Yale Forklift B876 (GDP80-120DB Europe) Service Manual – PDF DOWNLOAD

Yale Forklift B876 (GDP80-120DB Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift B876 (GDP80-120DB Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1736
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift B876 (GDP80-120DB Europe) Service Manual – PDF DOWNLOAD

524149351 8000YRM0934 (08 2001) UK EN 1
toc 1
Periodic Maintenance 1
Safety Precautions Maintenance and Repair 2
General 5
How to Move Disabled Lift Truck 5
How to Tow Lift Truck 5
How to Put Lift Truck on Blocks 6
How to Raise Drive Tires 6
How to Raise Steering Tires 6
Maintenance Schedule 7
Maintenance Procedures Every 8 Hours or Daily 12
How to Make Checks with Engine Stopped 12
Tires and Wheels 12
Forks 13
Adjust 13
Remove 13
Install 13
Forks, Mast, and Lift Chains, Inspect 13
Safety Labels 14
Operator Restraint System 15
Steering Column Latch 15
Drive Belts 15
Cooling System 16
Fuel, Oil, or Coolant Leaks, Check 16
Cab Hydraulic System 16
Hydraulic System 17
Engine Oil 17
Fuel System 18
Primary Fuel Filter 18
Battery 18
Air Filter 18
How to Make Checks with Engine Running 19
Gauges, Lights, Horn, and Fuses 19
Control Levers and Pedals 19
Transmission Oil 19
Lift System Operation 19
Brakes 20
Steering System 21
Maintenance Procedures Every 250 Hours or Every 2 Months 21
Engine Oil and Filter – Cummins Engine 21
Maintenance Procedures Every 500 Hours or Every 2 Months 22
Lift Chains 22
Lubrication 22
Adjust 22
Drive Shaft 22
Steering Axle 22
Wheel Nuts 23
Shafts for Brake Actuators 23
Drive Axle and Differential 23
Hydraulic Tank Breather 23
Air Filter, Engine, and Air Compressor 23
Cabin Air Filter, Heater 23
Engine Oil and Filter – Perkins Engine 23
Drive Belts 23
Mast 24
General Lubrication 25
Forks Wear and Damage Check 25
Lift Chains Wear Check 25
Fuel System 26
Idle Speed 26
Governor Speed (Diesel) 26
Maintenance Procedures Every 1000 Hours or 6 Months 27
Transmission Oil and Filter, Change 27
Final Fuel Filters, Diesel 27
Diesel Fuel System Air Removal 27
Fuel Injection Pump Without Vent Tube 28
Fuel Injection Pump Timing 28
Valve Adjustment 29
Maintenance Procedures Every 2000 Hours or Yearly 30
Hydraulic System 30
Hydraulic Oil Filter, Change 30
Hydraulic Oil, Change 30
Differential and Drive Axle 30
Wheel Bearings 30
Steer Wheels 30
Drive Wheels 30
Service Brakes 31
Cleaning Procedures (Dry Brake Axle) 31
Safety Procedures When Working Near Mast 31
Fuel Injectors Check 32
Lift and Tilt System Leak Check 33
Lift System 33
Tilt System 33
Welding Repairs 34
Wheel and Tire Replacement 34
Remove Wheels from Lift Truck 34
Pneumatic Tires 35
Remove Tire from Wheel 35
Remove Tire from Three- and Four-Piece Wheel 36
Install Tire on Wheel 37
Install Three- or Four-Piece Wheel in Tire 37
Add Air to Tires 38
Solid Rubber Tires 39
Remove Tire from Wheel 39
Install Tire on Wheel 40
Wheels, Install 42
tables 1
Table 1 Maintenance Schedule 8
Table 2 Allowable Mast Movement from Internal Leakage 33
524150772 0100YRM0927 (11 2015) UK EN 45
General 49
Description 49
Counterweight Repair 50
Remove 50
Install 52
Fenders 52
Remove 52
Install 52
Side Counterweights GDP130-160EB (GP300-360EB) 52
Side Counterweight, Replace 52
Hood and Air Cleaner Repair 52
Remove 53
Install 55
Hydraulic Tank Repair 55
Remove 55
Repairs, All Units 58
Small Leaks 58
Large Leaks 58
Clean 58
Steam Method 59
Chemical Solution Method 59
Other Methods of Preparation for Repair 59
Install 60
Fuel Tank Repair 60
Remove 60
Repairs 61
Install 61
Cooling System and Radiator Repair 64
Remove 64
Install 64
Cab Repair 67
Rear Cab Assembly 67
Bottom Cab Assembly 68
Raising and Lowering Cab 68
Raise Cab 68
Lower Cab 69
Cab Repair 69
Remove 69
Install 71
Engine and Transmission Repair 72
Transmission, Remove 72
Transmission, Install 74
TE-10 Transmission 75
Remove 75
Install 79
Label Replacement 83
524150774 0600YRM0705 (03 2006) UK EN 91
toc 91
Perkins Diesel Engines 91
Safety Precautions Maintenance and Repair 92
General 99
General Safety Rules 99
Description 100
Engine Serial Number Codes 103
Engine Data 103
Engine Removal and Installation 105
Lift Engine 105
Cylinder Head Assembly Repair 105
Valve Cover 105
Remove 105
Install 106
Rocker Arm Assembly 106
Remove 106
Install 106
Disassemble 106
Inspect 107
Assemble 107
Valve Clearance Adjustments 107
Four-Cylinder Engines 108
Six-Cylinder Engines 108
Valve Springs 108
Cylinder Head Assembly 110
Remove 110
Install 112
Valves and Valve Springs 116
Remove 116
Inspect 116
Install 117
Valve Guides 117
Inspect 117
Remove 118
Install 118
Cylinder Head and Valve Seats 118
Inspect 118
Repair 118
New Valve Seats, Install 118
Piston and Connecting Rod Assemblies Repair 120
Rod Bearings 120
Remove 121
Install 121
Piston and Connecting Rod Assembly 122
Service Note 122
Remove 122
Install 123
Piston Rings 124
Remove 124
Inspect 124
Install 124
Piston and Connecting Rod 125
Disassemble 125
Inspect 126
How to Select Correct Replacements 126
Install 127
Piston Cooling Jets 127
Remove 127
Install 128
Crankshaft Assembly Repair 128
General 128
Crankshaft Pulley 129
Engine AR, Remove 129
Engines YG and YH, Remove 129
Inspect 130
Engine AR, Install 130
Engines YG and YH, Install 130
Rear Oil Seal 131
Replace 131
Main Bearings 132
Remove 132
Inspect 133
Install 133
Thrust Washers 133
Crankshaft Axial Movement, Check 133
Remove 134
Install 134
Crankshaft 135
Remove 135
Inspect 135
Install 135
Flywheel 137
Remove 137
Ring Gear, Replace 137
Install 137
Flywheel Housing 138
Remove 138
Install 138
Timing Case and Timing Gears Repair 139
General 139
Timing Case Cover 139
Remove 139
Install 140
Front Oil Seal 140
Remove 140
Install 140
Crankshaft Pulley Wear Sleeve 141
Install 141
Idler Gear and Hub 141
Remove 141
Install 142
Air Compressor Drive, Bendix 143
Disassemble 143
Assemble 144
Fuel Injection Pump Gear 144
Remove 145
Install 145
Camshaft Gear 146
Remove 146
Install 146
Crankshaft Gear 147
Remove 147
Install 147
Timing Case 147
Remove 147
Install 148
Camshaft and Tappets 149
Remove 149
Install 149
Cylinder Block Assembly Repair 150
Description 150
Cylinder Block 150
Disassemble 150
Inspect 151
Assemble 151
Cylinder Bore (Four-Cylinder Engines) 151
Cylinder Liner (Six-Cylinder Engines) 152
Inspect 152
Cylinder Liner Condition, Check 152
Remove 153
Service Liner, Install 153
Partially Finished Liner, Install 155
Engine Timing 155
Description 155
How to Set Number One Piston to TDC on Compression Stroke 157
How to Set Number One Piston to TDC on Compression Stroke (Alter 157
Valve Timing, Check 158
Fuel Injection Pump Timing, Check 159
Turbocharger – Engine YH Repair 160
General 160
Remove 160
Install 160
Impeller and Compressor Housing, Clean 161
Lubrication System Repair 162
General 162
Oil Filter, Replace 162
Filter Head 162
Remove and Install 162
Oil Sump 163
Remove 163
Install 163
Oil Pump 163
Remove 163
Inspect 164
Install 165
Relief Valve 165
Remove 165
Disassemble 166
Inspect 166
Assemble 166
Install 166
Idler Gear Shaft, Replace 167
Remove 167
Remove (Alternative) 167
Install 168
Install (Alternative) 168
Install (Alternative for Four-Cylinder Engines Only) 169
Fuel System Repair 169
Description 169
Fuel Injection Pump 170
Remove 170
Install 171
Check and Adjust 171
Fuel System Air Removal 172
Fuel Filter, Replace 173
Canister Type 173
Quick Release Canister Type 174
Fuel Injectors 175
Remove 175
Inspect 175
Install 175
Fuel Pump 176
Remove 176
Disassemble 176
Assemble 177
Install 178
Test 178
Cooling System Repair 178
General 178
Thermostat 178
Remove 178
Install 179
Test 179
Coolant Pump 179
Remove 179
Disassemble 180
Assemble 181
Install 184
Fan and Fan Drive 184
Remove 184
Install 185
Oil Cooler (Six-Cylinder Engines) 185
Remove 185
Disassemble and Assemble 185
Install 186
Oil Cooler Bypass Valve 186
Electrical Equipment Repair 186
Drive Belts 186
Adjustment 186
Remove 187
Install 187
Alternator 187
Remove 187
Install 187
Starter Motor 188
Remove 188
Install 188
Cold Start Aid 188
Air Compressor – Engines YG and YH 188
General 188
Repair 188
Remove 188
Install 189
Rotary Exhauster Replacement 190
Remove 190
Clean 190
Install 190
Engine Specifications 191
Cylinder Head Assembly 191
Piston and Connecting Rods 194
Crankshaft Assembly 197
Crankshaft Overhaul 198
Timing Case and Drive Assembly 200
Engine Block Assembly 201
Turbocharger 204
Lubrication System 204
Fuel System 205
Cooling System 207
Flywheel and Housing 207
Electrical Equipment 208
Torque Specifications 208
Cylinder Head Assembly 208
Piston and Connecting Rod Assemblies 208
Crankshaft Assembly 208
Timing Case and Drive Assembly 209
Turbocharger 209
Lubrication System 209
Fuel System 209
Cooling System 209
Flywheel 209
Auxiliary Equipment 209
Special Torque Specifications 210
Flywheel and Housing 210
Turbocharger 210
Electrical Equipment 210
Auxiliary Equipment 210
Special Tools* 211
Troubleshooting 216
tables 91
Table 1 Cylinder Head 191
Table 2 Valve Guides 191
Table 3 Inlet Valves 191
Table 4 Exhaust Valves 192
Table 5 Valve Springs 194
Table 6 Tappets 194
Table 7 Rocker Arm Shaft 194
Table 8 Rocker Arms and Bushings 194
Table 9 Pistons (Engine AR) 194
Table 10 Pistons (Engines YG and YH) 194
Table 11 Piston Rings (Engine AR) 195
Table 12 Piston Rings (Engines YG and YH) 195
Table 13 Piston Pins 196
Table 14 Connecting Rods 196
Table 15 Small End Bushings 196
Table 16 Connecting Rod Bearings (Engines AR and YG) 196
Table 17 Connecting Rod Bearings (Engine YH) 196
Table 18 Piston Cooling Jets 197
Table 19 Crankshaft 197
Table 20 Main Bearings 197
Table 21 Crankshaft Thrust Washers 197
Table 22 Crankshaft Heat Treatment 198
Table 23 Crankshaft Overhaul Specifications 198
Table 24 Maximum Variation (Run-out) 200
Table 25 Camshaft 200
Table 26 Camshaft Thrust Washer 200
Table 27 Camshaft Gear 200
Table 28 Gear for Fuel Injection Pump 201
Table 29 Crankshaft Gear 201
Table 30 Idler Gear and Hub 201
Table 31 Cylinder Block (Engine AR) 201
Table 32 Cylinder Bore Specifications 202
Table 33 Cylinder Block (Engines YG and YH) 203
Table 34 Cylinder Liners (Engines YG and YH) 203
Table 35 Cylinder Liner Specifications (Partially Finished) 203
Table 36 Oil Pump (Engine AR) 204
Table 37 Oil Pump (Engines YG and YH) 204
Table 38 Idler Gear for Oil Pump 204
Table 39 Relief Valve 205
Table 40 Oil Filter 205
Table 41 Lucas Fuel Injection Pump 205
Table 42 Fuel Injector Codes 206
Table 43 Fuel Pump (Engine AR) 207
Table 44 Fuel Pump (Engines YG and YH) 207
Table 45 Fuel Filter 207
Table 46 Coolant Pump 207
Table 47 Thermostat 207
Table 48 Fan Drive Housing 207
Table 49 Limits for Flywheel Run Out and Alignment (Total Indic 207
Table 50 Alternator 208
Table 51 Starter Motor 208
Table 52 Cold Start Aid 208
Table 53 List of Possible Causes 216
524150775 0700YRM0626 (03 2003) UK EN 221
toc 221
Cooling System 221
Safety Precautions Maintenance and Repair 222
General 225
Description 226
Radiator 226
Radiator Cap 226
Thermostat 226
Water Pump 227
Fan and Fan Shroud 227
Cooling System Checks 227
Radiator 227
Thermostat 227
Water Pump 228
Exhaust Leaks 228
Fan and Fan Shroud 228
Radiator Cleaning 228
Drain 228
Clean 228
Fill 229
Troubleshooting 230
524150776 1300YRM0930 (08 2001) UK EN 233
toc 233
Three-Speed Powershift Transmission 233
Safety Precautions Maintenance and Repair 234
General 237
Mechanical Description 237
General 237
Torque Converter 237
Description 237
Operation 237
Clutch Assemblies 241
Description 241
Operation 242
Forward and First-Speed Clutch Assembly 242
Reverse and Second-Speed Shaft, First and Second Gear Shaft 243
Third-Speed Shaft 243
Output Shaft 243
Hydraulic Operation 245
Sump, Filter and Pump 245
Transmission Control Valve 245
Solenoid Valves 245
Inching Spool 246
Direction Spools 246
Range Spool 246
Modulator Valve 247
Operation 247
Modulator Operation 248
Transmission Control System 251
Foot Directional Control Pedal 251
Control Lever 252
Hydraulic Circuits 253
Cooling and Lubrication 253
Neutral 253
Forward-First 253
Reverse-First 256
From First to Second Speed 257
From Second to Third Speed 258
Inching 259
524150777 1300YRM0931 (08 2001) UK EN 263
toc 263
Three-Speed Powershift Transmission 263
Safety Precautions Maintenance and Repair 264
General 267
Transmission Repair 270
Remove 270
Disassemble 272
Torque Converter Housing and Pump Gears 272
Transmission Cover, Remove 273
Clutch Assemblies, Remove 275
Forward and Low-Speed Clutches 276
Forward Clutch, Disassemble 276
First-Speed Clutch, Disassemble 278
Reverse and Second-Speed Clutches, Disassemble 278
Second-Speed Clutch, Disassemble 278
Reverse Clutch, Disassemble 280
Third-Speed Clutch, Disassemble 280
Output Gears, Disassemble 282
Clean 282
Inspect 282
Assemble 284
Output Gears, Assemble 284
Third-Speed Clutch, Assemble 284
Reverse and Second-Speed Clutches, Assemble 284
Second-Speed Clutch, Assemble 284
Reverse Clutch, Assemble 287
Forward and First-Speed Clutches, Assemble 287
Forward Clutch, Assemble 287
First-Speed Clutch, Assemble 289
Clutch Assemblies, Install 289
Input Shaft and Forward Clutch Hub, Install 290
Transmission Cover, Install 291
Torque Converter Housing 293
Install 295
Control Valve Repair 297
Remove 297
Disassemble and Assemble 298
Clean and Inspect 298
Install 298
Modulator Valve Repair 300
Remove 300
Disassemble 300
Clean and Inspect 300
Install 300
Transmission Pump Repair 302
Remove 302
Disassemble 302
Clean and Inspect 302
Assemble 302
Install 302
Foot Directional Pedal Repair 304
Remove and Disassemble 304
Assemble and Install 304
Inching/Brake Pedal Linkage Adjustment 306
Stall Test 307
Transmission Oil Pressure Check 308
Troubleshooting 310
tables 263
Table 1 Transmission Pressures 309
524150778 1300YRM0932 (12 2004) UK EN 315
toc 315
Autoshift Transmission Controller 315
Safety Precautions Maintenance and Repair 316
General 319
Autoshift Control Module 319
Transmission Shift Control Valve 319
Autoshift Functions 320
System Interaction With Operator Display 320
Error Code Descriptions 320
System Audible Alarm 320
Park Brake Interlock 322
System Reset/Override 322
System Degraded Operating Mode 322
System Failure Mode 322
Transmission Oil High-Temperature Fault 322
Loss of Transmission Oil Pressure Fault 322
Controller Bypass 323
Automatic/Manual Shift Mode 323
Automatic Transmission Shifting 323
Manual Transmission Shifting 324
Direction Change 324
Direction Change Inhibit 324
Downshift Inhibit 325
Driveshaft Engagement Inhibit 325
Lift Height Transmission Interrupt (Optional) 325
Engine Dethrottle (Optional) 326
Autoshift Hardware 326
Autoshift Lever 326
Speed Sensors 327
Transmission System Monitor Diagnostics 327
Controller Parameter Adjustment Software User Interface 328
User Interface Description 328
Components Required to Communicate With Controller 328
Userlink Installation Instructions 328
Start Procedures 328
Controller Product Codes 328
Main Menu Description 329
Language Selection 329
Help Menu 329
PC Serial Communication Port 329
Monitor Screen 329
Event Log 330
Parameter Adjustment 331
Current Parameters 331
Load Parameters 331
Restore Factory Parameters 331
Load Controller Software from File 331
Exit Menu 331
Controller Connector Pin-Out Tables 333
tables 315
Table 1 Error Code Descriptions 321
Table 2 Automatic Transmission Upshift 323
Table 3 Automatic Transmission Downshift 324
Table 4 Event Log Descriptions and Values 330
Table 5 Parameter Descriptions and Values 332
Table 6 J2 Controller Connector (Black) 333
Table 7 J1 Controller Connector (Blue) 335
524150779 1400YRM0046 (08 2012) UK EN 339
toc 339
Differential 339
Safety Precautions Maintenance and Repair 340
General 343
Description 343
Differential Repair 343
Remove 343
Differential Carrier From Axle Housing, Remove 343
Differential and Ring Gear From Differential Carrier, Remove 347
Drive Pinion and Pinion Carrier From Differential Carrier, Remov 349
Disassemble 350
Differential and Ring Gear Assembly, Disassemble 350
Drive Pinion and Pinion Carrier, Disassemble 351
Clean and Inspect 354
Assemble 355
Pinion, Bearings, and Pinion Carrier, Assemble 355
Pinion Bearings, Adjust Preload 355
Press Method 355
Yoke or Flange Method 356
Triple-Lip Seal, Install 357
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion) 358
Differential and Ring Gear, Assemble 360
Differential Gears Rotating Torque, Check 362
Differential and Ring Gear Assembly, Install 363
Differential Bearings, Preload Adjust 364
Ring Gear, Runout Check 365
Ring Gear Backlash, Adjust 366
Gear Set, Tooth Contact Pattern Check 368
Thrust Screw, Install and Adjust 371
Install 371
Differential Assembly Into Axle Housing, Install 371
Specifications 372
Troubleshooting 376
tables 339
Table 1 Ring Gear Backlash Adjustment Specifications 367
Table 2 Ring and Pinion Tooth Contact Adjustment 368
Table 3 General Specifications 372
Table 4 Rivet Installation Pressure 372
Table 5 Pinion Adjustment 372
Table 6 Pinion Preload Pressure 373
Table 7 Torque Specifications 374
Table 8 Torque Specifications for Metric Hardware 375
Table 9 Torque Specifications for Metric (Fine) Hardware 375
524150780 1400YRM0944 (08 2012) UK EN 379
toc 379
Planetary Drive Axle 379
Safety Precautions Maintenance and Repair 380
General 383
Description 383
Operation 385
Identification 385
Removal 386
Disassembly 386
Planetary Spider and Gearing Assembly GDP80-120DB (GP170-280DB) 387
Planetary Spider and Gearing Assembly GDP130-160EB (GP300-360EB) 388
Wheel End 390
Spindle and Piston Housing 391
Cleaning 392
Clean Ground or Polished Parts 392
Clean Parts With Rough Finish 392
Clean Axle Assemblies 392
Drying Cleaned Parts 392
Corrosion Prevention 392
Parts Inspection 393
Tapered Roller Bearings 393
Bevel Pinion and Ring Gear Sets 394
Main Differential Assembly 394
Axle Shafts 394
Yoke 394
Brakes 394
Repair or Replace Parts 394
Repair Welding 395
Apply Silicone Gasket Material 395
Assembly 395
Spindle and Piston Housing to Axle Housing 395
Wet Disc Brakes 396
Adjust Wheel Bearing Preload 397
Planetary Spider and Gearing Assembly GDP80-120DB (GP170-280DB) 398
Planetary Spider and Gearing Assembly GDP130-160EB (GP300-360EB) 398
Planetary Spider Assembly 399
Installation 400
Fill Wet Disc Brakes With Hydraulic Fluid 400
Torque Specifications 401
Lubrication Specification 402
524150781 1400YRM0945 (08 2011) UK EN 405
toc 405
Planetary Drive Axle 405
Safety Precautions Maintenance and Repair 406
General 409
Description 409
Operation 411
Identification 411
Removal 412
Disassembly 413
Brake Drum 413
Planetary Spider and Gearing Assembly GDP/GLP80-120DB (GDP/GLP17 414
Dry Brakes 414
Planetary Spider and Gearing Assembly GDP/GLP130-160EB (GDP/GLP3 416
Spindle and Brake Spider 418
Cleaning 418
Ground or Polished Parts 418
Parts With Rough Finish 419
Axle Assemblies 419
Drying Cleaned Parts 419
Corrosion Prevention 419
Parts Inspection 419
Tapered Roller Bearings 419
Bevel Pinion and Ring Gear Sets 420
Main Differential Assembly 421
Axle Shafts 421
Yoke 421
Brakes 421
Repair or Replace Parts 421
Repair Welding 421
Apply Silicone Gasket Material 421
Assembly 422
Spindle, Brake Spider, and Brake 422
Wheel End 423
Adjust Wheel Bearing Preload 423
Planetary Spider and Gearing Assembly GDP/GLP80-120DB (GDP/GLP17 424
Planetary Spider and Gearing Assembly GDP/GLP130-160EB (GDP/GLP3 425
Planetary Spider Assembly 425
Installation 426
Torque Specifications 427
Lubrication Specification 428
524150782 1600YRM0936 (03 2007) UK EN 431
toc 431
Steering System 431
Safety Precautions Maintenance and Repair 432
General 435
Description 435
Steering Wheel and Column Assembly 437
General 437
Steering Wheel and Horn 437
Remove 437
Install 437
Steering Control Unit Repair 439
General 439
Description 439
Operation 439
Remove 440
Disassemble 440
Clean 443
Assemble and Install 443
Steering System Air Removal 449
Steering Relief Pressure Check 450
Troubleshooting 450
524150783 1600YRM0326 (03 2007) UK EN 455
toc 455
Steering Axle 455
Safety Precautions Maintenance and Repair 456
General 459
Description 459
Steering Axle Assembly Repair 464
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 464
Remove 464
Install 464
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP 465
Remove 465
Install 465
Wheels and Hubs Repair (All Units) 466
Remove and Disassemble 466
Clean 466
Inspect 466
Assemble and Install 466
Spindles and Bearings Repair (All Units) 468
Remove 468
Clean 468
Assemble and Install 469
Tie Rods Repair (All Units) 470
Remove 470
Clean 470
Install 470
Steering Cylinder Repair 473
Remove and Disassemble 473
Clean and Inspect 473
Assemble and Install 473
Troubleshooting 474
524150784 1800YRM0937 (04 2010) UK EN 479
toc 479
Dry Brake System 479
Safety Precautions Maintenance and Repair 480
General 483
Description 483
Operation 484
Service Brakes 484
Parking Brake 485
Air Tank Repair 486
Relief Valve 486
Drain Valve 487
Brake Pedal Valve Repair 487
Remove 487
Disassemble, Inspect, and Assemble 488
Install 488
Air Chambers Repair 489
Remove 489
Disassemble 489
Inspect 489
Assemble 491
Install 491
Actuator Arms Repair 491
Remove 491
Inspect 492
Install 492
Brake Assemblies Repair 493
Brake Shoe, Remove 493
Camshaft, Remove 495
Clean 495
Inspect 496
Camshaft, Install 496
Brake Shoe, Install 497
Air Dryer 497
Description 497
Cartridge 497
Remove 497
Install 497
Filter 499
Remove 499
Install 499
Quick-Release Valve 499
Governor Check and Adjustment for Air Compressor 500
Brake Shoes Adjustment 500
Specifications 502
Troubleshooting 503
Service Brakes 503
Service Brakes, Park Function 505
tables 479
Table 1 Air Chambers Operation 485
524150785 1800YRM0951 (02 2018) UK EN 509
General 513
Description and Operation 513
Service Brakes 513
Parking Brake 513
Oil Cooler Circuit 513
Pressure Switch Replacement 516
Accumulators Replacement 517
Brake Treadle Valve Repair 517
Remove and Disassemble 517
Clean and Inspect 518
Assemble and Install 518
Parking Brake Valve Repair 518
Remove 518
Clean and Inspect 518
Repair 518
Install 518
Parking Brake Caliper Repair 518
Remove 518
Disassemble 521
Inspect 521
Install 521
Adjust 521
Brake Pad Repair 522
Inspect 522
Remove 522
Install 522
Seals Repair 522
Remove 522
Install 522
Service Brake Repair 523
Remove and Disassemble 523
Drain Lubricating Oil 523
Drain Coolant Oil 529
Disconnect Brake Lines 529
Wheel End With Outer Bearing on Ring Gear Hub Journal, Lift Truck Models GDP/GLP130-160EB (GP/GDP/GLP300-360EB) 529
Wheel End With Outer Bearing on Spindle Journal, Lift Truck Models GDP/GLP80-120DB (GP/GDP/GLP170-280DB) 530
Brake Disc Housing Assembly Wheel End 531
Brake Piston Housing 532
Brake Piston Housing and Wheel Spindle 533
Inspect 533
Clean 535
Assemble 536
Wheel Spindle 536
Brake Piston Housing 537
Piston Assembly 538
Brake Disc Housing 539
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub 540
Check for Correct Installation of Duo-Cone Seal 542
Wheel Hub to Brake Disc Housing 542
Adjust 543
Fill Brake System With Coolant Oil 544
System Air Removal 544
Adjust Brake With New Disc Pack 544
Coolant Change Intervals 545
Coolant Draining and Filling 545
Wet Brake Noise Reduction 546
General 546
Adding Additive To Transmission 547
Specifications 548
Minimum Brake Disc Thickness 551
Hydraulic Fluid for Brake Actuation 551
Brake Coolant Specifications 551
Coolant Change Intervals 551
Hydraulic Fluid Specifications 551
Troubleshooting 552
524150787 1900YRM0938 (03 2007) UK EN 557
toc 557
Hydraulic System 557
Safety Precautions Maintenance and Repair 558
General 561
Description and Operation 561
Hydraulic Tank 561
Hydraulic Pump 562
Steering Priority Flow Valve 562
Pilot Valve 563
Main Control Valve 565
Unloader Valve 566
Hydraulic Operation 567
Checks And Adjustments 570
Quick Disconnect Fittings 570
Steering Priority Flow Valve 570
Steering Relief Pressure 570
Modulator Valve 571
Pilot Valve and Pressure Reducing Valve 571
Accumulator 572
Filter 572
Main Control Valve 572
Relief Pressure Check 572
Check Valves 573
Unloader Valve 573
Hydraulic Pump Repair 574
Remove 574
Disassemble 574
Clean and Inspect 574
Assemble 575
Install 576
Pilot Accumulator Replacement 576
Remove 576
Install 576
Pilot Valve Repair 576
Remove 576
Disassemble 577
Clean and Inspect 577
Assemble 577
Install 578
Control Levers and Joystick Repair 579
Remove 579
Install 579
Calibration and Diagnostics 580
General 580
Description 580
Lever and Joystick Calibration 580
Flow Adjustment 580
Dead Band Value Setting 581
Lowering Delay 582
PWM and I/O Module Readouts 582
Function Disable 583
General Startup 583
Minimum system requirements 583
Install the Hydraulic Controls Program 583
DelayTimeFile (Reset) 583
Select the Processor Speed 584
Hydraulic Controls Program 584
Calibration 585
Joystick/Lever Calibration 585
Levers 585
Joystick 586
Valve Flow Adjustment 586
Diagnostics 587
Calibration System Shutdown 587
LED Diagnostics 588
Electrical Connections 590
Specifications 594
tables 557
Table 1 Main Control Valve Port Settings 563
Table 2 Processor Speed Settings 583
Table 3 PWM Board LED Error Codes 588
Table 4 Altering PT I/O Board LED’s (Old Logic) 589
Table 5 Altering PT I/O Board LED’s (New Logic) 589
Table 6 Fixed PT Logic I/O Boards LED’s 590
Table 7 PWM Driver Module 591
Table 8 Input/Output Module 1 591
Table 9 Input/Output Module 2 592
Table 10 Altering PT 593
Table 11 Fixed PT 593
524150788 2000YRM0943 (03 2007) UK EN 597
toc 597
Main Control Valve 597
Safety Precautions Maintenance and Repair 598
General 601
Description 601
Operation 604
Lift Section 604
Tilt/Auxiliary Section 604
Relief Valves 604
Unloader Valve 604
Main Control Valve Repair 607
Remove 607
Disassemble 607
Auxiliary Side 607
Lift Side 607
Clean and Inspect 610
Assemble 610
Auxiliary Side 610
Lift Side 610
Install 610
Pressure Relief Valve Check and Adjustment 611
Check and Adjust 611
Replace 611
Specifications 612
Troubleshooting 612
524150790 2100YRM0103 (03 2007) UK EN 617
toc 617
Tilt Cylinders 617
Safety Precautions Maintenance and Repair 618
General 621
Description 621
Tilt Cylinder Repair 621
Remove 621
Disassemble 621
Clean 621
Assemble 622
Tilt Cylinders With O-Ring or Single-Lip Seals 622
Tilt Cylinders 623
Install 624
Tilt Cylinder Leak Check 626
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 627
Torque Specifications 627
Piston Rod Nut 627
Retainer 627
Troubleshooting 628
tables 617
Table 1 Movement Rates (Maximum) for Tilt Cylinders 626
524150791 2200YRM0002 (01 2016) UK EN 633
General 637
Description 638
Alternator Repair 640
Alternator Type A 640
Remove and Disassemble 640
Clean 642
Assemble 642
Install 643
Alternator Type B 646
Remove and Disassemble 646
Clean 646
Assemble 647
Install 648
General Check and Adjustment 648
Low Output Check (Type A or Type B) 649
High Output Check (Type A or Type B) 652
Brushes Circuit Check 653
Delco Alternators 653
Motorola Alternators 653
Diodes Check 654
Diode Bridge Check 654
Delco and Leece-Neville Alternators 654
Motorola Alternators 654
Rotor Field Winding Check 655
Stator Windings Check 656
Voltage Regulator Check 656
Troubleshooting 656
524150792 2200YRM0106 (01 2016) UK EN 661
General 665
Description and Operation 666
Starter Repair 670
Remove 670
Disassemble 670
Clean 671
Assemble 671
Install 672
General Checks and Adjustments 672
Troubleshooting 674
524150793 2200YRM0939 (12 2004) UK EN 681
toc 681
Instrument Panel Indicators and Senders 681
Safety Precautions Maintenance and Repair 682
General 685
Description 685
General 685
Instrument Panel Meters, Indicators, and LCD Display 685
Error Code Display, Transmission 692
Error Code Display, Engine 693
Connector 694
Seat Switch Logic 694
Central Warning Light Output 696
Buzzer Output 696
Engine Shutdown Output 696
Instrument Panel Component Replacement 699
Instrument Panel 699
Remove 699
Light 700
Replace 700
Sender Replacement 700
Fuel Level Sender 700
Transmission Pressure and Temperature Sender, Tier 1 701
Pressure Sender, Tier 2 702
Temperature Sender, Tier 2 702
Low Coolant Sender 702
Vacuum Switch 702
Crankshaft Position Sensor 703
Specifications 703
Troubleshooting 705
tables 681
Table 1 Instrument Panel and Indicators 686
Table 2 Engine Error Code Descriptions 694
Table 3 Pin Description 695
Table 4 Sender Description 696
524150794 4000YRM0135 (03 2011) UK EN 709
toc 709
Lift Cylinders 709
Safety Precautions Maintenance and Repair 710
Safety Procedures When Working Near Mast 713
General 717
Description 717
Lowering Control Valve 717
Cylinders (General) 720
Lift Cylinder Repair 720
Lift Cylinder Removal Without Removing Mast 720
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 720
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 721
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift 722
Disassemble 722
Assemble 722
Lift Cylinder Installation in Mast 724
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 724
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 724
Chevron-Style Packing 725
Chevron-Style Packing Installation on Piston 725
Chevron-Style Packing Installation in Packing Gland 727
Lift Cylinders for HI VIS® Masts 729
Description 729
Lowering Control Valve 729
Remove 731
Disassemble 732
Assemble 732
Install 734
Main Lift Cylinders 734
Free-Lift Cylinder 734
Lift System Leak Check 734
Specifications 735
Troubleshooting 736
tables 709
Table 1 Cylinder Retainer Torque Specifications and Weight Guid 735
524150795 4000YRM0445 (08 2001) UK EN 741
toc 741
Masts 741
Safety Precautions Maintenance and Repair 742
General 745
Description 745
Safety Procedures When Working Near Mast 746
Operation 748
Two-Stage Mast 748
Three-Stage Mast 748
Forks Repair 750
Remove 750
Install 750
Carriage Repair 750
Remove 750
Sideshift Carriage, Disassemble 750
Sideshift Carriage, Assemble 752
Sideshift Cylinder, Disassemble 753
Sideshift Cylinder, Assemble 753
Fork Positioner Cylinder, Disassemble 754
Fork Positioner Cylinder, Assemble 755
Install 756
Mast Repairs 756
Remove 756
Two-Stage Mast, Disassemble 756
Three-Stage Mast, Disassemble 760
Clean and Inspect 762
Two-Stage Mast, Assemble 762
Three-Stage Mast, Assemble 765
Install 768
Lift Cylinders Description 770
Piston-Type Cylinders 770
All Lift Cylinders Repair 770
Remove 771
Disassemble 771
Clean and Inspect 772
Assemble 772
Install 772
Mast Operation Check 773
Lift and Tilt System Leak Checks 773
Lift System 773
Tilt System 773
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 774
Lift Chain Adjustments 774
Mast Adjustments 775
Bearing Blocks 775
Wear Plates 775
Load Roller Adjustments 776
Carriage Adjustment 778
Troubleshooting 780
tables 741
Table 1 Carriage and Fork Weights 753
Table 2 Mast Weights 760
Table 3 Allowable Mast Movement from Internal Leakage 774
524150797 8000YRM0231 (02 2023) US EN 785
General 791
Threaded Fasteners 791
Nomenclature, Threads 791
Strength Identification 792
Cotter (Split) Pins 793
Fastener Torque Tables 798
Conversion Table 800
524150797 8000YRM0231 (03 2020) UK EN 807
General 811
Threaded Fasteners 811
Nomenclature, Threads 811
Strength Identification 812
Cotter (Split) Pins 813
Fastener Torque Tables 818
Conversion Table 820
524150798 8000YRM0940 (07 2013) UK EN 827
toc 827
Capacities and Specifications 827
Safety Precautions Maintenance and Repair 828
Lift Truck Weights 831
Capacities 832
Engine Specifications 833
Perkins Diesel 833
Cummins Diesel/LPG 834
Hydraulic System 835
Electrical System 836
Tire Sizes 836
Mast Speeds 837
Perkins Diesel 837
Cummins Diesel/LPG 838
Torque Specifications, Cummins Diesel 839
Lubrication System 839
Torque Specifications, Perkins Diesel 839
Engine 839
Cylinder Head Assembly 839
Piston and Connecting Rod Assemblies 839
Crankshaft Assembly 839
Timing Case and Drive Assembly 839
Turbocharger 839
Lubrication System 840
Fuel System 840
Cooling System 840
Flywheel and Housing 840
Aspiration System 840
Electrical Equipment 840
Auxiliary Equipment 840
Torque Specifications, General 841
Transmission 841
Driveline and Axle 841
Differential 841
Brakes – Wet 841
Brakes – Dry 841
Steering 841
Hydraulic System 841
Mast 842
Carriage 842
Tilt Cylinders 842
Frame 842
Wiper Arms, Front 842
Transmission Pressures (Powershift and Automatic) 843
TE-10 Transmission Specifications 844
Electrical 844
Hydraulic Cooler Lines 844
Torque Specifications for Lubricated or Plated Screw Threads 844
tables 827
Table 1 Temperature Sensor (In Speed Sensor) Resistance vs Temp 844
Table 2 Grade 5 845
Table 3 Grade 8 845
Table 4 Grades 8 8, 10 9, and 12 9 846
Table 5 O-ring Port Plug Torque Chart 847
Table 6 Pipe Plug Torque Chart 847
524150799 8000YRM0941 (01 2006) UK EN 851
toc 851
Diagrams 851
Safety Precautions Maintenance and Repair 852
General 855
Description 855
524192598 8000YRM1066 (09 2005) UK EN 913
toc 913
Periodic Maintenance 913
Safety Precautions Maintenance and Repair 914
General 917
How to Move Disabled Lift Truck 917
How to Tow Lift Truck 917
How to Put Lift Truck on Blocks 918
How to Raise Drive Tires 918
How to Raise Steering Tires 918
Maintenance Schedule 920
Maintenance Procedures Every 8 Hours or Daily 925
How to Make Checks With Engine Stopped 925
Hydraulic System Oil 925
Engine Oil 926
Cooling System 927
Fuel System 927
Water Separator/Fuel Filter 927
Fuel, Oil, or Coolant Leaks, Check 927
Cab Hydraulic System 927
Drive Belts 928
Battery 928
Air Filters 928
Forks 928
Adjust 929
Remove 929
Install 929
Forks, Mast, and Lift Chains, Inspect 929
Tires and Wheels 930
Operator Restraint System 931
Steering Column Latch 931
Safety Labels 932
How to Make Checks With Engine Running 932
Gauges, Lights, Horn and Fuses 932
Control Levers and Pedals 934
Transmission Oil 934
Lift System Operation 934
Brakes 934
Steering System 934
Maintenance Procedures Every 500 Hours or Every 3 Months 935
Lift Chains 935
Lubrication 935
Adjust 935
Drive Shaft 935
Steering Axle 935
Wheel Nuts 936
Shafts for Brake Actuators 936
Drive Axle and Differential 936
Hydraulic Tank Breather 936
Air Filter, Engine, and Air Compressor 936
Cabin Air Filter, Heater 936
Engine Oil and Filter 936
Drive Belts 937
Mast 937
General Lubrication 938
Fork Wear and Damage Check 938
Lift Chains Wear Check 939
Maintenance Procedures Every 1000 Hours or 6 Months 939
Transmission Oil and Filter, Change 939
Fuel Filter 940
Diesel Fuel System Air Removal 940
Fuel Injection Pump Without Vent Tube 940
Fuel Injection Pump Timing 941
Valve Adjustment 941
Pilot Accumulator Pressure Charge Check 942
Maintenance Procedures Every 2000 Hours or Yearly 942
Hydraulic System 942
Hydraulic Oil Filter, Change 942
Hydraulic Oil, Change 942
Differential and Drive Axle 943
Wheel Bearings 943
Steer Wheels 943
Drive Wheels 943
Service Brakes 944
Cleaning Procedures (Dry Brake Axle) 944
Safety Procedures When Working Near Mast 944
Fuel Injectors Check 945
Perkins 945
Lift and Tilt System Leak Check 946
Lift System 946
Tilt System 946
Welding Repairs 947
Wheel and Tire Replacement 948
Remove Wheels From Lift Truck 948
Pneumatic Tires 948
Remove Tire From Wheel 948
Remove Tire From Three- and Four-Piece Wheel 949
Install Tire on Wheel 950
Install Three- or Four-Piece Wheel in Tire 950
Add Air to Tires 951
Solid Rubber Tires 952
Remove Tire From Wheel 952
Install Tire on Wheel 953
Wheels, Install 955
tables 913
Table 1 Daily Inspections − Condition Check 920
Table 2 Daily Inspections − Fluid Level Check 921
Table 3 Daily Inspections − Checks With the Engine Running 921
Table 4 First Inspection After First 100 Hours of Operation 922
Table 5 Periodic Maintenance Schedule − Inspect and Adjust 923
Table 6 Periodic Maintenance Schedule − Lubricate 924
Table 7 Periodic Maintenance Schedule − Change 924
Table 8 Allowable Mast Movement from Internal Leakage 947
524192855 0600YRM1068 (05 2004) UK EN 959
toc 959
Perkins Tier 2 Diesel Engines 959
Safety Precautions Maintenance and Repair 960
General 967
General Safety Rules 967
Description 968
Engine Serial Number Codes 970
Engine Data 970
Engine Removal and Installation 971
Cylinder Head Assembly Repair 971
Valve Cover 971
Remove 971
Install 972
Rocker Arm Assembly 972
Remove 972
Disassemble 972
Inspect 972
Assemble 972
Install 972
Valve Clearance Adjustments 973
Valve Springs 974
Cylinder Head Assembly 975
Remove 975
Install 977
Valves and Valve Springs 980
Remove 980
Inspect 980
Install 981
Valve Guides 981
Inspect 981
Remove 981
Install 981
Cylinder Head and Valve Seats 982
Inspect 982
Repair 983
New Valve Seats, Install 983
Piston and Connecting Rod Assemblies Repair 983
Rod Bearings 984
Remove 984
Install 984
Piston and Connecting Rod Assembly 985
Service Note 985
Remove 985
Install 986
Piston Rings 987
Remove 987
Inspect 987
Install 987
Piston and Connecting Rod 988
Disassemble 988
Inspect 988
How to Select Correct Replacements 989
Install 990
Piston Cooling Jets 990
Remove 990
Install 990
Crankshaft Assembly Repair 991
General 991
Crankshaft Pulley 991
Remove 991
Inspect 991
Install 992
Rear Oil Seal 992
Remove 992
Install 993
Main Bearings 994
Remove 994
Inspect 994
Install 994
Thrust Washers 995
Crankshaft Axial Movement, Check 995
Remove 996
Install 996
Crankshaft 996
Remove 996
Inspect 997
Install 997
Flywheel 998
Remove 999
Ring Gear, Replace 999
Install 999
Flywheel Housing 999
Remove 999
Install 1000
Timing Case and Timing Gears Repair 1000
General 1000
Timing Case Cover 1000
Remove 1000
Install 1001
Front Oil Seal 1001
Remove 1001
Install 1002
Crankshaft Pulley Wear Sleeve 1002
Install 1002
Idler Gear and Hub 1003
Remove 1003
Install 1003
Air Compressor Drive, Bendix 1004
Disassemble 1004
Assemble 1005
Fuel Injection Pump Gear 1005
Remove 1005
Install 1006
Camshaft Gear 1006
Remove 1006
Install 1007
Crankshaft Gear 1007
Remove 1007
Install 1008
Timing Case 1008
Remove 1008
Install 1008
Camshaft and Tappets 1009
Remove 1009
Install 1010
Cylinder Block Assembly Repair 1010
Description 1010
Cylinder Block 1010
Disassemble 1010
Inspect 1011
Assemble 1012
Cylinder Liner 1012
Inspect 1012
Cylinder Liner Condition, Check 1012
Remove 1013
Service Liner, Install 1014
Partially Finished Liner, Install 1015
Engine Timing 1016
Description 1016
How to Set Number One Piston to TDC on Compression Stroke 1017
How to Set Number One Piston to TDC on Compression Stroke (Alter 1018
How to Set Number One Piston to 4° After TDC on Compression Stro 1019
Valve Timing, Check 1020
Fuel Injection Pump Timing, Check 1021
Turbocharger 1021
General 1021
Remove 1021
Install 1022
Impeller and Compressor Housing, Clean 1022
Waste-Gate Valve Check 1023
Closed Circuit Breather System (CCB) 1024
CCB Assembly, Remove 1024
Closed Circuit Drain Valve, Remove 1024
CCB Assembly, Install 1024
Closed Circuit Drain Valve, Install 1024
Lubrication System Repair 1025
General 1025
Oil Filter, Replace 1025
Oil Filter Head 1025
Remove 1025
Install 1026
Oil Filter Head Bypass Valve 1026
Remove and Install 1026
Oil Sump 1026
Remove 1026
Install 1026
Oil Pump 1027
Remove 1027
Inspect 1027
Install 1028
Relief Valve 1028
Remove 1028
Disassemble 1029
Inspect 1029
Assemble 1029
Install 1029
Idler Gear Shaft, Replace 1029
Remove 1030
Remove (Alternative) 1030
Install 1031
Install (Alternative) 1031
Fuel System Repair 1032
Description 1032
Fuel Injection Pump 1034
Remove 1034
Install 1035
Fuel System Air Removal 1036
Fuel Filter, Replace 1038
Fuel Injectors 1038
Remove 1038
Inspect 1039
Install 1039
Fuel Lift Pump 1040
Remove 1040
Disassemble 1040
Assemble 1040
Install 1041
Test 1041
Cooling System Repair 1042
General 1042
Thermostat 1042
Remove 1042
Install 1042
Test 1042
Coolant Pump 1043
Remove 1043
Disassemble 1043
Assemble 1045
Install 1048
Fan and Fan Drive 1049
Remove 1049
Install 1049
Oil Cooler 1049
Remove 1049
Disassemble and Assemble 1049
Install 1050
Electrical Equipment Repair 1050
Drive Belts 1050
Alternator 1051
Remove 1051
Install 1051
Electronic Control Module (ECM) 1051
Remove 1051
Inspect 1052
Install 1052
Voltage Load and Protection Module (VLPM) 1052
Remove 1052
Install 1053
Engine Speed and Timing Sensor 1053
Remove 1053
Install 1053
Pressure Sensors (Engine Oil and Air Intake) 1053
Remove 1053
Install 1054
Temperature Sensor 1054
Remove 1054
Install 1055
Starter Motor 1055
Remove 1055
Install 1055
Cold Start Aid 1055
Air Compressor 1056
General 1056
Repair 1056
Remove 1056
Install 1056
Rotary Exhauster Replacement 1058
Remove 1058
Clean 1058
Install 1058
Engine Specifications 1058
Cylinder Head Assembly 1058
Piston and Connecting Rods 1061
Crankshaft Assembly 1062
Crankshaft Overhaul 1063
Timing Case and Drive Assembly 1065
Engine Block Assembly 1066
Turbocharger 1068
Lubrication System 1068
Cooling System 1070
Flywheel and Housing 1070
Electrical Equipment 1070
Torque Specifications 1071
Cylinder Head Assembly 1071
Piston and Connecting Rod Assemblies 1071
Crankshaft Assembly 1071
Timing Case and Drive Assembly 1071
Turbocharger 1071
Lubrication System 1071
Fuel System 1071
Cooling System 1072
Flywheel 1072
Auxiliary Equipment 1072
Special Torque Specifications 1073
Flywheel and Housing 1073
Electrical Equipment 1073
Auxiliary Equipment 1073
Special Tools 1074
Troubleshooting 1079
Turbocharger Troubleshooting 1081
tables 959
Table 1 Cylinder Head 1058
Table 2 Valve Guides 1059
Table 3 Inlet Valves 1059
Table 4 Exhaust Valves 1060
Table 5 Valve Springs 1060
Table 6 Tappets 1060
Table 7 Rocker Arm Shaft 1061
Table 8 Rocker Arms and Bushings 1061
Table 9 Pistons 1061
Table 10 Piston Rings 1061
Table 11 Piston Pins 1061
Table 12 Connecting Rods 1062
Table 13 Small End Bushings 1062
Table 14 Connecting Rod Bearings 1062
Table 15 Piston Cooling Jets 1062
Table 16 Crankshaft 1062
Table 17 Main Bearings 1063
Table 18 Crankshaft Thrust Washers 1063
Table 19 Crankshaft Heat Treatment 1063
Table 20 Crankshaft Overhaul Specifications 1064
Table 21 Maximum Variation (Run-Out) 1065
Table 22 Camshaft 1065
Table 23 Camshaft Thrust Washer 1065
Table 24 Camshaft Gear 1065
Table 25 Gear for Fuel Injection Pump 1066
Table 26 Crankshaft Gear 1066
Table 27 Idler Gear and Hub 1066
Table 28 Cylinder Block 1066
Table 29 Cylinder Liners 1067
Table 30 Cylinder Liner Specifications (Partially Finished) 1067
Table 31 Oil Pump 1068
Table 32 Idler Gear for Oil Pump 1068
Table 33 Relief Valve 1068
Table 34 Oil Filter 1068
Table 35 Bosch Fuel Injection Pump 1068
Table 36 Fuel Injector Codes 1069
Table 37 Fuel Pump 1070
Table 38 Fuel Filter 1070
Table 39 Coolant Pump 1070
Table 40 Thermostat 1070
Table 41 Fan Drive Housing 1070
Table 42 Limits for Flywheel Run Out and Alignment (Total Indic 1070
Table 43 Alternator 1070
Table 44 Starter Motor 1070
Table 45 Cold Start Aid 1070
Table 46 List of Possible Causes 1079
Table 47 List of Possible Causes 1081
524203754 4000YRM1062 (08 2012) UK EN 1085
toc 1085
Masts and Carriages 1085
Safety Precautions Maintenance and Repair 1086
General 1089
Description 1089
Operation 1090
Two-Stage Mast 1090
Three-Stage Mast 1091
Safety Procedures When Working Near Mast 1092
Forks Repair 1093
Remove 1093
Inspect and Adjust 1093
Install 1093
Carriage Repair 1095
Description 1095
Three Function 1095
Four to Six Function 1095
Remove 1095
Disassemble 1098
Clean and Inspect 1098
Assemble 1098
Install 1099
Sideshift Cylinder Repair 1099
Remove 1099
Disassemble 1099
Clean and Inspect 1102
Assemble 1102
Install 1103
Fork Positioner Cylinders Repair 1103
Remove 1103
Disassemble 1103
Clean and Inspect 1103
Assemble 1103
Install 1103
Directional Control Valve Repair 1110
Remove 1110
Disassemble 1110
Clean and Inspect 1110
Assemble 1111
Install 1111
Mast Repair 1111
Two- and Three-Stage Mast 1111
Remove 1111
Disassemble 1116
Clean and Inspect 1116
Assemble 1118
Install 1119
Three-Stage Mast (Four Cylinders) 1120
Remove 1120
Disassemble 1122
Clean and Inspect 1124
Assemble 1124
Install 1124
Fork Carriage Chains 1126
Adjust 1126
Bearing Rollers 1128
Description 1128
Lubrication 1128
Clearance 1128
Remove and Disassemble 1128
Assemble 1129
Mast Profile 1129
Lift Cylinders Description 1129
Piston-Type Cylinders 1129
Lift Cylinders Repair 1130
Remove 1130
Disassemble 1131
Clean and Inspect 1131
Assemble 1131
Install 1132
Mast Operation Check 1132
Lift and Tilt System Leak Checks 1133
Lift System 1133
Tilt System 1133
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 1134
Lift Chain Adjustments 1134
Mast Adjustments 1135
Bearing Blocks, Two-Stage Masts 1135
Wear Plates 1135
Carriage Adjustment 1136
Troubleshooting 1138
tables 1085
Table 1 Allowable Mast Movement from Internal Leakage 1133
524203841 0600YRM1072 (06 2005) UK EN 1143
toc 1143
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide 1143
Safety Precautions Maintenance and Repair 1144
Electronic Troubleshooting 1167
System Operation 1167
Electronic Controls 1167
Engine Governor 1168
Timing Considerations 1168
Fuel Injection 1168
Diagnostic Codes 1168
Diagnostic Fault Codes 1168
Diagnostic Event Codes 1168
Programmable Parameters 1168
Passwords 1169
Electronic Service Tools 1169
Electronic Service Tool (EST) 1169
Connecting the Electronic Service Tool and the Communication Ada 1169
Support for the Electronic Service Tool 1170
Optional Service Tools 1170
Diagnostic Codes 1170
Diagnostic Fault Code Access Via Indicator Lamps 1173
Replacing the ECM 1175
Self Diagnostics 1176
Glossary 1176
Sensors and Electrical Connectors 1180
Engine Wiring Information 1183
Harness Wire Identification 1186
Diagnostic Code Reader 1186
General 1186
Reference Documents 1186
Abbreviations 1186
Environmental Specification 1186
Hardware 1187
Connection Cable 1188
Software 1188
Engine Communication 1188
User Controls 1188
Power Supply 1188
Display Screen 1189
Operation Controls 1189
Audible Warning 1189
Operation Instructions 1189
How to Connect the Diagnostic Code Reader to the Engine 1189
How to Turn ON the Diagnostic Code Reader 1189
How to use the Display Screen 1189
How to Operate the Diagnostic Code Reader 1190
Main Menu 1190
Active Codes 1190
Inactive Codes 1190
How to Clear Codes 1191
Status Lamp 1191
Data List 1191
Diagnostics 1192
Programming Parameters 1193
Passwords 1193
Factory Passwords 1193
Customer Passwords 1193
Flash Programming 1194
Flash Programming a Personality Module 1194
WinFlash Error Messages 1194
System Configuration Parameters 1194
Full Load Setting 1194
Full Torque Setting 1194
Rating Interlock 1194
Engine Serial Number 1195
ECM Software Release Date 1195
Troubleshooting Without a Diagnostic Code 1195
Alternator Noise (Noisy Operation) 1195
Probable Causes 1195
Recommended Actions 1195
Alternator Drive Belts 1195
Alternator Drive Pulley 1195
Alternator Bearings 1195
Alternator Will Not Charge (Charging Problem) 1195
Probable Causes 1195
Recommended Actions 1195
Alternator Drive Belts 1195
Charging Circuit 1196
Alternator or Regulator 1196
Battery 1196
Probable Causes 1196
Recommended Actions 1196
Faulty Battery 1196
Auxiliary Device 1196
Cannot Reach Top Engine RPM 1196
Probable Causes 1196
Recommended Actions 1196
Diagnostic Codes 1196
Fuel Supply 1196
Air Intake and Exhaust System 1196
Individual Malfunctioning Cylinders 1197
Valve Lash 1197
Check for Low Compression 1197
Check the Fuel Injection Nozzles 1197
Check the Turbocharger 1197
ECM Parameters 1197
Check the Signal for the Throttle Position Sensor 1198
Coolant in Engine Oil 1198
Probable Causes 1198
Recommended Actions 1198
Engine Oil Cooler Core 1198
Cylinder Head Gasket 1198
Cylinder Head 1198
Cylinder Block 1198
Coolant Temperature Is Too High 1198
Probable Causes 1198
Recommended Actions 1198
Radiator Fins 1198
Coolant Level 1198
Radiator Cap and/or Pressure Relief Valve 1198
Combustion Gases in the Cooling System 1199
Water Temperature Regulator 1199
Restriction in the Coolant System 1199
Coolant Temperature Gauge 1199
Coolant Pump 1199
Excessive Load on the System 1199
ECM Will Not Accept Factory Passwords 1199
Probable Causes 1199
Recommended Actions 1199
ECM Will Not Communicate With Other Systems or Display Modules 1199
Probable Causes 1199
Recommended Actions 1199
Electronic Service Tool Will Not Communicate With ECM 1199
Probable Causes 1199
Recommended Actions 1200
Engine Cranks but Will Not Start 1200
Probable Causes 1200
Recommended Actions 1200
Diagnostic Codes 1200
Visual Checks 1200
Crank Without Injection 1200
Starting Motor Solenoid or Starting Circuit 1201
Valve Lash 1201
Fuel Injection Nozzles 1201
Air Inlet Heater Starting Aid 1201
Air Intake and Exhaust System 1201
Low Compression 1201
Fuel Supply 1201
Engine Has Early Wear 1202
Probable Causes 1202
Recommended Actions 1202
Dirt in Engine Oil 1202
Leaks in Air Intake System 1202
Low Oil Pressure 1202
Engine Misfires, Runs Rough or Is Unstable 1202
Probable Causes 1202
Recommended Actions 1202
Logged Codes 1202
Fuel Supply 1202
Air Intake and Exhaust System 1203
Individual Malfunctioning Cylinders 1203
Valve Lash 1203
Check for Low Compression 1203
Check the Fuel Injection Nozzles 1203
Check the Air Inlet Heater Starting Aid 1203
Check the Engine Speed/Timing Sensors 1203
Check the Signal for the Throttle Position Sensor 1203
Check the Fuel Injection Pump 1204
Engine Oil in Cooling System 1204
Probable Causes 1204
Recommended Actions 1204
Engine Oil Cooler Core 1204
Cylinder Head Gasket 1204
Cylinder Head 1204
Engine Speed Does Not Change 1204
Probable Causes 1204
Recommended Repairs 1204
Diagnostic Codes 1204
Engine Stalls at Low RPM 1205
Probable Causes 1205
Recommended Actions 1205
Diagnostic Codes 1205
Fuel Injection Nozzles 1205
Fuel Supply 1205
Accessory Equipment 1205
Power Mode Control 1205
Engine Vibration 1205
Probable Causes 1205
Recommended Actions 1205
Engine Supports 1205
Malfunctioning Individual Cylinder 1206
Valve Lash 1206
Check for Low Compression (cylinder pressure) 1206
Check the Fuel Injection Nozzles 1206
Turbocharger 1206
Engine Will Not Crank 1206
Probable Causes 1206
Recommended Repairs 1206
Machine Security System 1206
Battery Cables and/or Batteries 1207
Starting Motor Solenoid or Starting Circuit 1207
Starting Motor and/or Flywheel Ring Gear 1207
Electrical Power Supply 1207
Internal Engine Problem 1207
Excessive Black Smoke 1207
Probable Causes 1207
Recommended Actions 1207
Air Intake System or Exhaust System 1207
Individual Malfunctioning Cylinder 1207
Valve Lash 1207
Low Compression (cylinder pressure) 1207
Check the Fuel Injection Nozzles 1208
Check the Turbocharger 1208
Broken 5-Volt Supply Wire 1208
Verifying the ECM Software 1208
Excessive Engine Oil Consumption 1208
Probable Causes 1208
Recommended Actions 1208
Oil Level 1208
Engine Crankcase Breather 1208
Air Intake and Exhaust System 1208
Turbocharger 1209
Low Compression (cylinder pressure) 1209
Excessive Valve Lash 1209
Probable Causes 1209
Recommended Actions 1209
Lubrication 1209
Valve Lash 1209
Valve Train Components 1209
Excessive White Smoke 1209
Probable Causes 1210
Recommended Actions 1210
Fuel Supply 1210
Individual Malfunctioning Cylinder 1210
Valve Lash 1210
Low Compression (cylinder pressure) 1210
Air Inlet Heater Starting Aid 1210
Fuel Injection Nozzles 1210
Coolant Temperature Sensor Circuit 1210
Engine Pressure Sensors 1211
Intake Air Temperature Is Too High 1211
Probable Causes 1211
Recommended Repairs 1211
High Ambient Air Temperature 1211
Coolant Temperature 1211
Check for High Intake Air Restriction and/or High Altitude 1211
Intake Air Restriction 1211
High Altitude 1211
Check the Intake Manifold Air Temperature Sensor and/or the Circ 1211
Check for Sufficient Coolant Flow Through the Aftercooler (if eq 1211
Check for Sufficient Flow of Air Through the Aftercooler (if equ 1211
Intermittent Engine Shutdown 1211
Probable Causes 1211
Recommended Actions 1212
Logged Codes 1212
Fuel Supply 1212
Engine Protection Device 1212
Electrical Connectors 1212
Intermittent Low Power or Power Cutout 1212
Probable Causes 1212
Recommended Repairs 1212
Diagnostic Codes 1213
Electrical Connectors 1213
Fuel Supply 1213
Check the Intake Manifold Pressure 1213
Air Intake and Exhaust System 1213
Individual Malfunctioning Cylinders 1213
Valve Lash 1213
Check for Low Compression 1214
Check the Fuel Injection Nozzles 1214
Check the Turbocharger 1214
ECM Parameters 1214
Electronic System Problem 1214
Low Engine Oil Pressure 1215
Probable Causes 1215
Recommended Actions 1215
Engine Oil Level 1215
Engine Oil Pressure Gauge 1215
Engine Oil Bypass Valves 1215
Piston Cooling Jets 1215
Engine Oil Suction Tube 1215
Engine Oil Pump 1215
Bearing Clearance 1215
Low Power/Poor or No Response to Throttle 1215
Probable Causes 1215
Recommended Actions 1215
Diagnostic Codes 1215
Fuel Supply 1215
Air Intake and Exhaust System 1216
Individual Malfunctioning Cylinders 1216
Valve Lash 1216
Check for Low Compression 1216
Check the Fuel Injection Nozzles 1216
Check the Turbocharger 1216
ECM Parameters 1217
Electronic System Problem 1217
Mechanical Noise (Knock) in Engine 1217
Probable Causes 1217
Recommended Actions 1217
Accessory Equipment 1217
Valve Train Components 1217
Connecting Rod and Main Bearings 1217
Noise Coming from Cylinder 1217
Probable Causes 1217
Recommended Actions 1217
Fuel Quality 1217
Fuel Injection Nozzles 1218
Valve Lash 1218
Poor Acceleration or Response 1218
Probable Causes 1218
Recommended Repairs 1218
Diagnostic Codes 1218
Fuel Supply 1218
Individual Malfunctioning Cylinder 1218
Valve Lash 1218
Check for Low Compression 1218
Check the Fuel Injection Nozzles 1218
Check the Turbocharger 1219
ECM Parameters 1219
Check Intake Manifold Pressure 1219
Troubleshooting With a Diagnostic Code 1219
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal 1219
Conditions Which Generate This Code 1219
System Response 1219
Possible Performance Effect 1219
Troubleshooting 1219
Results 1219
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent 1220
Conditions Which Generate This Code 1220
System Response 1220
Possible Performance Effect 1220
Troubleshooting 1220
Test Step 1 1220
Results 1220
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted 1220
Conditions Which Generate This Code 1220
System Response 1220
Possible Performance Effect 1220
CID 0091 FMI 04 Throttle Position Sensor Shorted Low 1220
Conditions Which Generate This Code 1220
System Response 1220
Possible Performance Effect 1220
Troubleshooting 1220
Results 1220
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal 1220
Conditions Which Generate This Code 1220
System Response 1220
Troubleshooting 1221
Results 1221
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration 1221
Conditions Which Generate This Code 1221
Possible Performance Effect 1221
Troubleshooting 1221
Results 1221
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short 1221
Conditions Which Generate This Code 1221
System Response 1221
Troubleshooting 1221
Results 1221
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low 1221
Conditions Which Generate This Code 1221
System Response 1221
Troubleshooting 1221
Results 1221
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci 1222
Conditions Which Generate This Code 1222
System Response 1222
Possible Performance Effect 1222
Results 1222
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or 1222
Conditions Which Generate This Code 1222
System Response 1222
Possible Performance Effect 1222
Results 1222
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low 1222
Conditions Which Generate This Code 1222
System Response 1222
Possible Performance Effect 1222
Results 1222
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope 1223
Conditions Which Generate This Code 1223
System Response 1223
Results 1223
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit 1223
Conditions Which Generate This Code 1223
System Response 1223
Possible Performance Effect 1223
Troubleshooting 1223
Results 1223
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low 1223
Conditions Which Generate This Code 1223
System Response 1223
Possible Performance Effect 1223
Troubleshooting 1223
Results 1223
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o 1223
Conditions Which Generate This Code 1223
System Response 1224
Possible Performance Effect 1224
Troubleshooting 1224
Results 1224
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low 1224
Conditions Which Generate This Code 1224
System Response 1224
Possible Performance Effect 1224
Troubleshooting 1224
Results 1224
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent 1224
Conditions Which Generate This Code 1224
System Response 1224
Possible Performance Effect 1224
Troubleshooting 1224
Results 1224
CID 0247 FMI 09 J1939 Datalink, Abnormal Update 1224
Conditions Which Generate This Code 1224
System Response 1225
Results 1225
CID 0253 FMI 02 Incorrect ECM Software 1225
Conditions Which Generate This Code 1225
System Response 1225
Possible Performance Effect 1225
Troubleshooting 1225
Expected Result 1225
Results 1225
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal 1225
Conditions Which Generate This Code 1225
System Response 1225
Possible Performance Effect 1225
Troubleshooting 1225
Results 1225
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal 1225
Conditions Which Generate This Code 1225
System Response 1225
Possible Performance Effect 1226
Troubleshooting 1226
Results 1226
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs 1226
Conditions Which Generate This Code 1226
System Response 1226
Possible Performance Effect 1226
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig 1226
Conditions Which Generate This Code 1226
System Response 1226
Possible Performance Effect 1226
Results 1226
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal 1226
Conditions Which Generate This Code 1226
System Response 1226
Possible Performance Effect 1226
Results 1226
CID 0342 FMI 02 Speed and Timing Sensor No 2 Intermittent Signa 1227
Conditions Which Generate This Code 1227
System Response 1227
Possible Performance Effect 1227
Test Step 1 1227
Results 1227
Test Step 2 1227
Results 1227
CID 0774 FMI 02 Throttle Position Sensor No 2 Erratic or Interm 1227
Conditions Which Generate This Code 1227
System Response 1227
Possible Performance Effect 1227
Results 1227
CID 0774 FMI 03 Throttle Position Sensor No 2 Open Circuit or S 1227
Conditions Which Generate This Code 1227
System Response 1227
Possible Performance Effect 1228
Troubleshooting 1228
Results 1228
CID 0774 FMI 04 Throttle Position Sensor No 2 Shorted Low 1228
Conditions Which Generate This Code 1228
System Response 1228
Possible Performance Effect 1228
Troubleshooting 1228
Results 1228
CID 0774 FMI 08 Throttle Position Sensor No 2 Abnormal Signal 1228
Conditions Which Generate This Code 1228
System Response 1228
Possible Performance Effect 1228
Results 1228
CID 0774 FMI 12 Throttle Position Sensor No 2 Out of Calibratio 1228
Conditions Which Generate This Code 1228
System Response 1228
Possible Performance Effect 1228
Results 1228
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off 1228
Conditions Which Generate This Code 1228
System Response 1229
Possible Performance Effect 1229
Results 1229
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than 1229
Conditions Which Generate This Code 1229
System Response 1229
Possible Performance Effect 1229
Test Step 1 1229
Results 1229
Test Step 2 1229
Results 1229
CID 1684 FMI 02 Fuel Injection Pump, Software Failure 1229
Conditions Which Generate This Code 1229
System Response 1229
Possible Performance Effect 1229
Troubleshooting 1229
Results 1229
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault 1230
Conditions Which Generate This Code 1230
System Response 1230
Possible Performance Effect 1230
Troubleshooting 1230
Results 1230
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault 1230
Conditions Which Generate This Code 1230
System Response 1230
Possible Performance Effect 1230
Troubleshooting 1230
Results 1230
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width 1230
Conditions Which Generate This Code 1230
Troubleshooting 1230
Results 1230
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault 1231
Conditions Which Generate This Code 1231
System Response 1231
Possible Performance Effect 1231
Troubleshooting 1231
Results 1231
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault 1231
Conditions Which Generate This Code 1231
System Response 1231
Possible Performance Effect 1231
Troubleshooting 1231
Test Step 1 1231
Results 1231
Test Step 2 1231
Results 1231
Test Step 3 1231
Results 1231
Test Step 4 1231
Expected Result 1231
Results 1231
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault 1232
Conditions Which Generate This Code 1232
System Response 1232
Possible Performance Effect 1232
Troubleshooting 1232
Expected Result 1232
Results 1232
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error 1232
Conditions Which Generate This Code 1232
System Response 1232
Troubleshooting 1232
Test Step 1 1232
Results 1232
Test Step 2 1232
Results 1232
Test Step 3 1233
Results 1233
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault 1233
Conditions Which Generate This Code 1233
System Response 1233
Possible Performance Effect 1233
Troubleshooting 1233
Test Step 1 1233
Results 1233
Test Step 2 1233
Results 1233
CID 1684 FMI 14 Fuel Injection Pump, No Communications 1233
Conditions Which Generate This Code 1233
System Response 1233
Troubleshooting 1233
Test Step 1 1233
Results 1233
Test Step 2 1233
Results 1233
Test Step 3 1233
Results 1234
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali 1234
Conditions Which Generate This Code 1234
System Response 1234
Possible Performance Effect 1234
Troubleshooting 1234
Results 1234
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali 1234
Conditions Which Generate This Code 1234
System Response 1234
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S 1234
Conditions Which Generate This Code 1234
System Response 1234
Troubleshooting With an Event Code 1234
Event Codes 1234
Programmable Engine Parameters 1234
E015 High Engine Coolant Temperature Derate 1235
Conditions Which Generate This Code 1235
System Response 1235
Possible Performance Effect 1235
Troubleshooting 1235
Results 1235
E016 High Engine Coolant Temperature Shutdown 1235
Conditions Which Generate This Code 1235
System Response 1235
Possible Performance Effect 1235
Troubleshooting 1235
Results 1235
E017 High Engine Coolant Temperature Warning 1235
Conditions Which Generate This Code 1235
System Response 1235
Possible Performance Effect 1235
Troubleshooting 1235
Results 1235
E025 High Intake Air Temperature Derate 1235
Conditions Which Generate This Code 1235
System Response 1235
Possible Performance Effect 1235
Troubleshooting 1235
Results 1235
E027 High Intake Air Temperature Warning 1236
Conditions Which Generate This Code: 1236
System Response 1236
Possible Performance Effect 1236
Troubleshooting 1236
Results 1236
E040 Low Engine Oil Pressure Shutdown 1236
Conditions Which Generate This Code 1236
System Response 1236
Possible Performance Effect 1236
Troubleshooting 1236
Results 1236
E054 High Fuel Temperature Derate 1236
Conditions Which Generate This Code 1236
System Response 1236
Troubleshooting 1236
Test Step 1 – Check for Diagnostic Codes 1236
Expected Result 1237
Results 1237
Test Step 2 – Perform a Check of the Fuel System 1237
Expected Result 1237
Results 1237
E056 High Fuel Temperature Warning 1237
Conditions Which Generate This Code 1237
System Response 1237
Troubleshooting 1237
Test Step 1 – Check for Diagnostic Codes 1237
Expected Result 1237
Results 1237
Test Step 2 – Perform a Check of the Fuel System 1237
Expected Result 1237
Results 1237
E100 Low Engine Oil Pressure Warning 1238
Conditions Which Generate This Code 1238
System Response 1238
Possible Performance Effect 1238
Troubleshooting 1238
Test Step 1 – Check for Active Diagnostic Codes 1238
Expected Result 1238
Results 1238
Test Step 2 – Perform a Check of the Engine Lubrication System 1238
Expected Result 1238
Results 1238
E190 Engine Overspeed Warning 1238
Conditions Which Generate This Code 1238
System Response 1238
Possible Performance Effect 1238
Troubleshooting 1238
Engine Overspeed Warning 1239
Expected Result 1239
Results 1239
E442 Engine Failed to Stop With a No-Fuel Command 1239
Conditions Which Generate This Code 1239
System Response 1239
Possible Performance Effect 1239
Troubleshooting 1239
Test Step 1 1239
Results 1239
Test Step 2 1239
Results 1239
E883 Engine Failed to Stop When Fuel Solenoid Disengaged 1239
Conditions Which Generate This Code 1239
System Response 1239
Possible Performance Effect 1239
Troubleshooting 1239
Test Step 1 1239
Results 1239
Test Step 2 1240
Results 1240
Test Step 3 1240
Results 1240
Diagnostic Function Tests 1240
5-Volt Engine Pressure Sensor Supply Circuit – Test 1240
System Operation Description 1240
Background Information 1240
Test Step 1 1241
Inspect Electrical Connectors and Wiring 1241
Expected Result 1241
Results 1241
Test Step 2 1242
Check for Active Diagnostic Codes 1242
Expected Result 1242
Results 1242
Test Step 3 1242
Disconnect the ECM Engine Harness Connector From the ECM 1242
Expected Result 1243
Results 1243
Test Step 4 1243
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei 1243
Expected Result 1243
Results 1243
Test Step 5 1244
Check the Engine Harness 1244
Expected Result 1244
Results 1244
Air Inlet Heater Circuit – Test 1244
System Operation Description 1244
Test Step 1 1244
Inspect Electrical Connectors and Wiring 1244
Expected Result 1245
Results 1245
Test Step 2 1245
Check the Supply to the Power Relay for the Air Inlet Heater Sta 1245
Expected Result 1245
Results 1245
Test Step 3 1245
Check the Output From the Power Relay for the Air Inlet Heater S 1245
Expected Result 1246
Results 1246
Test Step 4 1246
Ground the Input to the Power Relay at the MIC 1246
Expected Result 1246
Results 1246
Test Step 5 1246
Ground the Input to the Power Relay at the ECM Connector 1246
Expected Result 1246
Results 1246
Test Step 6 1246
Override the Air Inlet Heater Starting Aid to Test the ECM 1246
Results 1247
Checking Idle Validation Switching Point (Throttle Sensor) With 1247
Expected Result 1247
Analog Throttle Position Sensor Circuit – Test 1247
System Operation Description 1247
Checking the Throttle Sensor With Unconnected Output C 1248
Expected Result 1248
Test Step 1 1248
Check for Connector Damage 1248
Expected Result 1248
Results 1248
Test Step 2 1248
Check for Active Diagnostic Codes 1248
Expected Result 1248
Results 1249
Test Step 3 1249
Check the Throttle Position With the Electronic Service Tool 1249
Expected Result 1249
Results 1249
Test Step 4 1249
Check the Voltage at the Throttle Position Sensor 1249
Expected Result 1249
Results 1249
Test Step 5 1250
Disconnect the Throttle Position Sensor and Check for Active Dia 1250
Expected Result 1250
Results 1250
Test Step 6 1250
Check the Throttle Selection Status With the Electronic Service 1250
Expected Result 1250
Results 1250
Test Step 7 1250
Disconnect the Supply Terminals of the Throttle Position Sensor 1250
Expected Result 1251
Results 1251
Test Step 8 1251
Check the Position of Throttle Position Sensor 1251
Expected Result 1251
Results 1251
Test Step 9 1251
Check the Throttle Position Sensor at the ECM 1251
Expected Result 1252
Results 1252
CAN Data Link Circuit – Test 1252
System Operation Description 1252
Test Step 1 1252
Inspect Electrical Connectors and Wiring 1252
Expected Result 1252
Results 1252
Test Step 2 1253
Check the CAN Data Link Between the ECM and P40 Fuel Injection P 1253
Expected Result 1253
Results 1253
Test Step 3 1253
Check the CAN Data Link Between the ECM and P40 Fuel Injection P 1253
Expected Result 1253
Results 1253
Test Step 4 1253
Verify the Supply Voltage at the Fuel Injection Pump 1253
Expected Result 1253
Results 1253
Data Link Circuit – Test 1254
System Operation Description 1254
Background Information 1254
Communication 1254
Test Step 1 1254
Inspect Electrical Connectors and Wiring 1254
Expected Result 1255
Results 1255
Test Step 2 1255
Determine the Type of Problem With the Data Link 1255
Expected Result 1255
Results 1255
Test Step 3 1255
Check the Battery Voltage at the ECM 1255
Expected Result 1256
Results 1256
Test Step 4 1256
Check the Battery Voltage That is Coming to the Data Link Connec 1256
Expected Result 1256
Results 1256
Test Step 5 1256
Connect the Electronic Service Tool Directly to the ECM 1256
Expected Result 1257
Results 1257
Test Step 6 1257
Change Electronic Service Tool Components 1257
Expected Result 1257
Results 1257
Test Step 7 1257
Connect an Electronic Service Tool and the ECM to Another Batter 1257
Expected Result 1257
Results 1257
Electrical Connectors – Inspect 1258
System Operation Description 1258
Background Information 1258
Test Step 1 1261
Check the Locking of the DT Connector (Deutsch) and the Lock Rin 1261
Expected Result 1261
Results 1262
Test Step 2 1262
Check the Socket Head Screw on the Connector for the Electronic 1262
Expected Result 1262
Results 1262
Test Step 3 1262
Perform a Pull Test on Each Wire Terminal Connection 1262
Expected Result 1262
Results 1262
Test Step 4 1262
Monitor the Electronic Service Tool While the Wiring and the Con 1262
Expected Result 1262
Results 1263
Test Step 5 1263
Check Wires for Nicks and/or Abrasions in the Insulation 1263
Expected Result 1263
Results 1263
Test Step 6 1263
Check Connectors for Moisture or Corrosion 1263
Expected Result 1264
Results 1264
Test Step 7 1264
Inspect the Connector Terminals 1264
Expected Result 1264
Results 1264
Test Step 8 1264
Check Individual Pin Retention Into the Socket 1264
Expected Result 1265
Results 1265
Electrical Power Supply Circuit – Test 1265
System Operation Description 1265
Background Information 1265
Test Step 1 1266
Check the Batteries 1266
Expected Result 1266
Results 1266
Test Step 2 1267
Inspect Electrical Connectors and Wiring 1267
Expected Result 1267
Results 1267
Test Step 3 1267
Check the Battery Voltage at the ECM 1267
Expected Result 1267
Results 1268
Test Step 4 1268
Use the Bypass Harness for the Electronic Service Tool to Bypass 1268
Expected Result 1269
Results 1269
Engine Pressure Sensor Open or Short Circuit – Test 1269
System Operation Description 1269
Background Information 1269
Test Step 1 1269
Check for Active +5V Sensor Supply Diagnostic Codes 1269
Expected Result 1269
Results 1270
Test Step 2 1270
Verify All Active Diagnostic Codes 1270
Expected Result 1270
Results 1270
Test Step 3 1270
Inspect Electrical Connectors And Wiring 1270
Expected Result 1271
Results 1271
Test Step 4 1271
Verify That the Diagnostic Code is Still Active 1271
Expected Result 1271
Results 1271
Test Step 5 1271
Disconnect the Sensor to Create an Open Circuit 1271
Expected Result 1271
Results 1271
Test Step 6 1271
Measure the Sensor Supply Voltage 1271
Expected Result 1271
Results 1271
Test Step 7 1272
Determine if the Short Circuit is in the Connector or in the Sen 1272
Expected Result 1272
Results 1272
Test Step 8 1272
Create a Short Circuit Between the Signal and the Common Termina 1272
Expected Result 1273
Results 1273
Test Step 9 1273
Check the Operation of the ECM by Creating Open and Short Circui 1273
Expected Result 1273
Results 1273
Test Step 10 1273
Bypass the Harness Wiring Between the ECM and the Sensor Connect 1273
Expected Result 1274
Results 1274
Engine Speed/Timing Sensor Circuit – Test 1274
System Operation Description 1274
Test Step 1 1275
Inspect the Electrical Connectors and Cables 1275
Expected Result 1275
Results 1275
Test Step 2 1275
Check the Installation of the Engine Speed/Timing Sensors 1275
Expected Result 1275
Results 1275
Test Step 3 1275
Measure the Sensor Resistance Through the Wiring Harness 1275
Expected Result 1276
Results 1276
Test Step 4 1276
Measure the Resistance of the Sensor 1276
Expected Result 1276
Results 1276
Test Step 5 1276
Measure the Resistance of the Cables Between the Fuel Injection 1276
Expected Result 1276
Results 1276
Test Step 6 1277
Check the Continuity of the Cables From the ECM to the Fuel Inje 1277
Expected Result 1277
Results 1277
Engine Temperature Sensor Open or Short Circuit – Test 1277
System Operation Description 1277
Background Information 1278
Test Step 1 1278
Verify All Active Diagnostic Codes 1278
Expected Result 1279
Results 1279
Test Step 2 1279
Inspect Electrical Connectors and Wiring 1279
Expected Result 1279
Results 1279
Test Step 3 1279
Verify That the Diagnostic Code is Still Active 1279
Expected Result 1279
Results 1279
Test Step 4 1279
Disconnect the Sensor to Create an Open Circuit 1279
Expected Result 1280
Results 1280
Test Step 5 1280
Create a Short Circuit Between the Signal and the Common Termina 1280
Expected Result 1280
Results 1280
Test Step 6 1280
Check the Operation of the ECM by Creating an Open and a Short C 1280
Expected Result 1281
Results 1281
Test Step 7 1281
Bypass the Harness Wiring Between the ECM and the Sensor Connect 1281
Expected Result 1281
Results 1281
Fuel Injection Pump Circuit – Test 1281
System Operation Description 1281
Background Information 1282
Test Step 1 1282
Check the Batteries 1282
Expected Result 1282
Results 1282
Test Step 2 1282
Inspect the Electrical Connectors and Wiring 1282
Expected Result 1282
Results 1282
Test Step 3 1283
Check the Supply Voltage at the Machine Interface Connector 1283
Expected Result 1283
Results 1284
Test Step 4 1284
Check the Supply Voltage at the Fuel Injection Pump 1284
Expected Result 1284
Results 1284
Test Step 5 1284
Check the Supply to the Power Relay for the Fuel Injection Pump 1284
Expected Result 1284
Results 1284
Test Step 6 1284
Check the Output of the Power Relay for the Fuel Injection Pump 1284
Expected Result 1285
Results 1285
Test Step 7 1285
Check the Voltage at the Relay Coil for the Fuel Injection Pump 1285
Expected Result 1285
Results 1285
Test Step 8 1285
Check the Output of the ECM Fuel Pump Power Control at the Machi 1285
Expected Result 1285
Results 1285
Test Step 9 1285
Check the Output of the Fuel Injection Pump Power Control at the 1285
Expected Result 1286
Results 1286
Test Step 10 1286
Measure the Voltage at the Pump Power Supply 1286
Expected Result 1286
Results 1286
Test Step 11 1287
Check the Voltage Load Protection Module (VLPM) 1287
Expected Result 1287
Results 1287
Indicator Lamp Circuit – Test 1287
System Operation Description 1287
Test Step 1 1287
Inspect Electrical Connectors and Wiring 1287
Results 1289
Test Step 2 1289
Inspect the Lamp, the Fuse, and the Power Supply 1289
Expected Result 1289
Results 1289
Test Step 3 1289
Inspect the Input to the Lamp at the ECM connector 1289
Expected Result 1289
Results 1289
Test Step 4 1289
Test the Individual Lamp Circuits 1289
Expected Result 1289
Results 1289
Test Step 5 1289
Check the Voltage at the ECM 1289
Expected Result 1289
Results 1290
Idle Validation Circuit – Test 1290
System Operation Description 1290
Test Step 1 1290
Expected Result 1290
Results 1290
tables 1143
Table 1 Electronic Service Tool 1169
Table 2 Optional Service Tools 1170
Table 3 CID FMI Codes and J Code FMI Codes 1171
Table 4 Event Codes and CID FMI Codes 1173
Table 5 CID Numbers and Flash Codes 1174
Table 6 Engine Connectors 1182
Table 7 Color Codes for the Harness Wire 1186
Table 8 Pin Connections for Perkins Deutsch Socket Connector 1188
Table 9 Suspect Parameter Numbers 1192
Table 10 Failure Mode Indicators (FMI) Codes 1192
Table 11 Engine Oil Pressure Trip and Reset Points 1236
524206065 1300YRM1082 (01 2016) UK EN 1295
Series Code / Model Designation Reference Table 1299
Description of Operation 1300
General 1300
Torque Convertor, Pump Drive, and Pressure Regulating Valve 1300
Input Shaft and Directional Clutches 1301
Range Clutches 1304
Output Section 1304
Transmission Controls 1304
Operation of the Valve 1306
Selection of Range 1312
Pressure Switch 1312
Electric Solenoid Controls 1312
Transmission Specifications 1330
Transmission Identification 1330
Weight, Dimensions, and Oil Capacity 1330
Transmission Repair 1331
Disassemble 1331
Reverse and Second-Speed Clutch 1361
Clean and Inspect 1377
Housings 1377
Oil Seals and Gaskets 1378
Bearings 1378
Gears and Shafts 1378
Assemble 1378
Reverse and Second-Speed Clutch 1389
Control Valve Repair 1429
Remove 1429
Disassemble and Assemble 1429
Clean and Inspect 1432
Housings 1432
Oil Seals and Gaskets 1432
Install 1432
Stall Test 1434
Transmission Calibration and Electrical Troubleshooting 1435
Userlink® 1435
Connection 1435
Clutch Filling Calibration 1436
Purpose 1436
Clutch Filling Calibration Procedure 1436
Alternative Clutch Filling Calibration Procedure 1436
Heat-up Mode 1437
Heat-up Mode Stall Test 1437
Inching Pedal Calibration 1438
Purpose 1438
Troubleshooting 1438
Transmission Display Warning Codes 1438
Access 1439
Clear 1439
Exit 1439
Limp Home Mode 1476
Shutdown Mode 1476
Pressure Feedback Sensor 1476
Transmission Oil Pressure Check 1477
Pressure and Temperature Specifications 1477
Electrical Specifications 1483
Hydraulic Cooler Lines Specifications 1483
Torque Specifications 1484
Torque Specifications for Lubricated or Plated Screw Threads 1484
Troubleshooting 1486
524302733 1300YRM1356 (01 2016) UK EN 1493
Series Code / Model Designation Reference Table 1497
General 1497
Transmission Repair 1497
Remove 1497
Disassemble 1501
Reverse and Second-Speed Clutch 1531
Clean and Inspect 1547
Housings 1547
Oil Seals and Gaskets 1548
Bearings 1548
Gears and Shafts 1548
Assemble 1548
Reverse and Second-Speed Clutch 1558
Install 1599
Control Valve Removal and Installation 1602
Remove 1602
Install 1602
Control Valve Components 1603
Control Valve Disassemble and Assemble 1603
Remove 1603
Control Valve Cover 1603
Control Valve Components 1604
Install 1604
Control Valve Components 1604
Control Valve Cover 1604
Transmission Frame Bracket 1605
Torque Specifications 1605
Torque Specifications for Lubricated or Plated Screw Threads 1605
Troubleshooting 1607
524304019 1300YRM1358 (01 2016) UK EN 1611
Series Code / Model Designation Reference Table 1617
General 1618
Description 1618
General 1618
Operation 1621
Hydraulic Operation 1621
1st/3rd Selector Valve 1624
Cooling and Lubrication 1626
Control System 1627
General 1628
APC200 Controller 1628
Self Test 1628
Protection Modes 1628
Limp Home Mode 1628
Shut Down Mode 1628
Transmission Exceed Codes 1629
Fault Codes 1629
Description 1629
Fault Log Mode 1629
Access 1629
Exit 1630
Clear 1630
Fault Rectification 1630
Hydraulic Control Valve 1632
Hydraulic Control Valve Repair 1634
Solenoid Replacement 1634
Pressure Check 1634
Pressure Specifications 1635
Pressure, Speed, and Temperature Sensors 1635
Pressure Switch 1640
Test 1640
Speed Sensor 1641
Test 1641
Temperature Sensors 1642
Test 1642
Transmission Test and Calibration 1643
Precautions 1643
Stall Test 1643
Description 1643
Stall Test Procedure 1643
Clutch Calibration 1644
Description 1644
Procedure 1645
Inching Calibration 1645
Description 1645
Brake and Inching Pedal Adjustment 1646
Inching Sensor Adjustment 1646
Inching Sensor Calibration 1647
Electrical Specifications 1647
APC200 Display information 1647
General 1648
General Information Group 1648
Fault Codes 1649
Indication of Protection Modes 1649
Test Function Group 1650
Digital Input Test 1652
Analog Input Test 1653
Speed Sensor Test 1654
Output Test 1655
Voltage Test 1656
Calibration Group 1658
Calibration Mode 1658
Clutch Filling Calibration 1658
Heat Up Mode 1659
Inching Sensor Calibration 1659
Inching Pedal Sensor Adjustment 1659
Inching Sensor Calibration 1659
TE-Userlink 1660
Description 1660
Connection 1660
1660
Diagrams, Schematics, or Arrangements 1660
550022606 1300YRM1435 (01 2016) UK EN 1697
Series Code / Model Designation Reference Table 1701
General 1701
Transmission Exceed Codes 1701
Clutch Calibration Condition Messages 1701
Fault Codes During Clutch Calibration 1701
APC200 Fault Codes 1702
Limp Home Mode 1702
Shut Down Mode 1702
Pressure Feedback Sensor 1702
APC200 Fault Codes 1703
Transmission Exceed Codes 1703
Clutch Calibration Condition Messages 1707
Fault Codes During Clutch Calibration 1707
APC200 Fault Codes 1710