503 Results............................................................. 503 Test Step 11............................................................ 503 Check the Voltage Load Protection Module (VLPM)..................... 503 Expected Result..................................................... 504 Results............................................................. 504 Indicator Lamp Circuit - Test............................................... 504 System Operation Description............................................ 504 Test Step 1............................................................. 504 Inspect Electrical Connectors and Wiring............................ 504 Results............................................................. 505 Test Step 2............................................................. 505 Inspect the Lamp, the Fuse, and the Power Supply.................... 505 Expected Result..................................................... 505 Results............................................................. 505 Test Step 3............................................................. 505 Inspect the Input to the Lamp at the ECM connector.................. 505 Expected Result..................................................... 505 Results............................................................. 506 Test Step 4............................................................. 506 Test the Individual Lamp Circuits................................... 506 Expected Result..................................................... 506 Results............................................................. 506 Test Step 5............................................................. 506 Check the Voltage at the ECM........................................ 506 Expected Result..................................................... 506 Results............................................................. 506 Idle Validation Circuit - Test.............................................. 506 System Operation Description............................................ 506 Test Step 1............................................................. 506 Expected Result..................................................... 506 Results............................................................. 507 tables.............................................................................. 355 Table 1. Electronic Service Tool................................................ 381 Table 2. Optional Service Tools................................................. 382 Table 3. CID FMI Codes and J Code FMI Codes..................................... 383 Table 4. Event Codes and CID FMI Codes.......................................... 385 Table 5. Diagnostics Supported Over J1939....................................... 386 Table 6. Events Supported Over J1939............................................ 388 Table 7. Engine Connectors...................................................... 395 Table 8. Color Codes for the Harness Wire....................................... 400 Table 9. Pin Connections for Perkins Deutsch Socket Connector................... 402 Table 10. Suspect Parameter Numbers............................................. 406 Table 11. Failure Mode Indicators (FMI) Codes................................... 407 Table 12. Engine Oil Pressure Trip and Reset Points............................. 451 0700SRM626-897934(11-2001)-EN........................................................... 511 toc................................................................................. 511 Cooling System.................................................................. 511 Safety Precautions Maintenance and Repair....................................... 512 General......................................................................... 515 Description..................................................................... 516 Radiator.................................................................... 516 Radiator Cap................................................................ 516 Thermostat.................................................................. 516 Water Pump.................................................................. 517 Fan and Fan Shroud.......................................................... 517 Cooling System Checks........................................................... 517 Radiator.................................................................... 517 Thermostat.................................................................. 517 Water Pump.................................................................. 518 Exhaust Leaks............................................................... 518 Fan and Fan Shroud.......................................................... 518 Radiator Cleaning............................................................... 518 Drain....................................................................... 518 Clean....................................................................... 518 Fill........................................................................ 519 Troubleshooting................................................................. 520 1300SRM1082-1556600(06-2005)-EN......................................................... 523 toc................................................................................. 523 Transmission.................................................................... 523 Safety Precautions Maintenance and Repair....................................... 524 Description of Operation........................................................ 527 General..................................................................... 527 Torque Convertor, Pump Drive, and Pressure Regulating Valve................. 527 Input Shaft and Directional Clutches........................................ 527 Range Clutches.............................................................. 529 Output Section.............................................................. 529 Transmission Controls....................................................... 530 Operation of the Valve.................................................. 530 Selection of Range...................................................... 531 Pressure Switch......................................................... 531 Electric Solenoid Controls.................................................. 531 Transmission Specifications................................................. 552 Transmission Identification............................................. 552 Weight, Dimensions, and Oil Capacity.................................... 552 Transmission Repair............................................................. 553 Remove...................................................................... 553 Disassemble................................................................. 555 Transmission Case, Disassemble.......................................... 556 Torque Convertor Housing, Disassemble................................... 573 Forward Clutch, Disassemble............................................. 578 First-Speed Clutch, Disassemble......................................... 580 Reverse and Second-Speed Clutch......................................... 585 Reverse Clutch, Disassemble......................................... 585 Second-Speed Clutch, Disassemble.................................... 590 Third-Speed Clutch, Disassemble......................................... 592 Third Clutch Shaft, Disassemble......................................... 594 Turbine Shaft, Disassemble.............................................. 595 Output Shaft, Disassemble............................................... 596 Impeller, Disassemble................................................... 597 Turbine, Disassemble.................................................... 599 Clean and Inspect........................................................... 601 Housings................................................................ 601 Oil Seals and Gaskets................................................... 601 Bearings................................................................ 602 Gears and Shafts........................................................ 602 Assemble.................................................................... 602 Turbine, Assemble....................................................... 602 Impeller, Assemble...................................................... 604 Output Shaft, Assemble.................................................. 606 Turbine Shaft, Assemble................................................. 608 Third Clutch Shaft, Assemble............................................ 609 Third-Speed Clutch, Assemble............................................ 610 Reverse and Second-Speed Clutch......................................... 612 Second-Speed Clutch, Assemble....................................... 612 Reverse Clutch, Assemble............................................ 615 First-Speed Clutch, Assemble............................................ 619 Forward Clutch, Assemble................................................ 624 Torque Convertor Housing, Assemble...................................... 627 Transmission Case, Assemble............................................. 632 Install..................................................................... 653 Control Valve Repair............................................................ 655 Remove...................................................................... 655 Disassemble and Assemble.................................................... 655 Clean and Inspect........................................................... 657 Housings................................................................ 658 Oil Seals and Gaskets................................................... 658 Install..................................................................... 658 Stall Test...................................................................... 660 Transmission Calibration and Electrical Troubleshooting......................... 660 Userlink®................................................................... 660 Calibration................................................................. 661 Clutch Filling Calibration.................................................. 661 Purpose................................................................. 661 Clutch Filling Calibration Procedure.................................... 661 Heat-up Mode............................................................ 661 Alternative Clutch Filling Calibration.................................. 661 Inching Pedal Calibration................................................... 662 Purpose................................................................. 662 Inching Pedal Calibration Procedure..................................... 662 Troubleshooting............................................................. 662 Transmission Display Warning Codes.......................................... 662 Access.................................................................. 662 Clear................................................................... 663 Exit.................................................................... 663 Limp Home Mode.......................................................... 692 Shutdown Mode........................................................... 692 Pressure Feedback Sensor................................................ 692 Transmission Oil Pressure Check................................................. 693 Pressure and Temperature Specifications..................................... 693 Electrical Specifications....................................................... 696 Hydraulic Cooler Lines Specifications........................................... 697 Torque Specifications........................................................... 697 Torque Specifications for Lubricated or Plated Screw Threads................ 697 Troubleshooting................................................................. 699 tables.............................................................................. 523 Table 1. Wire to Pin Number Cross Reference Chart............................... 663 Table 2. Display Warning Codes.................................................. 664 Table 3. Display Warning Exceed Codes........................................... 690 Table 4. Type of Warning Codes.................................................. 691 Table 5. Temperature Sensor (In Speed Sensor) Resistance Versus ................ 696 Table 6. Grade 5................................................................ 697 Table 7. Grade 8................................................................ 698 Table 8. Grades 8.8, 10.9, and 12.9............................................. 698 Table 9. O-ring Port Plug Torque Chart.......................................... 699 Table 10. Pipe Plug Torque Chart................................................ 699 1400SRM046-910072(08-2005)-EN........................................................... 703 toc................................................................................. 703 Differential.................................................................... 703 Safety Precautions Maintenance and Repair....................................... 704 General......................................................................... 707 Description..................................................................... 707 Differential Repair............................................................. 707 Remove...................................................................... 707 Differential Carrier From Axle Housing, Remove.......................... 707 Differential and Ring Gear From Differential Carrier, Remove............ 711 Drive Pinion and Pinion Carrier From Differential Carrier, Remov........ 712 Disassemble................................................................. 714 Differential and Ring Gear Assembly, Disassemble........................ 714 Drive Pinion and Pinion Carrier, Disassemble............................ 715 Clean and Inspect........................................................... 718 Assemble.................................................................... 718 Pinion, Bearings, and Pinion Carrier, Assemble.......................... 718 Pinion Bearings, Adjust Preload......................................... 719 Press Method........................................................ 719 Yoke or Flange Method............................................... 720 Triple-Lip Seal, Install................................................ 720 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)............. 722 Differential and Ring Gear, Assemble.................................... 725 Differential Gears Rotating Torque, Check............................... 727 Differential and Ring Gear Assembly, Install............................ 727 Differential Bearings, Preload Adjust................................... 729 Ring Gear, Runout Check................................................. 730 Ring Gear Backlash, Adjust.............................................. 730 Gear Set, Tooth Contact Pattern Check................................... 732 Thrust Screw, Install and Adjust........................................ 735 Install..................................................................... 735 Differential Assembly Into Axle Housing, Install........................ 735 Specifications.................................................................. 737 Troubleshooting................................................................. 741 tables.............................................................................. 703 Table 1. Ring Gear Backlash Adjustment Specifications........................... 732 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 733 Table 3. General Specifications................................................. 737 Table 4. Rivet Installation Pressure............................................ 737 Table 5. Pinion Adjustment...................................................... 737 Table 6. Pinion Preload Pressure................................................ 738 Table 7. Torque Specifications.................................................. 739 Table 8. Torque Specifications for Metric Hardware.............................. 740 Table 9. Torque Specifications for Metric (Fine) Hardware....................... 740 1400SRM944-1494953(09-2003)-EN.......................................................... 745 toc................................................................................. 745 Planetary Drive Axle............................................................ 745 Safety Precautions Maintenance and Repair....................................... 746 General......................................................................... 749 Description..................................................................... 749 Operation....................................................................... 751 Identification.............................................................. 751 Removal......................................................................... 752 Disassembly..................................................................... 752 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 752 Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD............ 754 Wheel End................................................................... 756 Spindle and Piston Housing.................................................. 757 Cleaning........................................................................ 758 Clean Ground or Polished Parts.............................................. 758 Clean Parts With Rough Finish............................................... 758 Clean Axle Assemblies....................................................... 758 Drying Cleaned Parts........................................................ 758 Corrosion Prevention............................................................ 758 Parts Inspection................................................................ 759 Tapered Roller Bearings..................................................... 759 Bevel Pinion and Ring Gear Sets............................................. 760 Main Differential Assembly.................................................. 760 Axle Shafts................................................................. 760 Yoke........................................................................ 760 Brakes...................................................................... 760 Repair or Replace Parts..................................................... 760 Repair Welding.............................................................. 760 Apply Silicone Gasket Material.............................................. 761 Assembly........................................................................ 761 Spindle and Piston Housing to Axle Housing.................................. 761 Wet Disc Brakes............................................................. 762 Adjust Wheel Bearing Preload................................................ 763 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 764 Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD............ 764 Planetary Spider Assembly................................................... 765 Installation.................................................................... 766 Fill Wet Disc Brakes With Hydraulic Fluid................................... 766 Torque Specifications........................................................... 767 Lubrication Specification....................................................... 768 1400SRM945-1498445(09-2003)-EN.......................................................... 771 toc................................................................................. 771 Planetary Drive Axle............................................................ 771 Safety Precautions Maintenance and Repair....................................... 772 General......................................................................... 775 Description..................................................................... 775 Operation....................................................................... 777 Identification.............................................................. 777 Removal......................................................................... 778 Disassembly..................................................................... 778 Brake Drum.................................................................. 778 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 779 Dry Brakes.................................................................. 781 Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD............ 781 Spindle and Brake Spider.................................................... 783 Cleaning........................................................................ 784 Ground or Polished Parts.................................................... 784 Parts With Rough Finish..................................................... 784 Axle Assemblies............................................................. 784 Drying Cleaned Parts........................................................ 784 Corrosion Prevention............................................................ 784 Parts Inspection................................................................ 785 Tapered Roller Bearings..................................................... 785 Bevel Pinion and Ring Gear Sets............................................. 786 Main Differential Assembly.................................................. 786 Axle Shafts................................................................. 786 Yoke........................................................................ 786 Brakes...................................................................... 786 Repair or Replace Parts..................................................... 786 Repair Welding.............................................................. 786 Apply Silicone Gasket Material.............................................. 787 Assembly........................................................................ 787 Spindle, Brake Spider, and Brake............................................ 787 Wheel End................................................................... 788 Adjust Wheel Bearing Preload................................................ 789 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)............ 790 Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD............ 790 Planetary Spider Assembly................................................... 791 Installation.................................................................... 792 Torque Specifications........................................................... 793 Lubrication Specification....................................................... 794 1600SRM326-897108(03-2005)-EN........................................................... 797 toc................................................................................. 797 Steering Axle................................................................... 797 Safety Precautions Maintenance and Repair....................................... 798 General......................................................................... 801 Description..................................................................... 801 Steering Axle Assembly Repair................................................... 806 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............ 806 Remove.................................................................. 806 Install................................................................. 806 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............ 807 Remove.................................................................. 807 Install................................................................. 807 Wheels and Hubs Repair (All Units).............................................. 808 Remove and Disassemble...................................................... 808 Clean....................................................................... 808 Inspect..................................................................... 808 Assemble and Install........................................................ 808 Spindles and Bearings Repair (All Units)........................................ 810 Remove...................................................................... 810 Clean....................................................................... 810 Assemble and Install........................................................ 810 Tie Rods Repair (All Units)..................................................... 811 Remove...................................................................... 811 Clean....................................................................... 811 Install..................................................................... 811 Steering Cylinder Repair........................................................ 814 Remove and Disassemble...................................................... 814 Clean and Inspect........................................................... 814 Assemble and Install........................................................ 814 Troubleshooting................................................................. 815 1600SRM936-1494140(09-2003)-EN.......................................................... 819 toc................................................................................. 819 Steering System................................................................. 819 Safety Precautions Maintenance and Repair....................................... 820 General......................................................................... 823 Description..................................................................... 823 Steering Wheel and Column Assembly.............................................. 825 General..................................................................... 825 Steering Wheel and Horn..................................................... 825 Remove.................................................................. 825 Install................................................................. 825 Steering Control Unit Repair.................................................... 827 General..................................................................... 827 Description................................................................. 827 Operation................................................................... 827 Remove...................................................................... 828 Disassemble................................................................. 828 Clean....................................................................... 831 Assemble and Install........................................................ 831 Steering System Air Removal..................................................... 837 Steering Relief Pressure Check.................................................. 838 Troubleshooting................................................................. 838 1800SRM937-1494141(12-2003)-EN.......................................................... 843 toc................................................................................. 843 Dry Brake System................................................................ 843 Safety Precautions Maintenance and Repair....................................... 844 General......................................................................... 847 Description..................................................................... 847 Operation....................................................................... 848 Service Brakes.............................................................. 848 Parking Brake............................................................... 848 Air Tank Repair................................................................. 851 Relief Valve................................................................ 851 Drain Valve................................................................. 851 Brake Pedal Valve Repair........................................................ 852 Remove...................................................................... 852 Disassemble, Inspect, and Assemble.......................................... 852 Install..................................................................... 853 Air Chambers Repair............................................................. 853 Remove...................................................................... 853 Disassemble................................................................. 853 Inspect..................................................................... 854 Assemble.................................................................... 855 Install..................................................................... 855 Actuator Arms Repair............................................................ 856 Remove...................................................................... 856 Inspect..................................................................... 856 Install..................................................................... 856 Brake Assemblies Repair......................................................... 857 Brake Shoe, Remove.......................................................... 857 Camshaft, Remove............................................................ 859 Clean....................................................................... 859 Inspect..................................................................... 860 Camshaft, Install........................................................... 860 Brake Shoe, Install......................................................... 861 Air Dryer....................................................................... 862 Description................................................................. 862 Cartridge................................................................... 862 Remove.................................................................. 862 Install................................................................. 862 Filter...................................................................... 862 Remove.................................................................. 862 Install................................................................. 862 Quick-Release Valve............................................................. 864 Governor Check and Adjustment for Air Compressor................................ 864 Brake Shoes Adjustment.......................................................... 865 Specifications.................................................................. 866 Troubleshooting................................................................. 867 Service Brakes.............................................................. 867 Service Brakes, Park Function .............................................. 869 tables.............................................................................. 843 Table 1. Air Chambers Operation................................................. 850 1800SRM951-1498450(09-2003)-EN.......................................................... 873 toc................................................................................. 873 Wet Brake System................................................................ 873 Safety Precautions Maintenance and Repair....................................... 874 General......................................................................... 877 Description and Operation....................................................... 877 Service Brakes.............................................................. 877 Parking Brake............................................................... 877 Oil Cooler Circuit.......................................................... 877 Pressure Switch Replacement..................................................... 881 Accumulators Replacement........................................................ 881 Brake Treadle Valve Repair...................................................... 881 Remove and Disassemble...................................................... 881 Clean and Inspect........................................................... 882 Assemble and Install........................................................ 882 Parking Brake Valve Repair...................................................... 882 Remove...................................................................... 882 Clean and Inspect........................................................... 882 Repair...................................................................... 882 Install..................................................................... 882 Parking Brake Caliper Repair.................................................... 883 Remove...................................................................... 883 Disassemble................................................................. 885 Inspect..................................................................... 885 Install..................................................................... 885 Adjust...................................................................... 885 Brake Pad Repair................................................................ 886 Inspect..................................................................... 886 Remove...................................................................... 886 Install..................................................................... 886 Seals Repair.................................................................... 886 Remove...................................................................... 886 Install..................................................................... 887 Service Brake Repair............................................................ 887 Remove and Disassemble...................................................... 887 Drain Lubricating Oil................................................... 887 Drain Coolant Oil....................................................... 893 Disconnect Brake Lines.................................................. 893 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-16......... 893 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H........ 894 Brake Disc Housing Assembly Wheel End................................... 895 Brake Piston Housing.................................................... 896 Brake Piston Housing and Wheel Spindle.................................. 897 Inspect..................................................................... 897 Clean....................................................................... 899 Assemble.................................................................... 900 Wheel Spindle........................................................... 900 Brake Piston Housing.................................................... 900 Piston Assembly......................................................... 902 Brake Disc Housing...................................................... 902 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub................. 904 Check for Correct Installation of Duo-Cone Seal......................... 905 Wheel Hub to Brake Disc Housing......................................... 906 Adjust...................................................................... 907 Fill Brake System With Coolant Oil...................................... 907 System Air Removal...................................................... 908 Adjust Brake With New Disc Pack......................................... 908 Coolant Change Intervals................................................ 909 Coolant Draining and Filling............................................ 909 Specifications.................................................................. 911 Minimum Brake Disc Thickness................................................ 914 Hydraulic Fluid for Brake Actuation......................................... 914 Brake Coolant Specifications................................................ 914 Coolant Change Intervals.................................................... 914 Hydraulic Fluid Specifications.............................................. 914 Troubleshooting................................................................. 914 Brake Does Not Apply........................................................ 914 Brake Does Not Release...................................................... 915 Brake Performance........................................................... 915 Brake Leaks Actuation Fluid................................................. 916 Brake Cooling Fluid Leakage................................................. 917 Brake Noise and Vibration................................................... 917 Brake Overheats............................................................. 917 tables.............................................................................. 873 Table 1. Brake Pad Adjustment................................................... 885 Table 2. Minimum Brake Disc Thickness........................................... 898 Table 3. Formed Seal Wear Chart................................................. 898 1900SRM938-1494142(12-2005)-EN.......................................................... 921 toc................................................................................. 921 Hydraulic System................................................................ 921 Safety Precautions Maintenance and Repair....................................... 922 General......................................................................... 925 Description and Operation....................................................... 925 Hydraulic Pump.............................................................. 925 Main Control Valve.......................................................... 925 Steering Control Unit....................................................... 927 Pilot Block................................................................. 927 Tilt Relief Valve........................................................... 927 Hydraulic Pump Repair........................................................... 927 Remove...................................................................... 927 Disassemble................................................................. 928 Clean and Inspect........................................................... 928 Assemble.................................................................... 928 Install..................................................................... 928 Priority Valve Repair........................................................... 929 Remove...................................................................... 929 Install..................................................................... 929 Pilot Accumulator Replacement .................................................. 930 Remove...................................................................... 930 Install..................................................................... 930 Pilot Valve Repair.............................................................. 930 Remove...................................................................... 930 Disassemble................................................................. 930 Clean and Inspect........................................................... 931 Assemble.................................................................... 931 Install..................................................................... 931 Control Levers and Joystick Repair.............................................. 933 Remove...................................................................... 933 Install..................................................................... 933 Pump Output Check............................................................... 933 First Method................................................................ 933 Second Method............................................................... 934 Steering Relief Pressure Check and Adjustment................................... 935 Calibration Procedure for Hydraulic Controls.................................... 936 Hydraulic User-Interface Communication Speed Synchronization Iss............ 936 General and Calibration Startup............................................. 936 Joystick/Lever Calibration.................................................. 939 Levers.................................................................. 939 Joystick................................................................ 940 Valve Flow Adjustment....................................................... 940 PWM Board Readouts/PV3 Readouts............................................. 941 I/O Board Readouts.......................................................... 941 Diagnostics................................................................. 942 Calibration System Shutdown................................................. 942 Diagnostics..................................................................... 942 Specifications.................................................................. 946 Troubleshooting................................................................. 946 Lift, Lower, Tilt, and Attachment Circuits (also see the section............ 947 Steering Circuit (Also see the section Steering System 1600 SRM ............ 948 tables.............................................................................. 921 Table 1. Processor Speed Settings............................................... 937 Table 2. Error Code Display..................................................... 943 Table 3. Altering PT FLT (Old Logic)............................................ 944 Table 4. Altering PT FLT (New Logic)............................................ 944 Table 5. Fixed PT Logic......................................................... 945 Table 6. ECH.................................................................... 945 2000SRM943-1494955(09-2003)-EN.......................................................... 955 toc................................................................................. 955 Main Control Valve.............................................................. 955 Safety Precautions Maintenance and Repair....................................... 956 General......................................................................... 959 Description..................................................................... 959 Operation....................................................................... 962 Lift Section................................................................ 962 Tilt/Auxiliary Section...................................................... 962 Relief Valves............................................................... 962 Unloader Valve.............................................................. 962 Main Control Valve Repair....................................................... 965 Remove...................................................................... 965 Disassemble................................................................. 965 Auxiliary Side.......................................................... 965 Lift Side............................................................... 965 Clean and Inspect........................................................... 966 Assemble.................................................................... 966 Auxiliary Side.......................................................... 966 Lift Side............................................................... 968 Install..................................................................... 968 Pressure Relief Valve Check and Adjustment...................................... 969 Check and Adjust............................................................ 969 Replace..................................................................... 969 Specifications.................................................................. 970 Troubleshooting................................................................. 970 2100SRM103-910102(03-2005)-EN........................................................... 975 toc................................................................................. 975 Tilt Cylinders.................................................................. 975 Safety Precautions Maintenance and Repair....................................... 976 General......................................................................... 979 Description..................................................................... 979 Tilt Cylinder Repair............................................................ 979 Remove...................................................................... 979 Disassemble................................................................. 979 Clean....................................................................... 979 Assemble.................................................................... 980 Tilt Cylinders With O-Ring or Single-Lip Seals.......................... 980 Tilt Cylinders for XM and XMS Models.................................... 981 Tilt Cylinders for XL, XLS, and XL 3 Models............................. 982 Tilt Cylinders for H700-800A and Early Model H700-920B.................. 984 Install..................................................................... 985 Tilt Cylinders Using Chevron Packing.................................... 985 Install............................................................. 986 Tilt Cylinder Leak Check........................................................ 988 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 990 Torque Specifications........................................................... 990 Piston Rod Nut.............................................................. 990 Retainer.................................................................... 991 Troubleshooting................................................................. 993 tables.............................................................................. 975 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 989 2200SRM002-899784(10-2003)-EN........................................................... 997 toc................................................................................. 997 Alternator with Regulator....................................................... 997 Safety Precautions Maintenance and Repair....................................... 998 General.........................................................................1001 Description.....................................................................1001 Alternator Repair...............................................................1003 Alternator Type A...........................................................1003 Remove and Disassemble..................................................1003 Clean...................................................................1004 Assemble................................................................1005 Install.................................................................1005 Alternator Type B...........................................................1008 Remove and Disassemble..................................................1008 Clean...................................................................1008 Assemble................................................................1009 Install.................................................................1010 General Check and Adjustment....................................................1011 Low Output Check (Type A or Type B).............................................1011 High Output Check (Type A or Type B)............................................1013 Brushes Circuit Check...........................................................1014 Delco Alternators...........................................................1014 Motorola Alternators........................................................1015 Diodes Check....................................................................1016 Diode Bridge Check..............................................................1016 Delco and Leece-Neville Alternators.........................................1016 Motorola Alternators........................................................1016 Rotor Field Winding Check.......................................................1017 Stator Windings Check...........................................................1018 Voltage Regulator Check.........................................................1018 Troubleshooting.................................................................1018 2200SRM106-910107(02-2001)-EN...........................................................1023 toc.................................................................................1023 Starter.........................................................................1023 Safety Precautions Maintenance and Repair.......................................1024 General.........................................................................1027 Description and Operation.......................................................1027 Starter Repair..................................................................1029 Remove......................................................................1029 Disassemble.................................................................1029 Clean.......................................................................1030 Assemble....................................................................1030 Install.....................................................................1031 General Checks and Adjustments..................................................1031 Troubleshooting.................................................................1034 2200SRM1105-1556871(01-2004)-EN.........................................................1039 toc.................................................................................1039 Instrument Panel Indicators and Senders.........................................1039 Safety Precautions Maintenance and Repair.......................................1040 General.........................................................................1043 Description.....................................................................1043 General.....................................................................1043 Instrument Panel Meters, Indicators, and LCD Display........................1043 Connector...................................................................1049 Seat Switch Logic.......................................................1050 Central Warning Light Output............................................1050 Buzzer Output...........................................................1050 Engine Shutdown Output..................................................1050 Instrument Panel Component Replacement..........................................1052 Instrument Panel............................................................1053 Remove..................................................................1053 Light.......................................................................1054 Replace.................................................................1054 Sender Replacement..............................................................1054 Fuel Level Sender...........................................................1054 Pressure Sender.............................................................1054 Temperature Sender..........................................................1055 Low Coolant Sender..........................................................1055 Vacuum Switch...............................................................1055 Crankshaft Position Sensor..................................................1056 Specifications..................................................................1056 Troubleshooting.................................................................1058 tables..............................................................................1039 Table 1. Instrument Panel and Indicators........................................1044 Table 2. Pin Description........................................................1049 Table 3. Sender Description.....................................................1050 4000SRM1062-1553599(02-2004)-EN.........................................................1061 toc.................................................................................1061 Masts and Carriages.............................................................1061 Safety Precautions Maintenance and Repair.......................................1062 General.........................................................................1065 Description.....................................................................1065 Operation.......................................................................1066 Two-Stage Mast..............................................................1066 Three-Stage Mast............................................................1066 Safety Procedures When Working Near Mast........................................1068 Forks Repair....................................................................1070 Remove......................................................................1070 Inspect and Adjust..........................................................1070 Install.....................................................................1071 Carriage Repair.................................................................1071 Description.................................................................1071 Three Function..........................................................1071 Four to Six Function....................................................1071 Remove......................................................................1071 Disassemble.................................................................1074 Clean and Inspect...........................................................1074 Assemble....................................................................1074 Install.....................................................................1075 Sideshift Cylinder Repair.......................................................1075 Remove......................................................................1075 Disassemble.................................................................1075 Clean and Inspect...........................................................1078 Assemble....................................................................1078 Install.....................................................................1079 Fork Positioner Cylinders Repair................................................1079 Remove......................................................................1079 Disassemble.................................................................1079 Clean and Inspect...........................................................1079 Assemble....................................................................1079 Install.....................................................................1079 Directional Control Valve Repair................................................1085 Remove......................................................................1085 Disassemble.................................................................1086 Clean and Inspect...........................................................1086 Assemble....................................................................1086 Install.....................................................................1086 Mast Repair.....................................................................1087 Two- and Three-Stage Mast...................................................1087 Remove..................................................................1087 Disassemble.............................................................1092 Clean and Inspect.......................................................1092 Assemble................................................................1094 Install.................................................................1095 Three-Stage Mast (Four Cylinders)...........................................1096 Remove..................................................................1096 Disassemble.............................................................1098 Clean and Inspect.......................................................1098 Assemble................................................................1098 Install.................................................................1100 Fork Carriage Chains........................................................1102 Adjust..................................................................1102 Bearing Rollers.............................................................1104 Description.............................................................1104 Lubrication.............................................................1104 Clearance...............................................................1104 Remove and Disassemble..................................................1104 Assemble................................................................1104 Mast Profile................................................................1105 Lift Cylinders Description......................................................1105 Piston-Type Cylinders.......................................................1105 Displacement-Type Cylinders.................................................1105 Lift Cylinders Repair...........................................................1106 Remove......................................................................1106 Disassemble.................................................................1108 Clean and Inspect...........................................................1108 Assemble....................................................................1108 Install.....................................................................1109 Mast Operation Check............................................................1109 Lift and Tilt System Leak Checks................................................1110 Lift System.................................................................1110 Tilt System.................................................................1110 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................1111 Lift Chain Adjustments..........................................................1111 Mast Adjustments................................................................1112 Bearing Blocks, Two Stage Masts.............................................1112 Wear Plates.................................................................1112 Carriage Adjustment.............................................................1112 Troubleshooting.................................................................1114 tables..............................................................................1061 Table 1. Allowable Mast Movement from Internal Leakage..........................1110 5000SRM969-1503241(09-2003)-EN..........................................................1119 toc.................................................................................1119 Empty Container Handling Attachment.............................................1119 Safety Precautions Maintenance and Repair.......................................1120 General.........................................................................1123 Description.....................................................................1123 Operation.......................................................................1123 General.....................................................................1123 Selector Valves.............................................................1123 Sideshift Circuit...........................................................1123 Extend and Retract Circuit..................................................1128 Twist Lock Circuit and Control..............................................1128 Model 553 - Horizontally Mounted........................................1128 Model 558 - Vertically Mounted..........................................1130 Lifting Hooks...............................................................1130 Model 555...............................................................1130 Indicator Lights and LEDs...................................................1131 Lift Interrupt and Override.................................................1131 Overlowering Interrupt and Override.........................................1131 Carriage and Attachment Repair..................................................1132 Remove......................................................................1132 Attachment Without Carriage Repair..............................................1132 Remove......................................................................1132 Sideshift Cylinders Repair......................................................1133 Remove......................................................................1133 Disassemble.................................................................1133 Assemble....................................................................1133 Extension Cylinders Repair......................................................1134 Remove......................................................................1134 Disassemble.................................................................1134 Clean and Inspect...........................................................1134 Assemble....................................................................1134 Install.....................................................................1134 Vertical End Beams Repair.......................................................1136 Remove......................................................................1136 Install.....................................................................1136 Hose Replacement in End Beams...............................................1136 Twist Locks Repair for Model 553................................................1137 Remove......................................................................1137 Disassemble.................................................................1137 Clean and Inspect...........................................................1137 Assemble....................................................................1137 Hooks Replacement for Model 555.................................................1138 Inspect.....................................................................1138 Remove......................................................................1138 Install.....................................................................1138 Twist Locks Repair for Model 558................................................1139 Disassemble.................................................................1139 Clean and Inspect...........................................................1139 Assemble....................................................................1140 Bleed the System................................................................1140 Valve Assembly..................................................................1141 Slide Pad Replacement...........................................................1141 Adjustments.....................................................................1142 Twist Lock Angle Adjustment.................................................1142 Model 558 Only..........................................................1142 LOCKED/NOT LOCKED Sensors Adjustment........................................1142 Model 553...............................................................1142 Model 558...............................................................1143 Seated Sensor Adjustment....................................................1143 Model 553...............................................................1143 Model 558...............................................................1143 Overlowering Protection Sensor Adjustment (Models 553 and 558)..............1143 Torque Chart................................................................1144 Maintenance.....................................................................1144 Additional Attachment Maintenance...........................................1146 Interface Boxes.............................................................1147 Model 555...............................................................1147 Models 553 and 558......................................................1147 Troubleshooting.................................................................1149 tables..............................................................................1119 Table 1. Torque Chart...........................................................1144 Table 2. Maintenance Schedule...................................................1145 8000SRM231-910442(12-2004)-EN...........................................................1165 toc.................................................................................1165 Metric and Inch (SAE) Fasteners.................................................1165 Safety Precautions Maintenance and Repair.......................................1166 General.........................................................................1169 Threaded Fasteners..........................................................1169 Nomenclature, Threads.......................................................1169 Strength Identification.....................................................1170 Cotter (Split) Pins.........................................................1170 Fastener Torque Tables......................................................1175 Conversion Table............................................................1177 tables..............................................................................1165 Table 1. Bolts and Screws.......................................................1171 Table 2. Studs and Nuts.........................................................1172 Table 3. Torque Nuts............................................................1173 Table 4. Torque Nuts With Nylon Insert..........................................1174 Table 5. Torque Values for Metric Fasteners*....................................1175 Table 6. Torque Values for Inch Fasteners*......................................1176 Table 7. Conversion Table for Metric and English Units..........................1177 Table 8. Cotter Pin Dimensional Data............................................1178 Table 9. Cotter Pin Dimensional Data............................................1179 Table 10. Cotter Pin Dimensional Data...........................................1180 Table 11. Cotter Pin Dimensional Data...........................................1182 8000SRM940-1494145(12-2005)-EN..........................................................1187 toc.................................................................................1187 Capacities and Specifications...................................................1187 Safety Precautions Maintenance and Repair.......................................1188 Lift Truck Weights..............................................................1191 Capacities......................................................................1191 Engine Specifications...........................................................1192 Perkins Diesel..............................................................1192 Cummins Diesel/LPG..........................................................1193 Hydraulic System................................................................1194 Electrical System...............................................................1195 Tire Sizes......................................................................1195 Mast Speeds.....................................................................1196 Perkins Diesel..............................................................1196 Cummins Diesel/LPG..........................................................1197 Torque Specifications, Cummins Diesel...........................................1197 Lubrication System..........................................................1197 Torque Specifications, Perkins Diesel...........................................1198 Engine......................................................................1198 Cylinder Head Assembly..................................................1198 Piston and Connecting Rod Assemblies....................................1198 Crankshaft Assembly.....................................................1198 Timing Case and Drive Assembly..........................................1198 Turbocharger............................................................1198 Lubrication System......................................................1198 Fuel System.............................................................1199 Cooling System..........................................................1199 Flywheel and Housing....................................................1199 Aspiration System.......................................................1199 Electrical Equipment....................................................1199 Auxiliary Equipment.....................................................1199 Torque Specifications - Perkins, Tier 2.........................................1200 Cylinder Head Assembly......................................................1200 Piston and Connecting Rod Assemblies........................................1200 Crankshaft Assembly.........................................................1200 Timing Case and Drive Assembly..............................................1200 Turbocharger................................................................1200 Lubrication System..........................................................1200 Fuel System.................................................................1200 Cooling System..............................................................1201 Flywheel....................................................................1201 Auxiliary Equipment.........................................................1201 Torque Specifications, General..................................................1201 Transmission................................................................1201 Driveline and Axle..........................................................1201 Differential................................................................1201 Brakes - Wet................................................................1201 Brakes - Dry................................................................1201 Steering....................................................................1202 Hydraulic System............................................................1202 Mast........................................................................1202 Carriage....................................................................1202 Tilt Cylinders..............................................................1202 Frame.......................................................................1203 Wiper Arms, Front...........................................................1203 Hyster T-50 Transmission Pressures (Powershift and Automatic)...................1203 TE-10 Transmission Specifications...............................................1204 Electrical..................................................................1204 Hydraulic Cooler Lines......................................................1204 Torque Specifications for Lubricated or Plated Screw Threads................1205 tables..............................................................................1187 Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp................1204 Table 2. Grade 5................................................................1205 Table 3. Grade 8................................................................1205 Table 4. Grades 8.8, 10.9, and 12.9.............................................1205 Table 5. O-ring Port Plug Torque Chart..........................................1206 Table 6. Pipe Plug Torque Chart.................................................1206 8000SRM1099-1556602(01-2005)-EN.........................................................1209 toc.................................................................................1209 Periodic Maintenance............................................................1209 Safety Precautions Maintenance and Repair.......................................1210 General.........................................................................1215 How to Move Disabled Lift Truck.............................................1215 How to Tow Lift Truck...................................................1215 How to Put Lift Truck on Blocks.............................................1216 How to Raise Drive Tires................................................1216 How to Raise Steering Tires.............................................1216 Maintenance Schedule............................................................1218 Empty Container Attachment Maintenance......................................1225 Maintenance Procedures Every 8 Hours or Daily...................................1227 How to Make Checks With Engine Stopped......................................1227 Safety Labels...........................................................1227 Forks...................................................................1227 Adjust..............................................................1227 Remove..............................................................1227 Install.............................................................1227 Forks, Mast, and Lift Chains, Inspect...................................1228 Operator Restraint System...............................................1229 Steering Column Latch...................................................1230 Tires and Wheels........................................................1230 Fuel, Oil, or Coolant Leaks, Check......................................1230 Air Intake Piping.......................................................1231 Cooling Fan.............................................................1231 Crankcase Breather Tube.................................................1231 Drive Belts.............................................................1231 Hydraulic System Oil....................................................1232 Cab Hydraulic System....................................................1232 Engine Oil..............................................................1233 Cooling System..........................................................1234 Battery.................................................................1234 Fuel System.............................................................1235 Water Separator/Fuel Filter.............................................1235 How to Make Checks With Engine Running......................................1235 Fault Codes.............................................................1235 Access..............................................................1235 Exit................................................................1236 Clear...............................................................1236 Gauges, Lights, Horn and Fuses..........................................1236 Control Levers and Pedals...............................................1238 Steering System.........................................................1238 Air Filters.............................................................1238 Transmission Oil........................................................1238 Brakes..................................................................1238 Lift System Operation...................................................1239 Attachments.............................................................1239 Maintenance Procedures Every 250 Hours or Every 2 Months........................1239 Empty Container Handler.....................................................1239 Maintenance Procedures Every 500 Hours or Every 3 Months........................1239 Lift Chains.................................................................1239 Lubrication.............................................................1239 Adjust..................................................................1239 Drive Shaft.................................................................1240 Steering Axle...............................................................1240 Wheel Nuts..................................................................1240 Shafts for Brake Actuators..................................................1240 Drive Axle and Differential.................................................1240 Hydraulic Tank Breather.....................................................1241 Cabin Air Filter, Heater....................................................1241 Air Filter, Engine..........................................................1241 Engine Oil and Filter.......................................................1241 Drive Belts.................................................................1241 Perkins.................................................................1241 Cummins.................................................................1242 Mast........................................................................1242 Bearing Rollers (Three-Stage Only)......................................1243 Lubrication.........................................................1243 Clearance...........................................................1243 General Lubrication.........................................................1244 Fork Wear and Damage Check..................................................1244 Lift Chains Wear Check......................................................1244 Empty Container Handler.....................................................1244 Maintenance Procedures Every 500 Hours or 6 Months..............................1245 Charge Air Cooler (Perkins Only)............................................1245 Air Compressor (Dry Brakes, Cummins)........................................1245 Fuel Pump (Cummins).........................................................1245 Fuel Filter.................................................................1245 Perkins.................................................................1245 Remove..............................................................1245 Install.............................................................1245 Cummins.................................................................1246 Remove..............................................................1246 Install.............................................................1246 Fuel System Air Removal (Perkins).......................................1247 Fuel System Air Removal (Cummins).......................................1247 Fuel Injection Pump Without Vent Tube...................................1247 Coolant.....................................................................1247 Maintenance Procedures Every 1000 Hours or 6 Months.............................1249 Transmission Oil and Filter, Change.........................................1249 Fuel Injection Pump Timing (Perkins Only)...................................1249 Valve Adjustment............................................................1249 Perkins.................................................................1249 Differential and Drive Axle.................................................1249 Maintenance Procedures Every 1000 Hours or Yearly...............................1250 Coolant Fan Belt Tensioner..................................................1250 Belt Driven Fan Hub.........................................................1251 Valve Adjustment............................................................1251 Cummins.................................................................1251 Accumulator and Wet Brakes..................................................1252 Wet Brake Oil Filter........................................................1252 Air Dryer Cartridge (Dry Brakes)............................................1252 Air Compressor Air Filter (Dry Brakes)......................................1252 Maintenance Procedures Every 2000 Hours or Yearly...............................1253 Hydraulic System............................................................1253 Hydraulic Oil Filter, Change............................................1253 Hydraulic Oil, Change...................................................1253 Hydraulic Pilot Valve Filter, Change....................................1253 Transmission Calibration....................................................1254 Wheel Bearings..............................................................1254 Steer Wheels............................................................1254 Drive Wheels............................................................1254 Service Brakes..............................................................1254 Cleaning Procedures (Dry Brake Axle)....................................1254 Maintenance Procedures Every 2000 Hours or 2 Years..............................1255 Air Compressor Discharge Lines..............................................1255 Rubber Vibration Damper.....................................................1256 Engine Coolant..............................................................1256 Maintenance Procedures Every 5000 Hours.........................................1257 Empty Container Handler.....................................................1257 Safety Procedures When Working Near Mast........................................1257 Fuel Injectors Check............................................................1258 Perkins.....................................................................1258 Lift and Tilt System Leak Check.................................................1259 Lift System.................................................................1259 Tilt System.................................................................1259 Welding Repairs.................................................................1260 Wheel and Tire Replacement......................................................1261 Remove Wheels From Lift Truck...............................................1261 Pneumatic Tires.............................................................1261 Remove Tire From Wheel..................................................1261 Remove Tire From Three- and Four-Piece Wheel........................1262 Install Tire on Wheel...................................................1263 Install Three- or Four-Piece Wheel in Tire..........................1263 Add Air to Tires............................................................1264 Solid Rubber Tires..........................................................1265 Remove Tire From Wheel..................................................1265 Install Tire on Wheel...................................................1267 Wheels, Install.............................................................1269 tables..............................................................................1209 Table 1. Daily Inspections − Condition Check....................................1219 Table 2. Daily Inspections − Fluid Level Check..................................1219 Table 3. Daily Inspections − Checks With the Engine Running.....................1220 Table 4. First Inspection After First 100 Hours of Operation....................1221 Table 5. Periodic Maintenance Schedule − Inspect and Adjust.....................1221 Table 6. Periodic Maintenance Schedule − Lubricate..............................1223 Table 7. Periodic Maintenance Schedule − Change.................................1224 Table 8. Empty Container Attachment Maintenance − Inspect and ..................1226 Table 9. Empty Container Attachment Maintenance − Lubricate.....................1226 Table 10. Empty Container Attachment Maintenance − Replace......................1226 Table 11. Nominal Valve Clearance...............................................1252 Table 12. Allowable Mast Movement from Internal Leakage.........................1260 8000SRM1103-1556604(10-2005)-EN.........................................................1273 toc.................................................................................1273 Diagrams........................................................................1273 Safety Precautions Maintenance and Repair.......................................1274
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