Yale Forklift C876 (GDP170190210230250280DB) Service Manual – PDF DOWNLOAD

Yale Forklift C876 (GDP170190210230250280DB) Service Manual – PDF DOWNLOAD

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Yale Forklift C876 (GDP170190210230250280DB) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1612
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File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C876 (GDP170190210230250280DB) Service Manual – PDF DOWNLOAD

524150772 0100YRM0927 (11 2015) US EN 1
General 5
Description 5
Counterweight Repair 6
Remove 6
Install 8
Fenders 8
Remove 8
Install 8
Side Counterweights GDP130-160EB (GP300-360EB) 8
Side Counterweight, Replace 8
Hood and Air Cleaner Repair 8
Remove 9
Install 11
Hydraulic Tank Repair 11
Remove 11
Repairs, All Units 14
Small Leaks 14
Large Leaks 14
Clean 14
Steam Method 15
Chemical Solution Method 15
Other Methods of Preparation for Repair 15
Install 16
Fuel Tank Repair 16
Remove 16
Repairs 17
Install 17
Cooling System and Radiator Repair 20
Remove 20
Install 20
Cab Repair 23
Rear Cab Assembly 23
Bottom Cab Assembly 24
Raising and Lowering Cab 24
Raise Cab 24
Lower Cab 25
Cab Repair 25
Remove 25
Install 27
Engine and Transmission Repair 28
Transmission, Remove 28
Transmission, Install 30
TE-10 Transmission 31
Remove 31
Install 35
Label Replacement 39
524150775 0700YRM0626 (03 2003) US EN 47
toc 47
Cooling System 47
Safety Precautions Maintenance and Repair 48
General 51
Description 52
Radiator 52
Radiator Cap 52
Thermostat 52
Water Pump 53
Fan and Fan Shroud 53
Cooling System Checks 53
Radiator 53
Thermostat 53
Water Pump 54
Exhaust Leaks 54
Fan and Fan Shroud 54
Radiator Cleaning 54
Drain 54
Clean 54
Fill 55
Troubleshooting 56
524150779 1400YRM0046 (08 2012) US EN 59
toc 59
Differential 59
Safety Precautions Maintenance and Repair 60
General 63
Description 63
Differential Repair 63
Remove 63
Differential Carrier From Axle Housing, Remove 63
Differential and Ring Gear From Differential Carrier, Remove 67
Drive Pinion and Pinion Carrier From Differential Carrier, Remov 69
Disassemble 70
Differential and Ring Gear Assembly, Disassemble 70
Drive Pinion and Pinion Carrier, Disassemble 71
Clean and Inspect 74
Assemble 75
Pinion, Bearings, and Pinion Carrier, Assemble 75
Pinion Bearings, Adjust Preload 75
Press Method 75
Yoke or Flange Method 76
Triple-Lip Seal, Install 77
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion) 78
Differential and Ring Gear, Assemble 80
Differential Gears Rotating Torque, Check 82
Differential and Ring Gear Assembly, Install 83
Differential Bearings, Preload Adjust 84
Ring Gear, Runout Check 85
Ring Gear Backlash, Adjust 86
Gear Set, Tooth Contact Pattern Check 88
Thrust Screw, Install and Adjust 91
Install 91
Differential Assembly Into Axle Housing, Install 91
Specifications 92
Troubleshooting 96
tables 59
Table 1 Ring Gear Backlash Adjustment Specifications 87
Table 2 Ring and Pinion Tooth Contact Adjustment 88
Table 3 General Specifications 92
Table 4 Rivet Installation Pressure 92
Table 5 Pinion Adjustment 92
Table 6 Pinion Preload Pressure 93
Table 7 Torque Specifications 94
Table 8 Torque Specifications for Metric Hardware 95
Table 9 Torque Specifications for Metric (Fine) Hardware 95
524150780 1400YRM0944 (08 2012) US EN 99
toc 99
Planetary Drive Axle 99
Safety Precautions Maintenance and Repair 100
General 103
Description 103
Operation 105
Identification 105
Removal 106
Disassembly 106
Planetary Spider and Gearing Assembly GDP80-120DB (GP170-280DB) 107
Planetary Spider and Gearing Assembly GDP130-160EB (GP300-360EB) 108
Wheel End 110
Spindle and Piston Housing 111
Cleaning 112
Clean Ground or Polished Parts 112
Clean Parts With Rough Finish 112
Clean Axle Assemblies 112
Drying Cleaned Parts 112
Corrosion Prevention 112
Parts Inspection 113
Tapered Roller Bearings 113
Bevel Pinion and Ring Gear Sets 114
Main Differential Assembly 114
Axle Shafts 114
Yoke 114
Brakes 114
Repair or Replace Parts 114
Repair Welding 115
Apply Silicone Gasket Material 115
Assembly 115
Spindle and Piston Housing to Axle Housing 115
Wet Disc Brakes 116
Adjust Wheel Bearing Preload 117
Planetary Spider and Gearing Assembly GDP80-120DB (GP170-280DB) 118
Planetary Spider and Gearing Assembly GDP130-160EB (GP300-360EB) 118
Planetary Spider Assembly 119
Installation 120
Fill Wet Disc Brakes With Hydraulic Fluid 120
Torque Specifications 121
Lubrication Specification 122
524150781 1400YRM0945 (08 2011) US EN 125
toc 125
Planetary Drive Axle 125
Safety Precautions Maintenance and Repair 126
General 129
Description 129
Operation 131
Identification 131
Removal 132
Disassembly 133
Brake Drum 133
Planetary Spider and Gearing Assembly GDP/GLP80-120DB (GDP/GLP17 134
Dry Brakes 134
Planetary Spider and Gearing Assembly GDP/GLP130-160EB (GDP/GLP3 136
Spindle and Brake Spider 138
Cleaning 138
Ground or Polished Parts 138
Parts With Rough Finish 139
Axle Assemblies 139
Drying Cleaned Parts 139
Corrosion Prevention 139
Parts Inspection 139
Tapered Roller Bearings 139
Bevel Pinion and Ring Gear Sets 140
Main Differential Assembly 141
Axle Shafts 141
Yoke 141
Brakes 141
Repair or Replace Parts 141
Repair Welding 141
Apply Silicone Gasket Material 141
Assembly 142
Spindle, Brake Spider, and Brake 142
Wheel End 143
Adjust Wheel Bearing Preload 143
Planetary Spider and Gearing Assembly GDP/GLP80-120DB (GDP/GLP17 144
Planetary Spider and Gearing Assembly GDP/GLP130-160EB (GDP/GLP3 145
Planetary Spider Assembly 145
Installation 146
Torque Specifications 147
Lubrication Specification 148
524150782 1600YRM0936 (03 2007) US EN 151
toc 151
Steering System 151
Safety Precautions Maintenance and Repair 152
General 155
Description 155
Steering Wheel and Column Assembly 157
General 157
Steering Wheel and Horn 157
Remove 157
Install 157
Steering Control Unit Repair 159
General 159
Description 159
Operation 159
Remove 160
Disassemble 160
Clean 163
Assemble and Install 163
Steering System Air Removal 169
Steering Relief Pressure Check 170
Troubleshooting 170
524150783 1600YRM0326 (03 2007) US EN 175
toc 175
Steering Axle 175
Safety Precautions Maintenance and Repair 176
General 179
Description 179
Steering Axle Assembly Repair 184
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 184
Remove 184
Install 184
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP 185
Remove 185
Install 185
Wheels and Hubs Repair (All Units) 186
Remove and Disassemble 186
Clean 186
Inspect 186
Assemble and Install 186
Spindles and Bearings Repair (All Units) 188
Remove 188
Clean 188
Assemble and Install 189
Tie Rods Repair (All Units) 190
Remove 190
Clean 190
Install 190
Steering Cylinder Repair 193
Remove and Disassemble 193
Clean and Inspect 193
Assemble and Install 193
Troubleshooting 194
524150784 1800YRM0937 (04 2010) US EN 199
toc 199
Dry Brake System 199
Safety Precautions Maintenance and Repair 200
General 203
Description 203
Operation 204
Service Brakes 204
Parking Brake 205
Air Tank Repair 206
Relief Valve 206
Drain Valve 207
Brake Pedal Valve Repair 207
Remove 207
Disassemble, Inspect, and Assemble 208
Install 208
Air Chambers Repair 209
Remove 209
Disassemble 209
Inspect 209
Assemble 211
Install 211
Actuator Arms Repair 211
Remove 211
Inspect 212
Install 212
Brake Assemblies Repair 213
Brake Shoe, Remove 213
Camshaft, Remove 215
Clean 215
Inspect 216
Camshaft, Install 216
Brake Shoe, Install 217
Air Dryer 217
Description 217
Cartridge 217
Remove 217
Install 217
Filter 219
Remove 219
Install 219
Quick-Release Valve 219
Governor Check and Adjustment for Air Compressor 220
Brake Shoes Adjustment 220
Specifications 222
Troubleshooting 223
Service Brakes 223
Service Brakes, Park Function 225
tables 199
Table 1 Air Chambers Operation 205
524150785 1800YRM0951 (02 2018) US EN 229
General 233
Description and Operation 233
Service Brakes 233
Parking Brake 233
Oil Cooler Circuit 233
Pressure Switch Replacement 236
Accumulators Replacement 237
Brake Treadle Valve Repair 237
Remove and Disassemble 237
Clean and Inspect 238
Assemble and Install 238
Parking Brake Valve Repair 238
Remove 238
Clean and Inspect 238
Repair 238
Install 238
Parking Brake Caliper Repair 238
Remove 238
Disassemble 241
Inspect 241
Install 241
Adjust 241
Brake Pad Repair 242
Inspect 242
Remove 242
Install 242
Seals Repair 242
Remove 242
Install 242
Service Brake Repair 243
Remove and Disassemble 243
Drain Lubricating Oil 243
Drain Coolant Oil 249
Disconnect Brake Lines 249
Wheel End With Outer Bearing on Ring Gear Hub Journal, Lift Truck Models GDP/GLP130-160EB (GP/GDP/GLP300-360EB) 249
Wheel End With Outer Bearing on Spindle Journal, Lift Truck Models GDP/GLP80-120DB (GP/GDP/GLP170-280DB) 250
Brake Disc Housing Assembly Wheel End 251
Brake Piston Housing 252
Brake Piston Housing and Wheel Spindle 253
Inspect 253
Clean 255
Assemble 256
Wheel Spindle 256
Brake Piston Housing 257
Piston Assembly 258
Brake Disc Housing 259
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub 260
Check for Correct Installation of Duo-Cone Seal 262
Wheel Hub to Brake Disc Housing 262
Adjust 263
Fill Brake System With Coolant Oil 264
System Air Removal 264
Adjust Brake With New Disc Pack 264
Coolant Change Intervals 265
Coolant Draining and Filling 265
Wet Brake Noise Reduction 266
General 266
Adding Additive To Transmission 267
Specifications 268
Minimum Brake Disc Thickness 271
Hydraulic Fluid for Brake Actuation 271
Brake Coolant Specifications 271
Coolant Change Intervals 271
Hydraulic Fluid Specifications 271
Troubleshooting 272
524150787 1900YRM0938 (03 2007) US EN 277
toc 277
Hydraulic System 277
Safety Precautions Maintenance and Repair 278
General 281
Description and Operation 281
Hydraulic Tank 281
Hydraulic Pump 282
Steering Priority Flow Valve 282
Pilot Valve 283
Main Control Valve 285
Unloader Valve 286
Hydraulic Operation 287
Checks And Adjustments 290
Quick Disconnect Fittings 290
Steering Priority Flow Valve 290
Steering Relief Pressure 290
Modulator Valve 291
Pilot Valve and Pressure Reducing Valve 291
Accumulator 292
Filter 292
Main Control Valve 292
Relief Pressure Check 292
Check Valves 293
Unloader Valve 293
Hydraulic Pump Repair 294
Remove 294
Disassemble 294
Clean and Inspect 294
Assemble 295
Install 296
Pilot Accumulator Replacement 296
Remove 296
Install 296
Pilot Valve Repair 296
Remove 296
Disassemble 297
Clean and Inspect 297
Assemble 297
Install 298
Control Levers and Joystick Repair 299
Remove 299
Install 299
Calibration and Diagnostics 300
General 300
Description 300
Lever and Joystick Calibration 300
Flow Adjustment 300
Dead Band Value Setting 301
Lowering Delay 302
PWM and I/O Module Readouts 302
Function Disable 303
General Startup 303
Minimum system requirements 303
Install the Hydraulic Controls Program 303
DelayTimeFile (Reset) 303
Select the Processor Speed 304
Hydraulic Controls Program 304
Calibration 305
Joystick/Lever Calibration 305
Levers 305
Joystick 306
Valve Flow Adjustment 306
Diagnostics 307
Calibration System Shutdown 307
LED Diagnostics 308
Electrical Connections 310
Specifications 314
tables 277
Table 1 Main Control Valve Port Settings 283
Table 2 Processor Speed Settings 303
Table 3 PWM Board LED Error Codes 308
Table 4 Altering PT I/O Board LED’s (Old Logic) 309
Table 5 Altering PT I/O Board LED’s (New Logic) 309
Table 6 Fixed PT Logic I/O Boards LED’s 310
Table 7 PWM Driver Module 311
Table 8 Input/Output Module 1 311
Table 9 Input/Output Module 2 312
Table 10 Altering PT 313
Table 11 Fixed PT 313
524150788 2000YRM0943 (03 2007) US EN 317
toc 317
Main Control Valve 317
Safety Precautions Maintenance and Repair 318
General 321
Description 321
Operation 324
Lift Section 324
Tilt/Auxiliary Section 324
Relief Valves 324
Unloader Valve 324
Main Control Valve Repair 327
Remove 327
Disassemble 327
Auxiliary Side 327
Lift Side 327
Clean and Inspect 330
Assemble 330
Auxiliary Side 330
Lift Side 330
Install 330
Pressure Relief Valve Check and Adjustment 331
Check and Adjust 331
Replace 331
Specifications 332
Troubleshooting 332
524150790 2100YRM0103 (03 2007) US EN 337
toc 337
Tilt Cylinders 337
Safety Precautions Maintenance and Repair 338
General 341
Description 341
Tilt Cylinder Repair 341
Remove 341
Disassemble 341
Clean 341
Assemble 342
Tilt Cylinders With O-Ring or Single-Lip Seals 342
Tilt Cylinders 343
Install 344
Tilt Cylinder Leak Check 346
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 347
Torque Specifications 347
Piston Rod Nut 347
Retainer 347
Troubleshooting 348
tables 337
Table 1 Movement Rates (Maximum) for Tilt Cylinders 346
524150791 2200YRM0002 (01 2016) US EN 353
General 357
Description 358
Alternator Repair 360
Alternator Type A 360
Remove and Disassemble 360
Clean 362
Assemble 362
Install 363
Alternator Type B 366
Remove and Disassemble 366
Clean 366
Assemble 367
Install 368
General Check and Adjustment 368
Low Output Check (Type A or Type B) 369
High Output Check (Type A or Type B) 372
Brushes Circuit Check 373
Delco Alternators 373
Motorola Alternators 373
Diodes Check 374
Diode Bridge Check 374
Delco and Leece-Neville Alternators 374
Motorola Alternators 374
Rotor Field Winding Check 375
Stator Windings Check 376
Voltage Regulator Check 376
Troubleshooting 376
524150792 2200YRM0106 (01 2016) US EN 381
General 385
Description and Operation 386
Starter Repair 390
Remove 390
Disassemble 390
Clean 391
Assemble 391
Install 392
General Checks and Adjustments 392
Troubleshooting 394
524150797 8000YRM0231 (02 2023) US EN 401
General 407
Threaded Fasteners 407
Nomenclature, Threads 407
Strength Identification 408
Cotter (Split) Pins 409
Fastener Torque Tables 414
Conversion Table 416
524150797 8000YRM0231 (03 2020) US EN 423
General 427
Threaded Fasteners 427
Nomenclature, Threads 427
Strength Identification 428
Cotter (Split) Pins 429
Fastener Torque Tables 434
Conversion Table 436
524150798 8000YRM0940 (07 2013) US EN 443
toc 443
Capacities and Specifications 443
Safety Precautions Maintenance and Repair 444
Lift Truck Weights 447
Capacities 448
Engine Specifications 449
Perkins Diesel 449
Cummins Diesel/LPG 450
Hydraulic System 451
Electrical System 452
Tire Sizes 452
Mast Speeds 453
Perkins Diesel 453
Cummins Diesel/LPG 454
Torque Specifications, Cummins Diesel 455
Lubrication System 455
Torque Specifications, Perkins Diesel 455
Engine 455
Cylinder Head Assembly 455
Piston and Connecting Rod Assemblies 455
Crankshaft Assembly 455
Timing Case and Drive Assembly 455
Turbocharger 455
Lubrication System 456
Fuel System 456
Cooling System 456
Flywheel and Housing 456
Aspiration System 456
Electrical Equipment 456
Auxiliary Equipment 456
Torque Specifications, General 457
Transmission 457
Driveline and Axle 457
Differential 457
Brakes – Wet 457
Brakes – Dry 457
Steering 457
Hydraulic System 457
Mast 458
Carriage 458
Tilt Cylinders 458
Frame 458
Wiper Arms, Front 458
Transmission Pressures (Powershift and Automatic) 459
TE-10 Transmission Specifications 460
Electrical 460
Hydraulic Cooler Lines 460
Torque Specifications for Lubricated or Plated Screw Threads 460
tables 443
Table 1 Temperature Sensor (In Speed Sensor) Resistance vs Temp 460
Table 2 Grade 5 461
Table 3 Grade 8 461
Table 4 Grades 8 8, 10 9, and 12 9 462
Table 5 O-ring Port Plug Torque Chart 463
Table 6 Pipe Plug Torque Chart 463
524192855 0600YRM1068 (05 2004) US EN 467
toc 467
Perkins Tier 2 Diesel Engines 467
Safety Precautions Maintenance and Repair 468
General 475
General Safety Rules 475
Description 476
Engine Serial Number Codes 478
Engine Data 478
Engine Removal and Installation 479
Cylinder Head Assembly Repair 479
Valve Cover 479
Remove 479
Install 480
Rocker Arm Assembly 480
Remove 480
Disassemble 480
Inspect 480
Assemble 480
Install 480
Valve Clearance Adjustments 481
Valve Springs 482
Cylinder Head Assembly 483
Remove 483
Install 485
Valves and Valve Springs 488
Remove 488
Inspect 488
Install 489
Valve Guides 489
Inspect 489
Remove 489
Install 489
Cylinder Head and Valve Seats 490
Inspect 490
Repair 491
New Valve Seats, Install 491
Piston and Connecting Rod Assemblies Repair 491
Rod Bearings 492
Remove 492
Install 492
Piston and Connecting Rod Assembly 493
Service Note 493
Remove 493
Install 494
Piston Rings 495
Remove 495
Inspect 495
Install 495
Piston and Connecting Rod 496
Disassemble 496
Inspect 496
How to Select Correct Replacements 497
Install 498
Piston Cooling Jets 498
Remove 498
Install 498
Crankshaft Assembly Repair 499
General 499
Crankshaft Pulley 499
Remove 499
Inspect 499
Install 500
Rear Oil Seal 500
Remove 500
Install 501
Main Bearings 502
Remove 502
Inspect 502
Install 502
Thrust Washers 503
Crankshaft Axial Movement, Check 503
Remove 504
Install 504
Crankshaft 504
Remove 504
Inspect 505
Install 505
Flywheel 506
Remove 507
Ring Gear, Replace 507
Install 507
Flywheel Housing 507
Remove 507
Install 508
Timing Case and Timing Gears Repair 508
General 508
Timing Case Cover 508
Remove 508
Install 509
Front Oil Seal 509
Remove 509
Install 510
Crankshaft Pulley Wear Sleeve 510
Install 510
Idler Gear and Hub 511
Remove 511
Install 511
Air Compressor Drive, Bendix 512
Disassemble 512
Assemble 513
Fuel Injection Pump Gear 513
Remove 513
Install 514
Camshaft Gear 514
Remove 514
Install 515
Crankshaft Gear 515
Remove 515
Install 516
Timing Case 516
Remove 516
Install 516
Camshaft and Tappets 517
Remove 517
Install 518
Cylinder Block Assembly Repair 518
Description 518
Cylinder Block 518
Disassemble 518
Inspect 519
Assemble 520
Cylinder Liner 520
Inspect 520
Cylinder Liner Condition, Check 520
Remove 521
Service Liner, Install 522
Partially Finished Liner, Install 523
Engine Timing 524
Description 524
How to Set Number One Piston to TDC on Compression Stroke 525
How to Set Number One Piston to TDC on Compression Stroke (Alter 526
How to Set Number One Piston to 4° After TDC on Compression Stro 527
Valve Timing, Check 528
Fuel Injection Pump Timing, Check 529
Turbocharger 529
General 529
Remove 529
Install 530
Impeller and Compressor Housing, Clean 530
Waste-Gate Valve Check 531
Closed Circuit Breather System (CCB) 532
CCB Assembly, Remove 532
Closed Circuit Drain Valve, Remove 532
CCB Assembly, Install 532
Closed Circuit Drain Valve, Install 532
Lubrication System Repair 533
General 533
Oil Filter, Replace 533
Oil Filter Head 533
Remove 533
Install 534
Oil Filter Head Bypass Valve 534
Remove and Install 534
Oil Sump 534
Remove 534
Install 534
Oil Pump 535
Remove 535
Inspect 535
Install 536
Relief Valve 536
Remove 536
Disassemble 537
Inspect 537
Assemble 537
Install 537
Idler Gear Shaft, Replace 537
Remove 538
Remove (Alternative) 538
Install 539
Install (Alternative) 539
Fuel System Repair 540
Description 540
Fuel Injection Pump 542
Remove 542
Install 543
Fuel System Air Removal 544
Fuel Filter, Replace 546
Fuel Injectors 546
Remove 546
Inspect 547
Install 547
Fuel Lift Pump 548
Remove 548
Disassemble 548
Assemble 548
Install 549
Test 549
Cooling System Repair 550
General 550
Thermostat 550
Remove 550
Install 550
Test 550
Coolant Pump 551
Remove 551
Disassemble 551
Assemble 553
Install 556
Fan and Fan Drive 557
Remove 557
Install 557
Oil Cooler 557
Remove 557
Disassemble and Assemble 557
Install 558
Electrical Equipment Repair 558
Drive Belts 558
Alternator 559
Remove 559
Install 559
Electronic Control Module (ECM) 559
Remove 559
Inspect 560
Install 560
Voltage Load and Protection Module (VLPM) 560
Remove 560
Install 561
Engine Speed and Timing Sensor 561
Remove 561
Install 561
Pressure Sensors (Engine Oil and Air Intake) 561
Remove 561
Install 562
Temperature Sensor 562
Remove 562
Install 563
Starter Motor 563
Remove 563
Install 563
Cold Start Aid 563
Air Compressor 564
General 564
Repair 564
Remove 564
Install 564
Rotary Exhauster Replacement 566
Remove 566
Clean 566
Install 566
Engine Specifications 566
Cylinder Head Assembly 566
Piston and Connecting Rods 569
Crankshaft Assembly 570
Crankshaft Overhaul 571
Timing Case and Drive Assembly 573
Engine Block Assembly 574
Turbocharger 576
Lubrication System 576
Cooling System 578
Flywheel and Housing 578
Electrical Equipment 578
Torque Specifications 579
Cylinder Head Assembly 579
Piston and Connecting Rod Assemblies 579
Crankshaft Assembly 579
Timing Case and Drive Assembly 579
Turbocharger 579
Lubrication System 579
Fuel System 579
Cooling System 580
Flywheel 580
Auxiliary Equipment 580
Special Torque Specifications 581
Flywheel and Housing 581
Electrical Equipment 581
Auxiliary Equipment 581
Special Tools 582
Troubleshooting 587
Turbocharger Troubleshooting 589
tables 467
Table 1 Cylinder Head 566
Table 2 Valve Guides 567
Table 3 Inlet Valves 567
Table 4 Exhaust Valves 568
Table 5 Valve Springs 568
Table 6 Tappets 568
Table 7 Rocker Arm Shaft 569
Table 8 Rocker Arms and Bushings 569
Table 9 Pistons 569
Table 10 Piston Rings 569
Table 11 Piston Pins 569
Table 12 Connecting Rods 570
Table 13 Small End Bushings 570
Table 14 Connecting Rod Bearings 570
Table 15 Piston Cooling Jets 570
Table 16 Crankshaft 570
Table 17 Main Bearings 571
Table 18 Crankshaft Thrust Washers 571
Table 19 Crankshaft Heat Treatment 571
Table 20 Crankshaft Overhaul Specifications 572
Table 21 Maximum Variation (Run-Out) 573
Table 22 Camshaft 573
Table 23 Camshaft Thrust Washer 573
Table 24 Camshaft Gear 573
Table 25 Gear for Fuel Injection Pump 574
Table 26 Crankshaft Gear 574
Table 27 Idler Gear and Hub 574
Table 28 Cylinder Block 574
Table 29 Cylinder Liners 575
Table 30 Cylinder Liner Specifications (Partially Finished) 575
Table 31 Oil Pump 576
Table 32 Idler Gear for Oil Pump 576
Table 33 Relief Valve 576
Table 34 Oil Filter 576
Table 35 Bosch Fuel Injection Pump 576
Table 36 Fuel Injector Codes 577
Table 37 Fuel Pump 578
Table 38 Fuel Filter 578
Table 39 Coolant Pump 578
Table 40 Thermostat 578
Table 41 Fan Drive Housing 578
Table 42 Limits for Flywheel Run Out and Alignment (Total Indic 578
Table 43 Alternator 578
Table 44 Starter Motor 578
Table 45 Cold Start Aid 578
Table 46 List of Possible Causes 587
Table 47 List of Possible Causes 589
524203754 4000YRM1062 (08 2012) US EN 593
toc 593
Masts and Carriages 593
Safety Precautions Maintenance and Repair 594
General 597
Description 597
Operation 598
Two-Stage Mast 598
Three-Stage Mast 599
Safety Procedures When Working Near Mast 600
Forks Repair 601
Remove 601
Inspect and Adjust 601
Install 601
Carriage Repair 603
Description 603
Three Function 603
Four to Six Function 603
Remove 603
Disassemble 606
Clean and Inspect 606
Assemble 606
Install 607
Sideshift Cylinder Repair 607
Remove 607
Disassemble 607
Clean and Inspect 610
Assemble 610
Install 611
Fork Positioner Cylinders Repair 611
Remove 611
Disassemble 611
Clean and Inspect 611
Assemble 611
Install 611
Directional Control Valve Repair 618
Remove 618
Disassemble 618
Clean and Inspect 618
Assemble 619
Install 619
Mast Repair 619
Two- and Three-Stage Mast 619
Remove 619
Disassemble 624
Clean and Inspect 624
Assemble 626
Install 627
Three-Stage Mast (Four Cylinders) 628
Remove 628
Disassemble 630
Clean and Inspect 632
Assemble 632
Install 632
Fork Carriage Chains 634
Adjust 634
Bearing Rollers 636
Description 636
Lubrication 636
Clearance 636
Remove and Disassemble 636
Assemble 637
Mast Profile 637
Lift Cylinders Description 637
Piston-Type Cylinders 637
Lift Cylinders Repair 638
Remove 638
Disassemble 639
Clean and Inspect 639
Assemble 639
Install 640
Mast Operation Check 640
Lift and Tilt System Leak Checks 641
Lift System 641
Tilt System 641
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 642
Lift Chain Adjustments 642
Mast Adjustments 643
Bearing Blocks, Two-Stage Masts 643
Wear Plates 643
Carriage Adjustment 644
Troubleshooting 646
tables 593
Table 1 Allowable Mast Movement from Internal Leakage 641
524206062 8000YRM1099 (09 2013) US EN 651
toc 651
Periodic Maintenance 651
Safety Precautions Maintenance and Repair 652
General 657
How to Move Disabled Lift Truck 657
How to Tow Lift Truck 657
How to Put Lift Truck on Blocks 658
How to Raise Drive Tires 658
How to Raise Steering Tires 658
Maintenance Schedule 659
Maintenance Procedures Every 8 Hours or Daily 673
How to Make Checks With Engine Stopped 673
Safety Labels 673
Forks 673
Adjust 673
Remove 673
Install 673
Forks, Mast, and Lift Chains, Inspect 674
Operator Restraint System 675
Steering Column Latch 676
Tires and Wheels 676
Fuel, Oil, or Coolant Leaks, Check 676
Air Intake Piping 677
Cooling Fan 677
Crankcase Breather Tube 677
Drive Belts 677
Hydraulic System Oil 678
Cab Hydraulic System 678
Engine Oil 679
Cooling System 681
Battery 681
Fuel System (Diesel Engines Only) 682
Water Separator/Fuel Filter (Diesel Engines Only) 682
How to Make Checks With Engine Running 682
Fault Codes 682
Access 682
Exit 683
Clear 683
Gauges, Lights, Horn and Fuses 683
Control Levers and Pedals 687
Steering System 687
Air Filters 687
Transmission Oil 687
Brakes 687
Lift System Operation 687
Maintenance Procedures Every 500 Hours or Every 3 Months 688
Lift Chains 688
Lubrication 688
Adjust 688
Drive Shaft 688
Steering Axle 688
Wheel Nuts 688
Shafts for Brake Actuators 689
Drive Axle and Differential 689
Hydraulic Tank Breather 689
Cabin Air Filter, Heater 689
Air Filter, Engine 689
Engine Oil and Filter 689
Drive Belts 690
Perkins 690
Cummins 690
Mast 690
Bearing Rollers (Three-Stage Only) 691
Lubrication 691
Clearance 692
General Lubrication 692
Fork Wear and Damage Check 692
Lift Chains Wear Check 692
Maintenance Procedures Every 500 Hours or 6 Months 694
Charge Air Cooler 694
Dry Brakes Air Compressor (Cummins) 694
Fuel Pump (Cummins) 694
Fuel Filter 694
Perkins 694
Remove 694
Install 694
Cummins 695
Remove 695
Install 695
Fuel System Air Removal (Perkins) 696
Fuel System Air Removal (Cummins) 696
Fuel Injection Pump Without Vent Tube 696
Coolant 696
Maintenance Procedures Every 1000 Hours or 6 Months 698
Transmission Oil and Filter, Change 698
Fuel Injection Pump Timing (Perkins Only) 698
Valve Adjustment 698
Perkins 698
Differential and Drive Axle 698
Pilot Accumulator Pressure Charge Check 698
Maintenance Procedures Every 1000 Hours or Yearly 700
Coolant Fan Belt Tensioner 700
Belt Driven Fan Hub 701
Valve Adjustment 701
Cummins 701
Accumulator and Wet Brakes 702
Wet Brake Oil Filter 702
Air Dryer Cartridge (Dry Brakes) 702
Air Compressor Air Filter (Dry Brakes) 702
Maintenance Procedures Every 2000 Hours or Yearly 703
Hydraulic System 703
Hydraulic Oil Filter, Change 703
Hydraulic Oil, Change 703
Hydraulic Pilot Valve Filter, Change 703
Transmission Calibration 704
Wheel Bearings 704
Steer Wheels 704
Drive Wheels 704
Service Brakes 704
Cleaning Procedures (Dry Brake Axle) 704
Maintenance Procedures Every 2000 Hours or 2 Years 706
Air Compressor Discharge Lines 706
Rubber Vibration Damper 707
Engine Coolant 707
Safety Procedures When Working Near Mast 708
Fuel Injectors Check 709
Perkins 709
Lift and Tilt System Leak Check 710
Lift System 710
Tilt System 710
Welding Repairs 711
Wheel and Tire Replacement 712
Remove Wheels From Lift Truck 712
Pneumatic Tires 712
Remove Tire From Wheel 712
Remove Tire From Three- and Four-Piece Wheel 713
Install Tire on Wheel 714
Install Three- or Four-Piece Wheel in Tire 714
Add Air to Tires 715
Solid Rubber Tires 716
Remove Tire From Wheel 716
Install Tire on Wheel 717
Wheels, Install 719
tables 651
Table 1 Daily Inspections − Condition Check 661
Table 2 Daily Inspections − Fluid Level Check 663
Table 3 Daily Inspections − Checks With the Engine Running 663
Table 4 First Inspection After First 100 Hours of Operation 665
Table 5 Periodic Maintenance Schedule − Inspect and Adjust 665
Table 6 Periodic Maintenance Schedule − Lubricate 669
Table 7 Periodic Maintenance Schedule − Change 670
Table 8 Nominal Valve Clearance 702
Table 9 Allowable Mast Movement from Internal Leakage 710
524206065 1300YRM1082 (01 2016) US EN 723
Series Code / Model Designation Reference Table 727
Description of Operation 728
General 728
Torque Convertor, Pump Drive, and Pressure Regulating Valve 728
Input Shaft and Directional Clutches 729
Range Clutches 732
Output Section 732
Transmission Controls 732
Operation of the Valve 734
Selection of Range 740
Pressure Switch 740
Electric Solenoid Controls 740
Transmission Specifications 758
Transmission Identification 758
Weight, Dimensions, and Oil Capacity 758
Transmission Repair 759
Disassemble 759
Reverse and Second-Speed Clutch 789
Clean and Inspect 805
Housings 805
Oil Seals and Gaskets 806
Bearings 806
Gears and Shafts 806
Assemble 806
Reverse and Second-Speed Clutch 817
Control Valve Repair 857
Remove 857
Disassemble and Assemble 857
Clean and Inspect 860
Housings 860
Oil Seals and Gaskets 860
Install 860
Stall Test 862
Transmission Calibration and Electrical Troubleshooting 863
Userlink® 863
Connection 863
Clutch Filling Calibration 864
Purpose 864
Clutch Filling Calibration Procedure 864
Alternative Clutch Filling Calibration Procedure 864
Heat-up Mode 865
Heat-up Mode Stall Test 865
Inching Pedal Calibration 866
Purpose 866
Troubleshooting 866
Transmission Display Warning Codes 866
Access 867
Clear 867
Exit 867
Limp Home Mode 904
Shutdown Mode 904
Pressure Feedback Sensor 904
Transmission Oil Pressure Check 905
Pressure and Temperature Specifications 905
Electrical Specifications 911
Hydraulic Cooler Lines Specifications 911
Torque Specifications 912
Torque Specifications for Lubricated or Plated Screw Threads 912
Troubleshooting 914
524206069 8000YRM1103 (11 2006) US EN 921
toc 921
Diagrams 921
Safety Precautions Maintenance and Repair 922
524206632 2200YRM1105 (03 2007) US EN 1003
toc 1003
Instrument Panel Indicators and Senders 1003
Safety Precautions Maintenance and Repair 1004
General 1007
Description 1007
General 1007
Instrument Panel Meters, Indicators, and LCD Display 1007
Connector 1012
Seat Switch Logic 1013
Central Warning Light Output 1013
Buzzer Output 1013
Instrument Panel 1014
Remove 1015
Sender Replacement 1016
Fuel Level Sender (Diesel Engine Only) 1016
Engine Oil Pressure Sender 1016
Brake Pressure Sender 1016
Low Coolant Sender 1017
Vacuum Switch 1017
Specifications 1018
Troubleshooting 1019
tables 1003
Table 1 Instrument Panel and Indicators 1008
Table 2 Pin Description 1012
Table 3 Sender Description 1013
524211827 0600YRM1101 (11 2018) US EN 1023
Series Code / Model Designation Reference Table 1027
General 1027
Fault Codes 1028
Normal Mode 1028
Fault Log Mode 1029
Access 1029
Exit 1029
Clear 1029
Electronic Throttle Calibration 1029
Electronic Throttle Calibration Procedure 1030
Stationary Regeneration Procedure 1030
524215925 0600YRM1158 (06 2005) US EN 1059
toc 1059
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide 1059
Safety Precautions Maintenance and Repair 1060
Electronic Troubleshooting 1083
System Operation 1083
Electronic Controls 1083
Engine Governor 1084
Timing Considerations 1084
Fuel Injection 1084
Diagnostic Codes 1084
Diagnostic Fault Codes 1084
Diagnostic Event Codes 1084
Programmable Parameters 1085
Passwords 1085
Electronic Service Tools 1085
Electronic Service Tool (EST) 1085
Connecting the Electronic Service Tool and the Communication Ada 1085
Support for the Electronic Service Tool 1086
Optional Service Tools 1086
Diagnostic Codes 1086
Engine Display Warning Codes 1090
Access 1090
Exit 1090
Clear 1090
Replacing the ECM 1092
Self Diagnostics 1093
Glossary 1094
Sensors and Electrical Connectors 1097
Engine Wiring Information 1100
Harness Wire Identification 1104
Diagnostic Code Reader 1104
General 1104
Reference Documents 1104
Abbreviations 1104
Environmental Specification 1104
Hardware 1105
Connection Cable 1106
Software 1106
Engine Communication 1106
User Controls 1106
Power Supply 1106
Display Screen 1106
Operation Controls 1106
Audible Warning 1107
Operation Instructions 1107
How to Connect the Diagnostic Code Reader to the Engine 1107
How to Turn ON the Diagnostic Code Reader 1107
How to use the Display Screen 1107
How to Operate the Diagnostic Code Reader 1108
Main Menu 1108
Active Codes 1108
Inactive Codes 1108
How to Clear Codes 1108
Status Lamp 1109
Data List 1109
Diagnostics 1110
Programming Parameters 1111
Passwords 1111
Factory Passwords 1111
Customer Passwords 1111
Flash Programming 1112
Flash Programming a Personality Module 1112
WinFlash Error Messages 1112
System Configuration Parameters 1112
Full Load Setting 1112
Full Torque Setting 1112
Rating Interlock 1112
Engine Serial Number 1113
ECM Software Release Date 1113
Troubleshooting Without A Diagnostic Code 1113
Alternator Noise (Noisy Operation) 1113
Probable Causes 1113
Recommended Actions 1113
Alternator Drive Belts 1113
Alternator Drive Pulley 1113
Alternator Bearings 1113
Alternator Will Not Charge (Charging Problem) 1113
Probable Causes 1113
Recommended Actions 1113
Alternator Drive Belts 1113
Charging Circuit 1114
Alternator or Regulator 1114
Battery 1114
Probable Causes 1114
Recommended Actions 1114
Faulty Battery 1114
Auxiliary Device 1114
Cannot Reach Top Engine RPM 1114
Probable Causes 1114
Recommended Actions 1114
Diagnostic Codes 1114
Fuel Supply 1114
Air Intake and Exhaust System 1114
Individual Malfunctioning Cylinders 1115
Valve Lash 1115
Check for Low Compression 1115
Check the Fuel Injection Nozzles 1115
Check the Turbocharger 1115
ECM Parameters 1115
Check the Signal for the Throttle Position Sensor 1116
Coolant in Engine Oil 1116
Probable Causes 1116
Recommended Actions 1116
Engine Oil Cooler Core 1116
Cylinder Head Gasket 1116
Cylinder Head 1116
Cylinder Block 1116
Coolant Temperature Is Too High 1116
Probable Causes 1116
Recommended Actions 1116
Radiator Fins 1116
Coolant Level 1116
Radiator Cap and/or Pressure Relief Valve 1116
Combustion Gases in the Cooling System 1117
Water Temperature Regulator 1117
Restriction in the Coolant System 1117
Coolant Temperature Gauge 1117
Coolant Pump 1117
Excessive Load on the System 1117
ECM Will Not Accept Factory Passwords 1117
Probable Causes 1117
Recommended Actions 1117
ECM Will Not Communicate With Other Systems or Display Modules 1117
Probable Causes 1117
Recommended Actions 1117
Electronic Service Tool Will Not Communicate With ECM 1117
Probable Causes 1117
Recommended Actions 1118
Engine Cranks but Will Not Start 1118
Probable Causes 1118
Recommended Actions 1118
Diagnostic Codes 1118
Visual Checks 1118
Crank Without Injection 1118
Starting Motor Solenoid or Starting Circuit 1119
Valve Lash 1119
Fuel Injection Nozzles 1119
Air Inlet Heater Starting Aid 1119
Air Intake and Exhaust System 1119
Low Compression 1119
Fuel Supply 1119
Engine Has Early Wear 1120
Probable Causes 1120
Recommended Actions 1120
Dirt in Engine Oil 1120
Leaks in Air Intake System 1120
Low Oil Pressure 1120
Engine Misfires, Runs Rough or Is Unstable 1120
Probable Causes 1120
Recommended Actions 1120
Logged Codes 1120
Fuel Supply 1120
Air Intake and Exhaust System 1120
Individual Malfunctioning Cylinders 1121
Valve Lash 1121
Check for Low Compression 1121
Check the Fuel Injection Nozzles 1121
Check the Air Inlet Heater Starting Aid 1121
Check the Engine Speed/Timing Sensors 1121
Check the Signal for the Throttle Position Sensor 1121
Check the Fuel Injection Pump 1121
Engine Oil in Cooling System 1122
Probable Causes 1122
Recommended Actions 1122
Engine Oil Cooler Core 1122
Cylinder Head Gasket 1122
Cylinder Head 1122
Engine Speed Does Not Change 1122
Probable Causes 1122
Recommended Repairs 1122
Diagnostic Codes 1122
Engine Stalls at Low RPM 1122
Probable Causes 1122
Recommended Actions 1123
Diagnostic Codes 1123
Fuel Injection Nozzles 1123
Fuel Supply 1123
Accessory Equipment 1123
Power Mode Control 1123
Engine Vibration 1123
Probable Causes 1123
Recommended Actions 1123
Engine Supports 1123
Malfunctioning Individual Cylinder 1123
Valve Lash 1124
Check for Low Compression (cylinder pressure) 1124
Check the Fuel Injection Nozzles 1124
Turbocharger 1124
Engine Will Not Crank 1124
Probable Causes 1124
Recommended Repairs 1124
Machine Security System 1124
Battery Cables and/or Batteries 1124
Starting Motor Solenoid or Starting Circuit 1125
Starting Motor and/or Flywheel Ring Gear 1125
Electrical Power Supply 1125
Internal Engine Problem 1125
Excessive Black Smoke 1125
Probable Causes 1125
Recommended Actions 1125
Air Intake System or Exhaust System 1125
Individual Malfunctioning Cylinder 1125
Valve Lash 1125
Low Compression (cylinder pressure) 1125
Check the Fuel Injection Nozzles 1125
Check the Turbocharger 1126
Broken 5-Volt Supply Wire 1126
Verifying the ECM Software 1126
Excessive Engine Oil Consumption 1126
Probable Causes 1126
Recommended Actions 1126
Oil Level 1126
Engine Crankcase Breather 1126
Air Intake and Exhaust System 1126
Turbocharger 1126
Low Compression (cylinder pressure) 1127
Excessive Valve Lash 1127
Probable Causes 1127
Recommended Actions 1127
Lubrication 1127
Valve Lash 1127
Valve Train Components 1127
Excessive White Smoke 1127
Probable Causes 1127
Recommended Actions 1127
Fuel Supply 1127
Individual Malfunctioning Cylinder 1128
Valve Lash 1128
Low Compression (cylinder pressure) 1128
Air Inlet Heater Starting Aid 1128
Fuel Injection Nozzles 1128
Coolant Temperature Sensor Circuit 1128
Engine Pressure Sensors 1128
Intake Air Temperature Is Too High 1128
Probable Causes 1128
Recommended Repairs 1129
High Ambient Air Temperature 1129
Coolant Temperature 1129
Check for High Intake Air Restriction and/or High Altitude 1129
Intake Air Restriction 1129
High Altitude 1129
Check the Intake Manifold Air Temperature Sensor and/or the Circ 1129
Check for Sufficient Coolant Flow Through the Aftercooler (if eq 1129
Check for Sufficient Flow of Air Through the Aftercooler (if equ 1129
Intermittent Engine Shutdown 1129
Probable Causes 1129
Recommended Actions 1129
Logged Codes 1129
Fuel Supply 1129
Engine Protection Device 1130
Electrical Connectors 1130
Intermittent Low Power or Power Cutout 1130
Probable Causes 1130
Recommended Repairs 1130
Diagnostic Codes 1130
Electrical Connectors 1130
Fuel Supply 1131
Check the Intake Manifold Pressure 1131
Air Intake and Exhaust System 1131
Individual Malfunctioning Cylinders 1131
Valve Lash 1131
Check for Low Compression 1131
Check the Fuel Injection Nozzles 1132
Check the Turbocharger 1132
ECM Parameters 1132
Electronic System Problem 1132
Low Engine Oil Pressure 1132
Probable Causes 1132
Recommended Actions 1133
Engine Oil Level 1133
Engine Oil Pressure Gauge 1133
Engine Oil Bypass Valves 1133
Piston Cooling Jets 1133
Engine Oil Suction Tube 1133
Engine Oil Pump 1133
Bearing Clearance 1133
Low Power/Poor or No Response to Throttle 1133
Probable Causes 1133
Recommended Actions 1133
Diagnostic Codes 1133
Fuel Supply 1133
Air Intake and Exhaust System 1134
Individual Malfunctioning Cylinders 1134
Valve Lash 1134
Check for Low Compression 1134
Check the Fuel Injection Nozzles 1134
Check the Turbocharger 1134
ECM Parameters 1135
Electronic System Problem 1135
Mechanical Noise (Knock) in Engine 1135
Probable Causes 1135
Recommended Actions 1135
Accessory Equipment 1135
Valve Train Components 1135
Connecting Rod and Main Bearings 1135
Noise Coming from Cylinder 1135
Probable Causes 1135
Recommended Actions 1135
Fuel Quality 1135
Fuel Injection Nozzles 1135
Valve Lash 1135
Poor Acceleration or Response 1136
Probable Causes 1136
Recommended Repairs 1136
Diagnostic Codes 1136
Fuel Supply 1136
Individual Malfunctioning Cylinder 1136
Valve Lash 1136
Check for Low Compression 1136
Check the Fuel Injection Nozzles 1136
Check the Turbocharger 1137
ECM Parameters 1137
Check Intake Manifold Pressure 1137
Troubleshooting With a Diagnostic Code 1137
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal 1137
Conditions Which Generate This Code 1137
System Response 1137
Possible Performance Effect 1137
Troubleshooting 1137
Results 1137
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent 1137
Conditions Which Generate This Code 1137
System Response 1138
Possible Performance Effect 1138
Troubleshooting 1138
Test Step 1 1138
Results 1138
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted 1138
Conditions Which Generate This Code 1138
System Response 1138
Possible Performance Effect 1138
CID 0091 FMI 04 Throttle Position Sensor Shorted Low 1138
Conditions Which Generate This Code 1138
System Response 1138
Possible Performance Effect 1138
Troubleshooting 1138
Results 1138
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal 1138
Conditions Which Generate This Code 1138
System Response 1138
Troubleshooting 1139
Results 1139
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration 1139
Conditions Which Generate This Code 1139
Possible Performance Effect 1139
Troubleshooting 1139
Results 1139
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short 1139
Conditions Which Generate This Code 1139
System Response 1139
Troubleshooting 1139
Results 1139
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low 1139
Conditions Which Generate This Code 1139
System Response 1139
Troubleshooting 1139
Results 1139
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci 1139
Conditions Which Generate This Code 1139
System Response 1140
Possible Performance Effect 1140
Results 1140
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or 1140
Conditions Which Generate This Code 1140
System Response 1140
Possible Performance Effect 1140
Results 1140
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low 1140
Conditions Which Generate This Code 1140
System Response 1140
Possible Performance Effect 1140
Results 1140
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope 1140
Conditions Which Generate This Code 1140
System Response 1141
Results 1141
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit 1141
Conditions Which Generate This Code 1141
System Response 1141
Possible Performance Effect 1141
Troubleshooting 1141
Results 1141
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low 1141
Conditions Which Generate This Code 1141
System Response 1141
Possible Performance Effect 1141
Troubleshooting 1141
Results 1141
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o 1141
Conditions Which Generate This Code 1141
System Response 1141
Possible Performance Effect 1141
Troubleshooting 1142
Results 1142
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low 1142
Conditions Which Generate This Code 1142
System Response 1142
Possible Performance Effect 1142
Troubleshooting 1142
Results 1142
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent 1142
Conditions Which Generate This Code 1142
System Response 1142
Possible Performance Effect 1142
Troubleshooting 1142
Results 1142
CID 0247 FMI 09 J1939 Datalink, Abnormal Update 1142
Conditions Which Generate This Code 1142
System Response 1142
Results 1142
CID 0253 FMI 02 Incorrect ECM Software 1143
Conditions Which Generate This Code 1143
System Response 1143
Possible Performance Effect 1143
Troubleshooting 1143
Expected Result 1143
Results 1143
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal 1143
Conditions Which Generate This Code 1143
System Response 1143
Possible Performance Effect 1143
Troubleshooting 1143
Results 1143
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal 1143
Conditions Which Generate This Code 1143
System Response 1143
Possible Performance Effect 1143
Troubleshooting 1143
Results 1144
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs 1144
Conditions Which Generate This Code 1144
System Response 1144
Possible Performance Effect 1144
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig 1144
Conditions Which Generate This Code 1144
System Response 1144
Possible Performance Effect 1144
Results 1144
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal 1144
Conditions Which Generate This Code 1144
System Response 1144
Possible Performance Effect 1144
Results 1144
CID 0342 FMI 02 Speed and Timing Sensor No 2 Intermittent Signa 1144
Conditions Which Generate This Code 1144
System Response 1145
Possible Performance Effect 1145
Test Step 1 1145
Results 1145
Test Step 2 1145
Results 1145
CID 0774 FMI 02 Throttle Position Sensor No 2 Erratic or Interm 1145
Conditions Which Generate This Code 1145
System Response 1145
Possible Performance Effect 1145
Results 1145
CID 0774 FMI 03 Throttle Position Sensor No 2 Open Circuit or S 1145
Conditions Which Generate This Code 1145
System Response 1145
Possible Performance Effect 1145
Troubleshooting 1145
Results 1145
CID 0774 FMI 04 Throttle Position Sensor No 2 Shorted Low 1145
Conditions Which Generate This Code 1145
System Response 1146
Possible Performance Effect 1146
Troubleshooting 1146
Results 1146
CID 0774 FMI 08 Throttle Position Sensor No 2 Abnormal Signal 1146
Conditions Which Generate This Code 1146
System Response 1146
Possible Performance Effect 1146
Results 1146
CID 0774 FMI 12 Throttle Position Sensor No 2 Out of Calibratio 1146
Conditions Which Generate This Code 1146
System Response 1146
Possible Performance Effect 1146
Results 1146
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off 1146
Conditions Which Generate This Code 1146
System Response 1146
Possible Performance Effect 1146
Results 1146
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than 1146
Conditions Which Generate This Code 1146
System Response 1147
Possible Performance Effect 1147
Test Step 1 1147
Results 1147
Test Step 2 1147
Results 1147
CID 1684 FMI 02 Fuel Injection Pump, Software Failure 1147
Conditions Which Generate This Code 1147
System Response 1147
Possible Performance Effect 1147
Troubleshooting 1147
Results 1147
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault 1147
Conditions Which Generate This Code 1147
System Response 1147
Possible Performance Effect 1147
Troubleshooting 1147
Results 1148
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault 1148
Conditions Which Generate This Code 1148
System Response 1148
Possible Performance Effect 1148
Troubleshooting 1148
Results 1148
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width 1148
Conditions Which Generate This Code 1148
Troubleshooting 1148
Results 1148
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault 1148
Conditions Which Generate This Code 1148
System Response 1148
Possible Performance Effect 1148
Troubleshooting 1148
Results 1148
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault 1149
Conditions Which Generate This Code 1149
System Response 1149
Possible Performance Effect 1149
Troubleshooting 1149
Test Step 1 1149
Results 1149
Test Step 2 1149
Results 1149
Test Step 3 1149
Results 1149
Test Step 4 1149
Expected Result 1149
Results 1149
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault 1149
Conditions Which Generate This Code 1149
System Response 1149
Possible Performance Effect 1149
Troubleshooting 1150
Expected Result 1150
Results 1150
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error 1150
Conditions Which Generate This Code 1150
System Response 1150
Troubleshooting 1150
Test Step 1 1150
Results 1150
Test Step 2 1150
Results 1150
Test Step 3 1150
Results 1150
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault 1150
Conditions Which Generate This Code 1150
System Response 1151
Possible Performance Effect 1151
Troubleshooting 1151
Test Step 1 1151
Results 1151
Test Step 2 1151
Results 1151
CID 1684 FMI 14 Fuel Injection Pump, No Communications 1151
Conditions Which Generate This Code 1151
System Response 1151
Troubleshooting 1151
Test Step 1 1151
Results 1151
Test Step 2 1151
Results 1151
Test Step 3 1151
Results 1151
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali 1151
Conditions Which Generate This Code 1151
System Response 1151
Possible Performance Effect 1152
Troubleshooting 1152
Results 1152
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali 1152
Conditions Which Generate This Code 1152
System Response 1152
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S 1152
Conditions Which Generate This Code 1152
System Response 1152
Troubleshooting With an Event Code 1152
Event Codes 1152
Programmable Engine Parameters 1152
E015 High Engine Coolant Temperature Derate 1152
Conditions Which Generate This Code 1152
System Response 1152
Possible Performance Effect 1152
Troubleshooting 1152
Results 1152
E016 High Engine Coolant Temperature Shutdown 1153
Conditions Which Generate This Code 1153
System Response 1153
Possible Performance Effect 1153
Troubleshooting 1153
Results 1153
E017 High Engine Coolant Temperature Warning 1153
Conditions Which Generate This Code 1153
System Response 1153
Possible Performance Effect 1153
Troubleshooting 1153
Results 1153
E025 High Intake Air Temperature Derate 1153
Conditions Which Generate This Code 1153
System Response 1153
Possible Performance Effect 1153
Troubleshooting 1153
Results 1153
E027 High Intake Air Temperature Warning 1153
Conditions Which Generate This Code: 1153
System Response 1153
Possible Performance Effect 1154
Troubleshooting 1154
Results 1154
E040 Low Engine Oil Pressure Shutdown 1154
Conditions Which Generate This Code 1154
System Response 1154
Possible Performance Effect 1154
Troubleshooting 1154
Results 1154
E054 High Fuel Temperature Derate 1154
Conditions Which Generate This Code 1154
System Response 1154
Troubleshooting 1154
Test Step 1 – Check for Diagnostic Codes 1154
Expected Result 1154
Results 1154
Test Step 2 – Perform a Check of the Fuel System 1154
Expected Result 1155
Results 1155
E056 High Fuel Temperature Warning 1155
Conditions Which Generate This Code 1155
System Response 1155
Troubleshooting 1155
Test Step 1 – Check for Diagnostic Codes 1155
Expected Result 1155
Results 1155
Test Step 2 – Perform a Check of the Fuel System 1155
Expected Result 1155
Results 1155
E100 Low Engine Oil Pressure Warning 1155
Conditions Which Generate This Code 1155
System Response 1155
Possible Performance Effect 1155
Troubleshooting 1156
Test Step 1 – Check for Active Diagnostic Codes 1156
Expected Result 1156
Results 1156
Test Step 2 – Perform a Check of the Engine Lubrication System 1156
Expected Result 1156
Results 1156
E190 Engine Overspeed Warning 1156
Conditions Which Generate This Code 1156
System Response 1156
Possible Performance Effect 1156
Troubleshooting 1156
Engine Overspeed Warning 1156
Expected Result 1156
Results 1156
E442 Engine Failed to Stop With a No-Fuel Command 1156
Conditions Which Generate This Code 1156
System Response 1156
Possible Performance Effect 1157
Troubleshooting 1157
Test Step 1 1157
Results 1157
Test Step 2 1157
Results 1157
E883 Engine Failed to Stop When Fuel Solenoid Disengaged 1157
Conditions Which Generate This Code 1157
System Response 1157
Possible Performance Effect 1157
Troubleshooting 1157
Test Step 1 1157
Results 1157
Test Step 2 1157
Results 1157
Test Step 3 1157
Results 1157
Diagnostic Function Tests 1158
5-Volt Engine Pressure Sensor Supply Circuit – Test 1158
System Operation Description 1158
Background Information 1158
Test Step 1 1159
Inspect Electrical Connectors and Wiring 1159
Expected Result 1159
Results 1159
Test Step 2 1159
Check for Active Diagnostic Codes 1159
Expected Result 1159
Results 1159
Test Step 3 1160
Disconnect the ECM Engine Harness Connector From the ECM 1160
Expected Result 1161
Results 1161
Test Step 4 1161
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei 1161
Expected Result 1161
Results 1161
Test Step 5 1161
Check the Engine Harness 1161
Expected Result 1161
Results 1161
Air Inlet Heater Circuit – Test 1162
System Operation Description 1162
Test Step 1 1162
Inspect Electrical Connectors and Wiring 1162
Expected Result 1162
Results 1162
Test Step 2 1163
Check the Supply to the Power Relay for the Air Inlet Heater Sta 1163
Expected Result 1163
Results 1163
Test Step 3 1163
Check the Output From the Power Relay for the Air Inlet Heater S 1163
Expected Result 1163
Results 1163
Test Step 4 1163
Ground the Input to the Power Relay at the MIC 1163
Expected Result 1164
Results 1164
Test Step 5 1164
Ground the Input to the Power Relay at the ECM Connector 1164
Expected Result 1164
Results 1164
Test Step 6 1164
Override the Air Inlet Heater Starting Aid to Test the ECM 1164
Results 1164
Checking Idle Validation Switching Point (Throttle Sensor) With 1165
Expected Result 1165
Analog Throttle Position Sensor Circuit – Test 1165
System Operation Description 1165
Checking the Throttle Sensor With Unconnected Output C 1166
Expected Result 1166
Test Step 1 1166
Check for Connector Damage 1166
Expected Result 1166
Results 1166
Test Step 2 1166
Check for Active Diagnostic Codes 1166
Expected Result 1166
Results 1167
Test Step 3 1167
Check the Throttle Position With the Electronic Service Tool 1167
Expected Result 1167
Results 1167
Test Step 4 1167
Check the Voltage at the Throttle Position Sensor 1167
Expected Result 1168
Results 1168
Test Step 5 1168
Disconnect the Throttle Position Sensor and Check for Active Dia 1168
Expected Result 1168
Results 1168
Test Step 6 1168
Check the Throttle Selection Status With the Electronic Service 1168
Expected Result 1168
Results 1168
Test Step 7 1168
Disconnect the Supply Terminals of the Throttle Position Sensor 1168
Expected Result 1168
Results 1169
Test Step 8 1169
Check the Position of Throttle Position Sensor 1169
Expected Result 1169
Results 1169
Test Step 9 1169
Check the Throttle Position Sensor at the ECM 1169
Expected Result 1170
Results 1170
CAN Data Link Circuit – Test 1170
System Operation Description 1170
Test Step 1 1170
Inspect Electrical Connectors and Wiring 1170
Expected Result 1171
Results 1171
Test Step 2 1171
Check the CAN Data Link Between the ECM and P40 Fuel Injection P 1171
Expected Result 1171
Results 1171
Test Step 3 1171
Check the CAN Data Link Between the ECM and P40 Fuel Injection P 1171
Expected Result 1171
Results 1171
Test Step 4 1171
Verify the Supply Voltage at the Fuel Injection Pump 1171
Expected Result 1171
Results 1172
Data Link Circuit – Test 1172
System Operation Description 1172
Background Information 1172
Communication 1172
Test Step 1 1173
Inspect Electrical Connectors and Wiring 1173
Expected Result 1173
Results 1173
Test Step 2 1173
Determine the Type of Problem With the Data Link 1173
Expected Result 1173
Results 1173
Test Step 3 1174
Check the Battery Voltage at the ECM 1174
Expected Result 1174
Results 1174
Test Step 4 1174
Check the Battery Voltage That is Coming to the Data Link Connec 1174
Expected Result 1174
Results 1174
Test Step 5 1175
Connect the Electronic Service Tool Directly to the ECM 1175
Expected Result 1175
Results 1175
Test Step 6 1175
Change Electronic Service Tool Components 1175
Expected Result 1175
Results 1175
Test Step 7 1176
Connect an Electronic Service Tool and the ECM to Another Batter 1176
Expected Result 1176
Results 1176
Electrical Connectors – Inspect 1176
System Operation Description 1176
Background Information 1176
Test Step 1 1181
Check the Locking of the DT Connector (Deutsch) and the Lock Rin 1181
Expected Result 1181
Results 1181
Test Step 2 1181
Check the Socket Head Screw on the Connector for the Electronic 1181
Expected Result 1181
Results 1181
Test Step 3 1181
Perform a Pull Test on Each Wire Terminal Connection 1181
Expected Result 1181
Results 1181
Test Step 4 1181
Monitor the Electronic Service Tool While the Wiring and the Con 1181
Expected Result 1182
Results 1182
Test Step 5 1182
Check Wires for Nicks and/or Abrasions in the Insulation 1182
Expected Result 1182
Results 1182
Test Step 6 1182
Check Connectors for Moisture or Corrosion 1182
Expected Result 1183
Results 1183
Test Step 7 1183
Inspect the Connector Terminals 1183
Expected Result 1183
Results 1183
Test Step 8 1183
Check Individual Pin Retention Into the Socket 1183
Expected Result 1184
Results 1184
Electrical Power Supply Circuit – Test 1184
System Operation Description 1184
Background Information 1184
Test Step 1 1185
Check the Batteries 1185
Expected Result 1185
Results 1185
Test Step 2 1186
Inspect Electrical Connectors and Wiring 1186
Expected Result 1186
Results 1186
Test Step 3 1186
Check the Battery Voltage at the ECM 1186
Expected Result 1187
Results 1187
Test Step 4 1187
Use the Bypass Harness for the Electronic Service Tool to Bypass 1187
Expected Result 1188
Results 1188
Engine Pressure Sensor Open or Short Circuit – Test 1188
System Operation Description 1188
Background Information 1188
Test Step 1 1188
Check for Active +5V Sensor Supply Diagnostic Codes 1188
Expected Result 1189
Results 1189
Test Step 2 1189
Verify All Active Diagnostic Codes 1189
Expected Result 1189
Results 1189
Test Step 3 1189
Inspect Electrical Connectors And Wiring 1189
Expected Result 1190
Results 1190
Test Step 4 1190
Verify That the Diagnostic Code is Still Active 1190
Expected Result 1190
Results 1190
Test Step 5 1190
Disconnect the Sensor to Create an Open Circuit 1190
Expected Result 1190
Results 1190
Test Step 6 1190
Measure the Sensor Supply Voltage 1190
Expected Result 1190
Results 1190
Test Step 7 1191
Determine if the Short Circuit is in the Connector or in the Sen 1191
Expected Result 1191
Results 1191
Test Step 8 1191
Create a Short Circuit Between the Signal and the Common Termina 1191
Expected Result 1192
Results 1192
Test Step 9 1192
Check the Operation of the ECM by Creating Open and Short Circui 1192
Expected Result 1192
Results 1192
Test Step 10 1192
Bypass the Harness Wiring Between the ECM and the Sensor Connect 1192
Expected Result 1193
Results 1193
Engine Speed/Timing Sensor Circuit – Test 1193
System Operation Description 1193
Test Step 1 1194
Inspect the Electrical Connectors and Cables 1194
Expected Result 1194
Results 1194
Test Step 2 1194
Check the Installation of the Engine Speed/Timing Sensors 1194
Expected Result 1194
Results 1194
Test Step 3 1194
Measure the Sensor Resistance Through the Wiring Harness 1194
Expected Result 1195
Results 1195
Test Step 4 1195
Measure the Resistance of the Sensor 1195
Expected Result 1195
Results 1195
Test Step 5 1195
Measure the Resistance of the Cables Between the Fuel Injection 1195
Expected Result 1196
Results 1196
Test Step 6 1196
Check the Continuity of the Cables From the ECM to the Fuel Inje 1196
Expected Result 1196
Results 1196
Engine Temperature Sensor Open or Short Circuit – Test 1197
System Operation Description 1197
Background Information 1197
Test Step 1 1198
Verify All Active Diagnostic Codes 1198
Expected Result 1198
Results 1198
Test Step 2 1198
Inspect Electrical Connectors and Wiring 1198
Expected Result 1198
Results 1199
Test Step 3 1199
Verify That the Diagnostic Code is Still Active 1199
Expected Result 1199
Results 1199
Test Step 4 1199
Disconnect the Sensor to Create an Open Circuit 1199
Expected Result 1199
Results 1199
Test Step 5 1199
Create a Short Circuit Between the Signal and the Common Termina 1199
Expected Result 1199
Results 1200
Test Step 6 1200
Check the Operation of the ECM by Creating an Open and a Short C 1200
Expected Result 1200
Results 1200
Test Step 7 1200
Bypass the Harness Wiring Between the ECM and the Sensor Connect 1200
Expected Result 1201
Results 1201
Fuel Injection Pump Circuit – Test 1201
System Operation Description 1201
Background Information 1201
Test Step 1 1201
Check the Batteries 1201
Expected Result 1201
Results 1201
Test Step 2 1202
Inspect the Electrical Connectors and Wiring 1202
Expected Result 1203
Results 1203
Test Step 3 1203
Check the Supply Voltage at the Machine Interface Connector 1203
Expected Result 1203
Results 1203
Test Step 4 1203
Check the Supply Voltage at the Fuel Injection Pump 1203
Expected Result 1203
Results 1203
Test Step 5 1204
Check the Supply to the Power Relay for the Fuel Injection Pump 1204
Expected Result 1204
Results 1204
Test Step 6 1204
Check the Output of the Power Relay for the Fuel Injection Pump 1204
Expected Result 1204
Results 1204
Test Step 7 1204
Check the Voltage at the Relay Coil for the Fuel Injection Pump 1204
Expected Result 1204
Results 1204
Test Step 8 1204
Check the Output of the ECM Fuel Pump Power Control at the Machi 1204
Expected Result 1205
Results 1205
Test Step 9 1205
Check the Output of the Fuel Injection Pump Power Control at the 1205
Expected Result 1205
Results 1205
Test Step 10 1205
Measure the Voltage at the Pump Power Supply 1205
Expected Result 1206
Results 1206
Test Step 11 1206
Check the Voltage Load Protection Module (VLPM) 1206
Expected Result 1206
Results 1207
Indicator Lamp Circuit – Test 1207
System Operation Description 1207
Test Step 1 1207
Inspect Electrical Connectors and Wiring 1207
Results 1207
Test Step 2 1208
Inspect the Lamp, the Fuse, and the Power Supply 1208
Expected Result 1208
Results 1208
Test Step 3 1208
Inspect the Input to the Lamp at the ECM connector 1208
Expected Result 1208
Results 1208
Test Step 4 1208
Test the Individual Lamp Circuits 1208
Expected Result 1209
Results 1209
Test Step 5 1209
Check the Voltage at the ECM 1209
Expected Result 1209
Results 1209
Idle Validation Circuit – Test 1209
System Operation Description 1209
Test Step 1 1209
Expected Result 1209
Results 1209
tables 1059
Table 1 Electronic Service Tool 1085
Table 2 Optional Service Tools 1086
Table 3 CID FMI Codes and J Code FMI Codes 1087
Table 4 Event Codes and CID FMI Codes 1089
Table 5 Diagnostics Supported Over J1939 1090
Table 6 Events Supported Over J1939 1091
Table 7 Engine Connectors 1099
Table 8 Color Codes for the Harness Wire 1104
Table 9 Pin Connections for Perkins Deutsch Socket Connector 1106
Table 10 Suspect Parameter Numbers 1110
Table 11 Failure Mode Indicators (FMI) Codes 1110
Table 12 Engine Oil Pressure Trip and Reset Points 1154
524230692 8000YRM1181 (01 2017) US EN 1213
Series Code / Model Designation Reference Table 1217
General 1218
Weight and Dimensions 1218
Loading Procedures 1226
Loading A Truck on a Transport 1226
Loading Disassembled Components 1226
Unloading Procedures 1227
Unloading Complete Truck or Basic Truck From Transport 1227
Lifting 1227
Driving On/Off a Trailer 1228
Unloading Disassembled Components 1228
Removal of Forks Attached to Basic Truck 1228
Removal of Forks Attached to the Carriage 1228
Truck Assembly 1229
Safety procedures When Working Near the Mast 1230
Mast Installation 1231
Preparations 1231
Adjusting the Tilt Cylinders 1233
Connecting the Lift Cylinders 1233
Connecting the Mast Supply Hoses 1234
Carriage and Forks 1235
Installing the Carriage 1235
Connecting the Header Hoses to the Carriage 1235
Install the Forks 1235
Installing Pin-Type Forks 1235
Installing Quick Disconnect DFSSFP Forks 1237
1238
Installing Integrated DFSSFP Forks 1238
Adjusting the Carriage 1238
Adjusting Header Hose Tension 1239
Adjusting the Electrical Cable Tension 1240
Installing the Cab Lights 1240
Adding the Mast Labels 1241
Lubrication Points 1241
Pre-Delivery Inspection 1242
Empty Seat Engine Shut Down 1242
Pre-Delivery Inspection 1242
Pneumatic Tires and Wheels 1243
Remove Wheels From Lift Truck 1243
Remove Tire From Wheel 1244
Install Tire on the Wheel 1246
Adding Air Pressure to the Tires 1248
Solid Rubber Tires, Remove Tire From the Wheel 1248
Solid Rubber Tires, Install Tire on the Wheel 1250
Install Wheels on Lift Truck 1252
Moving and Towing 1253
Moving a Disabled Lift Truck 1253
Precautions 1253
Towing A Lift Truck 1254
524302733 1300YRM1356 (01 2016) US EN 1257
Series Code / Model Designation Reference Table 1261
General 1261
Transmission Repair 1261
Remove 1261
Disassemble 1265
Reverse and Second-Speed Clutch 1295
Clean and Inspect 1311
Housings 1311
Oil Seals and Gaskets 1312
Bearings 1312
Gears and Shafts 1312
Assemble 1312
Reverse and Second-Speed Clutch 1322
Install 1363
Control Valve Removal and Installation 1366
Remove 1366
Install 1366
Control Valve Components 1367
Control Valve Disassemble and Assemble 1367
Remove 1367
Control Valve Cover 1367
Control Valve Components 1368
Install 1368
Control Valve Components 1368
Control Valve Cover 1368
Transmission Frame Bracket 1369
Torque Specifications 1369
Torque Specifications for Lubricated or Plated Screw Threads 1369
Troubleshooting 1371
524304019 1300YRM1358 (01 2016) US EN 1375
Series Code / Model Designation Reference Table 1381
General 1382
Description 1382
General 1382
Operation 1385
Hydraulic Operation 1385
1st/3rd Selector Valve 1388
Cooling and Lubrication 1390
Control System 1391
General 1392
APC200 Controller 1392
Self Test 1392
Protection Modes 1392
Limp Home Mode 1392
Shut Down Mode 1392
Transmission Exceed Codes 1393
Fault Codes 1393
Description 1393
Fault Log Mode 1393
Access 1393
Exit 1394
Clear 1394
Fault Rectification 1394
Hydraulic Control Valve 1396
Hydraulic Control Valve Repair 1398
Solenoid Replacement 1398
Pressure Check 1398
Pressure Specifications 1399
Pressure, Speed, and Temperature Sensors 1399
Pressure Switch 1404
Test 1404
Speed Sensor 1405
Test 1405
Temperature Sensors 1406
Test 1406
Transmission Test and Calibration 1407
Precautions 1407
Stall Test 1407
Description 1407
Stall Test Procedure 1407
Clutch Calibration 1408
Description 1408
Procedure 1409
Inching Calibration 1409
Description 1409
Brake and Inching Pedal Adjustment 1410
Inching Sensor Adjustment 1410
Inching Sensor Calibration 1411
Electrical Specifications 1411
APC200 Display information 1411
General 1412
General Information Group 1412
Fault Codes 1413
Indication of Protection Modes 1413
Test Function Group 1414
Digital Input Test 1416
Analog Input Test 1417
Speed Sensor Test 1418
Output Test 1419
Voltage Test 1420
Calibration Group 1422
Calibration Mode 1422
Clutch Filling Calibration 1422
Heat Up Mode 1423
Inching Sensor Calibration 1423
Inching Pedal Sensor Adjustment 1423
Inching Sensor Calibration 1423
TE-Userlink 1424
Description 1424
Connection 1424
1424
Diagrams, Schematics, or Arrangements 1424
550022606 1300YRM1435 (01 2016) US EN 1461
Series Code / Model Designation Reference Table 1465
General 1465
Transmission Exceed Codes 1465
Clutch Calibration Condition Messages 1465
Fault Codes During Clutch Calibration 1465
APC200 Fault Codes 1466
Limp Home Mode 1466
Shut Down Mode 1466
Pressure Feedback Sensor 1466
APC200 Fault Codes 1467
Transmission Exceed Codes 1467
Clutch Calibration Condition Messages 1471
Fault Codes During Clutch Calibration 1471
APC200 Fault Codes 1474
550033397 0100YRM1458 (04 2011) US EN 1501
toc 1501
Cab Heater (Prior to Oct 2008) 1501
Safety Precautions Maintenance and Repair 1502
Aurora Heater and Air Conditioner 1505
Heater System 1505
General 1505
Air Conditioning 1506
General 1506
Dryer 1507
Control Systems, Sensors, and Switches 1507
Heater System Repair 1509
Heater Assembly 1509
Access 1509
Remove 1509
Install 1509
Heater Assembly Parts, Replace 1510
Heater Core 1510
Remove 1510
Install 1510
Evaporator Core 1511
Remove 1511
Install 1511
Blower 1511
Remove 1511
Install 1511
Water Valve 1512
Remove 1512
Install 1512
Vent Door 1513
Remove 1513
Install 1513
Push/Pull Cable, Replace 1513
Water Valve Cable 1513
Remove 1513
Install 1514
Vent Door Cable 1514
Remove 1514
Install 1515
Electric-Operated Heater Control and Fan Control 1516
Remove 1516
Install 1516
Cable-Operated Heater Control and Air Control 1517
Remove 1517
Install 1517
Air Conditioning Switch 1517
Remove 1517
Install 1517
Technical Detail 1518
tables 1501
Table 1 Air Conditioning Specifications 1518
550033400 0100YRM1390 (12 2018) US EN 1521
Series Code / Model Designation Reference Table 1529
General 1529
Description of Operation 1531
Cab Structure 1531
Cab Tilt System 1531
Cab Tip-Up System 1533
Tilting the Cab 1534
Raising 1534
Lowering 1535
Remove and Install 1536
Cab Door Assembly 1536
Cab Door 1536
Remove 1536
Install 1536
Door Hinge 1537
Remove 1537
Install 1537
Door Latch 1538
Remove 1538
Install 1538
Door Handle 1538
Remove 1538
Install 1538
Door Release 1539
Remove 1539
Install 1539
Door Push Button 1539
Remove 1539
Install 1540
Cab Tilt System 1540
Electric Tilt Pump 1540
Remove 1540
Install 1540
Hand Tilt Pump 1540
Remove 1540
Install 1541
Cab Tilt Cylinder 1542
Remove 1542
Disassemble 1542
Clean 1544
Inspect 1544
Assemble 1544
Install 1545
Latch 1545
Remove 1545
Install 1546
Brake and Inching Pedal 1547
Remove 1547
Install 1547
Accelerator Pedal and Sensor 1548
Remove 1548
Install 1548
Adjust Sensor 1548
Seat Assembly 1548
Seat 1548
Remove 1548
Install 1549
Seat Cushion 1549
Remove 1549
Install 1550
Back Cushion 1550
Remove 1550
Install 1550
Seat Suspension Replacement 1550
Boot Replacement 1550
Power Assist Armrest 1574
Release Cable 1574
Remove 1574
Install 1574
Gas Spring 1574
Remove 1574
Install 1575
Joystick 1575
Remove 1575
Install 1575
Electrical Levers 1575
Remove 1575
Install 1576
Armrest Rocker Switches 1576
Remove 1576
Install 1576
Armrest Top Cover 1576
Remove 1576
Install 1576
Instrument Panel 1577
Key Switch 1577
Remove 1577
Install 1577
12V Power Socket 1577
Remove 1577
Install 1577
Electric-Operated Heat Control and Air Recirculation Control (Airco Only) 1578
Remove 1578
Install 1578
Cable-Operated Heater Control (Heater Only) 1579
Remove 1579
Install 1579
Air Conditioning Switch Replacement 1579
Instrument Panel Rocker Switches Replacement 1579
Parking Brake Switch 1580
Remove 1580
Install 1580
Indicator Display Replacement 1580
Instrument Panel Top Console 1580
Remove 1580
Install 1581
Steering Wheel and Column Assembly 1581
Steering Wheel and Horn 1581
Remove 1581
Install 1583
Steering Column Assembly 1583
Remove 1583
Install 1584
Adjustment Handle 1584
Remove 1584
Install 1584
Main Warning Lights 1585
Remove 1585
Install 1585
Shift Lever 1585
Remove 1585
Install 1585
Turn Signal Lever 1585
Remove 1585
Install 1585
Window Wipers 1586
Window Wiper Assembly Replacement 1586
Remove 1586
Install 1586
Window Wiper Motor Replacement 1586
Front Window Wiper Motor 1586
Install 1586
Rear Window Wiper Motor Assembly 1587
Remove 1587
Install 1587
Top Window Wiper Motor Assembly 1587
Remove 1587
Install 1587
Window Washer System 1588
Window Washer Reservoir and Pumps 1588
Remove 1588
Install 1588
Window Washer Hoses 1589
Hoses for Top and Rear Window 1589
Install 1590
Window Washer Spray Nozzles 1590
Front Window 1590
Remove 1590
Install 1590
Rear Window 1591
Remove 1591
Install 1591
Top Window 1591
Remove 1591
Install 1591
Window Replacement 1591
Front Window 1593
Remove 1593
Install 1593
Rear Window 1593
Remove 1593
Install 1593
Top Window 1594
Remove 1594
Install 1594
Door, Upper/Lower Window 1595
Remove 1595
Install 1595
Sliding Window and Sliding Tracks 1595
Remove 1595
Install 1597
Weather Strip Replacement 1597
Window Stopper Replacement 1597
Window Seal Replacement 1598
Sliding Window Frame 1598
Remove 1598
Install 1598
Floor Mat 1598
Front Floor Mat 1598
Remove 1598
Install 1599
Rear Floor Mat 1599
Remove 1599
Install 1600
Radio Console 1600
Remove 1600
Install 1600
Air Duct Replacement 1601
Remove Front 1601
Remove Rear 1601
Install 1602
Accessories 1602
Mirror Replacement 1602
Sunshade Replacement 1602
Top 1602
Rear 1603
Map Light Replacement 1603
Interior Fan Replacement 1603
Training Seat 1603
Field Installation 1603
Remove 1603
Label Replacement 1604
Checks and Adjustments 1604
Check Oil Level for Cab Tilt System 1604
Door Striker Pin Adjustment 1605
Brake Pedal Adjustment 1605
Dry Brake 1605
Wet Brake 1606
Inching Pedal Adjustment 1606
Inching Pedal Sensor Adjustment 1606
Sensor Adjustment Using Dana Dashboard Software 1606
Sensor Adjustment using the APC200 Display 1607
Sensor Adjustment for Trucks with ZF Transmission 1608
Inching Pedal Sensor Calibration 1608
Sensor Calibration using Dana Dashboard Software 1608
Sensor Calibration using APC200 Display 1608
Sensor Calibration for Trucks with ZF Transmission 1609