10. on 12. 13. 14, Z\ caution OBSERVE THE FOLLOWING PRECAUTIONS FOR MAXIMUM SAFETY OF MACHINE OPERATION Only trained and responsible operators shall be permitted to handle loads with the truck. Operate the truck from the operator's seat only. Do not allow riders. Test hydraulic controls for proper response before using the machine. Know your load. Do not attempt to lift or transport loads in excess of rated capacity. When the load obstructs the view, operate the truck in the reverse range, Do not stand or work under an elevated load. Transport the load low and tilted back. Avoid sudden stops with a load. Evenly distribute the weight of the load on both forks Back down a ramp in excess of 10 percent when loaded. The spotting brake is for temporary stops. Do not leave the truck unattended with only the spotting brake applied. Do not move the truck until the air system reaches recommended pressure. Air pressure is required for the service brakes. Have defects repaired immediately. Do not operate a truck with damaged or defective systems. When leaving truck, lifting mechanism shall be fully lowered, controls shall be neutralized, power shut off, parking brake set, and key removed, Block wheels If on incline.LIMITED WARRANTY Products manufactured by Taylor Machine Works, Inc. ("Taylor") and sold are warranted by Taylor to be tree trom detects in material and workmanship, under normal use and service, when Taylor products are operated at oF below rated capacity * in accarcance with operating instructions, This warranty is limited to ropair or replacement, (as Taylor may elect, and at an establishment authorized by Taylor) of such parts as shall appear to Taylor upon inspection to have been defective in material or ‘workmanship, ‘This warranty period shall begin on the delivery date of the product to the Purchaser and end on the earlier of twelve (12) months or two thousand (2000) hours. During the first six (6) months or one thousand (7000) hours, Taylor will provide genuine Taylor paris, labor, and travel time to raplace or repair any part furnished by Taylor and found to be detective in material and workmanship. If a defect in material and workmanship is found during ‘the first six (6) months and/or one thousand (1000) hours whichever occurs first of the warranty period, Taylor will replace lubricating oil, filters, antireeze, and other service items made unusable by the defect.” In the second six (6) months andior second one thousand (1000) hours after the dolivery date of the truck, Taylor will ‘approve parts only. Only genuine Taylor parts provided by Taylor's Sudden Service, Inc. will be used during the warranty period ‘THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY: 1. Normat maintenance services and parts or supplies used therein including, without limitation, engine tune-up, wheel alignment, brake and linkage adjustment, lubrication services, tightening and adjusting such as bolts, screws, hoses, fittings, otc. placement of fuses, bulbs, filters, tune-up parts, fluids and brake and ‘lutch linings, glass; shop supplies such as raga, oil dry, hand soaps, degreasers, cleaning solutions Including brake clean, etc.; and adjustments which are a part of the required or recommended predelivery inspection and periodic inspections in accordance with Operator's Manual. Electrical components inciuding wiring will be excluded after the frst six (6) months or one thousand (1000) hours whichever occurs first 2. Normal deterioration of appearance due 10 use and exposure; or conditions resulting trom misuse, negligence, or accident. 3. Any product on which any of the required or recommended periodic inspections or services have not been mado. 4. Any parts or accessories, installed on the product which were not manufactured or installed by Taylor whether or not such parts or accessories were selected, recommended or installed by Taylor (including without limitation, engines, tires, batteries, air conditioners, air dryers, etc.). Such parts or accessories shall be covered by the warranties given by the manufacturers thereat and any claim thereof shall be made to such manulacturers. 5. Loss of time, inconvenience, loss of eq specifically included, Taylor parts and assemblies which are furniched and installed under this warranty are themselves within tho coverage of the machine warranty and are covered only for the duration of the original machine warranty period. Note: All International warranty parts shipments are F.0.8. point of deberkation, duties, tarlfe, or local taxes excluded, ment use, other consequential damages or other matters not This warranty is expressly in lieu of any other warranties, expressed or implied, including any warranty of ‘merchantablilty or fitness for a particular purpost Replacement parts are warranted for ninety (90) days to be free from detects In materiel or workmanship. Parts only, no labor. Taylor Machine Works, Inc. does not authorize any person to create (for Taylor) any other obligation or Hiability in Connection with Taylor products. “For example, a machine rated capacity at any stipulated load center Is the rated lift capacity at less than load center. That Is, a machine rated at 20.000 pounds at 24-inch load center connotes 20,000 pounds is the maximum lift capacity even though the load center may be less than 24-inches. Subjecting Taylor products to conditions. or loads exceeding those stipulated Is justification tor Immediate cancellation of warranty for products involved TAYLOR MACHINE WORKS, INC. 650 North Church Avenue Louisville, Mississippi 39339 (601) 773-9421 / Fax 801-779-9846 Tiaweosr (7783)~ General Information Engine Lubrication . Fuel System. Air Intake System. Cooling System... Electrial System Transmission seen Steer Axle. Drive Axle. Brake System, Chassis Hydraulic System... Mast. Carriage. Attachments & ACCESSOTICS «nn Appendix CONTENTS MAINTENANCE SECTION 14 15 7 22 27 28 29GENERAL INFORMATION 41 INTRODUCTION. This manual is to be used as a guide for lubrication and maintenance as well as general equipment care. A separate section is provided to discuss each major compo: nent or system. This method of presenting the maintenance instructions enables TAY LOR MACHINE WORKS, INC. to assemble a mainte- nance manual with explicit instructions on the exact equipment installed on the machine. 4-2 LUBRICATION AND MAINTENANCE, Lubrication and maintenance should be per- formed at regular intervals by observing the Preventive Maintenance Schedule in the appen- dices, If the machine is being operated under ex- tremely dusty, sandy or humid conditions, the service interval may need to be shortened to pre- vent excessive wear and ensure longer trouble-free operation, NOTE An operator's guide which includes ‘the controls and indicators, daily checks, and safety precautions is, furnished with each machine and should remain with the machine at all times.ry 1200 GR 10x TRANSMISSION LINKAGE 1200 DR STEER 1200 GR 10x AXLE 2400 DR HYDRAULIC LEVERS Hua. HYDRAULIC RESERVOIR 100 x 12000R DRIVE AXLE 1200 GR INCHING PEDAL, 100 GR TT CYLINDER 70% 100 GR wor 1000R 100SR Sa DRIVESHAFT 10x Tit engine HOOD Greene Lowen 1000 oR CYLINDER HINGE TRANSMISSION C HOURLY SYMBOL LUBRICANT INTERVAL | ABBREVIATIONS Engine Oi1 X—Check Lubricant Torque Fluid Level Type C-4 DR—Drain and Gear Oi1, GL-5 Refill GR-Grease Grease Grade 1 or 2 NOTE: See fuel and lubricant specifications for types and weights of lubricants to be used in different temperature ranges. Figure 1, Lubrication Chart C TE-160 - 360 (Rev. 9/91)O SECTION 1 ENGINE LUBRICATION CUMMINS DIESEL, “B” SERIES OIL FILTER DRAIN PLUG. OIL FILL CAP Figure 1. Lubricating System DESCRIPTION. The pump draws oil from the pan and forces it through the lubrication system. The pressure regulating valve controls the oil pressure, The filter bypass valve ensures a supply of oil in the event the filter becomes plugged. The system includes an oil pump, pressure regulating valve, oil cooler, filter bypass vaive and oil filter. CHANGING THE OIL. Refer to the appendices in the back of this manual for the proper grade of oil to be used. The oil filter element should be replaced each time the engine oil is changed, It is recommended that new engines be started with 100-hour oi! change periods. a. Provide a suitable container and remove drain plug. (Rev. 11/91) b, Remove oil filter. NOTE The oil should be drained when the engine is warm, ©. Reinstall drain plug. d. Lubricate the oil seal on the oil filter with clean engine oil. e. Install new oil filter. Rotate the filter Ye turn after the seal contacts the filter head, f. Remove oil filler cap and fill the engine to full mark "H” on dipstick.NOTE Never operate the engine with the il level below the “L” (Low) mark or above the “H” (High) mark. 9. Operate the engine and inspect for leaks. GENERAL INFORMATION Oil Pressure. 30 + 60 psi Oil Capacity (includes filter change) ...nnnu11 gts. 4 Oyl 17 qts. ~6 Cyl (Rev. 11/81)SECTION 2 © FUEL SYSTEM CUMMINS DIESEL, "and “C" SERIES RETURN FUEL INJECTORS, UNE FUEL TANK FUEL FILTER FUEL’ PUMP FUEL WATER’ SEPARATOR ~ Figure 1. Fuel System DESCRIPTION. The fuel system consists of a fuel be changed after every 400 hours or more often if () tank, lift pump, fuel water separator, filter, inj conditions warrant, Refer to figure 2 for identifica ~’ tion ‘pump, manitold, injectors and lines. Fuel is tion of parts, drawn from the tank by the fuel pump. Fuel is then forced through the fuel water separator, fuel filter 1. Remove the filters from the adaptor and throughout the system, . Fill new filters with clean fuel. 2, 3. Lubricate the seal with clean oil. CHANGING FILTERS. With the engine shut down, upricate with clean oll perform the following procedures to replace the 4. Install filters and tighten them 1/2 turn after fuel filter and fuel water separator. They should seals contact adaptor. ADAPTOR SEAL SEAL. FUEL WATER, FUEL FILTER. SEPARATOR Figure 2. Servicing Fuel Filler and Fuel Water Separator (Rev. 6187)SECTION 3 AIR INTAKE SYSTEM DONALDSON AIR CLEANER INTERNAL FILTER i SAFETY INDICATOR ELEMENT MOUNTING STRAPS. ‘COVER, PRESS --, | TO ENGINE TO RESET ( FILTER EVACUATOR SERVICE Privany exeent service Figure 1. Air Intake System DESCRIPTION. The Donaldson air cleaner is NOTE designed for fast, easy disassembly so it can be serviced efficiently and quickly. Intake air enters the Normally the primary fiter air cleaner through the pre-cleaner cap. When the element should be changed air reaches the fier body, a helical ramp imparts a after 500 hours or when the high-speed circular motion to the intake air. This {iter service indicator shows red. action separates a large portion of the dust from In dusty working conditions the the air by centrifugal action. The dust is swept out primary fiter element may have through the evacuator. to be changed more often SERVICING. If the fork lift is being operated under extremely dusty conditions, the evacuator should be checked every day to be certain itis not clogged. 1. When the restriction indicator indicates element servicing is required, remove the wingnut Perform the following procedures to service the cover assembly, then remove the wingnut and filter element and service air cleaner components: primary fitter element. a (Rev, 6/92)2. Check the internal filter indicator to determine if the safety element also requires servicing. 3, If the internal indicator shows GREEN - continue to step 5. 4, If the internal indicator shows RED, remove the indicator and the safety element. NOTE Replace the safety element after 1500 hours or as indicated by the internal filter indicator. 5. Replace the primary filter element with new element 6. Remove all dust and foreign particles from the air cleaner components, and clean the inside of the air cleaner body. 7. Reinstall the safety element, internal fier indicator, primary element and wing nut. 8, Reinstall the cover. 9. Push the reset button on the filter elernent service indicator. (Rev. 6/92)SECTION § O COOLING SYSTEM DESCRIPTION. The cooling system consists of the radiator, piping connecting the radiator to the ‘engine, and a water pump to circulate the coolant through the system, A recovery tank is connected to the top of the radiator which supplies additional coolant and improves the cooling capability. CHECKING THE COOLANT LEVEL. The coolant level should be checked dally. Coolant should be visible in the recovery tank before starting the engine, when the coolant is cold. If the coolant level is too low, add coolant to the recovery tank Until coolant is visible between marks. Do not overfill WARNING Do not remove cap on radiator unless entire system is to be refilled after draining. COOLANT TEMPERATURE, When the engine warms up the indicator pointer for the coolant ~, temperature gauge should be in the green area Oo (180° to 200°F,) DRAINING THE COOLANT SYSTEM, The engine coolant is drained by opening the drain cocks in the bottom of the radiator and removing the drain plugs in the engine block. Removal of the recovery tank filler cap will allow air to enter the cooling passages and ensure that, the coolant drains completely from the system, A\ caution When freezing weather is expected, any cooling system not adequately pro- tected by antifreeze should be drained, Leave all drain cocks open until refilling the cool- ing system. The cooling system of this equipment is protected to -34°F, (36° Celsius) freezing, and 20°F, (104.4 Celsius) boiling. This is a 50 % ethylene glycol base antifreeze to water solution. It is fecommended that 50 % solution be maintained year round. NOTE If the 60 % antifreeze to water is not TE-160 — 360 (Rev. 2/88) maintained, water pump failure may occur. COOLANT RECOMMENDATIONS. The following recommendations are considered beneficial to trouble free operation of the cooling system. 1. Always use a properly inhibited coolant, 2. If freeze protection is required, always use antifreeze with an ethylene glycol base. 3. Re-inhibit antifreeze with a non-chromate inhibitor, 4, Always follow the manufacturer's recom- mendations on inhibitor usage and handling, 5. Do NOT use soluble oil. 6. Chromate inhibitors should NEVER be used. 7. Sealer type antifreeze should NOT be used, 8. Maintain prescribed inhibitor strength. FILLING THE COOLANT SYSTEM. Before starting the engine, close all drain cocks and fill the cool. ing system. If the capacity of the cooling system is unknown, measure the amount of water Necessary to fill the cooling system. Drain the cooling system and refill the desired amounts of water and antifreeze or pre-mix to pro- per proportions before filling, NOTE The use of clean soft water will eliminate the need for descaling solu- tions to clean the cooling system. A hard mineral-laden water should be softened with water softener chemicals before it is poured into the cooling system. FLUSHING. The cooling system should be flushed each spring and fall. The flushing operation cleans the system of antifesze solution in the spring and removes the summer rust inhibitor in the fall, preparing the cooling system for a new solution, INSPECTION. Components of the cooling system should be checked periodically to keep the engine operating at peak efficiency. The thermostat and radiator pressure cap should be checked and replaced if found defective. The cooling systemhoses should be inspected and any hose that is. abnormally hard or soft should be replaced im- mediately. Check the hose clamps to make sure they are tight. All external leaks should be cor rected as soon as detected. The shroud should be tight against the radiator core to prevent recir- culation of air which may lower cooling efficien- cy. Check the fan and water pump drive belts for proper tension. DRIVE BELT TENSION. The tension on the fan and water pump drive belts should be such that a firm push with the thumb midway between the pulleys will deflect the belt 1/2 to 3/4 inch. If either of the belts need to be replaced, replace both belts with a matched set. After replacing the belts and ad- justing the tension, operate the engine for 15 seconds to seat the belts and readjust the ten- sion, Re-check the belt tension after 1/2 hour of operation, and adjust if necessary. Thereafter, check the tension of the drive belts after every 50 hours of operation and adjust if necessary. NOTE Some Cummins engines have automatic tensioners and the above is not applicable. Z\ caution Too tight a drive belt is destructive to the bearings of the driven part, and a belt that is too loose will slip. ‘TE-160 — 360 (Rev. 2/88) CCc SECTION 6 ELECTRICAL SYSTEM DESCRIPTION. The electrical system con- sists of a battery (or batteries), a battery disconnect switch, a battery charging alter- nator with voltage regulator, ignition and starter switch, starter and starter solenoid. The remainder of the electrical system con- sists of instruments, switches, sending units, wiring, circuit breakers, etc., necessary for operation of the electrical system. Optional equipment selected by the customer will determine the electrical equipment to be installed in addition to the standard elec~ trical system. BATTERIES. The batteries are perishable items which require periodic servicing. A properly cared for battery will give long and trouble-free service. Refer to the appendices in the back of this manual for service intervals, and perform the fol- lowing procedures to maintain the bat- teries in a serviceable condition. 1. Check the level of the electrolyte regularly. Add water if necessary, but do not overfill. CAUTION: Overfilling can ‘cause poor performance or early failure. Keep the top of the batteries, termi- nals and cable clamps clean. When neces~ sary, Wash them with a solution of baking soda and water, and rinse with clean water. CAUTION: Do not allow the soda solution to enter the cells. 3. Inspect the cables, clamps and hold- down brackets regularly. Replace any dam- aged parts. Clean and re-apply a light coat- ing of grease to the terminals and cable clamps when necessary. 4, Check the electrical system if the batteries become discharged repeatedly. 5. Use the following quick in-the-unit (REV. 7/91) check as an indication of faulty components in the battery charging circuit. A fully charged battery and low charging rate indicates normal alternator regulator operation. b. A low battery and high charging rate indicates normal alternator-regulator operation. c. A fully charged battery and a high charging rate usually indicates the voltage regulator is not limiting the alternator out- put. CAUTION: A high charging rate ‘on a fully charged battery will damage the battery and other ‘components. dA low battery and low or no charg ing rate could be caused by loose connec- tions, damaged wiring, defective alternator, improper regulator operation, or defective alternator. NOTE If the machine is to be inopera~ tive or idle for more than 30 days, remove the batteries. The bat- teries should be stored in a cool dry place. The electrolyte level should be checked regularly and the batteries kept fully charged. ALTERNATOR. The alternator can be ex- pected to give long, trouble-free service; however, the diodes and transistors in the alternator circuit are very sensitive and can be easily destroyed, The following precau- tions should be observed when working on ‘or around the alternator. Avoid grounding the output wires or the field wires between the alternator and regu- lator. Never run an alternator on an openGrounding an alternator's output wire or ter- minals, which are always hot regardless of whether or not the engine is running, and ac~ cidentally reversing the battery's polarity will destroy the diodes. Grounding the field circuit will also result in the destruction of the diodes. Some voltage regulators provide protection against some of these circum- stances; however, it is recommended that extreme caution be used. Accidentally reversing the battery connec- tions must be avoided. If a booster battery is to be used, the batteries must be con- nected positive (+) to positive (+), and nega~ tive (-) to negative (-). Never disconnect the batteries while the alternator is in operation. Disconnecting the batteries will result in damage to the diodes, caused by the momentary high volt— age and current induced by the instantaneous collapse of the magnetic field surrounding the field windings. Drive Belt (Figure 1) Visually inspect the belt. Check the belt for intersecting cracks. Transverse (across the belt width) cracks are acceptable. Longi~ tudinal (direction of belt length) cracks that itersect with transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing, ; DRIVE BELT TENSION (Figure 2) Measure the belt deflection at the longest span of the belt. Maximum Deflection: 3/8 to 1/2 Inch. ‘On engines not equipped with automatic tensioners, the tension on the fan and water pump drive belts should be such that a firm push with the thumb midway between the pulleys will deflect the belt 1/2 to 3/4 inch. if either of the belts need to be replaced, replace both belts with a matched set. After replacing the belts and adjusting the tension, operate the engine for 15 seconds to seat the belts and readjust the tension. Re-check the belt tension after 1/2 hour of operation, and adjust if necessary. Thereafter, check the tension of the drive belts after every 50 hours of operation and adjust if necessary. CAUTION: Too tight a drive belt ¢ is destructive to the bearings of the driven part, and a belt that is too loose will slip. Figure 1. Drive Belt Inspection Figure 2. Drive Belt Tension Check Cc (REV. 7/91)SECTION 9 TRANSMISSION TC-28 TRANSMISSION BREATHER DIPSTICK FILL PLUG DRAIN PLUG SUMP SCREEN GASKET Figure 1. TC-28 Transmission DESCRIPTION. The TC-28 transmission has 3 speeds forward and 3 reverse. Direction and speed range are controlled by two levers to the left of the operator's seet. OIL LEVEL CHECK. The oil level should be checked daily, with the oil at normal operating temperature (+180°F to 200°F) and the engine ‘operating at 500 to 600 rpm. The oil level should be up to the FULL mark on the dipstick. The dipstick fs located under a small door to tho right of the operator's seat, on the floorboard, TE (Rev. 6/93) CHANGING FILTER ELEMENT. The oil fter element should be changed after 60 and 100 hours, and then atter every 500 hours of operation. Perform the following procedures to change the titer etement, @._ Refer to Figure 2 and remove the drain plug and drain the fer. Reinstall the drain plug b. Remove the center bolt, washer, shell, and element. c. Remove the o-ring and filter element.d. Clean the fiter shell, ©. Position a new o-ring on the cover, and a new element in the shell. 1. Install the shell on the cover and tighten the conter bolt only enough to prevent oll leakage, g. Operate the engine and check oil leaks. h. With the engine running at 500 to 600 rpm check the oil level, and add oll if necessary to bring the oil level to the FULL mark on the dipstick. i, _ Recheck the oil level when the temperature reaches +180°F to 200°F, | SHELL rive i Waster CENTER SOLT Figure 2. Transmission Oil Fitter CHANGING THE OIL. The oll should be changed ‘every 1000 hours. Perform the following procedures to change the oil. @. Provide a suitable container, and remove the drain plug (see figure 1) and drain the oi b. Remove the sump screen and gasket. ¢. Clean the screen thoroughly. NOTE ‘An accumulation of sludge or soft dirt in the sump should be removed with fushing oil d, _Use a new gasket and reinstall the screen. Tighten the screen to 10 to 15 foot pounds. €. Change the oil filter element (seo preceding paragraph). {Reinstall the drain plug and fl the transmission to the FULL mark on the dipstick. 9. Operate the engine and check for oll leaks. With the engine running at 500 to 600 rpm, recheck the oil level, and add oil ta bring the level to the FULL mark on the dipstick. fh. With the engine running at 500 to 600 tpm, make the final oil check when the temperature teaches +180°F to +200°F. CLEANING THE TRANSMISSION BREATHER. ‘The prevalence of dirt and dust will determine the frequency at which the breather requires cleaning. @._Clean the area around the breather before removing it (see figure 1) NOTE Care must be exercised when removing the breather to avoid damaging the breather. b. Remove the breather. ©. Wash the breather thoroughly in solvent and dry it with compressed air. d. Reinstall the breather. NOTE Oil and fiter element should be disposed of according to local regulations. GENERAL INFORMATION Oll Pressure .......... 240-280 psi Oil Temperature ....... 180- 200°F Oil Capacity .......... 26 quarts TE (Rev. 6/93)O SECTION 13 STEER AXLE 13.036 FILL AND DRAIN OIL LEVEL CHECK PLUG @ MOLY GREASE Figure 1. Steer Axle DESCRIPTION. This steer axle is of extremely rugged construction. The design prevents scuffing of the steer tires, and the pivotal mounting ensures equal loading on each steer wheel. The double action steer cylinder applies steering force to both steer wheels simultaneously. When hydraulic pressure is applied to elther end of the actuating cylinder, a pulling force is applied to one steer wheel and a Pushing force is applied to the opposite wheel. GREASE FITTINGS. Access for lubricating the grease fittings can be attained by steering the Machine first to one side and then the other. CHECKING OIL LEVEL. Perform the following procedures to check the oil level in the steer axle hubs. NOTE Refer to the appendices in the back ‘TE-160—360 (2/88) of this manual for servicing intervals and the type of oil to be used. a, Maneuver the machine until the fill and drain oil level check plug is in a horizontal position, b. Remove the plug, the oil level should be even with the bottom of the plug hole. «. If the oil is at the proper level, reinstall the plug. If the oil level Is too low, service the hub with oi! until oil begins to flow from the fill and drain oil level check plug hole, d. Reinstall the plug. e. Repeat the above procedures and service ‘the hub on the opposite end of the axle. CHANGING THE OIL. Perform the following procedures to change the oil in the steer axle hubs.NOTE Refer to the appendices in the back of this manual for service intervals and type of oil to be used. a. Maneuver the machine until the drain and fill plug is in a downward position. b. Remove the plug and drain the oil. c, When oll has drained, maneuver machine until fill and drain hole is in a horizontal position. C 4G. Fill the hub with oil until oil begins to flow from the fill and drain oil level check plug hole. e. Reinstall the plug. 1. Repeat the above procedures to service the hub on the opposite end of the axle. TE-160—360 (2/86)SECTION 14 DRIVE AXLES DRIVE AXLE 1, DIFFERENTIAL OIL LEVEL CHECK AND FILL PLUG 2, DIFFERENTIAL DRAIN PLUG 3. PLANETARY HUB OIL LEVEL CHECK PLUG 4, PLANETARY HUB DRAIN AND FILL PLUG 5, BREATHER Figure 1. Drive Axles DESCRIPTION. These axles are double-reduction _ differential and planetary hubs. type, and carry the second reduction in the form of planetary gears built into the wheel hubs. This arrangement permits the axie shafts and hypoid NOTE gearing to carry only a nominal torsional load while providing the highest practical gear reduction ‘The fork lift should be parked on at the wheels, The result is an enormously rugged axle, capable of bearing constant and severe loads without fatigue or failure, a level surface when the drive axle is being serviced. Refer to the appen- dices in the back of this manual for CHECKING OIL LEVEL. Perform the following servicing intervals, and type of oil procedures to check the oil level, and service the to be used. (Rev. 4/92) 1a. Differential (1) Check the oil level in the differential by removing the oil level check plug (1, figure 1). 2) The oil level should be even with the bottom of the oil level check plug hole, Fill the differential to the level, if the oil level is too low. (3) Reinstall the plug (1). b. Planetary hubs (1) Maneuver the fork lift until the planetary level check plug (3, figure 1) is horizontal with the center of the hub. The words HORIZ OIL FILL LEVEL should be upright. NOTE The oll level can be checked with the oil level check plug horizontal with the center of the hub on either side, however, if the words HORIZ OIL FILL LEVEL are upside down, the DRAIN- FILL plug (4) will be lower than the check plug. (2) Remove the oil level check plug (3). The oil level should be even with the bottom of the oil level check plug hole. (G) If the oil is at the proper level, reinstall the plug. If too low, perform steps (4), (6) and (6). (4) Remove the fill plug (4) and service the hub with oil until oil starts to flow from the oll level check plug hole, or service the hub with off through the oil level check plug hole. (8) When oil stops flowing from the oil level check plug hole, reinstall the plug (3). (6) Reinstall the plug (4) if removed. (7) Reposition the fork lift as necessary, and service the planetary hub on the opposite side Cc of the fork lift by performing steps (1) through (6) above. NOTE When the axle is completely serviced the oil should be at a com- mon level in the differentia! and both hubs. CHANGING THE OIL. Perform the following pro- ‘cedures to change the oil in the drive axle. ‘a, Remove the differential drain plug (2, tigure 1). b, Maneuver the fork lift until the drain plug (4) for one of the planetary hubs is at the bottom of the hub. ©. Remove the drain plug (4). d. Maneuver the fork lift until the drain plug for the opposite hub Is at the bottom of the hub, and remove the drain plug. a e. Reinstall the differential drain plug. f. Reinstall the drain plugs (4) in each plane tary hub. g. Remove the differential fill and oil level check plug (1). h. Service the differential with oil until the il level is even with the bottom of the hole for the plug (1). i. Perform the procedures for CHECKING. OIL LEVEL in the planetary hubs as described in the preceding paragraph, BREATHER. Remove and clean the breather after every 100 hours of operation. (rev. 4/92)C SECTION 15 BRAKE SYSTEM MANUAL, DRAIN VALVES AUTOMATIC DRAIN VALVE AUTOMATIC DRAIN VALVE AIR TANK Figure 1. Air Tanks AIR TANKS. All compressors pass a certain amount of oil in order to lubricate the cylin der walls and piston rings. Also, depending entering the compressor contains a certain amount of water. TI oil and water normally enters the air tanks in the form of vapor because of the heat generated during compression. After reach- ing the air tanks they condense to form water emulsion that must be drained off before entering the brake system. MANUAL DRAIN VALVE. Some air tanks are equipped with manually operated drain valves to drain any colleciton of oil and water emulsion from the tanks. Tanks ‘equipped with manual drain valves should be drained daily. AUTOMATIC DRAIN VALVE. Some air tanks are equipped with automatic drain valves. When the brakes are applied and the pressure in the air tank drops approx mately 2 psi the automatic drain valve will (REV. 7/91) ‘open momentarily allowing a small amount of air to escape. When this happens any collection of oil and water emulsion will also escape. Operation of the automatic drain valves should be checked every 200 hours of opera~ tion. This should be done with the engine operating and the brake system at normal operating pressure. NOTE It will be necessary for someone to observe the automatic drain valves to perform this check. When the operator applies the brakes, the automatic drain valves should be checked to see that a small amount of air escapes from the valve. The automatic drain valves on all air tanks must be checked, The automatic drain valves should be re~moved and cleaned every 6 months. WARNING: Never bleed the pres~ sure from the air tanks when the machine is being held with the spotting brake. Set the parking brake. Perform the following procedures to remove the automatic drain valves. 1. Set the parking brake. 2. Check to see that the spotting brake is in the released position. 3. Bleed the air pressure from the brake system by applying and releasing the ser- vice brakes. 4, Depress the plunger in the automatic drain valve to ensure that all pressure is released, 5. Remove the automatic drain valve. DISASSEMBLY AND CLEANING. Perform the following procedures to disassemble and clean the automatic drain valves. 1. Remove the four capscrews (1, Fig- ure 2) and lockwashers (2). 2. Remove cover (3) and sealing ring (4). 3. 4 (6). Remove inlet and exhaust valve (5). Remove adapter and filter assembly 5. Remove filter retainer (7) and filter (8). 6. Clean and inspect the filter. Replace the filter if it is clogged. 7, Wipe all rubber parts clean. Cleaning solvent may be used on metal parts. REASSEMBNLY. Perform the following pro~ cedures to reassemble the automatic drain valve. 1. Apply a light film of grease on the inlet valve seat (9, Figure 2). CAUTION: Do not apply oi! or grease to the inlet and exhaust valve. 2. Place sealing ring (4) in groove of cover @) 3. Place valve guide (10) over inlet and exhaust valve (5). 4, Place valve guide (10) and intet and exhaust valve assembly (5) into cover (3) with wire stem (11) projecting through exhaust port (12). 5. Place cover (3) on body (13) and install lockwashers (2) and capscrew (1). C 6. Install filter (8) in adapter and screw in filter retainer (7). 7. Install adapter and filter assembly (6) in body (13) and tighten. 8. Reinstall the automatic drain valve in the air tank. CAPSCREWS, LOCKWASHERS COVER SEALING RING INLET AND EXHAUST VALVE ADAPTER AND FILTER ASSEMBLY FILTER RETAINER FILTER INLET VALVE SEAT VALVE GUIDE WIRE STEM EXHAUST PORT 13, BODY Figure 2. Automa Drain Vatve (REV, 7/91)SECTION 15 C BRAKE SYSTEM ‘TREADLE ROLLER TREADLE PLUNGER ROLLER Pin TYPE E.3 BRAKE VALVE LockNuT STOP BUTTON FULCRUM PIN, TYPE E-5 BRAKE VALVE Figure 1. Brake Valves LUBRICATION OF TYPE E-3 BRAKE VALVE. The brake valve should be lubricated every 200 hours of operation. Refer to Figura 1 for identification of components and perform the following pro- cedures to lubricate the brake valve. a. Lubricate the treadle roiler, roller pin, and hinge pin with engine oil, b, Lift the boot away from the plunger or ‘mounting plate and put a few drops of light engine oil between the plunger and mou plate Q\ caution Avoid using too much oil between the plunger and mounting plate because oil could get on the rubber spring and cause it to deteriorate, rc (CO SERVICING THE E-5 BRAKE VALVE. The brake (Rev. 1/87) valve should be serviced every 200 hours of operation. Refer to Figure 1 for identification of components and perform the following pro- cedures to service the brake valve. a. Lubricate the roller, roller pin, and fulcrum pin with engine oil, b. Check pedal for free travel, There should be no free travel. NOTE If the pedal has free travel perform the following procedures, ©. Loosen the locknut and back the stop but- ton out until the roller is in contact with the plunger. d. Hold the stop button in position and tighten the locknut,SECTION 15 BRAKE SYSTEM BRAKE ACTUATOR RUBBER BOOT PUSH ROD SLACK ADJUSTER BRAKES RELEASED BRAKE ACTUATOR RUBBER 8007 PUSH ROD BRAKES APPLIED Figure 1. Brake Actuating Mechanism BRAKE ACTUATING MECHANISM. The brake actuating mechanism should be checked for smooth operation and proper adjustment. Per- form the following procedures to inspect and ad- just the brake actuating mechanism. a. Inspection. 1. Check the angle between the push rod and slack adjuster. The angle should be 90° or greater when the brakes are in either the releas- ed or applied position (see Figure 1). 2. When the brakes are being applied and released, check to see that the push rod moves in and out of the brake actuator without binding, b. Adjustment, The slack adjuster has an ad- justing mechanism to compensate for brake lin- ing wear. Perform the following procedures to adjust the brakes, 1. Position a socket wrench on the ad justing screw and apply pressure to depress the spring loaded lock sleeve (see Figure 2). 2. While holding the lock sleeve depressed, rotate the adjusting screw to adjust the brakes. 3. When adjustment is completed, remove the wrench and check to see that the spring loaded lock sleeve has moved into position to (C) lock the adjusting serew, if the sleeve has not (Rev. 4/87) ADJUSTING SCREW SPRING. SLACK ADJUSTER Figure 2. Brake Adjustment moved into the lock position, rotate the ad: justing screw slightly to allow the sleeve to move to the lock position, 4, Recheck the angle between the push rod and slack adjuster with the brakes In the releas- ed position, and with the brakes in the applied position, The angles between the push rods and slack adjusters on ail brake actuator assemblies should be approximately the same when check- ed with brakes released and applied, The pushrod travel should be as short as possible without brakes dragging. c. Leakage Test. Perform the following pro- cedures to check the brake actuator (see Figure 1). 1, Loosen the rubber boot from around the push rod hale in the brake actuator. 2. With brake air pressure in the normal ‘operating range, apply and hold a full brake ap- plication. 3, Coat the area around the push rod and push rod hole with soapsuds and check for leakage. There should be no leakage. 4. {f leakage is detected, this indicates a defective diaphragm. If there is no capability for replacing the diaphragm, the brake actator should be replaced. Awsrnine After any brake adjustment or maintenance, a safety check of brake operation with the machine in motion must be performed prior to returning the machine to service. (Rev. 4187) C a CSECTION 15 AIR BRAKE SYSTEM BRAKE ACTUATOR QUICK RELEASE BRAKE ACTUATOR VALVE eS ALI Q MODULATING VALVE LI sed with separate brake E==—= and Inching pedal} T roy i ot Lt TRS VALVE a AUTOMATIC GOVERNOR AIR ety) rain NK Tr TAI SPOTTING COMPRESSOR BRAKE vaive GHEE Figure 1. Air Brake System DESCRIPTION. The air brake system consists of moisture ceases. an air compressor, one air tank with automatic drain valve, and a safety valve. Air pressure from the air tank is controlled by 2 foot operated con- trol valve for applying and releasing the service brakes. The spotting brake control lever on the instrument panel will apply and lock the service brakes, and release the brakes as the operator desires. MAINTENANCE. Very little maintenance is re- quired on the brake system. Operation of the automatic drain valves on the air tanks should be checked daily by depressing the plunger in the valve stem. If m is depressed, continue draining until the flow of TE (Rev. 10/91) a CAUTION If the automatic drain valves are not operating properly, and are not checked, the accumulation of water in the tanks can fill them to the extent that the brakes will not work. All hoses, lines, and fittings should be checked Periodically for leaks and serviceable condition. ZY caution Any abnormal operation of the ture escapes when the plunger brakes or brake system should be checked immediately,SECTION 17 TIRE AND RIM SAFETY (>) GENERAL a. Never attempt to weld on an inflated tirerim assembly. b. Do not let anyone mount or demount tires without proper training, ¢. Do not, under any circumstances, attempt to rework, weld, heat or braze any rim com- Ponents that are cracked, broken or damaged. Replace with new parts, or parts that are not, cracked, broken or damaged and which are of ‘the same size, type and make, 4. Do not hammer on rims or components with steel hammers. Use rubber, lead, plastic or brass faced mallets components together, DEMOUNTING a. Always exhaust all air from a single tire and from both tires of a dual assembly prior to removing any rim components such as nuts and rim clamps. b. Make sure to remove valve core to exhaust all air from the tire. Remove both cores from a (‘dual assembly. c. Check the valve stem by running a piece of wite through the stem to make sure it is not plugged. 4. Demounting tools apply pressure to rim flanges to unseat tire beads. Keep your fingers clear. Slant demounting bead tool about 10° to keep it firmly in place. If it slips off, if can fly with enough force to Kill. Always stand to one side when you apply hydraulic pressure. INSPECTION a. Check rim components periodically for fatigue cracks. Replace ali cracked, badly worn, damaged and severely rusted components. b. Clean rims and repaint to stop detrimental effects of corrosion, Be very careful to clean all dirt and rust from the lock ring gutter. This is Important to secure the lock ring in its proper position. A filter on the air inflation equipment to remove the moisture from the air line prevents a lot of corrosion, The filter should be check periodically to see that it is working Properly. (Rev. 2187) c. Make sure correct parts are being assembl- ed. Check your distributor or the manufacturer if you have any doubts. 4. Mixing parts of one manufacturer's rims with those of another is potentially dangerous. Always check manufacturer for approval. 2. Do not be careless or take chances. If you are not sure about the proper mating of rim and wheel parts, consult a wheel and rim expert, This may be the tire man who is servic- ing your fleet, the rim and wheel distributor your area, or the Motor Wheel Sales Engineer. MOUNTING AND INFLATION a. Do not seat rings by hammering while the tire is inflated, Do not hammer on an inflated or partially inflated tireirim assembly. b. Do not inflate tire before all side and lock rings are in place. Double check to make sure all components are properly seated. ¢. Inflate in a safety cage or use safety chains during inflation, 4d. Check components for proper assembly again after inflating to approximately 5 psi. €. Never sit on or stand in front of a tire and rim assembly that is being inflated. Use a clip- ‘on chuck and make sure inflation hose is long enough to permit the person inflating the tire to stand to the side of the tire, not in front or in back of the tire assembly. OPERATION a. Do not overload rims or over-inilate tire/rim assembly. Check your rim manufacturer if special operating conditions are required. b, Do not use undersized rims. Use recom. mended rim for the tire. ¢, Never run a vehicle on one tire of a dual assembly. The carrying capacity of the single tire and rim is dangerously exceeded and operating a vehicle in this manner can result In damage to the rim and tire. d. Do not reinflate a tire that has been run flat without first inspecting the tire, rim and wheel assembly. Double check the lock ring for damage; make sure that it is secure in the gutter before inflation.SERVICING TIRE AND RIM ON VEHICLE a. Block the tire and wheel on the opposite side of the vehicle before you place the jack in Position. b, Regardless of how hard or firm the ground appears, put hardwood blocks under the jack. Always crib up vehicle with blocks just in case the jack should stip, ©, Remove the bead seat band slowly to pre- vent if from dropping off and crushing your toes. Support the band on your thigh and roll it slowly to the ground, This will protect your back and toes. d. When using a cable sling, stand clear, it might snap and lash out. COMPRESSOR PRECAUTIONS There have been instances of tires exploding violently while on vehicles. The forces involved in this type explosion are sufficient to cause serious personal injury to anyone in the im- mediate vicinity. Some of these explosions are believed to have been caused by flammable vapors entering the tire during inflation. When the machine is operating, the temperature of the air and vapor mixture inside the tire will in- crease. The temperature inside the tire will also increase with an increase in ambient temperature, and when subjected to direct sunlight. If the vapor and air mixture inside the tire is within the ratio limits that will support combustion, and any or all of the above heat in- creasing factors cause the temperature, an ex- Plosion will occur. Following are some precau- tions that can prevent flammable vapors from entering the compressor, and subsequently be entrapped in tires. a. Do not locate the compressor in a utility room used for storing flammable solvents, paints, thinners, etc, The flammable vapors will be sucked Into the compressor intake while the compressor is charging. b. Do not clean the compressor air filter with a flammable solvent, Use a non-flammable sol- vent, such as carbon tetrachloride. c. Do not use alcohol, methanol, or other flammable agent In the compressor. Drain the compressor tank frequently or locate the com- Pressor inside to eliminate the freezing problem. d. Do not locate the compressor near a bat- tery charger. Batteries emit hydrogen gas dui the charging process, which is highly flam- mable, and could be sucked into the compressor intake. (Rev. 2/87) CC SECTION 22 HYDRAULIC SYSTEM LIFT CYLINDER ial fl GyLINDERS FLOW REGULATOR e ORBITROL ACCESSORY VALVE CONTROL, VALVE HYDRAULIC FILTER INDICATOR i) e ' ' ' ' \ ' ' ' i i CHECK VALVE PRESSURE TANK CHECK ADAPTER STRAINERS STEER CYLINDER STEER CYLINDERS ¢ Figure 1, Hydraulie System ‘TE-160-360 (Rev. 2/91) 1HEX NUT 10 MICRON FILTER LOCKWASHER BREATHER ELEMENT FILTER O-RING ADAPTER FILLER CAP AND DIPSTICK ] FILLER NECK STRAINERS SCREEN HEX NUT LOCKWASHER FILTER HEAD O-RING BY-PASS VALVE DRAIN PLUG Figure 2. Hydrai DESCRIPTION. The hydraulic system consists basically of a hydraulic reservoir, hydraulic pump, a bank of control valves, and actuating cylinders. ‘The orbitrol steering valve receives hydraulic fluid under pressure from the pump through the sens- ing valve. The steering cylinders are actuated by the orbitrol steering valve when the operator turns the steering wheel, Lift and tilt circuits are stan- dard on all machines. If optional equipment is installed, such a5, sideshift or fork positioning, additional valves, controls, and actuating cylinders will be interconnected with the standard hydrau- lic system. uulic Tank SERVICING ‘a. Checking Oil Level. With the lift cylinder fully retracted (carriage down), remove the filler cap with attached dipstick (see Figure 2) and check to see that the oil level is even with the FULL mark on the dipstick. Perform this check daily and add oil if necessary. Check the condi- tion of the filler neck screen before adding oil NOTE Refer to the appendices in the back of this manual for the type of oi to be used. TE-160-360 (Rev. 2/91) ryWhen the dipstick and filler cap is reinstalled, be sure the cap is tightened securely. The filler cap is a pressure type cap that requires 4 PSI internal pressure to unseat the cap. This ensures that air entering or leaving the reservoir must pass through the breather filter. NOTE The filler neck has a safety link that can be raised into position above the filler cap and padlocked. b. Breather Filter. Replace the breather filter after the first 50 hours of operation and every 200 hours thereafter. More frequent replacement may be necessary if the machine is being operated under extremely dusty conditions, c. Hydraulic Filter. The hydraulic filter is a 10 micron corrugated paper and is non-reusable. ‘The 10 micron filter should be changed after the first 50 hours of operation and whenever the hy- draulic filter restriction indicator shows red. Per- form the following procedures to service the hy: draulic fitter. NOTE The hydraulic restriction indicator will move to the red zone when the hydraulic oil is cold, This is not an indication the filter requires servicing. Check the restriction indicator when the hydraulic oil is up to normal ‘operating temperature, with the engine running at full throttle and no hydraulic functions operating, (1) Remove the two hex nuts (see figure 2). {2) Remove the two lockwashers and lift the filter head assembly off the studs, NOTE The by-pass valve assembly is attached TE-160-360 (Rev. 2/91) NOTE (Cont'd) to the filter head. The by-pass valve and o-ring will both be removed with the filter head. (3) Remove the filter (4) Inspect the o-ring for serviceable condi- tion and replace if necessary. {8) Inspect the valve assembly for serviceable condition. Check sealing surface for nicks or burrs. (6) Install the filter assembly by reversing removal procedures. Torque nuts to 10-12 ft. Ibs, d. Changing Hydraulic Oil. Refer to the appendices in the back of this manual for service intervals and type of oil to be used, and perform the following procedures to change the hydraulic oil, NOTE When the hydraulic oil is changed, ‘two wire mesh strainers located in ‘the bottom of the hydraulic tank must be removed and cleaned in solvent. (1) Provide a suitable container and remove the drain plug (see figure 2) and drain the hydrau- lic reservoir. NOTE Drain plug must be removed to com- pletely drain tank, (2) Remove the filler cap and filter neck strainer, NOTE ‘The lift cylinder should be fully retracted to keep dilution of the(NOTE (Cont'd) new hydraulic oi! toa minimum. {3) Remove the breather filter. (4) Remove the ten hex nuts and lock- washers, and remove the hydraulic reservoir cover. (5) Inspect the cover gasket for serviceable condition and replace if necessary. (6) Inspect the interior of the reservoir and clean if necessary. (7) Remove the two wire strainers inside the hydraulic tank and clean in solvent. Dry with compressed air. A WaRNinc Cleaning the interior of the reser- voir with a flammable solvent can A WARNING (Conrad) create a serious fire hazard. (8) Reinstall the drain plug. {9) Reinstall the gasket and reservoir cover. (10) Install @ new breather filter. (11) Clean and reinstall the filler neck strainer. (12) Service the hydraulic reservoir with hydraulic oil to the FULL mark on the dipstick. TE-160-360 (Rev. 2/91) latSECTION 27 ULTRA-VU MAST CHAIN ROLLERS THRUST PADS SIDE ROLLERS MAIN ROLLERS SIDE ROLLERS @ MOLY GREASE Figure 1. Ultra-Vu Mast Assembly DESCRIPTION. The Ultra-Vu mast is equipped operations with limited overhead clearance. with extra heavy load rollers to accept forward Masts are available in various lift heights. and backward stress. Side rollers absorb side thrust and assure a snug fit between inner and LUBRICATION. Lubrication of the mast con- ‘outer channels. Heavy cross bracing is located sists primarily of lubricating the roller assem. to provide a maximum operator visibility. The blies, chains and mast hanger pins. Ultra-Vu telescopic mast is very desirable for ‘TE-160--360 (6/88) 271CAUTION: Do not over-lubricate ‘the roller assemblies. If the rollers are over lubricated, they will slide when subjected to a heavy load. If this happens a flat spot will be worn on the roller and it will con- tinue to slide until replaced with a new roller. Grease fittings are provided for lubricating the rollers and mast hanger pins. Holes are provided in the outer section of the mast for access to the grease fittings for the rollers on the inner section ‘of the mast. The mast must be operated until 21-2 the holes grease fittings. Refer to the appendices in the back of this manual for lubrication intervals and type of lubricant to be used. Refer to Figure 1 for location of lubrication points. INSPECTION. The mast assembly should be in- spected at frequent intervals for evidence of welds that have partially failed, excessive wear, and evidence of sliding rollers. The capscrews attaching the mast hanger pin retaining plates should be checked to assure that they are tight (190-200 ft.lbs.). TE-160-360 (6/88) the outer mast are aligned with the (— CSECTION 29 2040 ETPRF AND ETPRG EXPANDABLE EMPTY CONTAINER ATTACHMENTS FLOATING END OF EXPANSION CYLINDERS (Both Sides) CLAMP ON GUIDES ETPRG MODEL ONLY TWIST LOCKS (Both Sides) SLIDING SURFACE OF EACH EXPANSION BEAM (Both Sides) Figure 1. Main Beam Assembly LUBRICATION. The Taylor Expandable Emp~ ty Container handling attachment has several moving parts which operate under extreme load conditions. Frequent periodic lubrica~ tion with a good quality grease is absolutely essential to keeping the attachment on the job performing satisfactorily, with a minimum of down time. Figures 1 and 2 indicate the loca~ tion of grease fittings and other areas that re- quire lubrication. Refer to the service chart in the appendices for service intervals and lu- bricant to be used. While performing the lu brication, take time to make the following inspections: 1. Check the hydraul cylinders and hoses TEC-150L/155L (5/92) for leaks and serviceable condition. 2. Check the welds to see if they are solid. 3. Carriage rollers should be inspected for flat spots or evidence of sliding. CAUTION: The roller assemblies must not be over lubricated. Ex- cess grease inside the mast rails will cause the rollers to slide when subjected to a heavy load. If this happens a flat spot will be worn on the roller and the rotler will continue to slide until re~ placed by a new roller.BEAM PIVOT PILE SLOPE CYLINDER ENDS (Both Sides) SIDE SHIFT CYLINDER ENDS BEAM FLOATING. PILE SLOPE POST SLIDING SURFACES (Both Sides) PivoT (Both Sides) @ GREASE Figure 2. Carriage Assembly TEC-150L/155L (5/92)TROUBLESHOOTING POWER UNIT POWER TRANSFER AXLES BRAKE CONTROL SYSTEM y STEERING CONTROL CHASSIS HYDRAULIC SYSTEM ATTACHMENTS ‘Troubleshooting is the application of a definite procedure, in a logical sequence, to locate and eliminate the cause of trouble in a particular system or unit, Always look first for the obvious ‘causes of trouble. Check first the items most easily and inexpensively corrected; then proceed ‘to the more difficult, time-consuming and expensive items. Rev. 2/79© TROUBLESHOOTING THE CUMMINS AND "C" SERIES DIESEL ENGINES Troubleshooting is an organized study of the problem and a planned method of investigation and correction of the difficulty. The following chart includes some of the problems that an operator may encounter during the service life of a Cummins Diesel Engine. Always check the easiest and obvious things first, such as the master disconnect switch, the neutral start switch, an empty fuel tank, closed fuel shut off, dead battery or corroded terminals. Study the problem thoroughly before starting to work on the engine. Ask yourself the following 1. What were the warning signs preceding the trouble? 2. Has the engine been subjected to recent repair or maintenance? 3. Has a similar trouble occurred before? 4, If the engine still runs, is it safe to continue operation of the engine in an effort to diagnose the trouble? Check the items most easily and inexpensively corrected before proceeding to the more diffi~ cult, time consuming and expensive items. After a malfunction has been corrected, locate and correct the cause of the trouble to prevent recurrence of the same trouble. No voltage to starter solenoid Solenoid or starting motor malfunction 6 h | TROUBLE CAUSE CORRECTIVE ACTION Engine Will Not Crank or 1. Starting motor operat- | 1. Remove the starting Cranks Stowly g but not cranking motor and check for the engine broken teeth on the fly- wheel or broken starting motor spring. 2 Crankshaft rotation 2. Bar the engine to check restricted for rotational resistance, 3. Starting circult con- 3. Check and tighten con nections loose or cor- nections. roded 4, Battery charge low 4. Check battery voltage. Check voltage to sole- noid. Replace starting motor. Replace key switch. (1/89)TROUBLESHOOTING THE CUMMINS "B" AND "C" SERIES DIESEL ENGINES [ TROUBLE CAUSE CORRECTIVE ACTION Engine Cranks, But Will Not Start - No Smoke From Ex- No fuel in tank ‘Add fuel. cold weather or not working properly haust 2. Electrical or manual 2. Check for loose wires and fuel shutdown not open verify that the solenoid is functioning. Check to be sure manual shut off lever| is in the run position. If the condition occurs | 3. Bleed the fuel system. during initial start, fol towing an extended period of non use or after replacing a fuel system component, air in the fuel system 4, If previous engine opera~ | 4 Loosen the bleed plug at ion had been nomal, the filler head end. Op- injection pump not get- erate the hand primer on ting fuel the lift pump to check for} fuel. Clean-replace lift pump if necessary. 5. Fuel filter plugged with | 5. Drain fuel-water separa water or other contami~ tor or replace fuel filter. nation 6. Worn or malfunctioning Loosen the high pressure injection pump ine at two injectors and visually check fuel de~ livery while cranking the engine. Replace the pump if fuel is not being delivered, 7. Injection pump timing | 7. Verify timing/time the incorrect injection pump. Engine Hard to Start or Will | 1. Engine cranking speed | 1. Check engine cranking Not Start (Exhaust Smoke too slow RPM, Refer to Engine Present) Will Not Crank or Cranks Slowly. 2 Starting aid needed for | 2. Check-repair or replace cold starting aid, if necessary. (1/89)C TROUBLESHOOTING THE CUMMINS "B" AND "C" SERIES DIESEL ENGINES [ TROUBLE CAUSE CORRECTIVE ACTION Engine Hard to Start or Will | 3. Air in the fuel system | 3. Bleed the fuel system Not Start (Exhaust Smoke and check for suction Present) (Cont'd) leaks. 4, Fuel supply restricted | 4, Clean or replace pre~ filters and screens and check fuel lines for re~ strictions. 5. Intake air system re~ 5. Check intake air system stricted for restrictions. 6. Fuel contaminated 6. Verify by operating en- gine from a temporary supply tank. 7. Injection pump 7. Check injection pump not correct timing. C 8 Valves incorrectly 8. Adjust valves. “ adjusted 9. One or more injectors | 9 Check/replace injectors. worn or malfunctioning 10. Engine shutdown fuel 10. Replace fuel shutdown switch maifunctioning switch. 11. Exhaust system re~ 11. Correct restriction. stricted 12, Injection pump worn or | 12. Replace pump. malfunctioning Starts But Will Not | 1, Idle speed too low 1. Adjust idle speed, Keep Running 2, Low fuel level 2. Fill supply tank. 3. Malfunctioning engine | 3. Make sure shutdown is shut down device not occurring too soon. 4. Air in the fuel system | 4, Bleed the fuel system and check for suction leaks. (1/89)TROUBLESHOOTING THE CUMMINS "B" AND "'C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Engine Starts But Will Not Keep Running (Cont'd) 6 10. Tn 12, 13. Fuel filter plugged or fuel waxing due to cold weather Low or no oil pressure Fuel supply restricted Fuel contaminated Injection pump out of time Exhaust restricted Restricted fuel return drain manifold One or more injectors malfunctioning Worn or malfunctioning injection pump 5 6. ra a 10. u 12. 13, Drain fuel-water separa tor or replace filter. Check for fuel waxing in cold weather. Check oil level and veri- fy pressure. Clean or replace pre- filters and screens and check for fuel line re~ strictions, Verify by operating engine from a temporary supply tank. Check/correct pump timing. Check/correct exhaust restriction. Check/remove restric~ tion. Check/replace injectors. Replace injection pump. Engine Surges at Idle 2 3. Low fuel level in the tank Idle speed set too low ‘ir in the fuel system Restricted fuel supply L 2. 3. 4a Fill supply tank. Check/adjust low idle screw. Bleed fuel system and check for suction leaks. Clean or replace pre- filters and screens and check fuel lines for restriction, (1/89)TROUBLESHOOTING THE CUMMINS "B" AND "C" SERIES DIESEL ENGINES 4 TROUBLE CAUSE CORRECTIVE ACTION Engine Surges at Idle ioning or worn | 5. Remove pump. Have (Cont'd) injection pump pump recalibrated or replace pump. 6 One or more injectors. | 6, Check/replace injectors. malfunctioning Rough Idle, Warm Engine 1. Idle speed set too low 1. Check/adjust low idle screw setting. 2. Air in fuel system 2. Bleed fuel system and check for suction teaks. Injection timing incor- | 3. Check/correct injection rect timing. Injector nozzles plugged | 4. Replace injectors. or inoperative 5. Broken engine mounts | 5. Replace mounts. 6. Wrong high pressure 6. Install correct lines. lines 7. Injection pump mal- 7. Replace pump. functioning Engine Misfiring 1, Contaminated fuel 1. Verify by operating from a temporary supply tank. Air in fuel system 2, Bleed fuel system and check for suction leaks. Fuel injection lines 3, Inspect and replace a 5. leaking Incorrect valve adjust- ment Injector nozzles plugged or inoperative Injection pump timing incorrect 5. 6 broken lines. Inspect push rods, springs and adjust valves. Replace injectors. Check/time injection pump. (1/89)TROUBLESHOOTING THE CUMMINS "B" AND "C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE action | Engine Misfiring (Cont'd) Replace injection pump. Lubricating Oi! Pressure Low 7. Defective injection pump | 7. 1. Incorrect oif level 1 2. Oil diluted with fuel 2 but engine operation normal 3. Oil diluted with fuel 3. accompanied by rough engine operation or low power oil. 4. Oil diluted with water | 4, 5. Oil diluted with coolant | 5. (Anti-freeze) 6 Incorrect oil specifica~ | 6. tions, 7. Oil suction tube loose | 7. on block, seal leaking seal. 8 8 plug 9. Oil viscosity low due to | 9. operating above normal coolant temperature range of 100 degrees C. (212 Degrees F.) Add or dr engine oi Remove and check lift pump plunger seal. Re~ place leaking pump. Change oil. Check for a stuck in- jector nozzle. If injec~ tors are okay, replace injection pump. Change Look for missing rain caps, oil fill caps, dip- sticks, etc. Change oil. Check oil cooler, after cooler, core plugs, cyl~ inder liner, head gasket, and cracked passages in the block and head for leaks. Replace leak— ing component and change oil. Check oil specifications. Tighten tube, replace Check for external leak at rear of cylinder head, along fuel pump side of block, oil cooler cover and gear housing. Refer to coolant temper-| ature above normal chart. (1789)TROUBLESHOOTING THE CUMMINS "B" AND "'C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Lubricating Oil Pressure 10. Oil pressure gauge mal- | 10. Check oil pressure gauge.| Low (Cont'd) function 11. Regulating valve stuck | 11, Check and clean. Re- ‘open or broken spring place spring if broken. 12. Olt filter plugged 12, Change oil and replace filter. 13. If oil cooler was replaced) 13. Check/remove plugs. shipping plugs left in cooler — Lubricating Oil Pressure 1. Malfunctioning pressure | 1. Verify the pressure Too High switch/gage switch is functioning correctly. 2. Engine running too cold | 2. Refer to troubleshooting O logic for coolant tem- perature below normal. 3. Oil viscosity too thick | 3. Make sure the correct oil is being used. 4, Relief valve stuck 4. Check/replace valve. closed Lube Oi! Loss 1. External teaks 1. Visually inspect for oil leaks. 2, Crankease being over- | 2. Verify that the dipstick filled is correctly marked, 3. Incorrect oit (specif 3. Make sure the correct cation or viscosity) oil is being used, Look for reduced vis~ cosity from dilution with fuel. Review/reduce the oi! change intervals. (1/89)TROUBLESHOOTING THE CUMMINS "B" AND "'C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION | Lube Oil Loss (Cont'd) 4 5. 6. A Oil cooler teak If equipped, air com- pressor pumping oil High blowby forcing oil out the breather Turbocharger leaking oil to the air intake or exhaust a 5 6 a Check for oil in the coolant. Check/replace air com- pressor. Check the breather tube area for signs of oil loss. Measure the blowby and perform the required repairs. Inspect the turbocharger inlet and outlet for evi- dence of oil transfer. Contaminated Lube Oil 2 4 5. 6 Coolant in the oil, in- ternal engine component leaks Excessive oil sludge Fuel in the oil, engine operating too cold Lift pump seal leaking Injector needle valves not sealing Worn injection pump plungers 2 Refer to troubleshooting logic for coolant loss. Review oif and filter change intervals. Make sure the correct oil is being used. Review the operation for excessive idling re- sulting in the engine running below normal temperature. Replace lift pump. Locate and replace mat- functioning injector. Replace the pump. Coolant Temperature Above Normat 2. Low coolant tevel Radiator fins damaged or obstructed with debris 2 Add coolant. Inspect radiator fins clean or repair if necessary. (1/89)THE CUMMINS "'B" AND " TROUBLESHOOTING " SERIES DIESEL ENGINES TROUBLE Coolant Temperature Above Normal (Cont'd) r 8 a 10. 1 13. CAUSE Collapsed radiator hose Incorrect oil level Cooling fan shroud damaged or missing Loose fan drive belt Incorrect or malfunc~ tioning radiator cap ‘Temperature gauge ‘or sensor malfunction Incorrect thermostat Overfueled injection Vehicle overloaded Malfunctioning water pump Air in cooling system Plugged cooling pas~ sages in radiator, cyl- inder head, head gasket or cylinder block 9% 10. M1 12. 13. 14. CORRECTIVE ACTION Inspect hoses - replace if necessary. ‘Add or dra engine oil. Inspect shroud; repair replace or install. Check the belt tensioner. Check the radiator cap. Replace if necessary. Test the gauge and sensor-repair or replace if necessary. Check/replace thermo- stat. Check/replace pump. Reduce load. Use lower gear. Measure cylinder block coolant pressure. Check/replace water pump. Check hose clamps for leaks on the suction side of the pump. Check for compression leak through cylinder head gasket. Flush the cooling system, fill with new coolant, (1/89)THE CUMMINS TROUBLESHOOTING AND "C" SERIES DIESEL ENGINES TROUBLE CAUSE —_———___——_ CORRECTIVE ACTION Coolant Loss 3. 6 Radiator or cab heater leaking External engine leak Overheating or leaking compression gases re~ in loss through the radiator overflow If equipped, transmis- sion cooler leak If equipped with a water cooled air compressor, leaking head or head gasket Lube oil cooler leak a 3 6 Visually inspect the radiator heater, hoses and connections to lo cate the leak. If oil is present in the coolant, check for a transmission or lube oil cooler leak. Visually inspect the en- gine and components for seal or gasket leaks. Review the operation for overheating and low power. (Refer to troubleshooting logic for coolant temperature above normal). Check for mixing of coolant and transmis- sion fluid. Look for coolant in the oil. Check/replace head or gasket. Check/replace the oil cooler. Look for coolant the of Coolant Temperature Below Normal de Temperature sensor malfunction Temperature gauge malfunction Thermostats incorrect or malfunctioning 2 Check/clean sensor and coolant passage. Test/replace sensor. Test the gauge - repair or replace if necessary. Check thermostats and replace if necessary. ___] 10 (1/89)THE CUMMINS "B" AND TROUBLESHOOTING SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Contaminated Coolant 1 2. 3. Rusty coolant, oper tion without correct mixture of antifreeze and water If equipped, leaking transmission oil Oil leaks from oil cooler, head gasket, head and cylinder block nn oil cooler a 1 Pa 3 Drain and flush the coo! ing system. Fill with correct mixture of anti: freeze and water. Review the coolant change interval. Check/repla (Refer to equipment manufacturer's proce- dures) Refer to troubleshootin: logic for lube oil loss. oil cooler.| 1g Engine Will Not Shut Off Electrical or manual 1 fuel shutoff not closing Fuel leaking to intal manifold ke 2 Verify the solenoid is not being energized by a short in the wiring, Check the linkage to the shutoff lever for binding. Check for the ability of the spring in the pump to pull the lever to the shutoff position. Check for porosity be tween the fuel mounting to the intake manifold. Fuel or Oil Leaking from Exhaust Manifold 1 2. Intake air restriction 1 Injector needle valve de stuck open Obstructed turbo- charger drain line 3. —1 Check/replace filter element. Review operation for excessive idling, Locate and replace mal functioning injector. Check/clean tine. (1/89) nyTROUBLESHOOTING THE CUMMINS "B" AND "C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Fuel or Oil Leaking from Exhaust Manifold (Cont'd) Turbocharger seals leaking oil Check/reptace turbo- charger. Exhaust Smoke Excessive Under Load 1 2 3. 5. 6 he 8 9% 10. Lugging engine Air in fuel system Air cleaner plugged Air fuel control line leak Injection pump timing not correct Air leak between turbo~ charger and intake or exhaust manifold More than one seat washer under injector nozzle Injector nozzle mal- functioning Malfunctioning turbo- charger Engine running too cold 2 te a o 10. Use lower gear. Bleed fuel system and check for suction leaks. Inspect air cleaner. Clean and replace. Check/tighten fittings. Check and adjust injec tion pump timing. Correct leak. Remove extra washers. Remove and have noz~ zles tested. Replace injectors if necessary. Replace turbocharger. Check thermostat and cooling system. Excessive Vibration 2 Engine not running smoothly Loose or broken engine mounts 2 Refer to troubleshooting logic for rough running or misfiring. Check/replace engine mounts (refer to the equipment manufac~ turer's service instruc~ tions). 12 (1/9)C TROUBLESHOOTING THE CUMMINS "B" AND “C SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Excessive Vibration 3. Damaged fan or mal- 3. Check/replace the vi~ (Cont'a) functioning accessories brating component (refer to equipment manu- facturer's service in- structions). a Inspect/replace the vibration damper. 5. Worn or damaged 5. Check/replace the alternator bearing alternator. Fuel Knock 1. Engine overloaded Use lower gear. 2. Poor quality fuel 2. Drain tank; fill with correct fuel. 3. Air in fuel system 3. Bleed fuel system and ‘check for suction leaks. Incorrect injection 4, Check pump timing. pump timing Injection nozzles 5. Remove nozzles, Test malfunctioning and repair. Engine RPM Wil! Not 1. Throttle linkage in- 1. Adjust linkage for stop- Reach Rated Speed - correctly adjusted to-stop fuel control No Load lever travel. 2. Partially engaged 2. Check/place shutdown mechanical shutdown lever in run position. lever 3. Malfunctioning tacho- | 3. Verify engine speed with meter hand tachometer ~ cor rect as required, 4, High speed stop screw | 4. Check/set high speed Incorrectly adjusted stop screw. 5. Restricted manifold 5. Check/remove restric~ drain line tion, (1/89) 13TROUBLESHOOTING THE CUMMINS "8" AND "C" SERIES DIESEL ENGINES CAUSE TROUBLE CORRECTIVE ACTION Engine RPM Will Not 6. Malfunctioning In- 6. Replace pump. Reach Rated Speed - jection pump No Load (Cont'd) Low Power 1. Vehicle overloaded 1, Reduce load or use lower gears. 2. Lubricating oil level 2. Drain oil to proper level. too high 3. Throttle linkage ad~ 3. Check and adjust throt- justment wrong tle linkage for full travel of the fuel control lever. 4. Shut down lever par 4, Adjust linkage. tially engaged 5. Intake or exhaust sys~ | 5. Check intake and ex- tem restricted haust systems for re~ strictions. Inspect air filter and replace as necessary. - Air fuel control tube Tighten fittings. Re- leaking and/or re- place tube if necessary. stricted 7. Ait leak between turbo-| 7. Correct teak. charger and intake manifold 8 Exhaust leak between | 8 Correct leaks turbocharger and ex- haust manifold 8. Air in the fuel system | 9, Bleed the fuel system and check for suction leaks. 10. Fuel quality poor 10. Verify by operating en~ gine from a temporary tank that contains good fuel and refer to fuel oil specifications. 4 (1/89)TROUBLESHOOTING THE CUMMINS "B" AND "'C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Low Power (Cont'd) Ww 12. 13. Te 15. 16. 7. 18. Fuel supply restricted Malfunctioning lift pump Injection pump timing not correct ‘Turbocharger worn or malfunctioning Valves not set properly Injector nozzles worn ‘or malfunctioning Restricted fuel drain manifold Worn or malfunctioning injection pump We 12. 13. 4 15. 16. ra 18, Clean pre-filters and screens and check fuel line for restriction. Re- place fuel filter. Check/reptace lift pump. Check timing. Replace turbocharger. Adjust valves. Inspect push rods, springs, etc. Replace injectors. Clear restriction, Replace injection pump. Engine Will Not Reach Rated Speed When Loaded 2 Ea 4 5. Vehicle overloaded Throttle linkage ad- justment wrong Tachometer has a malfunction Air fuel contro! tube leaking and/or re~ stricted Fuel supply restricted Pa 3 5 Reduce load or use lower gear. Check throttle linkage adjustment for full travel to the high idte stop screw. Check with hand or digi tal tachometer. Tighten fittings. Re- place tube if necessary. Change the fuel filter and check fuel Tine, pre~ filter and screens for restrictions. (1/89) 15TROUBLESHOOTING THE CUMMINS 8" AND "C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Engine Will Not Reach Rated Speed When Loaded (Cont'd) 8 High speed screw correctly adjusted Partially engaged shutdown lever Malfunctioning injec~ tion pump a Check/adjust high speed screw. Check/adjust shutdown lever. Replace injection pump. Excessive Fuel Consump- tion 2 3. 4 5. 6. te 8. Fuel leak Additional loading from malfunctioning accessories Operator technique Poor quality fuel Inadequate intake air or exhaust restriction Fuel pump timing Worn or malfunction~ ing injectors Valves not seating 2 3. 4 5. 6. 8 Check/correct the source of the leak. Check/repair acces sories and vehicle com- ponents. (Refer to the equipment manufac~ turer's procedures). Review operation for correct gear shifts, de- celeration, and idling. Make sure quality No. 2 fuel is being used. Refer to troubleshoot~ ing logic for excessive exhaust smoke. Check/time the pump. Check/replace injec tors. Check/adjust valves. Excessive Engine Noises ‘or abnormally high loading Check the tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub and alternator turn freely. 16 (1/89) r (TROUBLESHOOTING THE CUMMINS "B" AND "'C" SERIES DIESEL ENGINES TROUBLE CAUSE CORRECTIVE ACTION Excessive Engine Noises (Cont'd) 2 5. Drive belt squeal, insufficient tension or abnormally high loading (Cont'd) Intake air or exhaust leaks Excessive valve lash Turbocharger noise Gear train noise 3. Check the tension of accessory drive belts. (Refer to the equip- ment manufacturer's procedures.) Make sure the accessories turn freely. Refer to troubleshoot- ing logic for excessive exhaust smoke. Adjust valves. Make sure the push rods are not bent or the rocker levers are not severely worn, Check turbocharger im- peller and turbine wheel for housing contact. Check/replace vibration damper. (1/89) 7TROUBLESHOOTING TC TRANSMISSION HYDRAULIC CHECKS. Before checking the torque converter, transmission, and associated hydraulic system for pressures and rate of flow, it is essential that the following preliminary checks be made. 1 Check the oil level in the trans- mission. This should be done with the oil temperature between +180°F and +200°F, and the engine operat- ing at 500-600 rpm. NOTE Do not attempt these checks with cold oil. 3. the converter can be stalled to bring the oil temperature up to the operating range. Perform the following procedures to stall the converter. With the brakes applied, move the ctional contro! lever to forward and the speed control lever to 3 speed range. Continue to apply the brakes and ac celerate the engine approximately one half to three-quarter throttle. Hold the stall until the desired con verter outlet temperature is reached. 2. Work the machine to bring the oil temperature up to the operating A CAUTION: Full throttle stall range. speeds for an excessive length of time will overheat the con- NOTE verter. If the machine cannot be worked, Problem Cause Correction Low Clutch Pressure | 1. Low oil level. 1. Fill to proper level. shaft or rings. stuck open. Clutch pressure regulat- ing valve spool stuck open. 3. Faulty charging pump. 44, Broken or worn clutch iston sealing 5. Clutch piston bleed valve 6. Broken spring in trans- mission regulator valve. 7. Broken or worn sealing rings on clutch support. 2. Clean valve spool and housing,| 3. Replace pump. 4, Replace sealing rings or clutch shaft. 5. Clean bleed valves thorough- ly. 6. Replace spring. 7. Replace sealing rings. (Rev. 11/89)TROUBLESHOOTING TC TRANSMISSION Problem Cause Correction Overheating 44, Pump suction line taking Check connections, tighten (Cont'd) air. securely. Noisy Converter 1. Worn coupling gears. 1. Replace. 2. Worn oil pump. 2 Replace. 3. Worn or damaged bearings. | 3. A complete disassembly will be necessary to determine what bearing is faulty. Lack of Power 1. Low engine RPM at con- 1, Turn engine check governor. verter stall. 2 2, Remove, disassemble, and rebuild converter assembly. 3. Worn oil pump. 3. Replace. 4, Low oil level. Fill to proper level. (Rev. 11/89)‘TROUBLESHOOTING DRIVE AXLES PROBLEM CAUSE CORRECTION Differential Overheats 1. Low oil level 2, Incorrect lubricant 3. Incorrect bearing adjustment 4, Breathor in differential housing plugged 5. Oil level too high 1. Fill to correct level with recom: mended lubricant. (See lubri- cant specifications.) 2. Drain, flush and refill with lubricant of recommended specifications 3. Adjust bearings. Replace any that are damaged or excessively worn 4, Clean breather; replace if damaged 5. Drain oll down to check plug level in different Loss of Oi Out of Differential 1. Damaged or badly worn pinion shaft oil seal 2. Loose cartier mounting bolts 3. Breather in differential housing plugged, forcing oil by seals 1. Replace oil seal and check for loose pinion bearings or pinion ut 2. Check and tighten mounting bolts. Replace gasket if dar. aged or broken, 3. Clean breather; replace if dam- aged Noisy Differential 1. Noise on Drive 2. Noise on Coast, 3. Constant Noise 4. Noise on Turns 1. Ring gear and pinion adjustment to0 loose (excessive backlash} 2. Ring gear and pinion adjustment too tight (insufficient backlash) 3. a, Worn bearings . Chipped gear teeth 4. Worn or damaged differential pinion gears, side gears or pini journals 1. Adjust 2. Adjust 3. a. Replace bearings b, Replace gears 4, Replace differential parts O Final Drives Over- hest (Planetary Axles) 1. Low oil level 2. Incorrect type and grade lubricant Fill to correct level with spe fied lubricant 2, Drain, flush, inspect, repai necessary; install specified lubricant Rev. 2778‘TROUBLESHOOTING DRIVE AXLES Page 2 PROBLEM CAUSE CORRECTION Final Drives Qverheat, (Cont’d) 3. Incorrect lubricant for operating temperature 4, Wheel bearings improperly adjusted 5. Scored planet pins 3. Install correct lubricant spet fied for temperature range 4, Adjust whee! bearings to ree: ‘ommended pretoad 5, Inspect and replace defective parts Loss of Oi! Out of Final Drives (Planetary Axles) 1, Damaged or broken whee! driver gasket 2. Damaged or broken hub cap gasket 3, Damaged or excessively worn wheat oil seals 4, Loose wheel bearings Replace gasket 2, Replace gasket 3. Replace oil seals and adjust wheel bearings properly 5. Adjust wheel bearings properly and replace oil seat Noisy Final Drives (Planetary Axies) 1. Lack of lubricant 2. Worn bearings in wheels or planet gears 3. Chipped goar teeth 1, Fill to proper level indicated on hub cap 2. Replace bearings 3. Replace gears Rev. 2779~ TROUBLESHOOTING AIR BRAKE SYSTEM PROBLEM. CAUSE CORRECTION Insufficient Brakes 1. Brakes need adjusting, lubricating or refining 2. Low air pressure in the brake system 3. Brake valve delivery pressure below normal 1. Adjust and/or lubricate, Replace linings if excessively worn 2. a. Check and correct excessive air leaks b. Check governor and repair or replace if defective . Check compressor and repair if defective 4. Replace or repair defective control valves 3. Repair or replace defective valve Brakes Apply Too Slowly 1. Brakes need adjusting or lubricating 2. Low air pressure in the brake system 3. Brake valve delivery pressure below normal 4, Excessive leakage with brakes applied 5. Restricted tubing or hose line 1. Adjust and/or lubricate 2, Make the same checks as in No, 2 under “Insufficient Brakes" above 3, Repair or replace defective valve 4, Check and correct air teak 6, Clear restriction by opening or placing restricted tubing or hose Brakes Release Too Slowly 1. Brakes need adjusting or lubricating 2. Brake valve not returning to fully relessed position or hose tine 4, Exhaust port of brake valve re- stricted of plugged 5, Defective brake valve 1, Adjust and/or lubricate 2, Remove, disessemble, check and clean valve. Replace excessively worn or damaged parts. Mount. valve and check, 3, Locate restriction and correct 4, Remove restriction or unplug to permit proper exhaust of air 5, Remove and repair or replace with a new valve Rev. 2/79\ ¢ ‘TROUBLESHOOTING STEERING SYSTEM PROBLEM CAUSE CORRECTION Slow or Hard 1. Dirt in system 1. Drain, flush and refill Steering 2. ‘and spo! in steering 2. Replace 3, Wear on orbit gear in steering valve 3. Replace 4, Steering pump defective 4, Repair or replace purnp 8, Partial restriction on hydraulic 5. Check suction lines for restrictions suction circuit 6, Low oil supply 6. Replenish oil supply with proper grade and weight off, (See lubri- cation specs.) 7. Filter in suction fine stopped up 7. Service the filter {if s0 equipped) 8 Steering control valve defective 8. Repair or replace control valve 9, Steering cylinder rod bent 8. Replace 10. Mixed or foaming oils in steering 10. Drain and flush system. Replace system oil with proper weight oil. (See lubrication specs.) 11, Low air pressure in tres 11. Inflate to correct pressure 12. Low steer pressure 12, Sot pressure Steering Wheel 7. Binding in linkage 7. Re-lign Does Not Center 2. Broken centering springs in steering 2. Replace soring valve 3. Bent steer column 3. Replace column No Response When 4. Dirt in system 1. Drain, flush and refill with clean Steering Wheel oil Turned Slowly 2. Oil lovel is low 2. Fill to proper level 3. Steer cylinder failure 3, Ropair steer cylinder Wrong Response 1. Lines hooked up to wrong ports in 1. Reconnect to Steering Wheel steering valve 2. Orbit gear misaligned in steering 2. Realign valve Rev. 2/78TROUBLESHOOTING Page 2 STEERING SYSTEM PROBLEM CAUSE CORRECTION Continuous Steering 1, Dirty fluid 1. Drain, flush and refit Wheel Rotation 2. Broken centering springs in steering 2. Replace valve 3, Input linkage binding 3. Realign 4, Burron sleeve or spool in steering 4, Repair valve No Response 1. Sleeve and spool locked in steering 1. Disassemble, repair or replace valve 2, Pump failure 2, Check and correct 3, Hose or filter clogged 3. Check and correct 4, Relief valve stuck 4, Drain, flush and refi NOTE: Field repair of the Orbitrol valve is not recommended except by qualified service personnel. Repair instructions available on request. Rev. 2/79Oy TROUBLESHOOTING CHASSIS PROBLEM CAUSE CORRECTION Cracks in Welds, especially at the point where mast is pinned to the chassis 1, The chassis is carefully engineered and ruggedly constructed so that need for service in this area is highly improbable; however, it occasionally is needed. 1, Have eracks in welds repaired Immediately. Hinged Doors and Acoass Panels Becoming Unhinged 1. Doors and access panels not being properly replaced after use 1. Make sure these are properly closed Rev. 2/76‘TROUBLESHOOTING HYDRAULIC SYSTEM One of the most misunderstood systems, and perhaps the hardest to troubleshoot, is the hydraulic system incorpo: ‘ated in fork lift trucks. What appears to be asimple failure of @ component is usually corrected by replace- ment of that component, without due regard to the cause of the failure. There may be several individual systoms such as lift, steer and attachment, tied together to become fone overall hydraulic system. In which event, what hep- ‘pens to one subsystem may affect every other subsystem, Therefore, it is absolutely necessary that special attention be given to pressures and cleanliness. ‘The most mesningful system check @ serviceman can use in diagnosing a problem is the check of the hydraulic cir- cuit pressure on any machine that uses hydraulic compo- ‘nents. The two cardinal rules that should be followed are: 1. Exoossive pressure does not offer any opere- tional advantage, It only shortens component life, 2, Pressure just high enough to achieve compo- nent function is always the most desirable setting. We must also remember that the only reasons for making a hydraulic pressure check are to verify that the system {s to specifications or to troubleshoot the system to pin- point a malfunction. Before an aceurate reading can be ‘obtained the following steps must be taken: 1. The hydraulic oil must be to Taylor specifica tions. Any oil not to these specifications can sive a faulty reading. 2. The hydraulic system should have been cun {ong enough to bring the system temperature to approximately 126 to 150°, NOTE: One of the best ways to attain this tem- perature is to bottom out a cylinder and keep it bottomed out which passes the oll over the relief valve, thereby generating heat. CAUTION: Ifa pump or valve is being replaced, always take a preliminary pressure reading on the cold oil, at idle rpm, because if there is a malfunctioning pressure-relief valve in the system it can burst the pump housing, Normally, if @ cylinder is bottomed out it will kill the engine before bursting the pump. If your gauge reading begins to exceed the maximum allowed pressure, do not bottom out the function completely. It is extremely important that pressure readings on Taylor equipment be taken at the point specified in service bul- letins. If the pressure gauge is installed at another point in the system, readings other than the correct one can or will bbe obtained due to back pressure and other causes. It should be noted that readings for accuracy should be ob- tained when the vehicle engine is running between 1000 and 1500 rpm. This gives a good reasonable flow of oil and YyoU are within the range of relief-valve settings and other units of the system without excessive back pressure. When # new pump is installed, allow engine to idle for 15.0r 20 minutes before pressuring the system. This allows the pump to become thoroughly lubricable and to reach the same temperature as the oil. Rev. 2/79‘TROUBLESHOOTING HYDRAULIC SYSTEM PROBLEM CAUSE CORRECTION Hydraulic Pressure Will Not Build Up 1, Low oil supply 2. Clogged filter 3. Broken hose or connecti Excessive ar leak on suction line to pump, Check and fil to proper level with correct grade and weight of oil, Clean or replace filter. Replace damaged hoses and tighten connections. Locete leak and correct. Replace damaged or broken hoses and connections. 5. Badly worn or dafective pump 5. Disassemble pump and replace worn or damaged parts; check shaft seals for source of trouble. 6. Badly worn or defective control 6, Disassemble, clean and inspect. valve Roplace weak or broken springs, seals and gaskets. If valve plung- ets are damaged or excessively worn, replace the complete valve assombly- 7. a, Stripped drive ring or flex plate 7. 2, Replace. on transmission. ’b, Broken pump drive shatt, b. Replace. Low Pressure in 1. Roliof valve setting to0 tow (oil may 1, Adjust relief vajve as necessary. System flow through relief valve and back to reservoir without reaching point of use) 2. Relief valve stuck open (may be an 2, Look for dirt and sludgo in valve. indication that system contains dirty If valve is dirty, disassemble and or deteriorated oil) clean, Be sure oil meets Taylor specifications. Hydraulic Pressure 1. Broken pump shaft 1. Disassemble pump and replace Builds Up but Drops broken and excessively worn, Off Rapidly parts. 2. Low oll supply 2, Fill reservoir to proper level with correct weight and grade of ofl 3. Obstructed hose, line or connection, 3, Locate and remove obstruction. Replace excessively worn or ‘damaged hoses or connections. Rev, 2/78 CTROUBLESHOOTING HYDRAULIC SYSTEM Page 2 PROBLEM CAUSE CORRECTION Hydraulic Pressure (Cont'd) 4 Defective control or relief valve 4 Disassemble, inspect and repair oF replace valve, Hydraulic Pressure Engine speed too slow Increase engine speed rpm and Builds Up Very Siowly check, or Jerkily 2. Low oil supply 2. Fill reservoir, 3. Excessively worn pump 3. Remove pump, disassemble and replace worn or damaged parts 4, Obstructed suction line of filzar 4, Locate and remove obstruction. 5. Dirt or other foreign matter under 5. Disassemble valve, clean and relief valve plunger assemble proporly. 6. Scored reliof valve plunger or seat 6. Replace damaged parts. Assemble properly. 7. Weak or broken relief valve spring 7. Replace spring. Erratic Action 1. Air in system 1. a. Check reservoir oil level. b. Check pump seals, pipe and ‘tubing connections, and all otter possible leak areas. 2. Valves, pistons, ete, sticking or 1. a, Check part for mechanical binding deficiencies. , Look for dirt, oil sludge, var- nishes and lacquers, ‘e. Replace worn parts and check 3. Sluggishness when machine is first 2. a, Check tank filters, started b. Under severe conditions use immersion heater. Pump Not Pumping 1. Intake clogged 1. Check filters, strainers and line ‘rom reservoir to pump. 2, Lowoll [evel 2. Bring oll up to recommended level in reservoir, Intake line must be below oil level. 3. Air leak in intake (indicated by 3. Pour oil over suspected leakage noisy pump) points. If noise stops, you have found the leak and ean repair it 4, Oil too heavy 4, Drain system and refill, Rev. 2/79‘TROUBLESHOOTING Page 3 HYDRAULICSYSTEM PROBLEM CAUSE CORRECTION Pump Not Pumping 5. Pump worn out 8. Check output pressure. if pump (Cont'd) 6. Mechanical trouble (broken shaft, loose coupling, etc.) is not producing specifi sure, replace pump. 6. Locate by noise, repair or replace. ‘System Overheating 1. Oil viscosity too high 2, Internal leakage too high 3, Excessive discharge pressure at relief setting 4, Low oll pressure 5. Lowoil 1. Check oil recommendations, If Jn doubt about the oil system, rain and refill. Adjust viscosity requirements for unusual tem- perature conditions, 2. Check for wear and loose pack- ings. Check to see if ol viscosity is too low. If you are tempted to try 2 higher viscosity, proceed with caution. 3. Reset pressure. 4, Reset pressure. 8. Indicated by high oil tempera- ture, Refill oil up to proper level. Noisy Pump 1, Air leaking into system 2. Cavitation {the formation of vacuum in a pump when it does not get ‘enough oil) 3. Loose or worn pump parts 1. a, Check reservoir oil level. ». Check pump seals, pipe and tubing connections, and all other possible leak areas. 2. Check for clogged oF restricted intake line or plugged air vent in reservoir, Check strainers in intake line, Check viscosity of oil. 3, a. Check manufacturer's mainten ance instructions. Look for worn gaskets and seals. Replace all worn parts. Check oil for proper grade and quality. b. Clean filter or strainer. Check filter capacity end quality of oil. ¢. Determine recommended speed. Slow or Excessive Cycle Time 1. Airin system 1. Bleed system, Rev. 2/79‘TROUBLESHOOTING HYDRAULIC SYSTEM Page 4 PROBLEM CORRECTION Slow or Excessive Cycle Time (Cont'd) External Oil Leakage Internal te control valve In motor, eylinder or 3. Worn pump 4. High viseosity ofl causing sluggish action during or after warm-up 2, Hose oF tubing loose or defective 2. Replace piston seals or repli cylinder if walls are scored. Repluce or repair valve, Clean unit 3. Repair or replace. 4. Consult your pump manufacturer's, recommendations or your oll sup plier for correct viseosity. 1. Replace seals. 2. Tighten or replace if necessary, Excessive Wear 1. Abrasive matter in oil passing through pump 2. Viscosity of oil too low at working ‘conditions 3. Sustained high pressure above max imum pump rating 4, Air recirculation causing chatter in systom 1. Install adequate filter or replace oil more often, 2. Check pump manufacturer's ree ‘ommendations or consult lubrication engineer, 3. Check relief or regulator valve max- num setting, 4, Remove alr from system. Breakage of Parts Inside Pump Housing 1. Excessive pressure above maximum, pump rating 2. Seizure due to lack of oil 3. Solid matter being wedged in pump 4, Excessive tightening of headserows 1. Check relief or regulator valve max: imum setting, 2, Check reservoir oil level, cil filter and possibility of restriction in suction line more often. 3. Inspect filter or suction line. 4, Follow pump manufacturer's recom- mendations Cylinders Creep When ‘Stopped in Inter ‘madiate Position 1. Internal leakage in actuating cylinders oF operating valves, 2. Load check in control valve not seating 1. Replace piston packing or replace cylinder if walls are scored. Replace ‘or repair valve. 2. Clean unit to remove foreign matter Roy. 2/78Preventive Maintenance ‘SERVICE SYMBOLS SERVICE INTERVALS ‘Seen 66-thanee % vo | 200] 0 | soo] om | veo ] tae] eo | a Greoreuse _Koneue ve | re | i | ee | rs | ie | ots. | ae | te | te | oe POWER UNIT ~| ENGINE: _ 7 [ot everest or eirce of eemal aiage ee Se ape ee Ol change and filter element, D D “0 D D D By pss ier leet (equiped eo [ea oo” | ee [eo ea “Troe contol inka ~ ‘an_| on on | an | an an Grankaso be e c Clean ening ~ — c cheek engine noun x Erergeeyshldown wachanan (Dovll isa x x Ege Protection yaa Chak bing or aka Sho vam ers on Maser Con and Coolant Lars Va {Grange ara Peter oa x|x x |x [x x FUEL SYSTEM: ~ Pill anechoct rie eps wpe pepe pe pe Dx 13 (diesel engines) Perkins: ~ D o | D D . o D . ‘stoments (diaee! engines) C3 co cy ements rca) es Foe an, apie and cla x x ‘AIR INTAKE SYSTEM: - Ghecktor teas ~ x)x fs fx[>x>x)x px} |x tx ‘Fare air cleaner element (or by filter indicator} - ce ca Donaldson air eleaner elements [or by lilter indioator) x x x x x x x x x | Primary element eo ee oa _| ce ‘Safety element (or by internal indicator) — ca “EXHAUST SYSTEM: | PTX Purifier - c c cooune sare Coolant level and fan bells x x x x * x x x x |x x Hoses, laps, and adiator-oheckforleake ex pee [poe Pe « Radiator (clean externally) as conditions warrant ~ - c c ‘Drain and flush cooling eystern_ > Tt "ELECTRICAL SYSTEM Batic = heck wal ov ond opel gray [x é epee = -Aleraior boo ~ Fa A POWER TRANSFER “TRANSMISSION: _ ~ aan aoe al a and he Tor oak ee ‘Clea raneission bear ee € ° ‘Drain and retil transmission. - ° D “Transmission filter element. Giean filter shell, Clean sump - Sceura uc ane goad co | co co co co | co DRIVE SHAFTS: - ‘Lubricate drive shalt, universal joints, slip joints, and. ~ - coher eninge on_| on | on | on | on | on | on | on | on ‘AXLES ‘STEER ARE - ~ ~ Libra grease Ringe on is ae [ on [oe | on [on [oe [om [om [on Maan ol evel ner ele ube to eho xe px x pe px pe px Orain and refil steer axle - > Wheel boaring adjusiment ~ ~ a DRIVE ANLE: ~ ~ Differential and planetary hubs ~ maintain oil evel - x x x x x x x x x ‘Drain and ralil differential and planetary hubs Z ° Wee beg aelsner — : i 7m TE-160.~ 360 (Rov. 69)SERVICE SYMBOLS ‘SERVICE INTERVALS Kidjust GGiean — CG-Change ie] @ | w ] a ] seo | soo | eco [1000 ] 1000 | veo | ooo Dibram _GAGrenso_ Check wea | wre_| ee | fre | Are | fr | fea | Are | fre | ie | te (DAWE ARLE (Continued) ‘Clean broathor ee eee Trapecl Brake Hnings x x ( ‘BRAKE CONTROL SYSTEM ‘AIR BRAKES! ‘Cheek automate daine x x x | heck air tines and connections — x x x x | ® x % Clean power duster breathr (i eulpped) ee e |e é CHASSIS LLubeat al oroane tinge an mao (WHEEL EQUIPMENT: ‘Check utes, valve cap, whose, igs, avd tre preseure ex_| on | on | oe | on | on | on | ca | on {cater to dia pate an tn ook or torgue eration) xie«tx|xtx|e} «| x} «|x |x HYDRAULIC SYSTEM VDRAULIG PIPING AND RESERVOIRS ‘sina oi aval nda tao mark x pe px pe ps pep= >. px > | ‘Cheek oiping for chang, cracked noses lose ings, and i“ xtxtx«lxe| «|x| «|x| xx ‘rain and oil onve hydraulic ystow and coun nace tank Drain and ralill every 2400 hour ‘WyORAUIIG FILTERS Pio yaw tk Santor i Ca we [ee [ee ya ucton tr (id ai i z an ture lr nt or analy 2@ NY % YORAULIG CviNERS (Check erloake [x ps >) xtx px px) x]. [ cteann prectrse z ep ee x ZC "ATTACHMENTS MAST: Lriate mast noe wee [oe | on [on fer | an | an [an ‘briale mast main, i, chaln and howe roller, Lablcale tikeyindor uoninge and oer grouse stings on meth Ineuaing special oqupment. on | cr | oe | cr | on | on | on | on | on ‘brea it chains wit engine ot areined Vom erankease T _whon engine ei is changes. on_| on | cr | cn | on | on | on | on | on ‘CARRIAGES: t Lubricate arsage main aie side rllors ca| en | oe | oa [om | on | oa | an | on Lubecat fork pin on Type C carriage ‘on_| en | an | on | an [on | on | on | ca bros ice shi oir, clinders, tor poivoner ayn ‘ors, and any ctor groaso tings on carriage assembly, on Inctuing spacal eaulpert. Wipe ot cess greaso on_| on | on | on | on | on | on | on “Forks must be magrais pavicle ested (nagnatunod) for cracks analy (2400 re) xftefx«f} xe} «|x fet} x | «| x PuLPwOOD: {bvcaio main and side rallor lubricate tip meshaniom, ‘ote and anyother grata iting on pupaond arlage ‘Wipe at excess groase on_| on | cr | oe | on | ox | cn | oa | on [EMPTY CONTAINER HANDLER: {ibscaie the sling sutacs f the expansion beams, IWstlek graase Hirga. expason cyndor end grea Mt tins, pie slope cylinder ands and any othr grease ings oetwcarage en_| on | on | on | on | on | on | on | on Viewllyiepect a wink and guide age spe psx fx |x) > [x | x Visual inspection of wisosss ane guid lugs By malni- ance poreennel on eyindors x ‘Check wislocke ad gui age uiveconzaly oy : _magratiox every 2400 hoor, Aoplae detective, Replace tistiocs and guide age every 4200 now {Spray wash dally ater boing submorged in saltwater ‘ofr to Fork Inspacton, Ropar and Test ‘Test80 ~ 340 (Rev. 6:93)SERVICE CAPACITIES FUEL TANK oc TEC-150H, TEG-185H - LP Gas... vn ENGINE (Includes Filter Change): Lubrication DDC 4-53 14 quarts ppc 4-71 22 quarts DDC 6.3544 46 quarts Ford 370 quarts Ford 460, quarts Cummins AT quarts TRANSMISSION OIL Includes ter and cooler: Taylor TC-28 (3-speed)... DRIVE AXLE LUBRICANT: Ditferential PRLC-615 29 pints PRLC-756 28 pints PRLM-855 30 pints PRLC-1786 39 pints HYDRAULIC TANK: TE, TEB, TEP, TEH, TEG. ‘TE-40-30, TEG-125L, TEC-150L TEOC-155L, TEC-150H, TEC-155H. FSE-60, 76,00 (05.1nch Wheelbase} TSE-76, 90 oo . TSE-190, 120... ‘STEER AXLE LUBRICANT (each wheel) .. OPERATING TEMPERATURES AND PRESSURES ENGINE OIL PRESSURE: DDC 4-63, DDC-4-71, Ford DDC 6.3544, Cummins. ENGINE COOLANT TEMPERATURE.. ‘TRANSMISSION OIL TEMPERATURE . ‘TRANSMISSION OIL PRESSURE. Cooling 7 gallons 7 gallons 7 gallons. 7 gallons 7 gallons 7 gallons, Wheel 7 pints 55 pints 8 pints 13 pints 33 gallons 65 gallons 225 gallons 26 quarts 40 gallons 55 gallons 75 gallons 48 gallons 55 gallons 75 gallons 1 quart 40-60 psi 30-60 psi 180°F - 200°F 250°F MAX 240 - 280 psi ‘TE-160 - 960 (Rev. 10/80HYDRAULIC PRESSURE SETTINGS c MODEL Urrerar STEER ACCESSORY Bin Gylinders —[___+-Lin Cylinder “1 Gylinder 2 Oyiinders TE isopa 1750 10 pot 2500 psi “600 psi spat Te 180 1750 pst 2100 psi 2500 pl 1500 pe Te-200 7200 psi 2300 psi 2500 pai 1500 psi "e220 2200 psi 2500 psi 2500 psi 1500 psi Te-250 2300 psi 2000 pst 2500 pal 1500 ps TE26 2300 psi 2200 psi 2200 psi 5003 —_| e300 2300 pet 2480 pst 2500 sl [800 pst Te.330 2500 pst 2800 pel 2500 psi [io00 pei E360 2500 psi 2500 pst | 2500 pst [e00 pst TeH-300 2500 pel 2500 psi 2500 si [1500 psi TE6-200| 2500 psi 2500 pal [1800 pst E4030 BoD pa [1500 pst TSE 200 pet 2D pal 1500 pt MODEL Fra rar STEER “REGESSORY_[_ EXPANSION | TWHSTLOGR ae Lie ovine Cylindoe soytindsr | 2.indors TEC, 2800 pi 2400 ps 2500 psi 1560 pal Tato pal eo pei S00 pst TEC-150. 2500 psi__|__2550 8 2500 psi 1500 pa _| 1600 pa 2200 psi__ |” sp TEC-156L 2500 psl__| 2500 pa 2500 psi 1560 pet 10 osi 2800 psi 50 psi ‘MODEL are TA, CONTROL LEVER PILOT TEC. 1608 2200 psi 400 pst "TECH 2800 psi 00 ‘TE-160 - 360 (Rev. 10/90)Load Range Designation - Ply Rating Equivalency Table Load Range Piy Rating Load Range Ply Rating A 2 6 4 B 4 # 16 c é J 8 D @ L 20 E 10 M 22 F 12 N [ee Note: Tire sizes above 12.00 x 20 will maintain ply rating designation.Fork Inspection, Repair, and Testing (Forks in use shall be visually inspected dally and must (be magnetic particle tested (magnatluxed) for cracks at intervais of not more than 2400 hours or whenever any defect or permanent detormation is detected. Severe applications will require more frequent inspection. When forks are used in pairs, the rated capecity of each fork shall be at least half of the manufacturer's rated capacity ofthe truck, and at the rated load center dis- ance shown on the lift truck nameplate, Fork inspection shall be carried out carefully by trained personnel with the aim of detecting any damage, failure, eformation, etc., which might impair safe use. Any fork which shows such a defect shall be withdrawn from service, and shall not be returned to service unless it has been satisfactorily repaired. A WARNING: Do not weld on forged forks. Failure to follow this warning could lead to seriously weak- ened forks that could fail prematurely under normal loads. When necessary, the welding ‘of fork bushings should only be done by qual- ified welders knowledgeable of the appro- priate welding practice, ‘The fork shall be thoroughly examined visually for racks and if considered necessary, subjected to a non- destructive crack detection process, special attention being paid to the heel and welds attaching all mounting ‘components to the fork blank. This inspection for cracks ‘must also include any special mounting mechanisms of the fork blank to the fork carrier including bolt type ‘mountings and forged upper mounting arrangements for hook or shatt type carriages. The forks shall not be returned to service if surface cracks are detected. mo ‘The straightness of the upper face of the blade and the front face of the shank shalll be checked. If the deviation from straightness exceeds 0.5% of the length of the blade and/or the height of the shank, respectively, the fork shall not be returned to service until it has been repaired. ‘Any fork that has @ deviation of greater than 3° fork angle from the original specification shall not be returned to service. The difference in height of one set of forks when mounted on the fork carrier shall be checked. if the dif- ference in tip heights exceeds 9% of the length of the blade, the set of forks shall not be returned to service until repaired. It shal be confirmed thatthe postioning tock isin ood _~feparr and corrct working oro. any fat ose, Co tere that be withdrew irom service unt sto: ~iory repairs have boon etected ‘The fork blade and shank shall be thoroughly checked for wear, special attention being paid to the vicinity of the heel. If the thickness is reduced to 90% of the ori- ginal thickness, the fork shall not be returned to service. ‘The support face of the top hook and the retaining faces of both hooks shall be checked for wear, crushing, and other local deformations. If these are apparent to such an extent that the clearance between the fork and the fork carrier becomes excessive, the fork shall not be returned to service until repaired If the fork marking is not clearly legible, it shall be renewed. Marking shall be renewed per instructions, from original supplier. Each fork shall be clearly stamped with its individual load rating in an area readily visible and not subject to wear, Only the manufacturer of the fork or an expert of equal competence shall decide if a fork may be repaired for continued use, and the repairs shall only be carried out, by such parties. {t is not recommended that surface cracks or wear be repaired by welding. When repairs necessitating reset- ting are required, the fork shall subsequently be sub- jected to an appropriate heat treatment, as necessary. A tork that has undergone repairs shall only be returned to service after being submitted to, and passing, the test procedures. The test load shall correspond to 2.5 times the rated capacity marked on the fork. Fig. 1 Typical Fork Fork strength shall permit the following loading and method of test. {a) The test load F shall be applied to it at the appli cable distance D from the front face of the fork arm shank (See Fig. 1). {b) The fork arm shall be restrained in a manner iden- tical to that used on the forkiift truck. {(c) The test load shall be applied twice, gradually and without shock, and maintained for 30 seconds each time. {d) The fork arm shall be checked before and after the second application of the test load. It shall not show any permanent deformation. (Rev. 9/93)RECOMMENDED GEAR OILS ChevonUSA, IN ee eee eee eee eee Borate ISO-VG 220 Continental Oil Company... . . . . . . . Conoco SCL Gear Lubricant, SAE 90 Gulf Oil Corporation . 2... . . . . .., Gulf Hypoid Gear Lubricant, SAE 90 Humble Oil and Refining Company... . . . . . . . . Eneo Gear Oil, SAE 90 Lion Oll Company... .. . . . . . . Multipurpose SCL Gear Lubricant, SAE 90 Standard Oil Company... . . . . . . . . Special SCL Gear Lubricant, SAE 90 Quaker State Oil and Refining Corporation . . . Quaker State Super Quadrolube X-SCL Gear Lubricant, SAE 90 Valvoline Oil Company . . 2... + + + +. Valvoline SCL Gear Lubricant, SAE 90 This list of commercially available oils was compiled for the convenience of owners and oper- ators. It is based on information received from the suppliers of these oils, Responsibility for the quality of olls and their performance in service must remain with the oil company fnar- keting the lubricant, This list is not to be construed as a complete list of oils meeting specifications for use and does not imply endorsement of any specific brand. NOTE: See attached list of recommended oils for Allison transmissions, Rev, 5/80‘This replaces all previously published Fuel and Lubricant Specifications. Fuel! and Lubricant Specifications Higher Temperatures PRODUCT USED IN ‘SPECIFICATIONS: ‘TEMPERATURE FACTORY FILLED ENGINE | Dotroit Diesel Diesels | API Classification CDi ‘Chevron Delo oll. (SAE 15W 40 To Aid Starting) 25° F. To °F. Mutti-crade SAE 40 All Other Temps. Heavy Duty Motor Oi Detroit Diesel API Classification CE/SG SAE 15W 40 Phaser-1000 4-cycle | SAE SW 30 “18° F. To 70°F. SAE 15W 40 48° F, To 125° F. “Cummins Diesels ‘API Classification CE/SG ‘Chevron Delo ‘SAE SW 30, -80° F, To 90° F. Multi-grade SAE 15W 40, “0° F, To 108° F. Heavy Duty Motor Oi SAE 15W 40 Teuzu/Perking Diesels | API Classification CE/SG ‘Chevron Delo SAE 10W 30 222 F. To 90° F. Multi-grade SAE 15W 40, “10° F. To 104°F. Heavy Duty Motor Oil SAE 15W 40 Gas & LP Engines ‘API Classification CE/SG ‘Chevron Delo ‘SAE SW 30 Below Mult-grade 10" F. To 30° F. Heavy Duty Motor Oil SAE 15W 40 10° F. To 104° F. SAE 150 40 DIESEL | All Diesel Engines ‘ASTM Spec D975 ‘All Temperatures Chevron Diese! FUEL No.1 or No. 2, No.2 0.8% Sulfur Maximum with Temp. Cantane Minimum Supressor 40 ‘Added November Thru March ANTE Gosling System Maintain 50 - 50% Soft Water™ Texaco 23 53) FREEZE Ethylene Glycol (Low Silicate Antifresze) | GM 6038-M or ASTM D3306 RUST Cooling Sysiom ‘Any Reputable Manufacturer ‘All Temperatures included in INHIEITOR| Non-Chromate Only Antitreeze TRANS [ Automatic Trans- (Chevron Tractor Hydraulic ‘All Temperatures ‘Chevron Tractor MISSION | mission Fluid or Equivalent’™ Hyaraulle Fluid C-4 With Frietion Control HYDRAU- | Hydraulic System Modifiers uc FLUID& wet Wet Disc Brakes Disc. BRAKE ‘COOLING GEAR Differentials Extreme Preseure Gear Oil ‘chevron oO Planetary Hubs (GL-5 or MIL-2105D) Uttra-gear Steer Axle Hubs ‘SAE TSW 140 40°F. Minimum and | Lubricant 90° F. Maximum SAE 85W 90 Grade 220, SAE 5W 90 0° F. Minimum & Any (rev. sfQUALIFIED LIST OF C-4 TRANSMISSION FLUIDS pega necrerone owoco ne, u9c0 cor HSS? reese nour merenor BERS nou nroure macunon A a ADVANCED) eSCER SELES ExgMig,geormmencon avrowaric rans ieaemece AUTOMATIC TRANS rid lea Taatonan Ene tsoEE DEON /MERCON AUTOMATIC TANG it, SERRE one wo ie AUTOMATIC TRANSNAGEION FLU DCARON Gtedupautountic Tass Fu OeARON EE wo. sours gue annsrER rene siannocK aoc. us. FagMeano mousrmes RERRE EO upricanon ances SUPER HEATED ESE ow Seeeaae Ie TRANS FO "TRanePowen ACTOR HYDRAULIC FLUID DaYReNE UnensaL raAcTOR a oRusranc LD AP SSE MERSSN aso US PEnfoitiaver ouPen naLanrAanae Sg urge eu ap ES ALRGE Aeon AUTOMATIC rRAYGIESSION FLUO MSTORGIAFT SUPER BUT SAE 38°" nevenzo1 opxnon wencen msusos aS NTE ATC CGERUNE URVERSAL TRACTOR HYDRA LUD SMU Beton omenos (oe ee /UREREBN (820585) REVOHLPBSRON MmEROSN 160 NONOLES POMER SLLND Revised 4/91QUALIFIED LIST OF C-4 TRANSMISSION FLUIDS Copan ee PM Re uaxen stare CORP Ege oeverenree HERG Bec soroumormeusnonrive cee Bate one neue am Suen State fox Ovens rueer woron ox. QUEREN State VnacrOn MUNA THenoNESSON manseren gyrorca.wetcuny cate RESTS a -enension SABES UNS inen © an arzsa co toa erate reo Eee Geis hea BA sees ‘ora wuvracntam gprennmercot —pgvestimencneroumeamamenon | A tenor oot gut ora. se pe Steretumirie: —twmnactone comumerrize Sners eee sina 7 aan fveiccawon.so. sour, IESE EAA LS a uae ES ERE Mure monon nee FEE vero arourre mecnscen EEE eR aueccnnsocran ea Be PRUNE mama vocomons SE SR rma.macronnise BeRrowermnercsonrunocrnan | prep woronot gg tans oscoNane ann Faiproun ae aomEL un oe TARSIIEOR! Ota BURN aS ‘OSCE GS Eee CER ere Gisiis SE et gra Sa Seine pctom Revises 4/1