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Operational Diagnostic Procedures Operational Checkout

Group 05
Operational Checkout

Operational Checkout Procedures


These procedures are designed so technicians can Adequate space is required to do the driving checks.
make a quick check of the operation of the machine Some checks require the engine and other major com-
while sitting in operator’s seat. ponents to be at operating temperature.

WARNING
Be sure to read the warnings prior to performing the
checkout procedures.

WARNING
Before operating the lift truck, FASTEN YOUR SEAT
BELT.

There are a number of operations, if not performed


carefully, that can cause the lift truck to tip. If you
have not read the WARNING page in front of the Op-
erating Manual, do so NOW. As you study the follow-
ing information about how to properly operate a lift
truck, remember the Warnings. Before performing the operational checkout, complete
the INSPECTION BEFORE OPERATION in the Oper-
WARNING ating Manual.
Mast parts are heavy and can move. Distances be-
tween parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast
or the carriage.

• Never put any part of the body into or under the


mast or carriage unless all parts are completely
lowered or a safety chain is installed. Also make
sure the power is off and the key is removed. Fas-
ten a DO NOT OPERATE tag in the operator’s com-
partment.
• Be careful of the forks. When the mast is raised,
the forks can be at a height that may cause an
injury.
• DO NOT climb on the mast or lift truck at any time.
Use a ladder or personnel lift to work on the mast. Before starting operational checkout, talk to the oper-
• DO NOT use blocks to support the mast weld- ator and check Diagnostic Trouble Codes (DTC) using
ments nor to restrain their movement. the Display Switch Cluster (DSC). See General Main-
• Mast repairs require disassembly and removal of tenance and Diagnostic Data, Troubleshooting Guide-
parts and can require removal of the mast or car- lines and Procedures, Page 9030-03-1. All DTCs must
riage. Follow the repair procedures in the correct be corrected or cleared before starting this checkout.
Service Manual for the mast.
No special tools or gauges are needed. Always start
sequence from left to right. Before doing check, read
each check completely.

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Operational Checkout Operational Diagnostic Procedures

At the end of each check, a question is asked: When a problem is found, stop operational checkout
and correct it before going to the next check. Repeat
• If the answer indicates the check is OK, you will be check after repair to confirm repair was successful be-
instructed to go to next check. fore proceeding with the remaining checks.
• If the answer indicates that the check is not OK, you
will be given a required SRM repair or be linked to the
test to perform.

CHECK PROCEDURE ACTION

DTC Check 1. Turn key switch to ON position or press power YES: Refer to Diagnostic Trou-
ON/OFF button. ble Codes, Page 9030-20-1.
2. Check display for any DTCs. See General Main- NO: DTCs are OK. Go to next
tenance and Diagnostic Data, Diagnostic Trouble check.
Codes, Page 9030-03-6.
Are any DTCs displayed?

Horn Circuit Check Press horn button. YES: Horn is OK. Go to next
Does horn sound? check.
NO: Refer to Observed
Symptoms, Observed Symp-
toms, Horn Failure, Page
9030-30-41.

Light Circuit Check 1. Turn key switch to ON position or press power YES: Lights are OK. Go to next
ON/OFF button. check.
2. Turn front and rear work light switches ON. NO: Check fuse. If OK, check
Do lights turn on? DSC to see if light switch is
turned ON. Check bulbs, see
Electrical Functions Do Not
Operate.

Windshield Washer NOTE: Do not operate windshield wipers on a dry YES: Washer function is OK.
Wiper Check (If windshield. Dirt and debris on windshield can cause Continue with this procedure.
equipped) scratches. If windshield is dry, use washer function to NO: Check windshield washer
start wiper checks or lift wiper arms from windshield fluid level. Refer to Trou-
and place in the cam-lock position. bleshooting Procedure SPN
1. Turn key switch to ON position or press power 524240. See General Mainte-
ON/OFF button. nance and Diagnostic Data,
2. Press windshield washer switch. Diagnostic Trouble Codes,
Does washer fluid spray on front and rear wind- Page 9030-03-6.
shields?
3. After wipers time out from washer cycle, lift front YES: Normal wiper operation
and rear wipers off windshield and place in cam- is OK. Continue with this pro-
lock position. Turn front and rear wipers on using cedure.
DSC switches. NO: Refer to Troubleshooting
Do front and rear wipers operate properly? Procedure for SPN 524237 or
524238. See General Mainte-
nance and Diagnostic Data,
Diagnostic Trouble Codes,
Page 9030-03-6.

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Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Continue: YES: Front wiper system de-


4. With wipers operating, press and hold front wiper layed sweep operates prop-
switch for greater than 1 second. erly. Turn front wipers OFF.
5. On the DSC, use the up arrow key to set the front Continue with this procedure.
wiper delay to approximately 10 seconds, (5 or 6 NO: Refer to Troubleshooting
segments displayed). Procedure for SPN 524237 or
Do the front wipers now operate with a delay of 524238. See General Mainte-
approximately 10 seconds? nance and Diagnostic Data,
Diagnostic Trouble Codes,
Page 9030-03-6.
Continue: YES: Wiper system is operat-
6. With wipers operating, press and hold rear wiper ing correctly. Turn wipers off
switch for greater than 1 second. and, if in cam-lock position, re-
7. On the DSC, use the up arrow key to set the rear store wiper arms to proper po-
wiper delay to approximately 10 seconds, (5 or 6 sition. Go to next check.
segments displayed). NO: Refer to Troubleshooting
Do the rear wipers now operate with a delay of Procedure for SPN 524237 or
approximately 10 seconds? 524238. See General Mainte-
nance and Diagnostic Data,
Diagnostic Trouble Codes,
Page 9030-03-6.

Heater Check (If 1. Turn key switch to ON position or press power YES: Heater fan function is
equipped) ON/OFF button. OK. Set heater fan switch to
2. Verify that air ducts in right hand cab door are desired position. Continue
open. with this procedure.
3. Turn heater fan switch to each of the three speed NO: Refer to Observed Symp-
select positions. toms, Heater Fan Does Not
Does fan speed increase at each switch position Operate Properly.
and does airflow increase accordingly?
NOTE: If engine is at normal operating temperature, YES: Heater operation is OK.
proceed to step 4. If engine is cold, wait until engine Adjust heater temperature to
has reached normal operating temperature, then pro- desired position. Go to next
ceed to step 4. check.
Continue: NO: Refer to Observed Symp-
4. Turn heater temperature control fully counter- toms, Heater Airflow Does Not
clockwise to the maximum heat position. Reach Desired Temperature.
Does hot air flow from the heater air ducts?

Dome Light Check (If 1. Turn interior cab dome light switch ON. YES: Dome light operation is
equipped) Does dome light operate? OK. Go to next check.
NO: Refer to Observed Symp-
tom, Dome Light Inoperative.

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Operational Checkout Operational Diagnostic Procedures

CHECK PROCEDURE ACTION

Circulating 1. Turn circulating fan switch ON. YES: Circulation fan function is
(Accessory) Fan Check Does circulating fan operate? OK. Go to next check.
(If equipped) NO: Refer to Observed Symp-
tom, Circulating (Accessory)
Fan Inoperative.

9010-05-4 Confidential/Proprietary - Do Not Copy or Duplicate


Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Indicator Light Power YES: Display power is OK.


Check Continue with this procedure.
NO: Check fuse F8 in Power
Distribution Module (PDM).
If fuse is OK, Vehicle Sys-
tem Manager (VSM) has lost
power. Go to Observed Symp-
toms, Vehicle Does Not Power
On, Page 9030-30-21. If any
one light does not turn on, re-
place DSC.

A. LCD SCREEN
B. WARNING AND INDICATOR LIGHTS
1. LEFT TURN SIGNAL
2. ENGINE MALFUNCTION
3. SYSTEM MALFUNCTION
4. AIR FILTER RESTRICTION
5. DIRECTION INDICATORS
6. BRAKE FLUID LEVEL
7. FASTEN SEAT BELT
8. PARK BRAKE
9. ALTERNATOR
10. RIGHT TURN SIGNAL
11. TRANSMISSION OIL TEMP
12. ENGINE OIL PRESSURE
13. ENGINE COOLANT TEMP
14. COOLANT LEVEL
15. FUEL LEVEL
16. 1ST GEAR LOCKING (If equipped)
17. WATER SEPARATOR (If equipped)
18. COLD START (If equipped)
Turn key switch to ON position or press power
ON/OFF button with park brake applied.
Do the following lights turn ON?
• Fasten Seat Belt (7); Park Brake (8), Alternator
(9), Direction Indicator (5) Engine Oil Pressure
(12).
NOTE: Fasten seat belt light will turn off after 10 sec-
onds.
Continue:
Are the following items in display window (A)? YES: Display is OK. Go to next
• Clock and Hourmeter. check.
NO: Replace DSC.

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Operational Checkout Operational Diagnostic Procedures

Engine Malfunction 1. Start engine and increase to governed speed for YES: Repair engine malfunc-
Indicator Check 5 seconds. tion. Go to General Mainte-
2. Decrease engine to low idle. nance and Diagnostic Data,
3. Check DSC for engine warning indicator lights. Diagnostic Trouble Codes,
Are any engine warning lights ON? Page 9030-03-6.
NO: Engine indicators are OK.
Resume operation.

Cold Start Check NOTE: Engine must be cold to properly check the YES: Go to next check.
(Cummins and cold start circuit. NO: Continue with this proce-
Yanmar) • Turn key switch to ON position or press power dure.
ON/OFF button.
Does cold start indicator illuminate?
Continue: YES: Engine temperature suf-
Turn key switch to Start position or press engine start ficient not to require cold start
button. aid.
Does engine start normally? NO: Check DSC for SPN
524195 and troubleshoot per
procedure. If DTC is not dis-
played, contact your autho-
rized service technician to
check cold start circuit.

Brake Pedal Check YES: Brake adjustment is OK.


Go to next check.
NO: Adjust brakes. For 1.0-
3.5 Ton Cushion and Pneu-
matic Trucks, see Brake Sys-
tem 1800 SRM 1135. For 4.0-
7.0 Ton Cushion and Pneu-
matic Trucks, see Brake Sys-
tem 1800 SRM 1247.

1. With engine running at slow idle, release park


brake.
2. Depress and hold brake pedal with approxi-
mately 45.4 kg (100 lb) force.
3. Measure pedal distance from floor plate as
shown in the illustration (this is taken from bot-
tom of brake pedal bracket to floor plate).
NOTE: It is normal for trucks equipped with
MONOTROL® to increase engine speed as park
brake is released.
Does brake pedal remain at least 25 mm (1 in.) off
floor plate?

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Operational Diagnostic Procedures Operational Checkout

Backup Alarm Check 1. With engine running, apply service brake. YES: Back up alarm is OK. Go
(If equipped) 2. Release park brake. to next check.
3. Shift transmission to reverse. NO: Check wiring connections
Does backup alarm sound? first. If connections are OK,
check DSC for SPN 522755
and troubleshoot per proce-
dure. See General Mainte-
nance and Diagnostic Data,
Diagnostic Trouble Codes,
Page 9030-03-6.

Operator Presence NOTE: This procedure requires Service Password. YES: Continue with this proce-
System Check NOTE: Operator presence sensor requires a mini- dure.
mum of 45.4 kg (100 lb) to actuate. NO: Check DSC for SPN
NOTE: Hydraulic Interlock message will result if op- 524245 and troubleshoot per
erator is not detected in seat or mini-levers not me- procedure. See General Main-
chanically or electronically in neutral position when tenance and Diagnostic Data,
power ON. Diagnostic Trouble Codes,
Page 9030-03-6.
1. While operator in seat, power truck ON.
2. At the DSC, Enter Main Menu, scroll to Diagnos-
tics, Enter, scroll to General Data Display.
3. Scroll display until seat sensor appears. Read
display.
Does display show 1.4 volts or greater?
Continue: YES: Operator presence sen-
While operator out of seat, power truck ON. sor is OK. Go to next check.
Does display show less than 0.8 volts? NO: Operator presence sen-
sor has failed. Replace seat
NOTE: BEFORE PROCEEDING TO NEXT CHECK,
sensor. See Electrical Sys-
RETURN TO SEAT AND FASTEN SEAT BELT.
tem 2200 SRM 1142.

Hydraulic Interlock NOTE: Hydraulic Interlock message will result if Op- YES: Be sure Operator Pres-
Check erator not detected in seat or mini-levers not mechan- ence System Check has been
ically or electronically in the neutral position when performed and passed, then
power ON. continue.
While operator in seat, power truck ON. NO: Hydraulic Interlock is OK.
Does display show "Hydraulic Interlock?"
Continue: YES: Go to Electrical System
While operator in seat and not touching MLM, power 2200 SRM 1142 and perform
truck ON. TEST, Mini-Levers.
Does display show "Hydraulic Interlock?" NO: Hydraulic Interlock is OK.

Armrest Hydraulic 1. With engine running and seated in seat, move YES: Inspect switch and
Interlock Check (If armrest upward. wiring. Go to Observed Symp-
equipped and with 2. Attempt to operate hydraulics (with armrest up). toms, Electro-Hydraulics Can
original Configuration Does hydraulic control function with armrest up? Still Function With Armrest
Data File (CDF)) Raised, Page 9030-30-18.
NO: Armrest switch is OK. Go
to next check.

Confidential/Proprietary - Do Not Copy or Duplicate 9010-05-7


Operational Checkout Operational Diagnostic Procedures

Engine Cover Latch 1. Apply park brake. YES: Sensor is OK. Go to next
Sensor Check (If 2. With engine running, open engine cover latch check.
equipped) and raise cover. NO: Check DSC to see if en-
Does engine stop? gine cover latch sensor is ON
in the VSM. If engine cover
latch is ON, go to Observed
Symptoms, Engine Continues
to Run When Engine Cover is
Raised, Page 9030-30-1.

Brake and Inching 1. With engine running, fully depress inching pedal. YES: Inching function is OK.
Pedal Check 2. Release park brake. Go to next check.
3. Shift to forward and increase engine to governed NO: Operate truck to 10 full
speed. stops in each direction while
NOTE: There is not an exact operating procedure for fully pressing inch/brake pedal
the inching function, except it must disengage the each time. The VSM will
transmission. Inching can be set to operator’s pref- re-learn the brake characteris-
erence to fit the lift truck application in the DSC. tics.
Does engine increase smoothly to governed
speed?

Park Brake Sensor 1. With engine running, release park brake. YES: Park brake sensor is OK.
Check 2. Slowly apply park brake and note when park Go to next check.
brake light comes ON. NO: Adjust park brake sen-
Does light come on before park brake reaches sor. For 1.0-3.5 Ton Cush-
first click of engagement? ion and Pneumatic Trucks,
see Brake System 1800 SRM
1135. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks,
see Brake System 1800 SRM
1247.

9010-05-8 Confidential/Proprietary - Do Not Copy or Duplicate


Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Park Brake Check YES: Park brake is OK. Go to


next check.
NO: Adjust park brake. For
1.0-3.5 Ton Cushion and
Pneumatic Trucks, see Brake
System 1800 SRM 1135.
For 4.0-7.0 Ton Cushion and
Pneumatic Trucks, see Brake
System 1800 SRM 1247.

WARNING
Ensure load is secured so it will not move when
mast is tilted fully forward.

1. Stop lift truck in an uphill direction with rated load


on 15% grade or less, and apply park brake.
2. Stop engine and note if machine remains static.
3. Start engine and remove rated load.
4. Position lift truck with No Load in a downhill direc-
tion, on 15% grade or less, and apply park brake.
5. Stop engine and note if machine remains static.
Does machine remain static on grade in both di-
rections?

Engine Speed Check Lift Trucks with Duramatch™ Transmissions YES: Engine speed is OK. Go
(All Cummins, Yanmar, Only to next check.
and Mazda Engines 1. Scroll DSC to display engine rpm. NO: Adjust throttle cable or
Except 2007 Mazda 2. Run engine at low idle. Record engine rpm. accelerator pedal. For 1.0-2.0
Emission Compliant 3. Run engine at governed speed. Record engine Ton Cushion and Pneumatic
Engines) rpm. Trucks and 2.0-3.5 Ton Cush-
Does engine rpm match below specifications? ion and Pneumatic Trucks,
see Frame 100 SRM 1120.
• Low Idle - refer to Operating Manual for your lift
For 4.0-5.5 Ton Cushion and
truck.
Pneumatic Trucks, see Frame
• Governed Speed - refer to Operating Manual for
100 SRM 1243. For 6.0-7.0
your lift truck.
Ton Cushion Trucks, see
Frame 100 SRM 1316. For
6.0-7.0 Ton Pneumatic Trucks,
see Frame 100 SRM 1321.

Confidential/Proprietary - Do Not Copy or Duplicate 9010-05-9


Operational Checkout Operational Diagnostic Procedures

CHECK PROCEDURE ACTION

Engine Power Check 1. Ensure lift truck transmission and engine are at YES: Engine power is OK. Go
operating temperature, fully warmed transmis- to next check.
sion temperature 66 C (150 F). NO: To diagnose this problem,
go to Tests and Adjustments,
WARNING Torque Converter Stall Test,
Ensure load is secured so it will not move Page 9040-40-5.
when mast is tilted fully forward.

2. Put capacity secured load on forks.


3. Position forks against an immovable object, like
a loading dock.
4. Scroll the DSC to display engine rpm.
5. Shift to forward and operate engine at governed
speed. Record the highest rpm achieved with
transmission engaged after 10 seconds, then
disengage transmission for 10 second and re-
lease accelerator pedal. Repeat test three times
to get highest stall speeding reading.
Does engine stall speed meet stall speed specifi-
cations? For lift truck stall speed specifications,
refer to Table 9040-40-10, Page 9040-40-6.
NOTE: If engine speed is low, check if air filter re-
striction light is ON. A plugged air filter will lower stall
speeds.

Transmission Clutch YES: Transmission clutch is


Check WARNING not slipping. Go to next check.
Ensure load is secured so it will not move when NO: Transmission clutches
mast is tilted fully forward. are slipping. Go to Tests and
Adjustments, Transmission
1. Put capacity secured load on forks.
Clutch Drag Test (1.0-5.5 Ton
2. Position fork against an immovable object, like a
Trucks Only), Page 9040-40-5.
loading dock.
3. Ensure lift truck transmission and engine are at
operating temperature.
4. Adjust the DSC to display Transmission Input
Speed Sensor (TISS) rpm.
5. Perform torque converter stall in forward at gov-
erned speed and record the lowest rpm after 10
seconds.
6. Turn lift truck around in opposite direction.
7. Operate engine at governed speed and do a
torque converter stall in reverse, record the low-
est rpm after 10 seconds.
Does TISS rpm go to 0 rpm in both directions?

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Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Transmission Check NOTE: Make sure you have clear driving area for this YES: Transmission shift pro-
check. gram is OK. Go to next check.
1. Drive lift truck at governed speed for a short dis- NO: Install Service Tool and
tance. check program. See Calibra-
2. Decelerate and shift to opposite direction. Ob- tion Procedures 8000 SRM
serve lift truck direction changes. 1134.
3. Repeat above steps three times and observe en-
gine rpm and tire engagement during direction
changes.
Does truck make smooth direction changes with-
out excessive delay or engine surges?

Transmission Speed NOTE: Make sure you have clear driving area for this YES: Transmission Output
Selection Check (If check. Speed Sensor (TOSS) speed
equipped) 1. Check DSC to see if 1st gear locking light is OFF. is OK. Go to next check.
2. Go to Diagnostic menu in DSC and display speed NO: Check 1st gear lockup
in kph or mph. switch. Go to Observed Symp-
3. Drive truck in forward and increase speed until toms, Transmission Will Not
transmission shifts to high speed. Shift To Forward High Range,
Does lift truck make shift to high range above Page 9040-30-39.
8 km/h (5 mph)?

Brake and Axle Drag NOTE: Move truck to level surface before performing YES: Repair brakes. For 1.0-
Check the following steps. 3.5 Ton Cushion and Pneu-
1. Raise lift truck until drive tires are off ground. matic Trucks, see Brake Sys-
Support lift truck using suitable shop standard. tem 1800 SRM 1135. For 4.0-
(See "How to Raise Drive Tire" procedure in 7.0 Ton Cushion and Pneu-
Operating Manual.) matic Trucks, see Brake Sys-
2. Stop engine and release park brake. tem 1800 SRM 1247.
3. Back off park brake adjustment on handle. NO: Brakes are OK. Continue
4. Check brakes for dragging. with this procedure.
Are the brakes dragging?

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Operational Checkout Operational Diagnostic Procedures

CHECK PROCEDURE ACTION

Continue: YES: Axle is OK. Adjust park


Manually turn one tire by hand. brake back to correct setting.
Go to next check.
Does the tire turn with moderate force and does
the other tire turn in the opposite direction? NO: For 1.0-3.5 Ton Cush-
ion and Pneumatic Trucks,
see Brake System 1800 SRM
1135. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks,
see Brake System 1800 SRM
1247. If opposite wheel does
not turn, differential is dam-
aged. If equipped, remove
differential cover and inspect.
For 1.0-2.0 Ton Cushion and
Pneumatic Trucks, see Drive
Axle and Differential As-
sembly Repair 1400 SRM
1206. For 2.0-3.5 Ton Cush-
ion Trucks, see Drive Axle
and Differential Assembly
Repair 1400 SRM 1132. For
2.0-3.5 Ton Pneumatic Trucks,
see Drive Axle and Differ-
ential Assembly Repair,
(Dry Brake) 1400 SRM 1214
or Drive Axle Repair, (Wet
Brake) 1400 SRM 1215. For
6.0-7.0 Ton Cushion Trucks,
see Drive Axle and Differen-
tial Assembly Repair, (Wet
Brake) 1400 SRM 1318. For
6.0-7.0 Ton Pneumatic Trucks,
see Drive Axle and Differen-
tial Assembly Repair, (Wet
Brake) 1400 SRM 1344.

Hydraulic Pump Flow YES: Hydraulic pump output is


Check WARNING OK. Go to next check.
Ensure load is secured so it will not move when NO: If load raises only at
mast is tilted fully forward. increased governed speed,
pump flow is low. Go to
1. Put secured capacity load on forks.
Tests and Adjustments, Hy-
2. With engine running at slow idle, raise forks ap-
draulic Pump Flow Test, Page
proximately 1 m (3 ft) off floor.
9050-40-5.
Does load raise at low idle speed?

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Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Priority Flow Divider NOTE: Observe the movement of lift carriage frame YES: Continue with this proce-
Valve Check (1) during the following two operations: dure.
NO: If no steering, flow divider
spool is stuck. Remove, clean,
and inspect spool. See Main
Control Valve 2000 SRM
1137.

1. With engine running at slow idle, turn steering


wheel to right axle stop and then back to left axle
stop in one continuous cycle while raising lift car-
riage.
Does carriage lift speed decrease while steering?
2. Continue: YES: Flow divider is OK. Go to
3. Release steering wheel. next check.
Does carriage lift speed increase when not steer- NO: Inspect and clean steer-
ing? ing priority flow divider spool.
See Steering Control Unit
(SCU) Repair, Hydraulic Gear
Pump 1900 SRM 1136.

Steering Relief Valve 1. With engine running at slow idle. YES: Relief pressure is OK.
Low Pressure Check 2. Position steer axle wheels straight to start check. Go to next check.
3. Turn steering wheel stop-to-stop in both direc- NO: If steer axle wheels do
tions. not turn stop-to-stop, pressure
Does steer axle wheels turn stop-to-stop without is too low. Adjust steering
stopping? relief pressure. Go to Tests
and Adjustments, Steering Re-
lief Pressure Test and Adjust-
ment, Page 9050-40-14.

Confidential/Proprietary - Do Not Copy or Duplicate 9010-05-13


Operational Checkout Operational Diagnostic Procedures

CHECK PROCEDURE ACTION

Steering Relief Valve 1. With engine running, turn steering wheel to stop, YES: Steering relief valve high
High Pressure Check then jerk wheel against the stop and continue to pressure setting is OK. Con-
turn with moderate force. tinue with this procedure.
2. Observe reaction of steering wheel as tilt func- NO: If steering wheel does not
tion is held over relief. Repeat several times. jerk and moves faster when tilt
Does steering wheel jerk each time tilt function is is held over relief, relief pres-
held over relief? sure is set too high. Adjust
NOTE: Continue: steering relief pressure. Go to
Tests and Adjustments, Steer-
It is normal for steering wheel to jerk when tilt function ing Relief Pressure Test and
is held over relief because the secondary relief valve Adjustment, Page 9050-40-14.
is set higher than the steering relief.
Does engine rpm drop when tilt function goes YES: Secondary relief is work-
over relief? ing. Go to next check.
NO: Do Tests and Adjust-
ments, Secondary Relief Valve
Test and Adjustment, Page
9050-40-3.

Control Valve Load YES: Repair upper load check


Check Valve (Manual WARNING valves in the function that
Valve) Ensure load is secured so it will not move when moved. See Main Control
mast is tilted fully forward. Valve 2000 SRM 1137.
NO: Load check valves are
1. Put secured capacity load on forks and raise
OK. Go to next check.
forks approximately 1 m (3 ft) and tilt slightly
forward.
2. Stop engine.
3. Move lift lever to raise forks and observe move-
ment.
4. Move tilt lever to tilt back position and observe
movement.
Did the forks drop or tilt forward?

Lift E-Valve Check


Lift Check (E-Valve) NOTE: The air bleed procedure is necessary if the YES: Repeat until the lift con-
carriage moves slightly when the engine is started trol lever functions are operat-
without activating the lift control lever. Cycling of the ing smoothly.
lift control lever is intended to bleed the air from the NO: Lift E-Valves are OK. Go
poppets (internal in the valve). to next check.
1. Activate the lift control lever from neutral to full
and then back to neutral at a rate of one or two
times per second. Repeat until the lift control
lever functions are operating smoothly and there
is no mast movement upon engine start.
Does symptoms still exist?

9010-05-14 Confidential/Proprietary - Do Not Copy or Duplicate


Operational Diagnostic Procedures Operational Checkout

Tilt Function YES: Counterbalance is OK.


Counterbalance Check WARNING Go to next check.
Ensure load is secured so it will not move when NO: Repair counterbalance
mast is tilted fully forward. valve in tilt spool. See Main
Control Valve 2000 SRM
1. Put secured capacity load on forks and raise
1137.
forks approximately 1 m (3 ft).
2. Run engine at low idle speed and tilt load back
to tilt stop.
3. Move tilt lever to tilt forks forward full stroke and
observe speed.
Can tilt speed be controlled?

Lift Drift Check Ensure the following before starting procedure: YES: Go to Tests and Adjust-
• Truck operating on flat surface. ments, Lift Cylinder Leakage
• Hydraulic oil at operating temperature. Test, Page 9050-40-16 to iso-
late if problem is in cylinder or
control valve.
WARNING
NO: Main cylinder drift is OK.
Ensure load is secured so it will not move when Continue with this procedure.
mast is tilted fully forward.

• Secured capacity load on forks.


1. Install angle meter on mast and position mast at
approximately 90 angle to ground.
2. Raise mast until approximately 75 mm (3 in.)
of main lift cylinder rods are exposed on mast.
Record this measurement.
3. Stop engine.
4. After 5 minutes, measure mast main lift cylinder
drop.
Does main lift cylinder rod retract more than
50 mm (2 in.)?
Continue: YES: Go to Tests and Adjust-
5. Raise free lift cylinder approximately 75 mm ments, Lift Cylinder Leakage
(3 in.) and mark cylinder rod to record move- Test, Page 9050-40-16 to iso-
ment. late if problem is in cylinder or
6. After 5 minutes, measure free lift cylinder drop. control valve.
Does free lift drop more than 50 mm (2 in.)? NO: Free lift drift is OK. Go to
next check.

Confidential/Proprietary - Do Not Copy or Duplicate 9010-05-15


Operational Checkout Operational Diagnostic Procedures

CHECK PROCEDURE ACTION

Tilt Function Drift Ensure the following before starting procedure: YES: Go to Tests and Adjust-
Check • Truck operating on flat surface. ments, Tilt Cylinder Leakage
• Hydraulic oil at operating temperature. Test, Page 9050-40-18 to con-
firm if cylinder or control valve
is leaking.
WARNING
NO: Tilt drift is OK. Go to next
Ensure load is secured so it will not move when check.
mast is tilted fully forward.

• Secured capacity load on forks.


1. Raise mast approximately 300 mm (12 in.) off
floor.
2. Install angle meter on mast and position mast at
approximately 90 angle to ground.
3. Stop engine.
4. After 5 minutes, measure mast angle and com-
pare to original reading.
Does mast tilt drift more than 2 degrees in 5 min-
utes?

Mast Cushion Check Ensure the following before starting procedure: YES: Cushion valve is OK. Go
(All Except 2-Stage • Truck operating on flat surface. to next check.
Mast) • Adequate overhead clearance to raise forks to NO: Inspect and clean cushion
maximum height. valve. For 1.0-5.5 Ton Cushion
and Pneumatic Trucks, See
Cylinder Repair 2100 SRM
WARNING
1139. For 6.0-7.0 Ton Cush-
Ensure load is secured so it will not move when ion and Pneumatic Trucks,
mast is tilted fully forward. See Cylinder Repair 2100
• Secured capacity load on forks. SRM 1328.
1. Operate engine at low idle and raise forks to max-
imum height of main lift cylinders.
2. Lower forks as fast as possible and observe
cylinder rod as main lift cylinders reach bottom
of stroke.
Does fork speed slow and does a hissing sound
come from cylinder at bottom of stroke?

Lift/Tilt Mast Ensure the following before starting procedure: YES: Shim lift cylinders. For
Adjustment Check • Truck operating on flat surface. 1.0-3.5 Ton Cushion and
• Adequate overhead clearance to raise forks to Pneumatic Trucks, see Mast
maximum height. Repairs, 2, 3, and 4-Stage
• No load on forks. Masts 4000 SRM 1148. For
4.0-7.0 Ton Cushion and
1. Operate engine at governed speed and raise
Pneumatic Trucks, see Mast
forks to maximum height
Repairs, 2 and 3-Stage
Does the top sections of mast kick to one side at Masts 4000 SRM 1250.
maximum height?
NO: Mast cylinder is adjusted
OK. Continue with this proce-
dure.

9010-05-16 Confidential/Proprietary - Do Not Copy or Duplicate


Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Continue: YES: Shim and adjust mast.


2. Reduce engine speed to low idle. Tilt the mast For 1.0-3.5 Ton Cushion
full forward and then full backward at maximum and Pneumatic Trucks, see
height and observe movement of mast. Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
Does the top sections of mast make noise dur-
1148. For 4.0-7.0 Ton Cush-
ing tilting and show excessive movement of mast
ion and Pneumatic Trucks, see
sections?
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NO: Mast shimming is OK. Go
to next check.

Tilt Racking Check Actuate mast back tilt function until hydraulic valve YES: Tilt stops are adjusted
goes over relief. OK. Go to next check.
Do both sides of mast stop evenly? NO: Adjust tilt stops. See
Mast Adjustment, For 1.0-3.5
Ton Cushion and Pneumatic
Trucks, see Mast Repairs,
2, 3, and 4-Stage Masts
4000 SRM 1148. For 4.0-7.0
Ton Cushion and Pneumatic
Trucks, see Mast Repairs,
2 and 3-Stage Masts 4000
SRM 1250.

Chain and Header Ensure the following before starting procedure: YES: Adjust lift chains. See
Hose Adjustment • Truck operating on flat surface. Lift Chains Adjustment, For
Check • Hydraulic oil at operating temperature. 1.0-3.5 Ton Cushion and
• No load on forks. Pneumatic Trucks, see Mast
1. Install angle meter on mast and position mast at Repairs, 2, 3, and 4-Stage
approximately 90 angle to ground. Masts 4000 SRM 1148. For
2. Raise and lower forks through two complete lift 4.0-7.0 Ton Cushion and
cycles. Pneumatic Trucks, see Mast
3. Lower forks to lowest position. Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NOTE: The correct fork height adjustment is approx-
imately 6 mm (0.25 in.) off floor. NO: Chains are adjusted OK.
Continue with this procedure.
Does the heel of forks touch the floor?
Continue: YES: Adjust header hoses.
4. Look at condition of hoses as they go over See Header Hose Arrange-
sheaves. ment, For 1.0-3.5 Ton Cush-
ion and Pneumatic Trucks,
Are the hoses compressed?
see Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NO: Hose tension is OK. Con-
tinue with this procedure.

Confidential/Proprietary - Do Not Copy or Duplicate 9010-05-17


Operational Checkout Operational Diagnostic Procedures

CHECK PROCEDURE ACTION

Continue: YES: Adjust header hoses.


5. Inspect contact of hoses with any crossmember NO: Hose adjustment is OK.
or load backrest near sheave area. Go to next check.
Are the hoses contacting any crossmember or
the load backrest?

Mast Mounting Check 1. Move mast to lowered position and stop engine. YES: Inspect and repair
2. Inspect the mounting hardware at axle. mast mounting. For 1.0-3.5
3. Push the top of mast by hand while off the lift Ton Cushion and Pneumatic
truck and note any movement of lift truck. Trucks, see Mast Repairs,
NOTE: If the mast mounting is loose, mast will 2, 3, and 4-Stage Masts
move without moving truck frame. 4000 SRM 1148. For 4.0-7.0
Ton Cushion and Pneumatic
Is the mast mounting loose?
Trucks, see Mast Repairs,
2 and 3-Stage Masts 4000
SRM 1250.
NO: Mast mounting is OK. Go
to next check.

Mast Channel Check NOTE: This is a visual check of the mast to deter- YES: Repair mast chan-
mine if parts are worn or out of adjustment. nels. For 1.0-3.5 Ton Cush-
1. Raise mast to full height without load and stop ion and Pneumatic Trucks,
engine. see Mast Repairs, 2, 3, and
2. Inspect outer and inner channels for wear pattern 4-Stage Masts 4000 SRM
and gouging. 1148. For 4.0-7.0 Ton Cush-
3. Move forks to lowered position. ion and Pneumatic Trucks, see
4. Inspect the inner channel wear pattern for wear Mast Repairs, 2 and 3-Stage
or gouging. Masts 4000 SRM 1250.
Do channels show signs of excess wear? NO: Mast wear is OK. Con-
tinue with this procedure.
Continue: YES: Channel spacing is OK.
5. Inspect spacing between channels. Go to next check.
Is the channel spacing even on each side? NO: Adjust or repair mast.
For 1.0-3.5 Ton Cushion
and Pneumatic Trucks, see
Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.

9010-05-18 Confidential/Proprietary - Do Not Copy or Duplicate


Operational Diagnostic Procedures Operational Checkout

CHECK PROCEDURE ACTION

Carriage Adjustment 1. Stop engine and lower forks to approximately YES: Adjust or repair car-
Check 50 mm (2 in.) off ground. riage bearings. For 1.0-3.5
2. Rock the carriage frame side to side. Ton Cushion and Pneumatic
Does carriage move more than 0.5 mm (0.020 in.) Trucks, see Mast Repairs,
at tightest point? 2, 3, and 4-Stage Masts
4000 SRM 1148. For 4.0-7.0
Ton Cushion and Pneumatic
Trucks, see Mast Repairs,
2 and 3-Stage Masts 4000
SRM 1250.
NO: Carriage adjustment is
OK. Go to next check.

Chain Sheave Check 1. Stop engine and lower forks. YES: Chain sheaves are OK.
2. Inspect wear pattern on chain sheaves. Go to next check.
Does sheave show a wear pattern without side NO: Replace chain sheaves.
wear? For 1.0-3.5 Ton Cushion
and Pneumatic Trucks, see
Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.

Carriage Adjustment 1. Lower forks and stop engine. YES: Chains are out of adjust-
Check (Standard and 2. Inspect wear on carriage stop. ment. For 1.0-3.5 Ton Cush-
Integral Side Shift) Does carriage stop show a wear pattern on it? ion and Pneumatic Trucks,
see Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NO: Checks complete.

Confidential/Proprietary - Do Not Copy or Duplicate 9010-05-19