Maintenance Manual

TX180S – 360L
TXH300L, TXH350L, TXH400L
TXB180S – 300L

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 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
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 
Observe The Following Precautions For Maximum Safety Of Machine Operation

1. Only trained
trained and responsib
responsible
le operators
operators shall
shall be permitted
permitted to handle
handle loads with
with this
this truck.
truck.
2. Operat
Operate
e the truck
truck from
from the
the operator’s
operator’s seat
seat only
only. Do not
not allow
allow riders.
riders.
3. Test hydraulic
hydraulic controls
controls for
for proper response
response before
before using
using the machine.
machine.
4. Know your
your load.
load. Do not attem
attempt
pt to lift
lift or transp
transport
ort loads
loads in excess
excess of rated
rated capacity
capacity..
5. When the load obstruct
obstructs
s the view,
view, operate the
the truck in the reverse
reverse range
range (except
(except when climb-
climb-
ing ramps).
6. Do not
not stand
stand or
or work
work under
under an elev
elevate
ated
d load.
load.
7. Tran
ranspo
sport
rt the
the load
load low
low and tilt
tilted
ed back.
back.
8. Av
Avoid
oid sud
sudden
den sto
stops
ps wit
with
h a loa
load.
d.
9. Evenl
Evenly
y distribut
distribute
e the weight of the
the load on both
both forks.
forks.
10. Back down a ramp in excess
excess of 10 percent when loaded.
11. Do not move the truck until the brake pressure reaches a safe
safe operating level.
12. Have defects repaired immediately.
immediately. Do not operate a truck with damaged or defective
systems.
13. When leaving truck, lifting
lifting mechanism shall be fully lowered,
lowered, controls shall be neutralized,
parking brake set, power shut off,
off, and key removed.
removed. Block wheels if on incline.

TX / TXH / TXB 180S - 400L (4/07)

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 LIMITED WA
WARRANTY
RRANTY

Products manufactured by Taylor Machine Works, Inc. (“Taylor”) and sold are warranted by Taylor to be free from
defects in material and workmanship, under normal use and service, when Taylor
Taylor products are operated at or
below rated capacity* in accordance with operating
operating instructions.
This warranty is limited to repair 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 whichever
occurs first of the warranty period, twelve (12) months or two thousand (2000) hours. During this period, TaylorTaylor
will provide genuine Taylor parts, labor, and travel time to replace or repair any part furnished by Taylor and found
to be defective in material and workmanship.**
workmanship.** If a defect in material and workmanship
workmanship is found during the twelve
(12) months and/or two thousand (2000) hours whichever occurs first of the warranty period, TaylorTaylor will replace
lubricating oil, filters, antifreeze,
antifreeze, and other service items made unusable by the defect. Only genuine Taylor
Taylor parts
provided by Taylor’s
Taylor’s Sudden Service, Inc. will be used during the warranty period.

THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY:

1. Norma
Normall maintenance
maintenance services
services and parts
parts or supplies used
used therein including
including,, without limitati
limitation,
on, en-
gine tune-up, wheel alignment, brake and linkage adjustment, lubrication services, tightening and
adjusting such as bolts, screws, hoses, fittings, etc., replacement of fuses, bulbs, filters, tune-up
parts, fluids and brake and clutch linings, glass; shop supplies such as rags, 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 and electronic components including wiring will be excluded after
the first six (6) months or one thousand (1000) hours of operation. Electronic control modules
(ECM’s) for the engine and transmission, and Taylor
Taylor Integrated Control System
S ystem (TICS) modules
are not included in this exclusion and are covered under the standard warranty period.

2. Leaks due
due to o-ring
o-ring failures
failures and fittin
fittings
gs after
after one hundred
hundred (100)
(100) hours
hours of operati
operation.
on.
3. Norma
Normall deterioratio
deterioration
n of appearance
appearance due to useuse and exposure;
exposure; or conditi
conditions
ons resulting
resulting from
from mis-
use, negligence, or accident.
4. Any product
product on which any
any of the required
required or recomm
recommended
ended periodic
periodic inspectio
inspections
ns or services
services have
not been made.
5. Any parts
parts or accessories,
accessories, installe
installed
d on the product
product which were
were not manufactu
manufactured
red or installed
installed by
Taylor whether or not such parts or accessories were selected, recommended or installed by Tay-
lor (including without limitation, engines, tires,
tires, batteries, air conditioners, air dryers, etc.). Such
parts or accessories shall be covered by the warranties given by the manufacturers thereof and
any claim thereof shall be made to such manufacturers.
6. Loss of time,
time, inconvenienc
inconvenience,e, loss of equipment
equipment use,
use, other
other consequentia
consequentiall damages or other
other mat-
mat-
ters not specifically included.
Taylor parts and assemblies which are furnished and installed under this warranty are themselves within
the coverage
warranty of the machine warranty and are covered only for the duration of the original machine
period.
NOTE: All International warranty
warranty parts shipments are
are F.O.B.
F.O.B. point of debarkation,
debarkation, duties, tariffs,
tariffs, or local
taxes excluded.
This warranty is expressly in lieu of any other warranties, expressed or implied, including any warranty of
merchantability or fitness for a particular purpose.
Replacement parts are warranted
warranted for ninety (90) days to be free from defects in material or workmanship.
workmanship. Parts
only, no labor.
Taylor Machine Works, Inc. does not authorize any person to create (for Taylor) any other obligation or liability in
connection with Taylor products.
*For example, a machine rated capacity at any stipulated load
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 TaylorTaylor
products to conditions or loads exceeding those stipulated is justification for immediate cancellation
cancellation of
warranty for products involved.
**Travel
**Travel reimbursement
reimbursement will be limited to six (6) hours maximum
maximum paid
paid per claim, or to the nearest
nearest Taylor
Taylor
Machine Works’ dealer location in the assigned territory in which the truck is based.

TAYLOR MACHINE WORKS, INC.

650 North Church Avenue
Louisville, Mississippi 39339
(662) 773-3421 / Fax 662-773-9146
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 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 component or system. This method of presenting
pre senting
the maintenance instructions enables Taylor Machine Works, Inc. to assemble a maintenance manual with
explicit instructions on the exact equipment installed on the machine.
No single rule in the booklet can be followed to the
the exclusion of others. Each rule must be considered
considered in
light of the other rules, the knowledge and training of the man (operator), the limitations of the machine,
and the workplace environment.
Warnings and cautions are included to reduce the probability of personal injury, when performing mainte-
nance procedures which if improperly performed could be potentially hazardous. Failure to comply with
these warnings and cautions can result in serious injury and possible death.
All circumstances and conditions under which service will be performed cannot be anticipated. Do not
perform any service if you are unsure that it can be done safely. Contact your Taylor
Taylor Dealer or Taylor
Taylor
Machine Works, Inc. if you have questions about the proper service techniques.

 Operating this powered industrial truck when it is in need of repair can result in
death or serious injury to the operator or other personnel or cause severe property damage.

Machine checks must be performed daily:

1. before the machine is placed in service,
2. by qualified,
qualified, trained
trained,, and skilled
skilled personnel
personnel who
who have proper
proper tools and knowledge,
knowledge, and
and
3. in accordanc
accordance
e with the Operator’
Operator’s
s Guide,
Guide, Maintenanc
Maintenance
e Manual
Manual and Safety Check 2nd Edition booklet.

Maintenance Manual

Operators Guide

! .
! .

Regularly Scheduled maintenance, lubrication, and safety inspections will help ensure a safe and
productive work life for the machine and the operator(s).

 Do not operate the truck if it is in

in need of repair.
repair. Remove the ignition key and
attach a “Lock-out” tag.

 Do not attempt to perform maintenance procedures unless you have been
thoroughly trained and you have the proper tools.

TX / TXH / TXB 180S - 400L (4/07) Intro-1

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  Use only genuine Taylor
Taylor replacement parts. Lesser quality parts may fail,
resulting in property damage, personal injury or death.

Maintenance and / or service personnel who find it necessary to operate this machine, even for a short
period of time, must fully understand all operational literature including:
• OSHA operating rules found in 29 CFR 1910.178; Appendix A in Safety Check 2nd Edition
• ANSI B56.1 rules for operating a powered industrial truck; Appendix B in Safety Check 2nd Edition

• The Operator’s Guide for the machine

• The manufacturer’s Safety Booklet

• The manufacturer’s Safety Video

• The manufacturer’s Service Bulletins

• The content and meaning of all machine decals


Fall Accidents Know of
Section how to avoid
Safety slip
Check and
2nd fall accidents such as those described in the Slip and
Edition.

Intro-2 TX / TXH / TXB 180S - 400L (4/07)

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 Safety

Safety First

Important Safety Instructions Some of the common ways this can occur are as
Observe these rules. They are recognized as follows:
practices that reduce the risk of injury to yourself 1. Use of hois
hoistin
ting
g device
devices
s not
not capab
capable
le of
and others, or damage to the lift truck or load. supporting the weight of the component being
This manual contains maintenance and service lifted.
procedures for filling, lubricating, removing, repair- 2. Improp
Imp roper
er attac
attachme
hmentnt of slin
slings
gs to heav
heavy y
ing, and installing various components comprising components being hoisted.
a heavy duty industrial lift truck.
truck. Because of the 3. Use of of inadeq
inadequat
uatee or rotten
rotten timb
timbers
ers for
for sup-
sup-
size and weight of the lift truck, and high pres- port, or improper alignment of supporting
sures in some of the components and systems, material.
improperly performing service on the truck can be
dangerous. 4. Failur
Fai lure
e to secure
securely
ly block
block the
the wheels,
wheels, when
when dis-
dis-
connecting or removing components that hold
Warnings and cautions are included to reduce the the lift truck stationary under normal
probability of personal injury, when performing conditions.
maintenance procedures which if improperly per- 5. Failur
Fai lure
e to read
read and under
understa
stand
nd the safe
safety
ty
formed could be potentially hazardous. Failure to precautions in this manual.
comply with these warnings and cautions can
result in serious injury and possible death.
No single rule in the booklet can be followed to  Know how to avoid accidents
such as those described in the Maintenance /
the exclusion of others. Each rule must be con- Service Accidents Section of Safety Check 2nd
sidered in light of the other rules, the knowledge Edition:
and training of the man (operator / maintenance),
the limitations of the machine, and the workplace Some Maintenance / Servicing Accidents
environment. Listed below:
Report all mechanical problems to mechanics and 1. Imp
Improp
roperl
erly
y refu
refueli
eling
ng the
the truc
truck.
k.
supervisors. 2. Impro
Improperly
perly check
checking
ing for
for hydrauli
hydraulicc leaks
leaks or fuel
fuel
Proper Training: leaks (gasoline, L.P. gas, or diesel).
3. Imp
Improp
roperl
erly
y checki
checkingng the
the engine
engine cooli
cooling
ng
Taylor Machine Works, Inc. publishes Safety system.
Check 2nd Edition, TMW-072 a booklet citing
some safety precautions to observe during lift 4. Imp
Improp
roperl
erly
y checkin
checking g battery
battery fluid
fluid level
levels
s or
truck operation. One copy is shipped with each lift “jump” starting engines.

truck; additional copies are available at a nominal 5. Puttin

Put
bly ting
g air in
without a mult
propermulti-p
i-piec
iece
tools e tire
and and rim asse
and
training. assem-
m-
fee from the authorized Taylor dealer from which
the equipment was initially purchased. 6. Attem
Attempting
pting to service
service a multi-pi
multi-piece
ece tire and rim
rim
Minimum Required Personnel Safety assembly without proper tools and training.
Equipment 7. Usi
Using
ng an impr
impropeoperly
rly suit
suited
ed chain
chain whil
while
e
performing maintenance.
1. Hard Hat
8. Using the liftlift truck
truck hydrau
hydrauliclic system
system as a sub-
2. Sa
Safe
fetty Sh
Shoe
oess stitute for a fixed stand.
3. Sa
Safe
fetty Glas
Glassses 9. Rel
Relyin
yingg on jacks
jacks or hois
hoists
ts to suppo
support
rt heavy
heavy
4. He
Heav
avy y Gl
Glov
oves
es loads.
5. He
Hear
arin
ing
g Prote
Protect
ctio
ion
n 10. Operating a truck that is damaged or in need
6. Re
Refl
flec
ecti
tive
ve Cl
Clot
othin
hingg of repair.
Failure to follow the safety precautions outlined in 11. Climbing on the mast mast of a fork lift, on the top
top of
this manual can create a dangerous situation. the cab, or other high places on the lift truck.

TX / TXH / TXB 180S - 400L (4/07) Safety-1

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12. Operating a lift truck which has been modified ing of the engine. Refer to Lock-Out / Tag-Out
without the manufacturer’s approval. This Procedure in the back of this section for the pro-
includes the attachment, counterweight, tires, cedures to be followed to perform lock-out / tag-
etc. out.
13. Lifting people with a fork lift not properly
equipped for elevating personnel.  Do not start the engine if the
14. Improper maintenance of lift chains. ignition switch, or engine control panel has
15. Improperly blocking and supporting mast, been locked-out / tagged-out by maintenance
carriage, or attachment before repairing truck. personnel. Doing so can result in personal
injury and / or damage to the equipment. If in
16. Working in an area not properly vented for
doubt, contact the maintenance supervisor.
supervisor.
toxic exhaust fumes.
Maintenance / Service Personnel: TICS Emergency Stop. The TICS emergency
stop must be pulled to the out position to enable
1. Keep the
the truck
truck clea
clean,
n, free
free of oil,
oil, greas
grease,
e, and
and the TICS controlled hydraulic functions of the
fuel. truck. Should a TICS controlled
controlled operation occur
2. Steam clean / wash
wash the
the truck
truck prior to perform
perform-- without an operator command, depress the TICS
ing maintenance.
maintenance. Wear anti-slip footwear
footwear emergency stop to disable thethe function. The TICS
when performing maintenance procedures. controlled functions that are disabled by the TICS
3. Use OSHA
OSHA appr
approve
ovedd ladder
ladderss and othe
otherr proper
proper emergency stop include mast, carriage and at-
cleaning accessories to access hard to reach tachment functions.
functions. Shut down the truck as soon
maintenance places. as
nel itimmediately.
is safe to do
immediately so. not
. Do Notify maintenance
return the truck toperson-
service
4. Keep grat
grating
ingss free
free of ice,
ice, dirt,
dirt, and
and gravel
gravel..
until all faults have been corrected.
5. Regula
Regularly
rly inspe
inspect
ct and replac
replacee anti-sl
anti-slip
ip mastic
mastic
on the vehicle as needed.
6. Ens
Ensure
ure all
all safety
safety deca
decalsls are
are in place
place onon the  When the TICS emergency
vehicle. stop is depressed, the TICS display and for-
ward and back-up alarms are disabled. Addi-
Mounting and Dismounting: tionally, the parking brake will be automatically
1. Face the
the lift
lift truck
truck when
when getting
getting on or off the lift
lift applied.
truck.
2. One hand
hand andand twotwo feet
feet or two han
hands
ds and
and one
one 
 
 




  
 

 


foot must be in contact with the lift truck at all 
  

 




 

  

 



 
times (3 point contact).  

  


  
  



 
3. Use hand
handrai
railsls and
and other
other grab
grab point
points.
s. 

 Serious falls and injuries can  

   

 


result from improper mounting or dismounting 
 

 



 

 


 

 


of the lift truck. 
 


 

 


  

 




 


  


 



 

  

 
 


 Serious falls or injuries can
result from being thrown from the lift truck! Proper Training:
Never allow riders on the lift truck or load.
1. Taylor Machi
Machinene Works,
Works, Inc. publis
publishes
hes Safety
Safety
Check 2nd Edition, TMW-072 a booklet citing
Lift Truck Lock-out / Tag-out: some safety precautions to observe during lift
The engine should be locked-out / tagged-out to truck operation. One copy is shipped with
prevent it from being inadvertently started before each lift truck; additional copies are available
performing maintenance
maintenance or repairs. The battery at a nominal fee from the authorized Taylor
should be locked-out / tagged-out to prevent acci- dealer from which the equipment was initially
dental activation of the starter and possible start- purchased.

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 these devices inoperable. If you discover that
 Remove all rings, watches, any safety device is malfunctioning, Do Not
chains, other jewelry, and all loose clothing operate the lift truck; notify appropriate main-
before working around moving parts! tenance personnel immediately.
immediately.

 If maintenance requires run-  Operating instructions,

ning the engine indoors, ensure the room has warnings, and caution labels are placed on the
adequate flow-through ventilation! lift truck to alert personnel to dangers and to
advise personnel of proper operating proce-
dures (of the lift truck). Do not remove
remove or
 Do not operate the vehicle or obscure any warning, caution, danger, or
attempt to perform maintenance on the vehicle instructional sign or label.
while under the influence of alcohol, drugs, or
any other medications or substances that slow
reflexes, alter safe judgement, or cause drows-  Keep all hydraulic com-
iness. ponents in good repair.

 Never operate the lift truck  Relieve pressure on

without proper
proper instruction.
instruction. Ignorance of hydraulic system before repairing or adjusting
operational characteristics and limitations can or disconnecting.
lead to equipment damage, personal injury, or
death.
 Wear proper hand and eye
protection when searching for leaks. Use
 Maintenance and service wood or cardboard instead of hands.
personnel should never operate this lift truck
unless they are thoroughly familiar with Safety
Check 2nd Edition, TMW-072 and the Opera-  Turn the engine off and
tors’ Guide for this lift truck. remove the ignition key before entering the tire
pivot area to prevent death or serious injury
from pivoting tires.
 This equipment is not electri-
cally insulated.
insulated. Contact with electricity can
cause severe injury or death. Electrocution  Deflate tires before removing
can occur without
without direct contact. Do not oper-
oper- them. Always remove
remove the valve core and
ate this lift truck in areas with energized power exhaust all air from a single tire and both tires
lines or a power
power supply.
supply. Check local, state of a dual assembly prior to removing any rim
and federal safety codes for proper clearance. components or wheel components such as
Use a groundman to ensure that there is prop- nuts and rim
rim clamps. Run a piece
piece of wire
er clearance. through the valve stem to make sure the valve
stem is not damaged or plugged and all air is
exhausted.
 Use only genuine Taylor
replacement parts.
parts. Lesser quality parts may
fail resulting in property damage, personal  Never park the lift truck on
injury, or death. an incline. Always park the lift
lift truck on a level
surface; otherwise, the lift truck could possibly
roll resulting in possible injury to personnel or
 Electrical, mechanical, and damage to the lift truck or other property.
property.
hydraulic safety devices have been installed
on this lift truck to help protect against person- Battery Safety:
al injury and / or damage to equipment. Under
no circumstances should any attempt be made
to disconnect or in any way render any of 
flames, Lighted
arcs, or sparks smoking
may materials,
result in battery

TX / TXH / TXB 180S - 400L (4/07) Safety-3

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explosion. Stored energy, such as that in capacitors,
1. Keep all meta
metall tools
tools away
away from
from batter
battery
y termi-
termi- springs, elevated crane members, rotating fly-
nals. wheels, hydraulic systems, and air, gas,
steam, or water pressure, etc. must also be
2. Batter
Batteries
ies conta
containin sulfur
sulfuric
ic acid
acid which will burn dissipated or restrained by methods such as
skin on contact; wear rubber gloves and eye grounding, repositioning, blocking, bleeding-

3. protection
Flush
Flu eyeswhen
sh eyes working
or wash
wash with
skin with
skin w batteries.
ith wate
w aterr and seek
seek down, etc.
4. Lock-out
Lock-out / tag-ou
tag-outt the
the energy
energy isolat
isolating
ing devic
devices
es
medical attention immediately in case of with an assigned individual lock / tag.
contact.
5. Aft
After
er ensur
ensuring
ing that
that no
no personn
personnel
el are expo
exposed
sed
4. Wh
Whenen ju
jump
mp st
star
arti
ting:
ng: and as a check on having disconnected the
a. Do not
not lean
lean over
over the bat
batter
tery
y while
while makin
makingg energy sources, operate the push button or
connection. other normal operating controls to make cer-
b. The
Then,n, conne
connectct the
the negativ
negativee (-) termi
terminal
nal of tain the equipment will not operate.
the booster battery to the engine or body
ground (-). Never Cross Polarity of
Terminals.  Return operating controls to
neutral after the test.
c. Dis
Discon
connec
nectt cables
cables in exact
exact rever
reversese order
order..
6. The equip
equipmen
mentt is now
now locked
locked out
out / tagged
tagged out.
out.
Lock-Out / Tag-Out Procedure
Restoring Equipment to Service
Purpose. This procedure establishes the mini-
mum requirements for lock-out / tag-out of energy 1. When
When the jobjob is com
complet
pletee and equi
equipme
pmentnt is
sources that could cause injury to personnel. All ready for testing or normal service, check the
employees shall comply with the procedure. equipment area to see that no one is exposed.
Responsibility. The responsibility
responsibility for seeing that 2. When equipme
equipment nt is all clear
clear,, remove
remove all
all locks
locks /
this procedure is followed is binding upon all tags. The energy isolating devices may be
employees. All employees shall be instructed in operated to restore energy to equipment.
the safety significance of the lock-out / tag-out Procedure Involving More Than One Person.
procedure by (designate individual). Each new or In the preceding steps, if more than one individual
transferred affected employee shall be instructed is required to lock-out / tag-out equipment, each
by (designate individuals) in the purpose and use shall place his own personal lock / tag on the
of the lock-out / tag-out procedure. energy isolating device(s). One designated indi-
Preparation for Lock-Out / Tag-Out. Employees vidual of a work crew or a supervisor, with the
authorized to perform lockout / tagout shall be cer- knowledge of the crew, may lock-out / tag-out
tain as to which switch, valve, or other energy iso- equipment for the whole crew.
crew. In such cases, it
lating devices apply to the equipment being shall
out allbesteps
the responsibility
of the lock-out of/the individual
tag-out to carry
procedure
locked out / tagged out.
out. More than one energy
source (electrical, mechanical, or others) may be and inform the crew when it is safe to work on the
involved. Any questionable identification
identification of equipment. Additionally
Additionally,, the designated individual
individual
sources shall be cleared by the employees with shall not remove a crew lock / tag until it has been
their supervisors. Before lock-out / tag-out com- verified that all individuals are clear.
mences, job authorization should be obtained. Rules for Using Lock-Out / Tag-Out Procedure.
Sequence of Lock-Out / Tag Tag-Out
-Out Procedure All equipment shall be locked out / tagged out to
protect against accidental or inadvertent operation
1. Notif
Notifyy all
all affect
affected
ed employees
employees that a lock-out
lock-out / when such operation could cause injury to person-
tag-out is required and the reason therefor. nel. Do not attempt to operate any switch, valve,
2. If the
the equipm
equipment ent is
is operat
operating
ing,, shut
shut it down
down by or other energy isolating device bearing a lock /
the normal stopping procedure. tag.
3. Operat
Operate e the
the switch,
switch, valve
valve,, or other energy iso-
lating device so that the energy source(s)
(electrical, mechanical, hydraulic, etc.) is dis-
connected or isolated from the equipment.

Safety-4 TX / TXH / TXB 180S - 400L (4/07)

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 Major Components Locations

TILT CYINDERS RADIATOR

(Section 22) (Section 5)

STEER AXLE
(Section 13)

MAST
(Section 27)

HYDRAULIC TANK
(Section 22)

CARRIAGE
(Section 28)

ENGINE
(Section 1)

DRIVE AXLE
(Section 14) TRANSMISSION
(Section 9)

FUEL TANK
(Section 2)

DRIVE SHAFT
(Section 11)

TX / TXH / TXB 180S - 400L (4/07)

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1-2 https://www.forkliftpdfmanuals.com/ (Rev. 11/94)
 Contents

Maintenance Manual

Section

Introduction

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Closed Circuit TV Cameras and Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Transmission Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A

Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C

Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Brake Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Wet Disc Brakes Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15C

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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https://www.forkliftpdfmanuals.com/
Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20A

Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20H

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22E

Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Appendices

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https://www.forkliftpdfmanuals.com/
 Section 1

Engine

FILLER
CAP

DRAIN
PLUG
OIL OIL
FILTER DIPSTICK

Illustration 1-1. Cummins QSB6.7 Engine Service Points

Introduction. The Cummins

Cummins QSB6.7 engine is Changing The Oil and Filter Element (Illustration
pressure lubricated. Oil pressure is supplied by a 1-1).. The engine lubricating oil and filter should
1-1)
gear-type lubricating oil pump and controlled by a be replaced periodically (refer to the Preventive
pressure regulator. The filter bypass valve ensur- Maintenance chart in the Appendices for oil and
es that a supply of oil, in the event the filter filter replacement interval). The oil filter should be
becomes plugged, is present. One full flow oil replaced each time the engine oil is changed.
filter is incorporated in the lubricating system to Refer to the Fuel and Lubricant Specifications
provide maximum cleansing and filtration of the chart in the Appendices for the proper grade of
engine lubricating oil. oil to use. Perform the following procedures to
replace the oil and filter:
Checking The Lubricating Oil (Illustration 1-1).
1-1).
The engine lubricating oil should be checked daily
on
thethe oil dipstick
proper amounttoofensure that the engine has
oil for operation. 
engine equipped Do not
with anuse etherheater
electric to start an

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-1
starting aid. Use of ether to start an engine 5. Clean
Clean the area
area of the
the filter
filter base
base that
that will
will con-
con-
equipped with an electric heater starting aid tact the gasket on the new oil filter.
may cause explosion and severe injury.
6. Fill the new filter
filter with clean engine oil before
before
installation.
 Death or serious injury could 7. Appl
Apply
y a light
light film
film of engi
engine
ne oil
oil on the
the gasket
gasket of
of
result
a hard,from
levela surface,
runawayapply
truck.the
Park the truck
parking on
brake, the new filter.
filter. Screw the new filter
filter onto the
filter base until the gasket comes in contact
block the wheels in both directions to prevent with the filter base and then tighten filter 1/2 to
movement of the truck and Lock Out O ut & Tag Out 3/4 turn by hand only.
the truck.
8. Remove
Remove the the oil fill
fill cap
cap and fill
fill crank
crankcas
case
e with
with
oil to the FULL mark on the oil dipstick (see
 Severe injury may occur from Illustration 1-1).
burns. Avoid touching exhaust components
while changing the oil. 9. Start
Start the
the engi
engine
ne and
and allo
allow
w to
to idle.
idle. Vi
Visua
sually
lly
check the drain plug and oil filter for leaks.

 Some state and federal 10. Shut down the the engine and wait approximately
agencies in the United States have determined 10 minutes for the oil to drain back into the oil
that used engine oil can be carcinogenic and pan. When the engine has cooled, recheck
can cause reproductive toxicity.
toxicity. Avoid inhala- the oil level and add oil as necessary to bring
the oil level to the FULL mark on the oil dip-
tion of vapors,
contact ingestion
with used engineand
oil. prolonged stick.
Drive Belts (Illustration 1-2).
1-2). Visually inspect the
drive belt daily.
daily. Check the belt for intersecting
 Dispose of oil and filter in
cracks. Transverse cracks (across the belt width)
accordance with federal and local regulations. are acceptable. Longitudinal cracks (direction of
belt length) that intersect with transverse cracks
 Do not use a strap wrench to are not acceptable. Replace the drive belt if belt
tighten the oil filter.
filter. Mechanical over-tight- is frayed or has pieces of material missing. Adjust
ening may distort the threads or damage the drive belts that have a glazed or shiny surface
filter gasket. which indicates belt slippage. Correctly installed
installed
and tensioned drive belts will show even pulley
and belt wear.
wear. After installation of a new drive
 Never operate the engine with belt, check the tension and adjust if necessary.
the oil level below the ADD mark or above the
FULL mark on the oil dipstick. NOTE: Ensure each rib of the drive belt is proper-
ly aligned in the corresponding grooves of each
1. The engin
engine
e should
should be atat operati
operating
ng temper
tempera-
a- pulley or damage to the belt will occur.
ture before the oil is changed.
changed .
2. Place
Place a suitable
suitable cont
contain
ainer
er under
under the drai
drain
n plug Drive belt damage can be caused by:
of the oil pan. Remove the drain plug (or open  Incorrect tension
drain valve if equipped) to drain the oil.  Incorrect size or length
3. When the oil has
has comple
completely
tely draine
drained,
d, re-inst
re-install
all  Pulley misalignment
the O-ring and drain plug (or close drain valve
 Incorrect installation
if equipped) on the Cummins engine and apply
a torque value of 59 ft-lbs (80 N ⋅m) to tighten  Severe operating environment
the drain plug.  Oil or grease on the belts

4. Unscrew
Unscrew the spin-o spin-off
ff type oil filter
filter (see Illus
Illustra-
tra- Drive Belt Tension. Proper drive belt tension is
tion 1-1). It should be possible to unscrew the automatically maintained by a belt tensioner
oil filter by hand; however, a band type filter supplied with the engine. Refer to the engine
wrench may be used if necessary.necessary. Discard the
used oil filter
filter..

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
manufacturer’s operation and maintenance standards shown. The proper settings are perma-
manual. nently stamped on a metal tag affixed to the
engine.
Air Conditioning Drive Belt Tension (if equipped
conditioning). Tension on the air condi-
with air conditioning). Engine Repair. If repair of the engine is needed,
tioning drive belt should be such that a firm push contact a Taylor
Taylor Machine Works, Inc. authorized
with the thumb at a point midway between the two
pulleys will deflect the belt about 3/8 to 1/2 inch dealer for service.
(9.5 to 12.7 mm). If the deflection
deflection measured is
greater than the amount specified above, the drive
belt must be replaced.
OEM (TAYLOR)
Checking Engine Mounting Bolts. The engine PLUG
mounting bolts should be checked for the
appropriate torque every 6 months or 1,500 hours,
whichever comes first. If a locknut
locknut requires retor-
quing, remove and clean the bolt and locknut. CUMMINS
Apply Loctite to the threads of the bolt, and PLUG
re-install the bolt and locknut. Torque the locknuts
on the Cummins engine mounting bolts to 200 -
220 ft-lbs (270 - 300 N ⋅m). Inspect the rubber
mounts for deterioration and age hardening. OEM (TAYLOR)
PLUG
Replace any broken or lost bolts and damaged
rubber mounts.
Illustration 1-3. ECM Plugs

Illustration 1-2. Drive Belt Inspection

Inspection

Cummins QSB6.7 Engine General Information

30 - 55 psi
Oil Pressure
(210 - 280 kPa)
Oil Capacity 15 Quarts
(includes filter change) (14.2 Liters)
Low RPMs (no load) 750 rpm

NOTE: Some special applications may use

engine speed settings that are different from the

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-3
 Illustration 1-4. Engine Diagnostics Icons

Calibration Of Electronic Accelerator Pedal To on the Engine Information Screen, are used to
ECM Of Engine. The Cummins QSB6.7 engine alert the operator of engine related problems.
uses an electronic accelerator to control engine Each diagnostic icon’s function is described as
speed. Each time the accelerator pedal is follows:
changed, disconnected and the ignition switch is
1. Yellow Icon (System Fault).
Fault). This icon will be
turned on, or ECM (Electronic Control Module) is
displayed during a non-fatal system error. The
changed out, the accelerator pedal must be cali-
engine can still be run, but the fault should be
brated to the ECM. Calibration procedures are as
corrected as soon as possible.
follows:
1. Apply
Apply the park
parking
ing brak
brake,
e, place
place the
the shift
shifter
er in NOTE: In the diagnostic mode, the yellow icon
neutral, and turn the ignition switch to the Igni- will flash after the red icon completes the three-
tion position (first click). digit fault code.

2. Cycle the accel

accelerator
erator pedal throu
through
gh its
its full 2. Red Icon (Engine Shutting Down).
Down). This icon
range of travel three times. will be displayed when the engine needs to be
shut off before permanent damage occurs to
3. Turn
Turn the ignit
ignition
ion switch
switch to the
the Off positi
position
on for
for the engine. Should the red icon be displayed
at least 30 seconds. while operating, the fault can be engine disab-
Engine Fault Code Warning Box (Illustration ling after approximately 32 seconds. Should
1-5).. An engine fault code warning box will be dis-
1-5) the engine shut down due to the severity of
played on the Engine Information screen when an the fault, it can be restarted and will run for
engine fault code is active. This warning box dis- approximately 32 seconds. The engine will
plays the number of the active fault code. To clear run for approximately 32 seconds each time it
the warning box after recording the fault code is restarted. There are no limits on the num-
number, depress the F2 (OK) button. Once the ber of times the engine may be restarted.
warning box has been cleared, the fault code will NOTES:
have to be flashed out in the Diagnostic Mode if it  The engine should be shut off as soon as it
was not recorded (refer to Diagnostic Fault safely.. The engine should not
can be shut off safely
Codes).
Codes ). be run until the fault is corrected.
Engine Diagnostic Icons (Illustration 1-4).
1-4). The  This icon is also used to flash out the fault
engine diagnostic icons, displayed by the Taylor code number in the diagnostic mode.
Integrated Control System (TICS) display module

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Illustration 1-5. Engine Fault Code Dialog Screen

Diagnostic Fault Codes (Illustration 1-4).

1-4). If the the Diagnostic Mode Status to the On position.
red icon (Engine Shutting Down) or yellow icon
5. If no acti
active
ve fault
fault code
codess are reco
recorde
rded,
d, the
the
(System Fault) is displayed on the Engine Infor-
yellow icon (System Fault) and red icon
mation Screen of the TICS Display Module when
(Engine Shutting Down) will illuminate and
the engine is running, it means a fault code has
stay on. If active fault
fault codes are recorded, the
been recorded. The icon will
will remain on as long as
yellow icon and red icon will illuminate momen-
the fault exists. The severity of the fault will deter-
tarily, and then the red icon will begin to flash
mine the icon that will be displayed. Only active
the three-digit code of the recorded fault(s).
fault codes can be viewed by use of the diagnostic
icons. To view inactive fault codes, a laptop com- 6. The faul
faultt code
code will
will flash
flash in the
the follo
followin
wing
g
puter equipped with Cummins Insite software is sequence:
required.
a. First,
First, the
the yellow
yellow icon
icon will
will flash
flash beginn
beginning
ing
To view active fault codes, perform the follow- the sequence. There will be a short 1 or 2
ing: second pause after which the red icon will
flash the first, second, and third digits of
1. Leave
Lea
key ve theaccessory
the
in its engine runni
engine running
ng or to
position haview
have
ve the
ththe
e ignitio
ignition
TICS n the recorded fault
fault code. There will be a 1
or 2 second pause between each number
display module screen.
of the code.
code. When all three digits of the
2. At the
the main
main screen
screen of
of the TICS
TICS disp
display
lay mod-
mod- fault code have flashed, the yellow icon will
ule, depress the F1 button (Diagnostics) to illuminate again and repeat the sequence
view the Diagnostics Select screen. until the fault is cleared or the Diagnostic
Mode Status is toggled to the OFF posi-
NOTE: If a diagnostics selection
selection button is not tion.
depressed within 5 seconds while the Diagnostics
Example:
Select screen is displayed, the TICS display will
automatically return to the Main Display screen. Fault Code 432
4 flashes, pause
3. At the
the Diagnos
Diagnostics
tics Selec
Selectt screen,
screen, depres
depress
s the
the 3 flashes, pause
F1 button (Engine) to view the Engine Infor- 2 flashes
mation screen. b. If mult
multipl
iple
e fault
fault codes
codes have
have been
been stor
stored,
ed,
4. At the Engin
Engine
e Inform
Informati
ation
on scree
screen,
n, depres
depress
s the the first
the secondfaultfault
code must
code bebe
can cleared before
displayed.
F2 button (Diagnostic Mode Select) to change

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-5
Cummins QSB6.7 Engine Fault Code Information
Fault Code - Light Failure Description Cause
111 - Red Engine Control Module Critical internal failure Bad intelligent Device or Component
115 - Red Engine Speed/Position Sensor Circuit lost both Data Erratic, Intermittent, or incorrect
of two signals from the magnetic pickup
sensor
122 - Yellow Intake Manifold Pressure Sensor Circuit Voltage Above Normal, or Shorted to High
Source
123 - Yellow Intake Manifold Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
131 - Red Accelerator Pedal or Lever Position Sensor Voltage Above Normal, or Shorted to High
Circuit Source
132 - Red Accelerator Pedal or Lever Position Sensor Voltage Below Normal, or Shorted to Low
Circuit Source
133 - Red Remote Accelerator Pedal or Lever Position Voltage Above Normal, or Shorted to High
Sensor Circuit Source
134 - Red Remote Accelerator Pedal or Lever Position Voltage Below Normal, or Shorted to Low
Sensor Circuit Source
135 - Yellow Oil Pressure Sensor Circuit Voltage Above Normal, or Shorted to High
Source
141 - Yellow Oil Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
143 - Yellow Oil Pressure Low Data Valid but Below Normal Operational
Range – Moderately Severe Level
144 - Yellow Coolant Temperature Sensor Circuit Voltage Above Normal, or Shorted to High
Source
145 - Yellow Coolant Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
146 - Yellow Coolant Temperature High Data Valid but Above Normal Operational
Range – Moderately Severe Level
147 - Red Accelerator Pedal or Lever Position Sensor Abnormal Frequency,
Frequency, Pulse Width, or Period
Circuit
148 - Red Accelerator Pedal or Lever Position Sensor Abnormal Frequency,
Frequency, Pulse Width, or Period
Circuit
151 - Red Coolant Temperature Low Data Valid but Above Normal Operational
Range – Most Severe Level
153 - Yellow Intake Manifold Air Temperature Sensor Circuit Voltage Above Normal, or Shorted to High
Source
154 - Yellow Intake Manifold Air Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
155 - Red Intake Manifold Air Temperature High Data Valid but Above Normal Operational
Range – Most Severe Level
187 - Yellow Sensor Supply Voltage #2 Circuit Voltage Below Normal, or Shorted to Low
Source
195 - Yellow Coolant Level Sensor Circuit Voltage Above Normal, or Shorted to High
Source
196 - Yellow Coolant Level Sensor Circuit Voltage Below Normal, or Shorted to Low
Source

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Fault Code - Light Failure Description Failure Results
197 - Yellow Coolant Level Data Valid but Below Normal Operational
Range – Moderately Severe Level
211 - None Additional Auxiliary Diagnostic Codes logged Condition Exists
212 - Y
Yellow
ellow Engine Oil Temperature Sensor
Sensor 1 Circuit Voltage
Voltage Above Normal,
Normal, or Shorted
Shorted to High
Source
213 - Yellow Engine Oil Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low
Source
214 - Red Engine Oil Temperature Data Valid but Above Normal Operational
Range – Most Severe Level
221 - Yellow Barometric Pressure Sensor Circuit Voltage Above Normal, or Shorted to High
Source
222 - Yellow Barometric Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
227 - Yellow Sensor Supply Voltage #2 Circuit Voltage Above Normal, or Shorted to High
Source
231 - Yellow Coolant Pressure Sensor Circuit Voltage Above Normal, or Shorted to High
Source
232 - Yellow Coolant Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
233 - Yellow Coolant Pressure Data Valid but Below Normal Operational
Range – Moderately Severe Level
234 - Red Engine Speed High Data Valid but Above Normal Operational
Range – Most Severe Level
235 - Red Coolant Level Low Data Valid but Below Normal Operational
Range – Most Severe Level
237 - Yellow External Speed Input (Multiple Unit Synchro- Data Erratic, Intermittent, or Incorrect
nization)
238 - Yellow Sensor Supply Voltage #3 Circuit Voltage Below Normal, or Shorted to Low
Source
241 - Yellow Vehicle Speed Sensor Circuit Data Erratic,Intermittent, or Incorrect
242 - Yellow Vehicle Speed Sensor Circuit tampering has Abnormal Rate of Change
been detected
245 - Yellow Fan Control Circuit Voltage Below Normal, or Shorted to Low
Source
249 - Yellow Ambient Air Temperature Sensor Circuit Voltage Above Normal, or Shorted to High
Source
256 - Yellow Ambient Air Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
261 - Yellow Engine Fuel Temperature Data Valid but Above Normal Operational
Range – Moderately Severe Level
263 - Yellow Engine Fuel Temperature Sensor 1 Circuit Voltage Above Normal, or Shorted to High
Source
265 - Yellow Engine Fuel Temperature Sensor 1 Circuit Voltage Below Normal, or Shorted to Low
Source
268 - Yellow Fuel Pressure Sensor Circuit Data Erratic, Intermittent, or Incorrect

271 - Yellow High Fuel Pressure Solenoid Valve Circuit Voltage Below Normal, or Shorted to Low
Source

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-7
 Fault Code - Light Failure Description Failure Results
272 - Yellow High Fuel Pressure Solenoid Valve Circuit Voltage Above Normal, or Shorted to High
Source
275 - Yellow Fuel Pumping Element (Front) Mechanical System Not Responding Properly
or Out of Adjustment

281 - Yellow High Fuel Pressure Solenoid Valve #1 Mechanical System Not Responding Properly
or Out of Adjustment
284 - Yellow Engine Speed/Position Sensor (Crankshaft) Voltage Below Normal, or Shorted to Low
Supply Voltage Circuit Source
285 - Yellow SAE J1939 Multiplexing PGN Timeout Error Abnormal Update Rate
286 - Yellow SAE J1939 Multiplexing Configuration Error Out of Calibration
287 - Red SAE J1939 Multiplexing Accelerator Pedal or Received Network Data In Error
Lever Sensor System Error
288 - Red SAE J1939 Multiplexing Remote Accelerator Received Network Data In Error
Pedal or Lever Data Error
293 - Yellow Auxiliary Temperature Sensor Input # 1 Circuit Voltage Above Normal, or Shorted to High
Source
294 - Yellow Auxiliary Te
Temperature Se
Sensor In
Input # 1 Ci
Circuit Voltage Be
Below Normal, or Sh
Shorted to
to Lo
Low
Source
295 - Yellow Barometric Pressure Sensor Circuit Data Erratic, Intermittent, or Incorrect
296 - Red Auxiliary Pressure Sensor Input 1 Special Instructions
297 - Yellow Auxiliary Pressure Sensor Input # 2 Circuit Voltage Above Normal, or Shorted to High
Source
298 - Yellow Auxiliary Pressure Sensor Input # 2 Circuit Voltage Below Normal, or Shorted to Low
Source
319 - Maint Real Time Clock Power Interrupt Data Erratic, Intermittent, or Incorrect
322 - Yellow Injector Solenoid Cylinder #1 Circuit Current Below Normal, or Open Circuit
323 - Yellow Injector Solenoid Cylinder #5 Circuit Current Below Normal, or Open Circuit
324 - Yellow Injector Solenoid Cylinder #3 Circuit Current Below Normal, or Open Circuit
325 - Yellow Injector Solenoid Cylinder #6 Circuit Current Below Normal, or Open Circuit
331 - Yellow Injector Solenoid Cylinder #2 Circuit Current Below Normal, or Open Circuit
332 - Yellow Injector Solenoid Cylinder #4 Circuit Current Below Normal, or Open Circuit
334 - Yellow Coolant Temperature Sensor Circuit Data Erratic, Intermittent, or Incorrect
338 - Yellow Idle Shutdown Vehicle Accessories Relay Voltage Above Normal, or Shorted to High
Driver Circuit Source
339 - Yellow Idle Shutdown Vehicle Accessories Relay Voltage Below Normal, or Shorted to Low
Driver Circuit Source
341 - Yellow Engine Control Module data lost Data Erratic, Intermittent, or Incorrect
342 - Red Electronic Calibration Code Incompatibility Out of Calibration
343 - Yellow Engine Control Module Warning internal hard- Bad Intelligent Device or Component
ware failure
351 - Yellow Injector Power Supply Bad Intelligent Device or Component
352 - Yellow Sensor Supply Voltage #1 Circuit Voltage Below Normal, or Shorted to Low
Source

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Fault Code - Light Failure Description Failure Results
386 - Yellow Sensor Supply Voltage #1 Circuit Voltage Above Normal, or Shorted to High
Source
387 - Yellow Accelerator Pedal or Lever Position Sensor Voltage Above Normal, or Shorted to High
Supply Voltage Circuit Source

415 - Red Oil Pressure Low – Data Valid but Below Most Severe Level
Normal Operational Range
418 - Maint Water in Fuel Indicator High Data Valid but Above Normal Operational
Range – Least Severe Level
422 - Yellow Coolant Level Data Erratic, Intermittent, or Incorrect
425 - Yellow Engine Oil Temperature Data Erratic, Intermittent, or Incorrect
428 - Yellow Water in Fuel Sensor Circuit Voltage Above Normal, or Shorted to High
Source
429 - Yellow Water in Fuel Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
431 - Yellow Accelerator Pedal or Lever Idle Validation Data Erratic, Intermittent, or Incorrect
Circuit
432 - Red Accelerator Pedal or Lever Idle Validation Out of Calibration
Circuit
433 - Yellow Intake Manifold Pressure Sensor Circuit Data Erratic, Intermittent, or Incorrect
434 - Yellow Power Lost without Ignition Off Data Erratic, Intermittent, or Incorrect
435 - Yellow Oil Pressure Sensor Circuit Data Erratic, Intermittent, or Incorrect
441 - Yellow Battery #1 Voltage Low Data Valid but Below Normal Operational
Range – Moderately Severe Level
442 - Yellow Battery #1 Voltage High Data Valid but Above Normal Operational
Range – Moderately Severe Level
443 - Yellow Accelerator Pedal or Lever Position Sensor Voltage Below Normal, or Shorted to Low
Supply Voltage Circuit Source
449 - Red Fuel Pressure High Data Valid but Above Normal Operational
Range – Moderately Severe Level
451 - Yellow Injector Metering Rail #1 Pressure Sensor Voltage Above Normal, or Shorted to High
Circuit Source

452 - Yellow Injector Metering Rail #1 Pressure Sensor Voltage Below Normal, or Shorted to Low
Circuit Source
488 - Yellow Intake Manifold 1 Temperature Data Valid but Above Normal Operational
Range – Moderately Severe Level
497 - Yellow Multiple Unit Synchronization Switch Circuit Data Erratic, Intermittent, or Incorrect
523 - Yellow OEM Intermediate (PTO) Speed switch Data Erratic, Intermittent, or Incorrect
Validation
527 - Yellow Auxiliary Input/Output 2 Circuit Voltage Above Normal, or Shorted to High
Source
528 - Yellow Auxiliary Alternate Torque Validation Switch Data Erratic, Intermittent, or Incorrect
529 - Yellow Auxiliary Input/Output 3 Circuit Voltage Above Normal, or Shorted to High
Source
551 - Yellow Accelerator Pedal or Lever Idle Validation Voltage Below Normal, or Shorted to Low
Circuit Source

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-9
 Fault Code - Light Failure Description Failure Results
553 - Yellow Injector Metering Rail #1 Pressure High Data Valid but Above Normal Operational
Range – Moderately Severe Level
554 - Yellow Fuel Pressure Sensor Error Data Erratic, Intermittent, or Incorrect
559 - Yellow Injector Metering Rail #1 Pressure Low Data Valid but Below Normal Operational
Range – Moderately Severe Level
584 - Yellow Starter Relay Circuit Voltage Above Normal, or Shorted to High
Source
585 - Yellow Starter Relay Circuit Voltage Below Normal, or Shorted to Low
Source
595 - Yellow Turbocharger #1 Speed High Data Valid but Above Normal Operational
Range – Moderately Severe Level
596 - Yellow Electrical Charging System Voltage High Data Valid but Above Normal Operational
Range – Moderately Severe Level
597 - Yellow Electrical Charging System Voltage Low Data Valid but Below Normal Operational
Range – Moderately Severe Level
598 - Red Electrical Charging System Voltage Low Data Valid but Below Normal Operational
Range – Most Severe Level
649 - Maint Change Lubricating Oil and Filter Condition Exists
687 - Yellow Turbocharger #1 Speed Low Data Valid but Below Normal Operational
Range – Moderately Severe Level
689 - Yellow Primary Engine Speed Sensor Error Data Erratic, Intermittent, or Incorrect
691 - Yellow Turbocharger #1 Compressor Inlet Tempera- Voltage Above Normal, or Shorted to High
ture Sensor Circuit Source
692 - Yellow Turbocharger #1 Compressor Inlet Tempera- Voltage Below Normal, or Shorted to Low
ture Sensor Circuit Source
697 - Yellow ECM Internal Temperature Sensor Circuit Voltage Above Normal, or Shorted to High
Source
698 - Yellow ECM Internal Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
719 - Yellow Extended Crankcase Blow–by Pressure Voltage Above Normal, or Shorted to High
Circuit Source

729 - Yellow Extended Crankcase Blow–by Pressure

Circuit Voltage
Source Below Normal, or Shorted to Low
731 - Yellow Engine Speed/Position #2 mechanical Mechanical System Not Responding Properly
misalignment between camshaft and crank- or Out of Adjustment
shaft sensors
753 - Yellow Engine Speed/Position #2 Camshaft sync Data Erratic, Intermittent, or Incorrect
error
757 - Yellow Electronic Control Module data lost Condition Exists
778 - Yellow Engine Speed Sensor (Camshaft) Error Data Erratic, Intermittent, or Incorrect
779 - Yellow Warning Auxiliary Equipment Sensor Input # 3 Root Cause Not Known
(OEM Switch)
951 - None Cylinder Power Imbalance Between Cylinders Data Erratic, Intermittent, or Incorrect
1117 - None Power Lost With Ignition On Data Erratic, Intermittent, or Incorrect
1139 - Yellow Injector Cylinder #1 Mechanical System Not Responding Properly
or Out of Adjustment

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Fault Code - Light Failure Description Failure Results
1141 - Yellow Injector Cylinder #2 Mechanical System Not Responding Properly
or Out of Adjustment
1142 - Yellow Injector Cylinder #3 Mechanical System Not Responding Properly
or Out of Adjustment

1143 - Yellow Injector Cylinder #4 Mechanical System Not Responding Properly

or Out of Adjustment
1144 - Yellow Injector Cylinder #5 Mechanical System Not Responding Properly
or Out of Adjustment
1145 - Yellow Injector Cylinder #6 Mechanical System Not Responding Properly
or Out of Adjustment
1239 - Yellow Accelerator Pedal or Lever Position Sensor 2 Voltage Above Normal, or Shorted to High
Circuit Source
1241 - Yellow Accelerator Pedal or Lever Position Sensor 2 Voltage Below Normal, or Shorted to Low
Circuit Source
1242 - Red Accelerator Pedal or Lever Position Sensor 1 Data Erratic, Intermittent, or Incorrect
and 2
1256 - Yellow Control Mo
Module Id
Identification In
Input St
State Er
Error Data Er
Erratic, In
Intermittent, or
or In
Incorrect
1257 - Re
Red Control Module Identification Input State Error Data Erratic, Intermittent, or Incorrect
1911 - Yellow Injector Metering Rail 1 Pressure Data Valid but Above Normal Operational
Range – Most Severe Level
2111 - Yellow Coolant Temperature 2 Sensor Circuit Voltage Above Normal, or Shorted to High
Source
2112 - Yellow Coolant Temperature 2 Sensor Circuit Voltage Below Normal, or Shorted to Low
Source
2113 - Yellow Coolant Temperature 2 Data Valid but Above Normal Operational
Range – Moderately Severe Level
2114 - Red Coolant Temperature 2 Data Valid but Above Normal Operational
Range – Most Severe Level
2115 - Yellow Coolant Pressure 2 Circuit Voltage Above Normal, or Shorted to High
Source
2116 - Yellow Coolant Pressure 2 Circuit Voltage Below Normal, or Shorted to Low
Source
2117 - Yellow Coolant Pressure 2 Data Valid but Below Normal Operational
Range – Moderately Severe Level
2185 - Yellow Sensor Supply Voltage #4 Circuit Voltage Above Normal, or Shorted to High
Source
2186 - Yellow Sensor Supply Voltage #4 Circuit Voltage Below Normal, or Shorted to Low
Source
2195 - Red Transmission’s temperature exceeds 245F Engine will shut down 30 seconds after the red
(118C). icon begins flashing.
2215 - Yellow Fuel Pump Delivery Pressure Data Valid but Below Normal Operational
Range – Moderately Severe Level
2216 - Yellow Fuel Pump Delivery Pressure Data Valid but Above Normal Operational
Range – Moderately Severe Level
2217 - Yellow ECM Program Memory (RAM) Corruption Condition Exists

2249 - Yellow Injector Metering Rail 1 Pressure Data Va–lid

Range but B
Most elow NLevel
Severe ormal Operational

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-11
 Fault Code - Light Failure Description Failure Results
2265 - Yellow Fuel Priming Pump Control Signal Circuit Voltage Above Normal, or Shorted to High
Source
2266 - Yellow Fuel Priming Pump Control Signal Circuit Voltage Below Normal, or Shorted to Low
Source

2292 - Yellow Fuel Inlet Meter Device Data Valid but Above Normal Operational
Range – Moderately Severe Level
2293 - Yellow Fuel Inlet Meter Device flow demand lower Data Valid but Below Normal Operational
than expected Range – Moderately Severe Level
2311 - Yellow Fueling Actuator #1 Circuit Error Condition Exists
2321 - None Engine Speed / Position Sensor #1 Data Erratic, Intermittent, or Incorrect
2322 - None Engine Speed / Position Sensor #2 Data Erratic, Intermittent, or Incorrect
2345 - Yellow Turbocharger speed invalid rate of change Abnormal Rate of Change
detected
2346 - None Turbocharger Turbine Inlet Temperature (Cal- Data Valid but Above Normal Operational
culated) Range – Least Severe Level
2347 - None Turbocharger Compressor Outlet Temperature Data Valid but Above Normal Operational
(Calculated) Range – Least Severe Level

2362 - Yellow Engine Brake Actuator Circuit #1 Voltage Below Normal, or Shorted to Low
Source
2363 - Yellow Engine Brake Actuator Circuit #2 Voltage Below Normal, or Shorted to Low
Source
2366 - Yellow Engine Brake Actuator Circuit #1 Voltage Above Normal, or Shorted to High
Source
2367 - Yellow Engine Brake Actuator Circuit #2 Voltage Above Normal, or Shorted to High
Source
2377 - Yellow Fan Control Circuit Voltage Above Normal, or Shorted to High
Source
2384 - Yellow VGT Actuator Driver Circuit Voltage Below Normal, or Shorted to Low
Source
2385 - Yellow VGT Actuator Driver Circuit Voltage Above Normal, or Shorted to High
Source

2555 - Yellow Intake Air Heater #1 Circuit Voltage Above Normal, or Shorted to High
Source
2556 - Yellow Intake Air Heater #1 Circuit Voltage Below Normal, or Shorted to Low
Source
2557 - Yellow Auxiliary PWM Driver #1 Voltage Above Normal, or Shorted to High
Source
2558 - Yellow Auxiliary PWM Driver #1 Voltage Below Normal, or Shorted to Low
Source
2963 - None Engine Coolant Temperature High Data Valid but Above Normal Operational
Range – Least Severe Level
2964 - None Intake Manifold Temperature High Data Valid but Above Normal Operational
Range – Least Severe Level
2973 - Yellow Intake Manifold Pressure Sensor Circuit Data Erratic, Intermittent, or Incorrect

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
Engine Troubleshooting

The following chart includes some of the problems noise. Use the following
following information as a guide to
that an operator may encounter during the service diagnosing engine noise.
life of a Cummins diesel engine. Always check
Main Bearing Noise (Refer to Problem 40.).
40.). The
the easiest and obvious things first, such as the
master disconnect switch, the neutral start switch, noise caused
dull knock by a
heard loose
when main
the bearing
engine is a loud,
is pulling a
an empty fuel tank, closed fuel shut off, dead bat-
load. If all main
main bearings are loose, a loud clatter
tery or corroded terminals. Study the problem
will be heard. The knock is heard regularly every
thoroughly before starting to work on the engine.
other revolution. The noise is the loudest when
Ask yourself the following questions.
the engine is lugging or under heavy load. The
1. Wha
Whatt were
were the warn
warning
ing sign
signss preced
preceding
ing the
the knock is duller than a connecting rod noise. Low
trouble? oil pressure can also accompany this condition.
2. Has the the engin
engine e been
been subjec
subjected
ted to
to recent
recent If the bearing is not loose enough to produce a
repair or maintenance? knock by itself, the bearing can knock if the oil is
3. Has a sim simila
ilarr troubl
troublee occurr
occurred ed befor
before?
e? too thin or if there is no oil on the bearing.
4. If the
the engine
engine still
still runs,
runs, is it safe to continue
continue An irregular noise can indicate worn crankshaft
operation of the engine in an effort to diag- thrust bearings.
nose the trouble?
Check the items most easily and inexpensively cor- An intermittent, sharp knock indicates excessive
rected before proceeding to the more difficult, time crankshaft end clearance. Repeated clutch
clutch disen-
consuming and expensive
expensive items.
items. After a malfunc- gagements can cause a change in the noise.
tion has been corrected, locate and correct the Connecting Rod Bearing Noise (Refer to Prob-
cause of the trouble to prevent recurrence of the 39.). Connecting rods with excessive clear-
lem 39.).
same trouble. ance will knock at all engine speeds under both
Engine Noise Diagnostic Procedures – General idle and load conditions. When the bearings
Information begin to become loose, the noise can be con-
fused with piston
piston slap or loose piston pins. The
NOTE: When diagnosing engine noise problems, noise increases in volume with engine speed.
make sure that noises caused by accessories, Low oil pressure can also accompany this
such as the air compressor and power take–off, condition.
are not mistaken for engine noises. Remove the Piston Noise (Refer to Problem 41.).
41.). It is difficult
accessory drive belts to eliminate noise caused by to tell the difference between piston pin, connect-
these units. Noise will also travel to other metal
metal ing rod, and piston noise. A loose piston pin
parts not related to the problem. The use of a
stethoscope can help locate an engine noise. causes
when the a loud
enginedouble knock
is idling. that is
When usually
the heard
injector to
this cylinder is cut out, a noticeable change will be
Engine noises heard at the crankshaft speed, heard in the sound of the knocking noise. Howev-
engine rpm, are noises related to the crankshaft, er, on some engines the knock becomes more
rods, pistons, and piston pins. Noises heard at noticeable when the vehicle is operated on the
the camshaft speed, one–half of the engine rpm, road at a steady speed.
are related to the valve train. A handheld digital
tachometer can help determine if the noise is
related to components operating at the crankshaft
or camshaft speed.
There is not a definite rule or test that will positive-
ly determine the source of a noise complaint.
Engine–driven components and accessories, such
as gear–driven fan clutches, hydraulic pumps,
belt–driven alternators, air–conditioning compres-
sors, and turbochargers, can contribute to engine

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-13
 Problem Cause Correction

1. Engi
Engine
ne wil
willl not
not 1. Batter
Battery y disc
disconne
onnect
ct swi
switch
tch is
is turned
turned 1. Turn batte
battery
ry disco
disconne
nnect
ct switc
switch
h on.
crank or cranks off.
slowly 2. Eng
Engineine dri
drive
ve uni
units
ts are enga
engagedged.. 2. Diseng
Disengageage engengine
ine dri
driven
ven uniunits.
ts.
3. Bat
Batter
tery
y conn
connect
ection
ionss are
are brok
broken,
en, 3. Che
Checkck for dam
damageage.. Rep Replaclace,
e, tig
tight-
ht-
loose or corroded. en or clean.
4. Lo
Loww babatt
tter
ery
y ch
char
arge.
ge. 4. Che
Checkck elect
electrol
rolyte
yte leve
levell and specspecifi
ific
c
gravity. Recharge or replace bat-
teries.
5. Batter
Batteryy rati
rating
ng is too low
low.. 5. Rep
Replac
lacee with corr
correct
ect rate
rated d battery
battery..
6. Oil for oper
operati
ating
ng cond
conditi
itions
ons is 6. Cha
Change
nge oil and fil filter
ter.. Ref
Referer to the
incorrect. Fuel and Lubricant Specifica-
tions in the Appendices for the
proper type of oil to be used.
7. Oi
Oill lev
level
el is to
too
o hig
high.
h. 7. Che
Checkck the oil lev
level.
el. Veri erify
fy the oil
pan capacity. Drain excess oil if
necessary. Fill the system to the
specified level.
8. Oil tem
temperperatu
ature
re is too low
low.. 8. In
Inst
stal
alll oil
oil pan
pan heat
heater er..
9. Ele
Electr
ctric
ic shif
shifter
ter is
is not in the
the neutra
neutrall 9. Pla
Place
ce elect
electric
ric shi
shifte
fterr in the
the neutra
neutrall
position. position.
10. Circu
Circuit
it breaker (CB13,
(CB13, CB14, 10. Reset or replace circuit breaker(s).
CB15, CB27, CB28 or ECM 30
amp; Illustrations 1-6 and 6-6 thru
6-8) is tripped or defective.
11.. Defective
11 Defective accessory
accessory power sole- 11. Replace accessory
accessory power solenoid
noid (L1). (L1).
12. Defective neutral start relay (K9, 12. Replace neutral start relay (K9).
Illustration 6-6).
13. Defective start assist solenoid (L2). 13. Replace start assist solenoid (L2).

14. Defec
Defective
tive starter.
starter. 14. Replace or repair starter.
starter.
15. Defec
Defective
tive ignition
ignition switch (S1). 15. Refer to Component
Component 4. of the
Component Troubleshooting
chart in Section 6.
16. Blown fuse
fuse (5 amp) to the
the ECM. 16. Replac
Replace
e fuse(s).
fuse(s).
17. Loose or broken
broken wires
wires / plugs / 17. Isola
Isolate
te and repair.
repair.
pins between any of the compo-
nents in Causes 9. thru 16. of this
Problem.
18. The TICS emergency
emergency hydraulic
hydraulic 18. Pull the TICS emergency
emergency hydraulic
hydraulic
movement stop has been stop to its Out position.
depressed to disable certain
functions.

1-14
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TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

2. Engi
Engine
ne dif
diffi
ficu
cult
lt to
to 1. Low
Low fue
fuell lev
level
el.. 1. Fill
Fill th
the
e fue
fuell tan
tank.
k.
start or will not 2. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 2. Refer to Diagnostic Fault Codes
start (no exhaust found earlier in this section for
smoke present) instructions on how to read active
fault codes.
codes. If fault
fault codes are
active, contact a Cummins Autho-
rized Repair Facility
Facility..
3. Ba
Batt
ttery
ery vo
volt
ltag
age
e is low
low.. 3. Che
Check ck the bat
batter
teries
ies and the
unswitched battery supply circuit.
4. Batter
Battery y volta
voltage ge suppl
supply y to the
the elec-
elec- 4. Che
Check ck the
the batt
battery
ery con
connec
nectio
tions
ns and
and
tronic control module (ECM) is low, fuses.
interrupted, or open.
5. Moi
Moistu
sturere is
is in the wir
wiring
ing har
harnes
nesss 5. Dry the con
connec
nector
tors
s with
with an elec
elec--
connectors. tronics cleaner.
6. Ai
Airr is in the
the fuel
fuel sy
syst
stem
em.. 6. Che
Checkck for
for air
air in
in the
the fuel
fuel syst
system.
em.
Tighten or replace the fuel connec-
tions, fuel lines, fuel hoses, and
fuel filters as required. Vent air
from the system.

3. Engin
Engine e dif
diffi
ficu
cult
lt to 1. Low
Low fue
fuell lev
level
el.. 1. Fill
Fill th
the
e fue
fuell tan
tank.
k.
start or will not 2. Ba
Batt
ttery
ery vo
voltltag
age e is low
low.. 2. Che
Check ck the bat
batter
teries
ies and the
start (exhaust unswitched battery supply circuit.
smoke present)
3. Eng
Engineine cran
crankin
king
g speed
speed is
is too
too slow
slow.. 3. Che
Check ck eng
engineine cra
cranki
nking
ng RPM
RPM..
Refer to Problem 1. in this trouble-
shooting chart.
4. Sta
Starti
rting
ng aid
aid needed
needed for col
coldd weath
weath-- 4. Che
Check-ck-rep
repair
air or
or replac
replace e cold
cold start-
start-
er or is not working properly. ing aid, if necessary.
5. Ai
Airr is in the
the fuel
fuel sy
syst
stem
em.. 5. Ref
Referer to
to Corre
Correcti
ction
on 6.
6. of Pro
Proble
blem
m
2. in this troubleshooting chart.
6. Fuel lea
eak
k. 6. Check
Check fuel
fuel lines
lines,, fuel
fuel connec
connectiotions,
ns,
and fuel filters for leaks.
7. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 7. Che
Check
ck inta
intakeke syst
system
em for
for rest
restric
ric--
tions. Replace air filter if required.
8. Incorr
Incorrect
ect fue
fuell grade
grade is being
being use
usedd 8. Use the cor
correc
rectt grade
grade of fue
fuel.
l.
or fuel quality is poor.
9. Eng
Engine
ine bloc
block
k heater
heater is
is malfun
malfuncti
ction-
on- 9. Che
Checkck the
the elec
electri
trical
cal sou
source
rces
s and
and
ing (if equipped). wiring to the cylinder block heater.
Replace the block heater is neces-
sary.
10. Fuel heater
heater is malfunctioning
malfunctioning (if 10. Check the fuel heater
heater.. Replace if
equipped). necessary.
11. Electronic fault codes are active. 11.. Refer to Correctio
11 Correctionn 2. of Problem
2. in this troubleshooting chart.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-15
 Problem Cause Correction

4. Engi
Enginene sta
start
rts,
s, bu
butt 1. Low
Low fue
fuell lev
level
el.. 1. Fill
Fill fu
fuel
el ta
tank
nk..
will not keep 2. Bat
Batter
tery
y volta
voltagege suppl
supply
y to the
the elec-
elec- 2. Che
Check ck the bat
batter
tery
y conn
connect
ection
ions.
s.
running tronic control module (ECM) is low,
interrupted, or open.
3. Ele
Electr
ctroni
onicc fault
fault codes
codes are acti
active.
ve. 3. Refer
Refer toto Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
2. in this troubleshooting chart.

5. Engi
Engine
ne spepeed
ed 1. Low
Low fue
fuell lev
level
el.. 1. Fill
Fill fu
fuel
el ta
tank
nk..
surges at low or 2. Ele
Electr
ctroni
onicc fault
fault codes
codes are acti
active.
ve. 2. Ref
Referer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
high idle 2. in this troubleshooting chart.
3. Moistu
Moisture re is
is in the wir
wiring
ing har
harnes
ness
s 3. Dry the conconnec
nector
tors
s with
with an elec
elec--
connectors. tronics cleaner
cleaner..
4. Ai
Airr is in the
the fue
fuell syst
system
em.. 4. Ref
Referer to
to Corre
Correcti
ction
on 6.
6. of Pro
Proble
blem
m
2. in this troubleshooting chart.
5. Incorr
Incorrect
ect fue
fuell grade
grade is bein
being
g used
used 5. Use the corcorrec
rectt grad
gradee of
of fuel
fuel..
or fuel quality is poor.

6. Engi
Engine
ne ru
runs
ns ro
roug
ugh
h 1. En
Engi
gine
ne is co
cold
ld.. 1. Allow
Allow the
the engi
engine
ne toto warm
warm to oper
oper--
at idle ating temperature. If the engine
will not reach operating tempera-
ture, refer to Problem 16. of this
troubleshooting chart.
2. Ele
Electr
ctroni
onic
c fault
fault codes
codes are acti
active.
ve. 2. Ref
Referer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blemm
2. in this troubleshooting chart.
3. Idle
Idle speed
speed is set too lowlow for
for acces
acces-- 3. Che
Checkck and adj
adjust
ust the low idlidle
e
sories. screw.
4. Ai
Airr is in the
the fue
fuell syst
system
em.. 4. Ref
Referer to
to Corre
Correcti
ction
on 6.
6. of Pro
Proble
blemm
2. in this troubleshooting chart.
5. Fu
Fuel
el sup
suppl
ply
y is res
restr
tric
icte
ted.
d. 5. Che
Checkck fuel
fuel line
lines
s for res
restri
tricti
ctions
ons..
6. Engi
Engine
ne moun
mounts ts are
are wor
wornn or 6. Re
Repl
plac
ace
e engi
engine
ne mou
mount
nts.
s.
damaged.
7. Moi
Moistu
sture
re is
is in the wir
wiring
ing har
harnes
ness
s 7. Dry the con
connec
nectortors
s with
with an elec
elec--
connectors. tronics cleaner
cleaner..
8. Inc
Incorr
orrect
ect fue
fuell grade
grade is bein
being
g used
used 8. Use the cor
correc
rectt grad
grade
e of
of fuel
fuel..
or fuel quality is poor.

7. Engi
Engine
ne ruruns
ns ro
roug
ugh
h 1. En
Engi
gine
ne is co
cold
ld.. 1. Refer
Refer toto Corre
Correcti
ction
on 1.
1. of Pro
Proble
blem
m
or misfires 6. in this troubleshooting chart.
2. Ele
Electr
ctroni
onic
c fault
fault codes
codes are acti
active.
ve. 2. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
2. in this troubleshooting chart.
3. Ai
Airr is in the
the fue
fuell syst
system
em.. 3. Ref
Refer
er to
to Corre
Correcti
ction
on 6.
6. of Pro
Proble
blem
m
continued 2. in this troubleshooting chart.

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1-16 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

7. Engi
Engine
ne ruruns
ns ro
roug
ugh
h 4. Fuel
Fuel supply
supply line
line or
or passag
passagee restri
restric-
c- 4. Che
Check
ck the fue
fuell suppl
supplyy line
line or
or misfires tion between the fuel pump and passage for restriction.
(Continued) injectors.
5. En
Engi
gine
ne mou
mount nts
s are
are worn
worn or
or 5. Re
Repl
plac
acee en
engi
gine
ne mo
moununts
ts..
damaged.
6. Moi
Moistu
sture
re is
is in the wir
wiring
ing har
harnes
nesss 6. Dry the con
connec
nector
tors
s with
with an elec
elec--
connectors. tronics cleaner.

8. Lubr
Lubric
icat
atin
ing
g oi
oill 1. Engine
Engine angu
angular
larity
ity dur
during
ing ope
operat
ration
ion 1. Refer
Refer to a CumCummin mins s Auth
Authoriorized
zed
pressure is low exceeds specification. Repair Facility
Facility..
2. Oil does not mee
meett speci
specific
ficati
ations
ons.. 2. Cha
Change
nge the oil and fil filter
ter.. Ref
Refer er to
Fuel and Lubricant Specifica-
tions in the Appendices for the
proper type of oil to be used.
3. Oil
Oil fil
filte
terr is
is plu
plugg
gged
ed.. 3. Cha
Change
nge oil
oil and
and repla
replacece oil
oil filt
filter
er..
4. Oil iis
s conta
contamin minate
atedd with
with cool
coolant
ant or 4. Ref
Refer
er to
to Proble
Problem m 10.
10. in thithis
s trou-
trou-
fuel. bleshooting chart.
5. Ex
Exte
tern
rnal
al oi
oill leak
leak.. 5. Ins
Inspec
pectt the
the engin
engine e for
for exter
externalnal oil
leaks. Tighten the capscrews, pipe
plugs, and fittings.
fittings. Replace dam-
aged gaskets.
6. In
Inco
corr
rrec
ectt oi
oill lev
level
el.. 6. Che
Checkck the oil levlevel.
el. Add or dra drainin
engine oil.
7. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 7. Ref
Refer
er to
to Corre
Correcti ction
on 2.
2. of Pro
Probleblem m
2. in this troubleshooting chart.
8. Oil pres
pressur
suree switc
switch,
h, gauge
gauge,, senso
sensorr 8. Che
Checkck the oil pre pressu
ssurere swit
switch,
ch,
or circuit is malfunctioning. gauge, sensor or circuit for correct
operation.

9. pressure
Lubr
Lubric
icat
atin
ingg oi
is oil
l
high 1. Engine
Eng
low. ine coo
coolan
lantt tempe
temperat
rature
ure is too
too 1. Refer
Ref er to
to Probl
bleshootingProblem
em 16.
chart. 16. of
of this
this trou-
trou-
2. Oil pres
pressur
suree switc
switch,
h, gauge
gauge,, senso
sensorr 2. Che
Checkck the oil pre
pressu
ssure
re swit
switch,
ch,
or circuit is malfunctioning. gauge, sensor or circuit for correct
operation.
3. Oil does not mee
meett speci
specific
ficati
ations
ons.. 3. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
8. in this troubleshooting chart.
4. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 4. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
2. in this troubleshooting chart.

10. Lubric
Lubricating
ating oil is 1. Oil is con
contam
tamina
inated
ted wit
with
h fuel
fuel.. 1. Change
Change the oil and fil
filter
ter.. Ref
Referer to
contaminated Problem 31. in this troubleshooting
chart.
2. Int
Interna
ernall engi
engine
ne coo
coolan
lantt leak
leak.. 2. Ref
Refer
er to
to Proble
Problem
m 14.
14. in thi
this
s trou-
trou-
continued bleshooting chart.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-17
 Problem Cause Correction

10. Lubric
Lubricating
ating oil is 3. Bu
Bulk
lk oi
oill su
supp
pply
ly is con
onta
tam
min
inat
ated
ed.. 3. Chec
Check k bu
bulk
lk oi
oill su
supp
pply
ly.. Dra
rain
in th
the
e oi
oill
contaminated and replace with non-contaminated
(Continued) oil. Replace oil filter(s).

11.. Coolant
11 Coolant tempera-
tempera- 1. Charge
Charge airair coole
coolerr fins,
fins, radi
radiato
atorr fins,
fins, 1. Ins
Inspec
pectt the charg
chargee air coole
coolerr, radia-
radia-
ture is above or air conditioner condenser fins tor, and air conditioner condenser
normal (Gradual are damaged or obstructed with fins. Clean if necessary
necessary..
Overheat) debris.
2. Co
Cool
olan
antt lev
level
el is lo
low
w. 2. Ins
Inspec
pectt the
the engine
engine and
and cool
cooling
ing sys
sys--
tem for external coolant leaks.
Repair if necessary
necessary.. Add coolant.
3. Ele
Electr
ctroni
onicc fault
fault codes
codes are acti
active.
ve. 3. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blemm
2. in this troubleshooting chart.
4. Fan shr
shroud
oud is dama
damaged ged or miss
missing
ing,, 4. Ins
Inspec
pectt the
the shrou
shroudd and
and recirc
recircula
ula--
or the air recirculation baffles are tion baffles. Repair
Repair,, replace, or
damaged or missing. install if necessary
necessary..
5. Inco
Incorr
rrec
ectt oil le
leve
vel.l. 5. Add
Add oror dra
drain
in en
engigine
ne oi
oil.
l.
6. Oil is cont
contami
aminat
nated
ed with
with coo
coolan
lantt or 6. Ref
Refer
er to
to a Cum
Cummin mins
s Auth
Authoriorized
zed
fuel. Repair Facility
Facility..
7. Rad
Radiat
iator
or hos
hose e is
is col
collap
lapsed
sed,, 7. Ins
Inspec
pectt the
the hose
hoses s and
and repla
replacece any
any
restricted, or leaking. defective hoses.
8. Inc
Incorr
orrect
ect coo
coolant
lant mix
mixtur
ture
e of anti
anti-- 8. Veri
erify
fy the
the conce
concentr
ntrati
ation
on of antanti-
i-
freeze and water. freeze in the coolant. Add anti-
freeze or water to bring concentra-
tion to the proper mixture. Refer to
Coolant in Section 5 for the cor-
rect coolant concentration.
9. Coolan
Coolantt tempe
temperat
rature
ure gau
gauge
ge isis mal-
mal- 9. Test the temtemper
peratu
ature
re gaug
gauge. e.
functioning. Replace the gauge if necessary.
10. Fan drive tight, or not
drive belt is loose, tight, 10. Check belt
belt tension and tighten
tighten /
correctly aligned. loosen if necessary
necessary.. Replace drive
drive
belt if necessary.
11. Radiator cap(s) is incorrect, mal- 11. Replac
Replace e radiator cap(s).
cap(s).
functioning, or has low pressure
rating.
12. Vent line is restricted.
restricted. 12. Check vent line for restricti
restriction.
on.
13. Intak
Intake
e manifold air temperature
temperature is 13. Refer to Problem
Problem 34. in this trou-
trou-
above normal. bleshooting chart.
14. Incorrect thermostat or thermostat
thermostat 14. Check the thermost
thermostat
at for the cor-
is malfunctioning. rect part number and for correct
operation.
15. Water pump is malfunctioning. 15. Check the water
water pump for correct
correct
operation. Replace water pump if
necessary.
continued

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1-18 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

11. Coolant
Coolant tempera-
tempera- 16. Radiat
Radiator
or core is internally
internally 16. Inspe
Inspect
ct the radiator
radiator and clean if
ture is above obstructed or damaged. necessary.
normal (Gradual
Overheat) 17. Engine is over–fue
over–fueled.
led. 17. Check
lem 21.the fuel troubleshooting
fuel
in this rate. Refer to Prob-
rate. Prob-
(Continued) chart.

12. Coolan
Coolantt tempera-
tempera- 1. Co
Cool
olan
antt lev
level
el is
is low
low.. 1. Inspec
Inspectt the
the engine
engine and cool
cooling
ing sys-
sys-
ture is above tem for external coolant leaks.
normal (Sudden Repair if necessary
necessary.. Add coolant.
Overheat) 2. Fan dri
drive
ve or
or fan
fan contr
controls
ols are mal
mal-- 2. Che
Checkck the
the fan
fan driv
drive
e and
and fan
fan con-
con-
functioning. trols.
3. Fan dri
drive
ve belt
belt is loos
loose,
e, brok
broken,
en, or 3. Che
Checkck belt
belt ten
tensio
sion
n and tig
tighte
htenn if
not correctly aligned. necessary. Replace drive drive belt if
necessary.
4. Radiat
Radiator
or cap(
cap(s)
s) is
is incorr
incorrect
ect,, mal-
mal- 4. Re
Repl
plac
ace
e radi
radiatator
or cap
cap(s
(s).
).
functioning, or has low-pressure
rating.
5. Radiat
Radiator or hos
hosee is
is col
collap
lapsed
sed,, 5. Inspec
Inspectt the
the hose
hosess and
and repla
replace
ce any
any
restricted, or leaking. defective hoses.
6. Coo
Coolan
lantt tempe
temperat
rature
ure gau
gauge
ge is mal
mal-- 6. Test the tem
temper
peratu
ature
re gaug
gauge.
e.
functioning. Replace the gauge if necessary.
7. Cha
Charge
rge air
air coole
coolerr fins,
fins, radia
radiator
tor fins
fins,, 7. Ins
Inspec
pectt the char
charge
ge air
air cooler
cooler,, radia-
radia-
or air conditioner condenser fins tor, and air conditioner condenser
are damaged or obstructed with fins. Clean if necessary
necessary..
debris.
8. Ven
entt line
line is
is rest
restri
rict
cted
ed.. 8. Che
Check
ck vent
vent lin
line
e for
for restr
restrict
iction
ion..

13. Coolan
Coolantt loss
loss – 1. Lo
Low
w coo
coola
lant
nt lev
level
el.. 1. Inspec
Inspectt the
the engine
engine and cool
cooling
ing sys-
sys-
External tem for external coolant leaks.
Repair / replace damaged cooling
components. Add coolant.
2. Ex
Exte
terna
rnall coo
coola
lant
nt le
leak
ak.. 2. In
Insp
spec
ectt the engi
engine
ne for cool
coolant
ant leak-
leak-
ing from hoses, draincocks, water
manifold, jumper tubes, expansion
and pipe plugs, fittings, radiator
core, air compressor and cylinder
head gaskets, lubricating oil cooler,
water pump seal, cylinder block, and
cab heater.
heater. Repair / replace dam-
aged components.
3. Radiat
Radiatoror cap(
cap(s)
s) is
is incorr
incorrect
ect,, mal-
mal- 3. Re
Repl
plac
acee radi
radiat
ator
or cap
cap(s(s).
).
functioning, or has low-pressure
rating.
4. Rad
Radiat
iator
or hos
hose
e is
is col
collap
lapsed
sed,, 4. Ins
Inspec
pectt the
the hose
hoses
s and
and repla
replace
ce any
any
restricted, or leaking. defective hoses.
continued

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-19
 Problem Cause Correction

13. Coola
Coolant
nt loss – 5. Coolan
Coolantt fill
fill line
line is rest
restric
ricted
ted or 5. Check
Check thethe cool
coolant
ant fil
filll line
line for
for
External obstructed. restrictions or obstructions.
(Continued)
6. En
Engi
gine
ne is over
overhe
heat
atin
ing.
g. 6. Refer
Ref
thiser to Proble
to Problems
ms 11.
troubleshooting11. and 12.
and
chart. 12. in
in

14. Coola
Coolant
nt loss
loss – 1. Coolan
Coolantt is leaki
leaking
ng into
into the
the lubric
lubricat-
at- 1. Check
Check for coo
coolan
lantt in the oil
oil.. Ref
Referer
Internal ing oil. to Problem 15. of this troubleshoot-
ing chart.
2. Cylind
Cyl inder
er head
head gas
gasket
ket is leak
leaking
ing.. 2. Rep
Replac
lace
e cyli
cylinde
nderr head
head gas
gasket
ket..
3. Coolan
Coo lantt is leak
leaking
ing int
into
o the
the combus
combus-- 3. RemRemoveove the cyl
cylind
inderer head
head,, and
and
tion chamber. inspect cylinder head, gasket, and
pistons for evidence of coolant.
4. Cylind
Cyl inder
er head
head is
is crack
crackeded or poro
porous.
us. 4. Pre
Pressu
ssure-
re-tes
testt the
the cylin
cylinder
der head
head..
5. Cylind
Cyl inder
er hea
headd expa
expansi
nsion
on plugs
plugs 5. Ins
Inspec
pectt the cyl
cylinde
inderr hea
head.d. Rep
Replac
lacee
leaking or misassembled. any damaged parts.
6. Cylind
Cyl inder
er blo
block
ck is cra
cracke
cked d or
or 6. Rem
Removeove the oil pan
pan.. Pre
Pressu
ssure–
re–tes
testt
porous. the cooling system to check for
leaks.

15. Coola
Coolant
nt In The 1. Cylind
Cylinder
er head
head cor
coree and
and expans
expansionion 1. Check
Check cyl
cylind
inder
er head
head.. Rep
Replac
lace
e any
Engine Oil plugs leaking or misassembled. damaged parts.
2. Cyl
Cylind
inder
er head
head gas
gasket
ket is leak
leaking
ing.. 2. Rep
Replac
lace
e cyli
cylinde
nderr head
head gas
gasket
ket..
3. Cyl
Cylind
inder
er head
head is
is crack
cracked
ed or poro
porous.
us. 3. Pre
Pressu
ssure-
re-tes
testt the
the cylin
cylinder
der head
head..
4. Cyl
Cylind
inder
er blo
block
ck is cra
cracke
ckedd or
or 4. Rem
Removeove the oil pan
pan.. Pre
Pressu
ssure–
re–tes
testt
porous. the cooling system to check for
leaks.

16. Coola
Coolantnt tempera-
tempera- 1. Coo
Coolan
lantt tempe
temperat
rature
ure gau
gauge
ge is
is mal-
mal- 1. Test the tem
temper
peratu
ature
re gaug
gauge.
e.
ture is below
normal 2. functioning.
Fan dri
drive
ve or
or fa
fan
n contr
controls
ols are mal
mal-- 2. Replace
Check
Che thefan
ck the
the gauge
fan eifand
drive
driv necessary.
and contr
controls
ols..
functioning.
3. Inc
Incorr
orrect
ect ther
thermos
mostat
tat or
or thermo
thermosta
statt 3. Check
Check the
the ther
thermos
mostat
tat for the cor
cor--
is malfunctioning. rect part number and for correct
operation.

17. Engine vibrati

vibration
on is 1. Belt-d
Belt-driv
riven
en acce
accesso
ssorie
ries
s are
are mal-
mal- 1. Check
Check thethe fan
fan hub,
hub, altern
alternato
atorr, and
excessive functioning. air conditioner compressor for
interference. Isolate belt-driven
accessories and check for vibra-
tion.
2. Engine
Engine idl
idle
e speed
speed is set
set too low 2. Veri
erify
fy the
the corre
correct
ct idle
idle spee
speedd set-
set-
(electronically-controlled fuel ting. Increase the idle speed with
systems). the idle increment switch or an
continued electronic service tool.

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1-20 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

17. Engine vibration

vibration is 3. Engi
Engine
ne mou
mount
nts
s are
are worn
worn or
or 3. Re
Repl
plac
ace
e engi
engine
ne mo
moun
unts
ts..
excessive damaged.
(Continued)
4. excessive
Fan is loo
loose,
se,
hubdam
damageaged,
bearingd,end
or has
play. 4. blade
Check
Che ckisthe fan.. Rep
fan
missing Replaclace
or fan eis fan if
damaged.
5. En
Engi
gine
ne is mi
misf
sfir
irin
ing.
g. 5. Ref
Refer
er to
to Probl
Problem
em 7. 7. in thi
thiss troub
trouble-
le-
shooting chart.
6. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 6. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blemm
2. in this troubleshooting chart.
7. Vib
Vibrat
ration
ion dam
damper
per is dam
damaged
aged.. 7. Ins
Inspec
pectt the
the vibrat
vibration
ion dam
damper per..
Replace if necessary
necessary..

18. Engine noise is 1. Incorr

Incorrect
ect fue
fuell grade
grade is being
being use
used
d 1. Us
Use
e corr
correc
ectt grade
grade of fue
fuel.
l.
excessive (Com- or fuel quality is poor.
bustion Knocks) 2. Ai
Airr is in the
the fuel
fuel sy
syst
stem
em.. 2. Refer
Refer toto Corre
Correcti
ction
on 6.
6. of Pro
Proble
blemm
2. in this troubleshooting chart.
3. Coo
Coolan
lantt temp
tempera
eratur
ture
e is
is abov
abovee 3. Ref
Refer
er to
to Probl
Problems
ems 11. and
and 12.
12. in
normal. this troubleshooting chart.
4. Ove
Overhe
rhead
ad adjus
adjustme
tmentnt are
are incorr
incorrect
ect.. 4. Mea
Measur
sure e and
and adjus
adjustt the
the over
overhea
headd
settings.

19. Engine will not 1. Ele

Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 1. Refer
Refer toto Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
reach rated speed 2. in this troubleshooting chart.
(rpm) 2. Truc
ruck
k paras
parasiti
itics
cs are
are exces
excessiv
sive.
e. 2. Che
Checkck the
the truc
truck
k brake
brakess for
for drag-
drag-
ging, transmission malfunction,
cooling fan operation cycle time,
and engine-driven units.
3. Eng
Engine
ine pow
power
er out
output
put is low
low.. 3. Ref
Refer
er to
to Proble
Problemm 20.
20. in thi
this
s trou-
trou-
bleshooting chart.

20. Engine power 1. Ele

Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 1. Refer
Refer toto Corre
Correcti
ction
on 4.
4. of Pro
Proble
blemm
output is low 2. in this troubleshooting chart.
2. Engine
Engine is oper
operati
ating
ng abov
above
e recom
recom-- 2. Eng
Engine
ine pow
powerer dec
decrea
reases
ses abo
aboveve
mended altitude. recommended altitude. Operate
this engine in altitudes under
11,000 feet (3,352.8 meters).
3. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 3. Che
Checkck air
air intake
intake syst
system
em for
for restr
restric-
ic-
tions. Replace air filter if required.
4. Air int
intake
ake or exh
exhaus
austt leak
leaks.
s. 4. Che
Checkck the
the inta
intake
ke and
and exhau
exhaust
st sys-
sys-
tems for loose or damaged piping
connections and / or missing pipe
plugs. Check the turbocharger and
exhaust manifold mounting.
5. Charge
Charge air coo
cooler
ler is rest
restric
ricted
ted or 5. Ins
Inspec
pectt the
the charge
charge air
air coole
coolerr for air
continued leaking. restrictions or leaks.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-21
 Problem Cause Correction

20. Eng
Engine
ine power
power 6. Fuel leak. 6. Check
Check thethe fuel
fuel lines
lines,, fuel
fuel conne
connec-
c-
output is low tions, and fuel filter(s) for leaks.
(Continued) Check the fuel lines to the fuel
tank.
7. Ai
Airr is in the
the fue
fuell syst
system
em.. 7. Ref
Referer to
to Corre
Correcti
ction
on 9.
9. of Pro
Proble
blem
m
2. in this troubleshooting chart.
8. Truc
ruck
k parasi
parasitic
tics
s are exc
excess
essive
ive.. 8. Ref
Referer to
to Corre
Correcti
ction
on 9.
9. of Pro
Proble
blem
m
22. in this troubleshooting chart.
9. Oi
Oill lev
level
el is to
too
o hig
high.
h. 9. Che
Check ck the oil lev
level.
el. Veri
erify
fy the oil
pan capacity. Drain excess oil if
necessary. Fill the system to the
specified level.
10. Low fuel
fuel level.
level. 10. Fill fuel
fuel tank.
tank.

21. Fuel consum

consumption
ption 1. Ope
Operat
rator
or tech
techniq
nique
ue is
is incor
incorrec
rect.
t. 1. Review
Review ope
operat
ration
ion for cor
correc
rectt gear
gear
is excessive shifts, deceleration, and idling.
2. Ele
Electr
ctroni
onic
c fault
fault codes
codes are acti
active.
ve. 2. Refer
Refer toto Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
2. in this troubleshooting chart.
3. Fuel leak. 3. Che
Checkck the
the fuel
fuel lines
lines,, fuel
fuel conne
connec-c-
tions, and fuel filters for leaks.
4. Air int
intake
ake or exh
exhaus
austt leak
leaks.
s. 4. Ref
Refer
er to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blem
m
20. in this troubleshooting chart.
5. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 5. Che
Checkck air
air intake
intake syst
system
em for
for restri
restric-
c-
tions. Replace air filter if required.
6. Equipm
Equ ipment
ent and envenviro
ironme
nmenta
ntall fac-
fac- 6. Con
Consid
sider
er ambi
ambient
ent tem
temper
peratu
atures
res,,
tors are affecting fuel consumption. wind, and routes when evaluating
fuel consumption.
7. Oill lev
Oi level
el is to
too
o hig
high.
h. 7. Ref
Refer
er to
to Corre
Correcti
ction
on 9.
9. of Pro
Proble
blem
m
20. in this troubleshooting chart.

22. Engine noise is 1. Fa

Fan
n dri
drive
ve be
belt
lt is lo
loos
ose.
e. 1. Check
Check belt
belt ten
tensio
sion n and
and tight
tighten
en ifif
excessive necessary. Replace drive belt if
necessary.
2. Oi
Oill is
is thi
thin
n or
or dil
dilut
uted
ed.. 2. Use pro
proper
per qua
qualitlity
y engin
engine e oil (re
(refer
fer
to the Fuel and Lubricant Specifi-
cations in the Appendices for the
proper type of oil to be used).
3. Vib
Vibrat
ration
ion dam
damper
per is dam
damage
aged.
d. 3. Ins
Inspec
pectt the
the vibra
vibratiotionn dampe
damperr.
Replace if necessary
necessary..
4. Com
Combus
bustio
tion
n nois
noise
e is
is exce
excessi
ssive
ve 4. Ref
Refer
er to
to Probl
Problem em 18. 18. in
in this
this trou-
trou-
bleshooting chart.
5. Ai
Airr filt
filter
er is
is rest
restri
rict
cted
ed.. 5. Che
Checkck air
air filte
filterr for res
restri
tricti
ctions
ons..
Replace air filter if required.

continued 6. Coolan
Coolantt temp
tempera
eratur
ture
e is
is abov
above
e 6. Refer
Refer toto Proble
Problems
ms 11.
11. and
and 12.
12. in
in
normal. this troubleshooting chart.

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1-22 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

22. Engine noise

noise is 7. Engi
Engine
ne mou
mount
nts
s are
are worn
worn or
or 7. Re
Repl
plac
ace
e engi
engine
ne mo
moun
unts
ts..
excessive damaged.
(Continued)
8. In
Inco
corr
rrec
ectt engin
engine
e oil lev
level
el.. 8. engine
Check
Che ck the
oil. oil lev
level.
el. Add or dra
drain
in
9. Air condi
conditio
tioner
ner comp
compres
ressor
sor noi
noise
se iis
s 9. Iso
Isolat
late
e comp
componeonentnt and che
check
ck for
excessive. noise.
10. Fan is loose, damaged,
damaged, or unb
unbal-
al- 10. Check the fan. Replac Replacee fan
fan if
anced. blade is missing or fan is damaged.
11. Hydra
Hydraulic
ulic pump or air conditioning
conditioning 1111.. Isola
Isolate
te each component
component and check
compressor noise is excessive. for noise.
12. Engine oil pressure
pressure is below
below 12. Check the oil oil pressure.
pressure. If the
the pres-
pres-
normal. sure is low, refer to Problem 8. in
this troubleshooting chart.
13. Drivetrain noise
noise is excessive. 13. Disconnect the drivetrain. Check
for engine noise.
14. Overhe
Overheadad adjustments
adjustments are 14. Measu
Measure re and adjust the overhead
overhead
incorrect. settings.
15. Air compressor noise is excessive. 15. Refer to Problem
Problem 45. in this
troubleshooting chart.

23. Altern
Alternator
ator is
is not 1. Altern
Alternato
atorr pulley
pulley is loos
loosee on shaf
shaft.
t. 1. Tig
ight
hten
en pul
pulle
ley
y.
charging or insuffi- 2. Bat
Batte
teri
ries
es have
have malfunc
malfuncti
tione
oned.
d. 2. Che
Checkck the
the cond
conditi
ition
on of
of the
the batter
batter--
ciently charging ies. Replace batteries if required.
3. Batte
Battery
ry cabl
cables
es or conne
connect
ctio
ions
ns are
are 3. Che
Checkck batt
battery
ery cab
cables
les and con
connec
nec--
loose, broken or corroded (exces- tions.
sive resistance).
4. Alt
Altern
ernato
atorr is over
overload
loaded
ed or alte
alterna
rna-- 4. Instal
Installl an alte
alterna
rnator
tor wit
with
h a highe
higherr
tor capacity is below specification. capacity.
5. Altern
Alternato
atorr or vol
voltag
tage
e regul
regulato
atorr is 5. Test the alt
alterna
ernator
tor out
output
put.. Rep
Replac
lacee
malfunctioning. the alternator or voltage regulator if
required.
6. Electr
Electrica
icall syste
system
m is ope
open
n (trip
(tripped
ped 6. Res
Reset
et circu
circuit
it break
breakers
ers,, repair
repair wire
wires,
s,
circuit breakers, broken wires, or or make good connections.
loose connections).

24. Altern
Alternator
ator is over-
over- 1. Ba
Batt
tteri
eries
es ha
have
ve fa
fail
iled
ed.. 1. Check
Check the
the cond
conditi
ition
on of
of the
the batter
batter--
charging ies. Replace batteries if required.
2. Volt
oltage
age regul
regulato
atorr is malfun
malfuncti
ctioni
oning.
ng. 2. Che
Check
ck the
the volt
voltage
age regu
regulat
lator
or..
Replace the voltage regulator if
required.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-23
 Problem Cause Correction

25. Exces
Excessive
sive white
white 1. En
Engi
gine
ne is co
cold
ld.. 1. Allow
Allow the
the engi
engine
ne toto warm
warm to oper
oper--
smoke ating temperature. If the engine
will not reach operating tempera-
ture, refer to Problem 16. in this
troubleshooting chart.
2. Engine
Engine is oper
operati
ating
ng at
at low
low ambien
ambientt 2. Use unde
under-t
r-the-
he-hood
hood int
intake
ake air in
temperature. cold weather.
3. Ele
Electr
ctroni
onic
c fault
fault codes
codes are acti
active.
ve. 3. Ref
Referer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem m
2. in this troubleshooting chart.
4. Starti
Starting
ng aid
aid (if
(if equi
equippe
pped) d) is
is mal-
mal- 4. Che
Checkck for
for corr
correct
ect ope
operat
ration
ion of
of the
the
functioning. cold starting aid.
5. Inc
Incorr
orrect
ect fue
fuell grade
grade is bein
beingg used
used 5. Use the corcorrec
rectt grad
gradee of
of fuel
fuel..
or fuel quality is poor.
6. Air int
intake
ake or exh
exhaus
austt leak
leaks.
s. 6. Refer
Refer to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blem
m
20. in this troubleshooting chart.
7. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 7. Che
Checkck air
air intake
intake syst
system
em for
for restri
restric-
c-
tions. Replace air filter if required.
8. Charge
Charge air coo
cooler
ler is rest
restric
ricted
ted or 8. Ins
Inspec
pectt the
the charge
charge air
air coole
coolerr for air
leaking. restrictions or leaks.

26. Exces
Excessive
sive black 1. Ele
Electr
ctroni
onic
c fault
fault codes
codes are acti
active.
ve. 1. Refer
Refer toto Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
smoke 2. in this troubleshooting chart.
2. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 2. Che
Checkck air
air intake
intake syst
system
em for
for restri
restric-
c-
tions. Replace air filter if required.
3. Air int
intake
ake or exh
exhaus
austt leak
leaks.
s. 3. Ref
Refer
er to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blem
m
20. in this troubleshooting chart.
4. Charge
Charge air coo
cooler
ler is rest
restric
ricted
ted or 4. Ins
Inspec
pectt the
the charge
charge air
air coole
coolerr for air
leaking. restrictions or leaks.

27. Crank
Cranking
sure ising
lowfuel
fuel pres- 1. Low
Low fue
fuell lev
level
el.. 1. Fill
Fill fu
fuel
el ta
tank
nk..
2. Fue
Fuell conne
connectictions
ons on the
the low-p
low-pres
res-- 2. Tigh
ighten
ten all
all fuel
fuel fitti
fittings
ngs and
and conne
connec- c-
sure side of the pump are loose. tions between the fuel tanks and
the fuel pump.
3. Fuel
Fuel sucti
suction
on stan
standpi
dpipe
pe in the fue
fuell 3. Che
Check ck and
and repa
repair
ir the
the stan
standpi
dpipe
pe ifif
tank is broken. necessary.

28. Engine accel

accelera-
era- 1. Ope
Operat
rator
or tech
techniq
nique
ue is
is incor
incorrec
rect.
t. 1. Review
Review ope operat
ration
ion for cor
correc
rectt gear
gear
tion or response is shifts, deceleration, and idling.
poor 2. Low
Low fue
fuell lev
level
el.. 2. Fi
Fill
ll fu
fuel
el ta
tank
nk..
3. Truc
ruck
k parasi
parasitic
ticss are exc
excess
essive
ive.. 3. Ref
Referer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
19. in this troubleshooting chart.
4. Ele
Electr
ctroni
onic
c fault
fault codes
codes are acti
active.
ve. 4. Ref
Referer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m

continued 2. in this troubleshooting chart.

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1-24 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

28. Engine accel

accelera-
era- 5. Fuel lea
eak
k. 5. Check
Check the
the fuel
fuel lin
lines,
es, fue
fuell conne
connec-
c-
tion or response is tions, and fuel filters for leaks.
poor (Continued)
6. Intake
Intake normal.
above manifol
mani fold
d air tem
temper
peratu
ature
re is 6. Refe
Re ferr to
to Pro
bleshootingProbl
blem
em 34. in this trou-
chart.
7. Cha
Charge
rge air coo
cooler
ler is rest
restric
ricted
ted or 7. Ins
Inspec
pectt the
the charge
charge air
air coole
coolerr for air
leaking. restrictions or leaks.
8. Air int
intake
ake or exh
exhaus
austt leak
leaks.
s. 8. Ref
Refer
er to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blem
m
20. in this troubleshooting chart.
9. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 9. Che
Checkck air
air intake
intake syst
system
em for
for restr
restric-
ic-
tions. Replace air filter if required.
10. Incor
Incorrect
rect fuel grade
grade is being used 10. Use the correct
correct grade
grade of fuel.
or fuel quality is poor.
11. Fuel supply line restriction between 11.
11. Check the
the fuel supply line from
from the
the fuel pump and injectors. fuel pump to the cylinder head for
sharp bends that can cause restric-
tions.

29. Engine shuts

shuts off
off 1. Low
Low fue
fuell lev
level
el.. 1. Fil
illl fue
fuell tan
tank
k.
unexpectedly or 2. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 2. Ref
Refer er to
to Corre
Correcti
ctionon 2.
2. of Pro
Proble
blem
m
dies during decel- 2. in this troubleshooting chart.
eration
3. Idl
Idle
e shutd
shutdown
own feat
feature
ure is
is activ
activate
ated.
d. 3. Che
Check ck the
the time
time lim
limit
it on
on idle
idle shut
shut--
down with an electronic service
tool.
4. Moistu
Moisture re is
is in the wir
wiring
ing har
harnes
ness
s 4. Dry the con connec
nector
torss with
with an elec
elec--
connectors. tronics cleaner.
5. Ai
Airr is in the
the fuel
fuel sy
syst
stem
em.. 5. Ref
Refer er to
to Corre
Correcti
ctionon 6.
6. of Pro
Proble
blem
m
2. in this troubleshooting chart.

30. Engine speed 1. Lo

Low
w fue
fuell lev
level
el.. 1. Fil
illl fue
fuell tan
tank
k.
surges under load
or in operating 2. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 2. Refer
Refer toto Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
2. in this troubleshooting chart.
range
3. Moistu
Moisture re is
is in the wir
wiring
ing har
harnes
ness
s 3. Dry the con
connec
nector
tors
s with
with an elec
elec--
connectors. tronics cleaner.
4. Ai
Airr is in the
the fuel
fuel sy
syst
stem
em.. 4. Ref
Refer
er to
to Corre
Correcti
ction
on 6.
6. of Pro
Proble
blem
m
2. in this troubleshooting chart.
5. Truc
ruck
k paras
parasiti
itics
cs are
are exces
excessiv
sive.
e. 5. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
19. in this troubleshooting chart.
6. Incorr
Incorrect
ect fue
fuell grade
grade is being
being use
used
d 6. Use the corcorrec
rectt grade
grade of fue
fuel.
l.
or fuel quality is poor.

31. Fault code warning

warning 1. Dia
Diagno
gnosti
stic
c sho
shorti
rting
ng plu
plug
g is 1. Remove
Remove the dia
diagno
gnosti
stic
c short
shorting
ing
lamps stay on (no installed. plug.
apparent reason) 2. Ele
Electr
ctronic
onic fau
fault
lt code
codes
s are act
active
ive.. 2. Refer
Refer toto Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
2. in this troubleshooting chart.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-25
 Problem Cause Correction

32. Fault code

code warning
warning 1. Ign
Igniti
ition
on swit
switch
ch is
is in the
the OFF
OFF posi-
posi- 1. Turn the
the ignit
ignition
ion swit
switch
ch to the ON
lamps do not illu- tion. position.
minate
2. Bat
Batter
tery
tronic ycontrol
voltage
volta ge supply
suppl
module y(ECM)
to the
theiselec-
ellow,
ec- 2. Che
Check
ck the bat
batter
tery
y conn
connect
ection
ions.
s.
interrupted, or open.

33. Fuel is
is in the oil 1. Eng
Engine
ine idl
idle
e time
time is exc
excess
essive
ive.. 1. Low oil and coo
coolan
lantt tempe
temperatrature
ures s
can be caused by long idle time
(greater than 10 minutes). Shut off
the engine rather than idle for long
periods. If idle time is necessary
necessary,,
raise the idle speed.
2. Bul
Bulk
k oil
oil suppl
supply
y is con
contam
taminat
inated.
ed. 2. Che
Check
ck the bul
bulk
k oil sup
supply
ply.. Dra
Drainin
the oil and replace with non-conta-
minated oil. Replace oil filter
filter..

34. Intak
Intake
e manifold
manifold air 1. Charge
Charge airair coole
coolerr fins,
fins, radi
radiato
atorr fins,
fins, 1. Ins
Inspec
pectt the charg
charge e air coole
coolerr, radia-
radia-
temperature is or air conditioner condenser fins tor, and air conditioner condenser
above normal are damaged or obstructed with fins. Clean if necessary
necessary..
debris.
2. Fan dri
drive
ve belt
belt is loos
loose e or brok
broken.
en. 2. Che
Checkck the fan dri
drive
ve bel
belt.
t. Tigh
ighten
ten
drive belt if necessary Replace
belt if required.
3. Fan shr
shroud
oud is dama
damaged ged or miss
missing
ing,, 3. Ref
Refer
er to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blemm
or the air recirculation baffles are 11. in this troubleshooting chart.
damaged or missing.
4. Tru
ruck
ck spe
speed
ed isis too
too low
low for
for 4. Red
Reduce
uce the eng
engine
ine loa
load.
d. Inc
Increa
rease
se
adequate cooling with high engine the engine (fan) rpm by downshift-
load. ing.
5. Truc
ruck
k cool
cooling
ing sys
system
tem is not 5. Veri
erify
fy that
that the eng
engine
ine and trutruck
ck
adequate. cooling systems are using the cor-
rect components.
6. Ele
Electr
ctroni
onicc fault
fault codes
codes are acti
active.
ve. 6. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blemm
2. in this troubleshooting chart.
7. Fan dri
drive
ve or
or fan
fan contr
controls
ols are mal
mal-- 7. Che
Checkck the
the fan
fan driv
drivee and
and contr
controls
ols..
functioning.
8. In
Inco
corr
rrec
ectt fa
fan.
n. 8. Che
Checkck the fan par
partt numb
number er and
compare it to the truck manufactur-
er’s fan part number.
9. Exh
Exhaus
austt syste
system m is leak
leaking
ing hot air 9. Che
Checkck the exh
exhaus
austt plum
plumbin
bing g for
for
into engine compartment. leaks or broken components.

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1-26 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

35. Intak
Intake
e manifold
manifold 1. Air int
intake
ake or exh
exhaus
austt leak
leaks.
s. 1. Refer
Refer to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blem
m
pressure (boost) is 20. in this troubleshooting chart.
below normal
2. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 2. Check
Che ck Replace
tions. air intake
air intakeair
system
syst emiffor
filter for restric-
restric-
required.
3. Cha
Charge
rge air coo
cooler
ler is rest
restric
ricted
ted or 3. Ins
Inspec
pectt the
the charge
charge air
air coole
coolerr for air
leaking. restrictions or leaks.
4. Ele
Electr
ctronic
onic fau
fault
lt code
codes s are act
active
ive.. 4. Ref
Refer
er to
to Corre
Correcti
ction
on 2.2. of Pro
Proble
blem
m
2. in this troubleshooting chart.
5. Eng
Engine
ine pow
power
er out
output
put is low
low.. 5. Ref
Refer
er to
to Proble
Problemm 20.
20. in thi
this
s trou-
trou-
bleshooting chart.

36. Lubric
Lubricating
ating oil 1. Crankc
Crankcase
ase ven
ventil
tilati
ation
on syst
system
em is
is 1. Che
Check
ck and cle
clean
an the ven
ventt tube.
tube.
consumption is plugged.
excessive 2. Oil does not mee
meett speci
specific
ficati
ations
ons.. 2. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m

3. Oil dra
drain
in inte
interva
rvall is exc
excess
essive
ive.. 3. 8.
Veriinfythis
erify thetroubleshooting
the correct oil
correct drainchart.
oil drain interval.
interval.
4. Ex
Exte
tern
rnal
al oi
oill leak
leak.. 4. Ref
Refer er tto
o Corre
Correcti
ction
on 5.
5. of Pro
Proble
blem
m
8. in this troubleshooting chart.
5. Veri
erifyfy the
the oil
oil consum
consumptiption
on rate.
rate. 5. Che
Check ck the amo
amount
unt of oil add
added
ed
versus the hours of operation.
6. Oill lev
Oi level
el is to
tooo high
high.. 6. Che
Check ck the oil lev
level.
el. Veri
erify
fy the oil
pan capacity.
capacity. Drain the excess oil
if necessary.
necessary. Fill the system
system to the
specified level.
7. Turb
urbochocharg
argerer oil
oil seal
seal is lea
leakin
king.
g. 7. Che
Check ck the
the turb
turboch
ocharg
arger
er comp
compres
res--
sor and turbine seals.
8. Lubric
Lub ricati
ating
ng oil
oil is cont
contami
aminat
nated
ed wi
with
th 8. Ref
Refer er to
to Proble
Problemm 10.
10. in thi
this
s trou-
trou-
coolant or fuel. bleshooting chart.
9. Air comp
compresressor
sor is
is pumping
pumping lub
lubric
ricat-
at- 9. Che
Check
ck the
the air
air lines
lines for
for carbo
carbon
n build-
build-
ing oil into the air system. up and lubricating oil.

37. Lubric
Lubricating
ating oil 1. Bul
Bulk
k oil
oil suppl
supply
y is con
contam
tamina
inated
ted.. 1. Refer
Refer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
sludge in the 33. in this troubleshooting chart.
crankcase is 2. Coolan
Coolantt temp
temperat
erature
ure is bel
below
ow 2. Ref
Refer
er to
to Proble
Problem m 16.
16. in thi
this
s trou-
trou-
excessive normal. bleshooting chart.
3. Cra
Crankc
nkcase
ase ven
ventil
tilati
ation
on syst
system
em is
is 3. Che
Checkck and cle
clean
an the cra
crankc
nkcase
ase
plugged. breather and vent tube.
4. Inc
Incorr
orrect
ect fue
fuell grade
grade is being
being use
usedd 4. Use the cor
correc
rectt grade
grade of fue
fuel.
l.
or fuel quality is poor.
5. Oil does not meemeett speci
specific
ficati
ations
ons.. 5. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
8. in this troubleshooting chart.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-27
 Problem Cause Correction

38. Tu
Turbocha
rbocharger
rger 1. Engine
Engine is bei
being
ng ope
operat
rated
ed for 1. Oper
Operat
atee engin
engine
e under
under load
loaded
ed
leaks engine oil or extended periods under light or no conditions.
fuel load conditions.
2. Lub
Lubric
ricati
ating
ng oil
oil or fue
fuell is ent
enteri
ering
ng 2. Remove
Remove the int intake
ake and exh
exhaus
austt
the turbocharger. piping, and check for oil or fuel.
3. Turb
urboch
ocharge
argerr drai
drain
n line
line is 3. Rem
Removeove the tur
turboc
bochar
harger
ger dra
drain
in
restricted. line, and check for restriction.
Clean or replace the drain line.
4. Lub
Lubric
ricati
ating
ng oil lin
lines
es leak oil
oil.. 4. Che
Checkck all
all oil
oil lines
lines and fitt
fitting
ings
s for
for
leaks. Tighten loose fittings and
replace leaking oil lines if neces-
sary.
5. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 5. Che
Checkck air
air intake
intake syst
system
em for
for restri
restric-
c-
tions. Replace air filter if required.
6. Exh
Exhaus
austt syst
system
em is res
restri
tricte
cted.
d. 6. Che
Checkck exha
exhaust
ust sys
system
tem for rest
restric
ric--
tions.

7. Crankc
Crankcase
ase ven
plugged. ventil
tilati
ation
on syst
system
em isis 7. Check
Che ck and
breather andclean
clean the
ventthe crankca
cran
tube. kcasese
8. Turb
urboch
ocharge
argerr oil
oil seal
seal is lea
leakin
king.
g. 8. Che
Check
ck the tur
turboc
bochar
harger
ger com
compre
pres-
s-
sor and turbine seals.
9. Wh
Whit
ite
e smo
smoke
ke is pr
pres
esen
ent.
t. 9. Ref
Refer
er to
to Probl
Problem
em 25.
25. in
in this
this trou-
trou-
bleshooting chart.

39. Engine noise is 1. Eng

Engine
ine oil lev
level
el is
is below
below nor
normal
mal.. 1. Check
Check the oil lev
level.
el. Fil
Filll the
the sys
system
tem
excessive to the specified level.
(Connecting Rod) 2. Engine
Engine oil pre
pressu
ssure
re is bel
below
ow 2. Che
Checkck the oil pre
pressu
ssure.
re. If the prepres-s-
normal. sure is low, refer to Problem 8. in
this troubleshooting chart.
3. Oi
Oill is
is thi
thin
n or
or dil
dilut
uted
ed.. 3. Ref
Referer to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem m
22. in this troubleshooting chart.
4. Block
Block stif
stiffen
fener
er plat
plate
e is mis
misas-
as- 4. Rem
Removeove and
and inspe
inspectct block
block stif
stiffen
fener
er
sembled. plate. Re-assemble block stiffener
plate if required.
5. Lubric
Lubricati
ating
ng oil
oil suctio
suction
n or tran
transfe
sferr 5. Rem
Removeove and
and insp
inspect
ect the lublubric
ricati
ating
ng
tube misassembled. oil suction or transfer tube. Re-as-
semble oil suction or transfer tube
if required.
6. Cranks
Crankshaf
haftt jour
journal
nals
s are
are dama
damaged
ged 6. Ins
Inspec
pectt the cra
cranks
nkshaf
haftt jou
journa
rnals.
ls. If
or out of round. found damaged or out of round,
replace journals.
7. Connec
Connectin
ting
g rod cap
capscr
screws
ews are 7. Che
Checkck the tor
torque
que on thethe conn
connectect--
loose or not tightened correctly. ing rod capscrews. Tighten to the
correct torque value if required.
8. Connec
Connectin
ting
g rod
rod is ben
bentt or out of 8. Rem
Removeove and ins
inspec
pectt the
the conne
connect- ct-
alignment. ing rods. Replace or re-align con-
continued necting rod.

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1-28 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
 Problem Cause Correction

39. Engine noise

noise is 9. Connec
Connectin
ting
g rod
rod and
and beari
bearings
ngs are 9. Inspec
Inspectt the
the con
connec
nectin
ting
g rod
rod and
excessive damaged or worn, are not bearings. Replace damaged parts
(Connecting Rod) assembled correctly, or are the or incorrect bearings if required.
(Continued) wrong bearings. Re-assemble connecting rod and
bearings if necessary.

40. Engine noise is 1. Engi

Engine
ne oil
oil pres
pressu
sure
re is bel
below
ow 1. Check
Check the oil pre
pressu
ssure.
re. If the pre
pres-
s-
excessive normal. sure is low, refer to Problem 8. in
(Main Bearing) this troubleshooting chart.
2. Eng
Engineine oil lev
level
el is
is below
below nor
normal
mal.. 2. Che
Checkck the oil lev
level.
el. Fil
Filll the
the sys
system
tem
to the specified level.
3. Oi
Oill is
is thi
thin
n or
or dil
dilut
uted
ed.. 3. Ref
Refer
er to
to Corre
Correcti
ction
on 2.
2. of Pro
Proble
blemm
22. in this troubleshooting chart.
4. Mai
Main n beari
bearing
ng caps
capscre
crews
ws are
are loos
loose,
e, 4. Ch
Chec
eckk the
the torq
torque
ue on
on the
the main
main
worn or not tightened correctly. bearing capscrews. Inspect the
capscrews for wear
wear.. Tighten caps-
crews to worn
Replace the correct torque value.
capscrews.
5. Main
Main bea
beari
ring
ngs
s are
are dama
damage
ged
d or 5. Inspec
Inspectt the
the main
main bea
bearin
rings
gs for
for dam-
dam-
worn, or the wrong bearings are age, excessive wear, and the cor-
installed. rect part number. Replace main main
bearings if required.
6. Block
Block stif
stiffen
fener
er plat
plate
e is mis
misas-
as- 6. Remove
Rem ove and
and inspe
inspect
ct block
block stif
stiffen
fener
er
sembled. plate. Re-assemble block stiffener
plate if required.
7. Cranks
Crankshaf
haftt journ
journals
als are dam
damage
agedd 7. Refer
Ref er to
to Corre
Correcti
ction
on 6.
6. of Pro
Proble
blem
m
or out of round. 39. in this troubleshooting chart.
8. Fly
Flywhe
wheel
el or
or flexp
flexplat
late
e capsc
capscrew
rews
s 8. Check
Che ck the
the flyw
flywheel
heel or flexp
flexplat
late
e and
are loose or broken. the mounting capscrews. Tighten
capscrews to the correct torque
value. Replace damaged caps-
crews.

41. Engine noise is 1. Electr

Electronic
onic fau
fault
lt codes
codes act
active
ive or 1. Read
Read the
the fault
fault cod
codes
es with
with an elec
elec--
excessive high counts of inactive fault codes. tronic service
service tool. Refer toto
(Piston) Correction 2. of Problem 2. in this
troubleshooting chart.
2. Incorr
Incorrect
ect fue
fuell grade
grade is being
being use
used
d 2. Use the cor
correc
rectt grade
grade of fue
fuel.
l.
or fuel quality is poor.
3. Ov
Overerhe
head
ad adju
adjuststme
mentnts
s are 3. Measur
Measure e and
and adjus
adjustt the
the over
overhea
headd
incorrect. settings.
4. Inj
Inject
ector
or is mal
malfun
functi
ctioni
oning.
ng. 4. Per
Perfor
form
m the
the aut
automa
omated
ted cyl
cylind
inder
er
performance test (refer to engine
manufacturer’s Troubleshooting

continued and Repair

injectors Manual). Replace
if required.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-29
 Problem Cause Correction

41. Eng
Engine
ine noise is 5. Connec
Connectin
ting
g rod
rod is ben
bentt or out of 5. Refer
Refer to
to Corre
Correcti
ction
on 8.
8. of Pro
Proble
blem
m
excessive alignment. 39. in this troubleshooting chart.
(Piston)
(Continued) 6. Con
Connec
nectin
ting
g rod
rod is mis
misass
assemb
embled
led.. 6. ing
Remove
Rem ove and
rods. inspec
inspectt the
Re-assemble theconnecting
connect-
conne ct-
rods if required.
7. Piston
Piston or pist
piston
on rings
rings are wor
worn
n or 7. Che
Checkck for
for air
air intake
intake syst
system
em leak
leaks.
s.
damaged. Check the pistons and piston rings
for wear or damage. Replace worn worn
or damaged pistons and piston
rings.
8. Pi
Pist
ston
on is
is misa
misass
ssem
embl
bled
ed.. 8. Rem
Removeove and ins
inspec
pectt the
the pist
piston.
on.
Re-assemble piston.
9. Piston
Piston pin or bus
bushin
hing
g is
is loos
loose,
e, 9. Rem
Removeove the pis
piston
tons
s and
and ins
inspec
pectt
worn, or not installed correctly. the piston pin and bushing for dam-
age, wear, and correct installation.
Re-install piston pin and bushing.
Replace piston pin or bushing if
required.

42. Engine noise is 1. In

Inco
corr
rrec
ectt tu
turb
rboc
ocha
harg
rger
er.. 1. Check
Check the turturboc
bocharg
hargerer part
part num
num--
excessive ber and compare it to the Control
(Turbocharger) Parts List (CPL).
(CPL). Replace turbo-
charger if required.
2. Air int
intake
ake sys
system
tem is rest
restric
ricted
ted.. 2. Che
Checkck air
air intake
intake syst
system
em for
for restri
restric-
c-
tions. Replace air filter if required.
3. Air inta
intake
ke or exh
exhaus
austt syste
system m lea
leaks.
ks. 3. Ref
Refer
er to
to Corre
Correcti
ction
on 4.
4. of Pro
Proble
blem
m
20. in this troubleshooting chart.
4. Exhaus
Exh austt syst
system
em is res
restri
tricte
cted.
d. 4. Che
Checkck exha
exhaust
ust sys
system
tem for rest
restric
ric--
tions.
5. Turb
urboch
ocharge
argerr is worn
worn or damdamageaged.
d. 5. Che
Checkck the tur
turboc
bochar
harger
ger for
damage.
required. Replace turbocharger if

43. Air compresso

compressorr air 1. Air inta
intake
ke syste
system
m restri
restricti
ction
on to air
air 1. Check
Check the air int
intake
ake pip
piping.
ing. Che
Checkck
pressure rises compressor is excessive. engine air intake restriction if the
slowly air compressor inlet is plumbed to
the vehicle or equipment intake
system.
2. Ai
Airr sys
syste
tem
m lea
leaks
ks.. 2. Blo
Block
ck the
the truc
truck
k wheel
wheelss and
and check
check
the air system for leaks with the
parking brake applied and
released. Check for leaks from the
air compressor gaskets and the air
system hoses, fittings, tanks, and
valves.

continued

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1 30 TX / TXH / TXB 180S 400L (Rev. 4/23/07)

Problem Cause Correction

43. Air compress

compressor
or air 3. Car
Carbon
bon buil
buildup
dup is exces
excessiv
sive
e in the
the 3. Check
Check for
for carb
carbon
on buil
buildup.
dup. RepReplac
lace
e
pressure rises air discharge line, downstream air the air compressor discharge line,
slowly (Continued) valves, or cylinder head. if necessary.
4. Air gov
governo
ernorr is mal
malfun
functi
ctioni
oning
ng or
or 4. Rep
Replac
lace
e air gov
govern
ernoror ifif defect
defective
ive or
not set correctly. readjust the air governor for the
proper pressure (refer to Air Gov-
ernor in Section 15 for adjustment
procedures).
5. Air syst
system
em comp
compone
onent
nt is
is malfu
malfunc-
nc- 5. Che
Checkck the ope
operat
ration
ion of che check
ck
tioning. valves, air dryer (if equipped), and
other air system components.

44. Air compr

compressor
essor 1. Ai
Airr sys
syste
tem
m lea
leaks
ks.. 1. Refer
Refer tto
o Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
cycles frequently 43. in this troubleshooting chart.
2. Air gov
governo
ernorr is mal
malfun
functi
ctioni
oning
ng or
or 2. Ref
Refer
er to Corre
to Correcti
ction
on 4.
4. of Pro
Proble
blem
m
not set correctly. 43. in this troubleshooting chart.
3. Carbon
Carbon buil
buildup
dup is exces
excessiv
sive
e in the
the 3. Refer
Refer to
to Corre
Correcti
ction
on 3.
3. of Pro
Proble
blem
m
air discharge line, downstream air 43. in this troubleshooting chart.
valves, or cylinder head.
4. Air com
compre
presso
ssorr pumpi
pumping
ng time
time is 4. Check
Check the air comcompre
presso
ssorr duty
duty
excessive. cycle.
5. Air syst
system
em comp
compone
onent
nt is
is malfu
malfunc-
nc- 5. Ref
Refer
er to
to Corre
Correcti
ction
on 5.
5. of Pro
Proble
blem
m
tioning. 43. in this troubleshooting chart.
6. Air drye
dryerr outlet
outlet chec
check
k valve
valve is
is stick-
stick- 6. Lub
Lubric
ricate
ate or repl
replace
ace the air dry
dryer
er
ing (if equipped with air dryer). outlet check valve assembly.

45. Air compr

compressor
essor 1. Carbon
Carbon buil
buildup
dup is exces
excessiv
sive
e in the
the 1. Refer
Refer to
to Corre
Correcti
ction
on 3.
3. of Pro
Proble
blem
m
noise is excessive air discharge line, check valve, or 43. in this troubleshooting chart.
cylinder head.
2. Ice bui
buildu
ldup
p in the air sys
system
tem com
com--
2. Check
Check for
for ice
ice in low
low spot
spotss of the air
ponents. discharge line, dryer inlet (if
equipped), and elbow fittings. On
Holset models, also check the
Econ valve (if equipped).
3. Air com
compre
presso
ssorr mount
mounting
ing har
hardwa
dware
re 3. Che
Check
ck air com
compre
presso
ssorr moun
mountin
ting
g
is loose, worn, or broken. hardware. Replace any mounting
hardware that is broken.

46. Air compress

compressor or is 1. Lubric
Lubricati
ating
ng oil
oil drai
drain
n inter
interval
val is 1. Veri
erify
fy the
the corre
correct
ct lubr
lubrica
icatin
tingg oil
pumping excess excessive. drain interval.
lubricating oil into 2. Air inta
intake
ke syst
systemem restr
restrict
iction
ion to
to air 2. Ref
Refer
er to
to Corre
Correcti
ction
on 1.
1. of Pro
Proble
blemm
the air system compressor is excessive. 43. in this troubleshooting chart.
3. Air com
compre
presso
ssorr pumpi
pumpingng time
time is 3. Che
Checkck the air com
compre
presso
ssorr duty
duty
excessive. cycle.
continued

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 TX / TXH / TXB 180S 400L (Rev. 4/23/07) 1 31

Problem Cause Correction

46. Air compres

compressor
sor is 4. Carbon
Carbon buil
buildup
dup is
is exces
excessiv
sive
e in the
the 4. Refer
Refer to
to Corre
Correcti
ction
on 3.
3. of Pro
Proble
blem
m
pumping excess air discharge line, check valve, or 43. in this troubleshooting chart.
lubricating oil into cylinder head.
the air system 5. Con
Contam
taminan
inants
ts are bui
buildi
lding
ng up
up in
in 5. Dra
Drain
in the res
reserv
ervoir
oirs
s dail
daily
y.
(Continued) the system reservoirs.
6. Eng
Engine
ine oil pre
pressu
ssure
re is abo
above
ve 6. Check
Check the engengine
ine oil pre
pressu
ssure.
re.
normal. Refer to Problem 9. in this trouble-
shooting chart.
7. Ai
Airr comp
compre
ress
ssor
or run
runss hot.
hot. 7. If the
the coola
coolant
nt temp
tempera
eratur
ture
e is abov
abovee
normal, refer to Problem 11. in this
troubleshooting chart.
8. Air com
compre
presso
ssorr is pum
pumpin
pingg too
too high
high 8. Che
Checkck the
the air
air gove
governo
rnorr for
for corre
correct
ct
air pressure. operation. Reset air governor
setting if required.

47. Air compress

compressor
or will 1. Ai
Airr sys
syste
tem
m lea
leaks
ks.. 1. Refer
Refer tto
o Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
not maintain ade- 43. in this troubleshooting chart.
quate air pressure 2. Air govgovern
ernor
or is
is malf
malfunc
unctio
tionin
ning
g or 2. Ref
Refer
er to Corre
to Correcti
ction
on 4.
4. of Pro
Proble
blem
m
(not pumping con- not set correctly. 43. in this troubleshooting chart.
tinuously)

48. Air compr

compressor
essor 1. Ai
Airr sys
syste
tem
m lea
leaks
ks.. 1. Refer
Refer tto
o Corre
Correcti
ction
on 2.
2. of Pro
Proble
blem
m
will not not stop 43. in this troubleshooting chart.
pumping 2. Air gov
govern
ernor
or is
is malf
malfunc
unctio
tionin
ning
g or 2. Ref
Refer
er to Corre
to Correcti
ction
on 4.
4. of Pro
Proble
blem
m
not set correctly. 43. in this troubleshooting chart.
3. Unl
Unload
oader
er valv
valve
e is mal
malfun
functi
ctioni
oning.
ng. 3. Check
Check the unlunload
oaderer val
valve
ve and
unloader body seal.
4. Air gov
govern
ernor
or sign
signal
al line
line or
or actua
actuator
tor 4. Ins
Inspec
pectt the
the signal
signal line
line and
and actua
actuator
tor
line is plugged. line.
5. Air sys
system
tem com
compone
ponentnt is
is malfu
malfunc-
nc- 5. Ref
Refer
er to
to Corre
Correcti
ction
on 5.
5. of Pro
Proble
blem
m
tioning. 43. in this troubleshooting chart.

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1 32 TX / TXH / TXB 180S 400L (Rev. 4/23/07)

Cummins QSB6.7 Diesel Engine

Engine Operating Conditions 2200 rpm
Lubrication System English Metric
Lubricating oil pressure (at max. rated speed) . . . . . . . . . . . . . . . . . . . . psi (kPa) 55.1 380
Minimum for safe operation (at idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (kPa) 10 69
*Lubrication oil temperature maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . F ( C)
  280.4 138
Total engine oil capacity with filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . qt (L) 15 14.2
Air System
Air inlet restriction, Dirty air cleaner . . . . . . . . . in H2O (kPa) 25 6.2
full load maximum
Clean air cleaner . . . . . . . . in H2O (kPa) 15 3.7
Exhaust back pressure maximum full load . . . . . . . . . . . . . . . . . . . . . in Hg (kPa) 3.01 10.2
Max. allowable temp. rise ambient air to eng. inlet . . . . . . . . . . . . . delta F ( C)   30.6 17
Fuel System
Maximum fuel inlet restriction Dirty fuel filter . . . . . . . . . . . . in Hg (kPa) NA NA
Clean fuel filter . . . . . . . . . . . in Hg (kPa) 6 20
Maxi
Maximu
mum
m fuel
fuel drain
drain res
restr
tric
icti
tion
on bef
befor
ore
e (or
(or with
withou
out)
t) che
check
ck val
valve
ve . . . in Hg (kP
(kPa)
a) 5.9 20
Maximum fuel flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lb/hr (kg/hr) 452 205
Cooling System
Coolant flow Normal temp. . . . . . . . . . . . . . . . . F ( C)  198 92
Full load speed . . . . . . . gal/min (L/min) 64 243
Engine coolant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . qt (L) 10.6 10
Min. pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (kPa) 15 103
Max. pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (kPa) 40 276
Full ON Fan engine coolant outlet temperature . . . . . . . . . . . . . . . . . . . . F ( C)
  195.8 91
Intake manifold air temperature derate/alarm temperature . . . . . . . . . . F ( C)
  205 96
 

Shutter opening coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . F ( C) 195.8 91

Thermostats Start to open . . . . . . . . . . . . . . . . F ( C)   190 88
Fully open . . . . . . . . . . . . . . . . . . F ( C)  205 96
*The lubricating oil temperature range is based on the the temperature measurement in the oil gallery.
gallery. When measur-
ing the oil temperature in the pan, it will normally be approximately 10 F higher than the oil gallery temperature.


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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-33

Hoist Circuit

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1-34 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

PLACE THE FOLLOWING ILLUSTRATIONS IN

FOLDER ENVELOPES:
Illustration 1-6 - 06B-2234 (Engine Electrical ANSI)
Illustration 1-7 - CUMMINS QSB6.7 CM850 ECM
CIRCUIT

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-35

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 Hoist Circuit

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1-36 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 2

Fuel System

Introduction.
through a fuel /Fuel
wateris separator
drawn fromandthefuel
fuel tankby
tank
filter 1. Park
Par
the kparking
the truc
truck
k on ablock
brake, hard,the
hard, level
level surfac
surface,
wheels ine,both
apply
apply
the fuel pump. From here, the fuel is sent to the the directions to prevent movement of the truck
fuel rail and onto the fuel injectors. Unused fuel is and Lock Out & Tag Out the truck.
returned into the fuel tank.
2. Disconnect
Disconnect the wire harnes
harness
s from
from the water
water-in-
-in-
fuel sensor located on the bottom of the fuel /
 Death or serious injury could water separator
separator..
result from high
high pressure fuel spray.
spray. The fuel 3. Provid
Providee a suitable
suitable cont
contain
ainer
er to catch
catch drai
drained
ned
pump, high-pressure fuel lines, and fuel rail fuel and use the drain valve to drain fuel out of
contain very high-pressure fuel. Do not loosen the fuel / water separator for approximately
any fittings while the
the engine is running.
running. Wait 5 seconds (refer to procedure 2. of Draining
at least 10 minutes after shutting down the The Fuel / Water Separator in this section).
engine before loosening any fittings in the This will eliminate fuel from running over the
high-pressure fuel system to allow pressure to top of the filter upon removal.
decrease to a lower level.
4. Remove
Remove thethe fuel filt
filter
er and fuel
fuel / water
water sepa
separa-
ra-
Major Components. The fuel system consists consists of tor from the adapters with a strap wrench.
a fuel tank, fuel / water separator, fuel filter, fuel 5. Cle
Clean
an the
the area
area aroun
around
d the fil
filter
ter head
heads.
s.
injection pump, fuel rail, fuel injectors and fuel
lines. NOTE: Do not fill the fuel / water separator or fuel
Adding Fuel (Illustration 2-3).
2-3). When adding filter with fuel before installation as this will allow
diesel fuel to the fuel tank, make sure the fuel unfiltered fuel to enter the system and may cause
strainer is in the filler neck and free of debris. damage to fuel system components.
Adding fuel with the strainer removed could lead
6. Install
Install the fuel / water separa
separator
tor and
and fuel filte
filterr.
to debris entering the fuel tank, resulting in poor
Tighten them 1/2 turn after the seals contact
engine performance.
the adapters.
Changing The Fuel Filters (Illustrations 2-1 and
7. Install
Install the
the water–i
water–in–fuel
n–fuel senso
sensorr into
into the
the fuel
fuel /
2-2).. With the engine shut down, perform the
2-2)
water separator
separator..
following procedures to replace the fuel / water
separator and fuel filter. https://www.forkliftpdfmanuals.com/
filter. They should be replaced 8. Pri
Prime
me the
the fuel
fuel sys
system
tem (ref
(refer to Priming The
er to
periodically or more often if conditions warrant Fuel System in this section).
 (refer to the Preventive Maintenance chart in the
Draining The Fuel / Water Separator (Illustration
Appendices for fuel / water separator and fuel
2-1).. The fuel / water separator should be drained
2-1)
filter replacement intervals).
daily to remove water and sediments from the
fuel. Perform the following procedures to drain
 Death or serious injury could the water from the fuel / water separator:
result from a runaway truck. Park the truck on
a hard, level surface, apply the parking brake,
 Death or serious injury could
block the wheels in both directions to prevent
result from a runaway truck. Park the truck on
movement of the truck and Lock Out & Tag Out
a hard, level surface, apply the parking brake,
the truck.
block the wheels in both directions to prevent
movement of the truck and Lock Out & Tag Out
 Dispose of used fuel filters the truck.
and drained fuel in accordance to federal and
local regulations.  Death or serious injury could
result from high pressure
pressure fuel spray.
spray. Do not
 Mechanical tightening of the open high pressure fuel system other than
fuel / water separator may result in seal and / opening the fuel / water separator drain valve.
or cartridge damage.
damage. Tighten the
the fuel / water
separator by hand only
only..  Dispose of drained fuel in

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 2-1

accordance to federal and local regulations. 4. Push

Pus h the pump
the handle pump handl
handle
clockwise e
toin untitil into
until
lock it seat
seats
s and
place turn
turn
(note
that pump handle is in locked position in
 Do not overtighten the drain Illustration 2-1).
valve. Overtightening may cause thread
thread
damage. 5. St
Star
artt eng
engin
ine.
e.
1. Park the truc
truck
k on a hard,
hard, level
level surf
surface
ace,, apply
apply
the parking brake, block the wheels in both PRIMING PUMP
directions to prevent movement of the truck HANDLE
and Lock Out & Tag Out the truck.
2. Provide
Provide a suita
suitable
ble conta
containe
inerr to catch
catch draine
drained
d
water and open the drain valve (see Illustra-
tion 2-1) approximately 2 1/2 complete turns
counterclockwise. Drain the fuel / water sepa-
rator of water until clear fuel is visible.
3. Once
Once the water
water has
has drained
drained,, turn cloc
clockwi
kwise
se to
close the drain valve.
Priming The Fuel System (Illustration 2-1).2-1). The
fuel system has to be primed with fuel after new
fuel filters have been installed prior to starting
engine. Perform thethe following procedures to
prime the fuel system:

DRAIN
 Death or serious injury could
VALVE WATER-IN-FUEL
result from a runaway truck. Park the truck on
a hard, level surface, apply the parking brake, SENSOR
block the wheels in both directions to prevent
movement of the truck and Lock OutO ut & Tag Out Illustration 2-1. Fuel / Water Separator
the truck. https://www.forkliftpdfmanuals.com/
  Death or serious injury could
result from high pressure
pressure fuel spray.
spray. Do not
open high pressure fuel system. Only use
priming pump handle to prime the fuel system.

 Damage to the engine’s fuel

system components could result from
pre–filling the fuel filters prior to priming the
system in an attempt to reduce priming time.
Prime fuel system as explained below.
1. Park the truc
truck
k on a hard,
hard, level
level surf
surface
ace,, apply
apply
the parking brake and block the wheels in both
directions to prevent movement of the truck.
2. Unl
Unlock
ock the
the primin
priming
g pump
pump handle
handle by turn
turning
ing itit
counterclockwise.
3. Pump
Pump the hand
handle
le by pull
pulling
ing the
the handl
handle
e out-
out-
ward and pushing handle inward until resist- Illustration 2-2. Fuel Filter
ance is felt (approximately 140–150 strokes) to
prime the fuel system.

2-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

General Information
Fuel
Fuel Ca
Capa
paci
city
ty TX18
TX 180S
0S–2
–220
20S
S – 42 Ga
Gall
llon
ons
s
(159 Liters)
TX250S–360L, TXB180–300
and TXH300–400 – 53 Gallons
(201 Liters)

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 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 2-3

FUEL LEVEL
SENDING UNIT

FILLER
CAP

FILLER
NECK

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 FUEL TANK

Illustration
Illustra tion 2-3. Fuel Tank

2-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 3

Air Intake System

SAFETY
FILTER

AIR CLEANER
HOUSING

VACUATOR

PRECLEANER CAP

PRIMARY https://www.forkliftpdfmanuals.com/
FILTER
COVER
 LATCH
IF EQUIPPED

Illustration 3-1. Air Intake System Components

Components

Introduction. The air cleaner is designed to be Major Components (Illustration 3-1). 3-1). The air
serviced efficiently and quickly.
quickly. Intake air enters
enters cleaner consists of the primary filter, internal filter
the air cleaner through the cap or optional pre- indicator, safety filter, air cleaner housing, cap (or
cleaner. When the air reaches the inlet of thethe air optional precleaner), vacuator and an air restric-
cleaner housing, a helical ramp imparts a high- tion indicator
indicator..
speed circular motion to the intake air.
air. This action
separates up to 85% of the dust from the air by Servicing (Illustration
being operated 3-1). If thedusty
3-1).
under extremely equipment is
conditions,
centrifugal action. The dust is then forced out the
the vacuator should be checked every day to be
vacuator. The air then passes through the the primary
certain it is not clogged. Perform the following
and safety filters, where the rest of the dust is
procedures to service the filters and air cleaner
removed, before the air enters the engine.
components. Overservicing of the filters is not
recommended. Filter efficiency
efficiency increases
increases with
initial operation.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 3-1

 Death or serious injury could nance chart in the Appendices

Appendices). ).
6. Replace
Replace the primar
primaryy filter
filter with
with a new filter
filter..
result from a runaway truck. Park the truck on
a hard, level surface, apply the parking brake, 7. Re
Re-i
-ins
nsta
tall
ll the
the cov
cover
er..
block the wheels in both directions to prevent
movement of the truck and Lock OutO ut & Tag Out NOTES:
the truck.  Ensure that cover gasket is assembled to
cover before re-installing the cover onto the air
cleaner housing.
 Replace the primary filter
periodically or when the air restriction  Never use the latches on the cover to force
indicator shows red (refer to the Preventive the primary filter into the air cleaner housing.
Maintenance chart in the Appendices for Using the latches to push the filter in could
primary filter
filter replacement
replacement interval). In dusty cause damage to the air cleaner housing. Do
conditions, the primary filter may have to be not use the cover to push the primary filter into
replaced more often. place.
8. Push
Push the res
reset
et butto
button n on the
the top
top of the
the air
air
 Replace the safety filter restriction indicator
indicator..
periodically (refer to the Preventive 9. Cle
Clean
an and
and inspec
inspectt the
the vacuat
vacuator
or..
Maintenance chart in the Appendices for
safety filter replacement interval). 10. Inspect the air intake system for leaks.

 Do Not use ether type fuels to

help start the engine for this may damage the
engine.
1. Park the
the truck
truck on a hard,
hard, level
level surf
surface
ace,, block
block
the wheels in both directions and apply the
parking brake.
2. When the airair restrict
restriction
ion indicat
indicator
or (see
(see Illustr
Illustra-
a-
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tion 3-2) indicates filter servicing (sight glass
 on indicator is red) is required or the service
interval has occurred, unlatch and remove the
cover. Remove the primary filter
filter.. In high
humidity situations, the air restriction indicator
may indicate a restricted condition due to
moisture in the filter.
filter. When the filter dries out,
restriction levels drop back to normal. The
indicator will now have to be reset (refer to
procedure 8. to reset the indicator).
3. Rem
Remove
ove the saf
safety
ety fil
filter
ter..
4. Remove
Remove all
all dust
dust and debri
debris
s from
from the air
air clean-
clean-
er housing with a water-dampened cloth.

 Do not use flammable liquids

Illustration 3-2. Air Restriction
Restriction Indicator
Indicator
to clean the inside of the air cleaner housing.
Only use a cloth dampened with water.
5. Re-install
Re-install the safet
safetyy filte
filterr. Replac
Replace
e safet
safety
y filter
if the safety filter replacement interval has
occurred (refer to the Preventive Mainte-

3-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Air Intake System Troubleshooting

Troubleshooting
Problem Cause Correction

1. Shor
Shortt fil
filte
terr lif
life
e 1. Imprope
Improperr assem
assembly
bly whe
when
n prior
prior filt
filter
er 1. Pr
Prop
oper
erly
ly ins
insta
tall
ll..
(primary filter) was replaced.
2. Dam
Damaged
aged or miss
missing
ing vac
vacuat
uator
or.. 2. Re
Repl
plac
ace
e va
vacu
cuat
ator
or..
3. Dama
Damaged
ged se
seal
al on
on the
the cove
coverr 3. Repl
Replac
ace
e seal
seal on
on the
the cove
coverr
assembly. assembly.
4. Da
Dama
maged
ged air
air clea
cleane
nerr body
body. 4. Re
Repl
plac
ace
e air cle
clean
aner
er body
body..
5. Lat
Latch
ch on cov
cover
er is unc
unclam
lamped
ped.. 5. Cl
Clam
amp
p lat
latch
ch do
down
wn..
6. Exc
Excess
essive
ively
ly dust
dusty
y envir
environm
onment
ent.. 6. Re
Repl
plac
ace
e filt
filter
er as
as need
needed
ed..
7. Inco
Incorr
rrec
ectt fil
filte
terr used.
used. 7. Replac
Replacee with
with pro
proper
per fil
filter
ter..
8. Sea
Seall on dus
dustt cove
coverr is not sea
sealin
ling.
g. 8. Ens
Ensure
ure tha
thatt no for
foreign
eign obj
object
ect is
between seal and metal mating
surface.

2. Shor
Shortt fil
filte
terr lif
life
e 1. Byp
Bypass
assing
ing pri
primar
mary
y fil
filter
ter.. 1.
(safety filter)
a. Seal
Seal of prim
primary
ary fil
filter
ter is not
not seal
seal-- a. Re
Repl
plac
ace
e fil
filte
terr.
ing.
b. Da
Dama
mage
ged
d prima
primary
ry fil
filte
terr. b. Re
Repl
plac
ace
e prima
primary
ry filt
filter
er..

3. Airb
Airbor
orne
ne con
conta
tami
mi-- 1. Da
Dama
mage
ged
d filte
filter(
r(s)
s).. 1. Re
Repl
plac
ace
e fi
filt
lter
er(s
(s).
).
nants entering the
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engine 2. Damaged
Damaged sea
seals
ls or sea
sealin
ling
g sur-
sur- 2. Rep
Replac
lace
e dam
damage
aged
d com
compon
ponent
ents.
s.
faces.
 3. Damaged
Damaged or loo
loose
se con
connec
nectio
tions
ns 3. Rep
Replac
lace
e or
or repa
repair
ir con
connec
nectio
tions.
ns.
between air cleaner body and
engine.
4. In
Inco
corr
rrec
ectt fil
filte
terr used.
used. 4. Rep
Replac
lace
e with
with pro
proper
per fil
filter
ter..

4. Air
Air res
restr
tric
icti
tion
on in
indi
di-- 1. Restri
Restricti
ction
on in air hose
hose betw
between
een the
the 1. Re
Remo
move
ve re
rest
stri
rict
ctio
ion.
n.
cator indicates pri- air restriction indicator and the
mary filter is good, safety fitting.
but primary filter is
clogged 2. Air lea
leakk in air hos
hose
e betwe
between
en the
the air
air 2. Re
Repai
pairr or rep
repla
lace
ce air
air hos
hose.
e.
restriction indicator and the safety
fitting.
3. Dam
Damaged
aged air
air restri
restricti
ction
on indica
indicator
tor.. 3. Rep
Replac
lace
e air restr
restrict
iction
ion indic
indicato
atorr.
4. Da
Dama
maged
ged saf
safet
ety
y fitt
fittin
ing.
g. 4. Re
Repl
plac
ace
e safe
safety
ty fit
fitti
ting.
ng.
5. Lo
Loos
ose
e syste
system
m conne
connect
ctio
ions
ns.. 5. Tig
ight
hten
en conn
connec
ecti
tion
ons.
s.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 3-3

Hoist Circuit

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3-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 4

Exhaust System

Introduction. The exhaust

for venting exhaust system is by
gases, generated responsible
the 6. Kee
Keep
p exhaus
exhaustt syste
system
m free
free of deb
debris
ris..
Exhaust Purifier (if equipped).
equipped). The exhaust puri-
engine, to the atmosphere. It also provides noise
fier converts up to 90% of the harmful diesel
suppression.
exhaust gases, such as carbon monoxide and
hydrocarbons, into harmless carbon dioxide and
 Do not service exhaust water vapor by forcing the exhaust gases to pass
system until exhaust system is cool. Failure through a porous ceramic honeycomb configured
to do so may result in severe burns. catalyst. This design promotes uniform gas flow
through the catalyst element while generating only
minimal back pressure.
 Keep all flammable materials
away from exhaust components.
 Avoid using fuel and oil addi-
tives which contain lead, sodium, arsenic,
 Avoid breathing toxic exhaust phosphorus, mercury, antimony, zinc, copper,
fumes.
tin,
will iron,
poisonnickel, and chrome.
chrome.
the exhaust These
purifier additives
and reduce its
 All internal combustion useful life.
engines produce carbon monoxide, which can Exhaust Purifier Maintenance (Illustration 4-1).4-1).
become concentrated in enclosed areas. If the diesel engine is allowed to idle for long peri-
Exposure to carbon monoxide can result in ods of time, the exhaust purifier may accumulate
serious injuries or health hazards, including deposits of soot. These deposits can block the
death. Properly ventilate work areas, vent effectiveness of the exhaust purifier and gradually
exhaust fumes, and keep shop clean and dry. reduce the engine’s power. The exhaust purifier
(A) Initial symptoms
symptoms of carbon monoxide
monoxide can be removed and cleaned using the proce-
poisoning include headaches, dizzi- dures listed below.
ness, and nausea. The smell of lift truck 1. Remove
Remove the the clamp
clamps
s to remov
remove
e the exha
exhaust
ust
exhaust means carbon monoxide is purifier from the exhaust system.
present.
2. Rem
Remove
ove clam
clamps
ps to rem
remove
ove the
the end
end cones
cones to
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(B) If
offyou
theexperience initial notify
initial
lift truck engine, sympto
symptoms,
ms, shut
your expose the catalyst.
 employer, and obtain medical attention. 3. Wash
Wash the
the exhaust
exhaust purif
purifier
ier by
by using
using steam
steam or
high pressure water [not greater than 100 psi
(7 bar)], keeping the tip of the nozzle at least 2
 Never rely on a control device inches away from the face
face of the catalyst. Do
to reduce carbon monoxide
monoxide output.
output. Carbon not use detergents.
detergents. Wash the exhaust purifier
monoxide levels can change depending on through both the inlet and outlet ends. Contin-
maintenance. Make sure carbon monoxide ue the washing operation until the water, com-
level testing is included in regular maint- ing from the exhaust purifier, is clear or almost
enance procedures and that ventilation is used clear.
as the primary control for emissions.
4. Dry the
the exhaus
exhaustt purifie
purifierr with
with compres
compressed
sed air
air
Maintenance. There is minimal maintenance (no greater than 100 psi), keeping the nozzle
required on the standard exhaust system. at least 2 inches (5.1 centimeters)
centimeters) away.
away. The
purpose of this operation is to remove as
1. Che
Check
ck for
for leaks
leaks at all
all pipe
pipe connec
connectio
tions.
ns.
2. Check
Check for
for holes
holes in the muf
muffle
flerr and exhaus
exhaustt much
sible. water from thepurifier
The exhaust exhaust purifier
should nowasbe
pos-
piping. clean.
3. Kee
Keep
p muffle
mufflerr guard
guard clea
clean
n and in place
place.. 5. Place
Place the
the exhaus
exhaustt purifi
purifier
er back
back into
into the
4. Ke
Keep
ep guar
guard
d clea
clean
n and in
in plac
place.
e. exhaust system
system and operate the engine. Be
sure to tighten all clamps and fittings as
5. Kee
Keep
p handl
handle
e clea
clean
n and
and in
in plac
place.
e. necessary.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 4-1

CLAMPS

Illustration 4-1. Exhaust Purifier

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4-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 5

Cooling System

Introduction. Thetoengine
the engine. Refer cooling
Section sys
system
9A for tem cools
transmission
cooling system and Section 15C for the wet disc
brakes cooling system to find more detailed cool-
ing information on these particular systems.
Major Components (Illustrations 5-3 and 5-4).5-4).
The engine cooling system consists of coolant,
radiator / charge air cooler, recovery bottle, hoses
connecting the radiator to the engine and a water
pump to circulate the coolant.
Operation (Illustration 5-4).
5-4). When the engine is
started, the water pump draws coolant from the
radiator into the engine block. The coolant is cir-
culated through the engine and the coolant filter
until
190 itF reaches a temperature
(88C), at of approximately
which point the thermostat will
start to open. This will allow coolant flow back into
the top of the radiator core.
Coolant. The cooling system of this equipment is
protected to -34F (-36C) and 228 F (110 C).
The solution is a 50 - 50 mixture of ethylene glycol
base antifreeze to water solution. Use soft water
in the coolant
coolant mixture. It is recommended that
Illustration 5-1. Coolant Level
50% solution be maintained year round.
Radiator (Illustration 5-3).
5-3). The radiator is force- Servicing The Cooling System
air-cooled. Access to its core is provided through
a 16 psi (110 kPa) radiator cap located on top of
the radiator. When changing the coolant, refer to  Severe injury may occur from
Draining / Flushing The Cooling System and burns. Radiator and cap can be hot. Heated
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Filling The Cooling System.
System. coolant can spray.
spray. Always shut down engine
engine
and allow to cool before attempting to open
 Charge Air Cooler (Illustration 5-3).
5-3). The engine the radiator cap or drain cock.
is equipped with a turbocharger which is driven by
engine exhaust. The exhaust turbine of the turbo-
charger is coupled to the intake turbine. The  Severe injury may occur from
exhaust turbine drives the intake turbine. The contact with moving engine parts. Always
intake turbine compresses the the intake air.
air. The act shut down engine before servicing or
of compressing the intake air generates heat and inspecting cooling system.
causes the air molecules to expand. To increase
combustion efficiency, a charge air cooler is inte-  Severe injury or death may
grated into the radiator.
radiator. The charge air cooler is occur from ingesting engine
engine coolant. Coolant
an air to air cooler.
cooler. By reducing the temperature
temperature is toxic. Keep away from
from children and pets.
of the intake air before it enters the piston cham- Dispose of coolant in accordance with federal
ber, the air becomes denser.
denser. The denser the air,
air, and local regulations.
the more during
chamber oxygencombustion.
will be present
Thein more
the piston
oxygen in Checking The Coolant Level (Illustration 5-1). 5-1).
the chamber, the hotter the combustion cycle The coolant level should be checked daily.
daily. Nor-
becomes. This results in a more complete burn- mally, the coolant level can be maintained by add-
ing of the
the fuel, emitting fewer pollutants. This ing coolant to the recovery bottle. The coolant
increase in combustion efficiency also creates level is full when the coolant is visible at the cold
lower engine operating temperatures, which pro- mark (engine has not been operated). If the cool-
longs the life of the engine and its’ components. ant level is too low, add coolant until the coolant

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 5-1

level reaches
recovery theDo
bottle. cold
notmark on
overfill. the side of the
overfill. fully open when205
approximately the coolant temperature reaches
 F (96 C).

Cooling Requirements. The following require-

ments must be followed for trouble-free operation General Information
of the cooling system.
Coolant Capacity 8 Gallons
1. Always
Always use
use a properl
properly
y corros
corrosion
ion inhib
inhibite
ited
d (30.3 Liters)
coolant.
2. Mai
Mainta
ntain
in prescri
prescribed
bed inhibi
inhibitor
tor stren
strength
gth.. Inspection. Components of the cooling system
should be checked periodically to keep the engine
3. Use low
low silicat
silicate
e antifre
antifreeze
eze with
with an ethyle
ethylene
ne operating at peak efficiency.
efficiency. The radiator and
glycol base. charge air cooler should be inspected externally
4. Always
Always follo
follow
w the manufa
manufactu
cturer’
rer’s
s recomme
recommen-
n- for excessive dirt or oil buildup. The radiator and
dations on inhibitor usage and handling. Refer charge air cooler should be cleaned externally as
to the engine operation and maintenance conditions warrant. The cooling system hoses
manual for coolant requirements. should be inspected
mally hard and any
or soft should hose that
be replaced is abnor-
immediately.
5. Do No
Nott use
use so
solu
lubl
ble
e oil
oil!! Check the hose clamps to make sure they are
6. Seal
Sealer
er type
type antifr
antifreez
eeze
e should
should Not
Not be used.
used. tight. All external leaks should be corrected as
soon as detected. The shroud should be tight
Draining / Flushing The Cooling System. The against the radiator core to prevent recirculation of
cooling system should be drained and flushed air which may lower cooling efficiency.
efficiency. Check the
periodically (refer to the Preventive Maintenance fan belts for proper tension.
chart in the Appendices for cooling system drain /
flush interval). The cooling system
system is drained by Charge Air Cooler Cleaning. The charge air
opening the drain cock on the bottom of the radia- cooler must be cleaned internally upon engine
tor. Removal of the radiator cap
cap will allow air to turbocharger failure or any other occasion where
enter the cooling passages, decreasing drain time oil or debris enters the charge air cooler.
cooler. Refer to
and ensuring that the coolant drains completely the engine manufacturers manual for cleaning
from the system.
system. Leave the drain cock
cock open until instructions.
all coolant has been allowed to drainhttps://www.forkliftpdfmanuals.com/
from the Drive Belt Tension. The proper tension should
system. belts. Refer to Drive
be maintained on all drive belts.
 Belt Tension in Section 1 for the proper tension
 When freezing weather is values.
expected, any cooling system not adequately Fan Ring Positioning (Illustration 5-2).
5-2). Perform
protected by antifreeze should be drained. the following procedures to correctly position the
engine fan ring:
Filling The Cooling System. Before starting the
engine, close the drain cock and fill the cooling
system by removing the 16 psi (110 kPa) cap  Death or serious injury could
located on top of the radiator.
radiator. Fill the radiator at result from a runaway truck. Park the truck on
this port. This will allow a quicker,
quicker, more efficient a hard, level surface, apply the parking brake,
method of filling the radiator.
radiator. If the capacity of the block the wheels in both directions to prevent
cooling system is unknown, measure the amount movement of the truck and Lock Out & Tag Out
of water necessary to fill the cooling system. the truck.
Drain the cooling system and refill with the desired
amounts of water and antifreeze or pre-mix to 1. Park
Park the truck
truck on hard
hard,, level
level surface
surface,, apply
apply the
proper proportions before filling. parking brake, block the wheels in both direc-
Coolant Temperature. When the engine warms tions to prevent movement, Lock Out & Tag
up, the indicator for the coolant temperature Out the truck, and allow the engine to cool.
gauge should be in the green temperature area 2. Positi
Position
on the
the engine
engine fan
fan ring to
to attain
attain equal
equal
[180 - 212 F (82 - 100 C)]. The thermostat will clearances [approximately 1/4 inch (6.4 mm)]
start to open at approximately 190 F (88C) and between all fan blades and engine fan ring

5-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

(refer to
to th
the le
left ph
photo in
in IlIllustration 5-
5-2). 3. Positioclearances
equal n th
the en
engin(”A”,
e fa
fanrefer
ring to
ri verIllustration
ve tically to
to at
at5-2).
tain

A
1/4” BOLT
1/4”

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 1/4 1/4
BOLT

Illustration 5-2. Fan Ring Positioning

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 5-3

16 PSI (110 kPa)

DEAERATION PRESSURE CAP

CHARGE AIR
COOLER HYDRAULIC
SYSTEM
COOLER

COOLANT
LEVEL
SENSOR
LOCATION

TRANSMISSION
OIL COOLER

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 FAN RING

RADIATOR
SHROUD

Illustration 5-3. Cooling Components

Components Identification
Identification

5-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Illustration 5-4. Engine Coolant

Coolant Circuit
Circuit

DEAERATION
LINE

COOLANT LEVEL
SENSOR

UPPER COOLANT
RADIATOR HOSE RECOVERY
BOTTLE

LOWER RADIATOR
RADIATOR
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HOSE
 CUMMINS QSB6.7
ENGINE

COOLANT FLOW
MAIN FLOW, THERMOSTAT OPEN
DEAERATION REMOVES UNWANTED AIR FROM COOLING CIRCUIT 05-2374

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 5-5

Hoist Circuit

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5-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 6

Electrical System

Introduction. This machine incorporates

incorporates a
12-Volt DC electrical system. Optional equipment  Overfilling cells of the battery
selected by the customer will determine the elec- can cause poor performance or early failure.
trical equipment to be installed in addition to the
standard electrical system. 1. Check the level of the
the electro
electrolyte
lyte regula
regularly
rly..
Major Components. The 12 volt electrical sys- Add distilled water if necessary to bring the
tem consists of a battery, battery charging alterna- electrolyte level to 3/8 inch (9.5 mm) above the
tor, voltage regulator, starter switch, starter, and separator plates. Do not overfill.
starter solenoid. The remainder of the electrical 2. Keep
Keep the top
top of the batte
battery
ry,, termin
terminals
als,, and
system consists of lights and / or gauges, cable clamps clean. When necessary,
necessary, wash
switches, circuit breakers, and accessory circuits. them with a solution of baking soda and water,
The above items are included as standard equip- and rinse with clean water.
ment in the electrical system. Refer to Illustrations
Illustrations
6-1 through 6-12 for location of components and
wiring diagrams.  Do not allow the soda and
Electrical Maintenance. All wiring harnesses, water solution to enter the battery cells.
battery cables and electrical connections should
be inspected for chaffing or wear periodically. 3. Inspec
Inspectt the cabl
cables,
es, clam
clamps,
ps, and
and hold
hold down
down
This is especially important where there is relative bracket regularly.
regularly. Replace any damaged
movement between the components. Clamps, parts. Clean and re-apply a light coating of
boots, and protective sleeves should be main- grease to the terminals and cable clamps
tained to prevent electrical shorts. when necessary.

NOTE: A number of devices and applications are

 Death or serious injury may available on the commercial market to deter corro-
occur from fire.
fire. Improper maintenance
maintenance of the sion on battery terminal connections.
electrical system can result in electrical shorts
which may cause fires. Regularly inspect
inspect and 4. Check
Check the
the electri
electrical
cal syste
system
m if the batt
battery
ery
maintain electrical harnesses, cables, and becomes discharged repeatedly.
electrical components as outlined in this 5. If the
the battery
battery indic
indicator
ator illumi
illuminates
nates,, the
the alterna-
alterna-
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manual. Ensure that harnesses are properly tor or alternator circuit is defective.
 routed and clamped after servicing the vehicle.
NOTE: If the truck is to be inoperative
inoperative or idle for
Battery. The machine is equipped with an indus- more than 30 days, remove the battery
battery.. The bat-
trial type, long life battery.
battery. The battery is perish- tery should be stored in a cool, dry place. The
able and requires servicing on a regular basis. electrolyte level should be checked regularly and
Batteries that are properly cared for can be the battery kept fully charged.
expected to give long trouble-free service.
Perform the following procedures to maintain the Booster Battery Connection Procedure. Acci-
battery in a serviceable condition: dentally reversing the battery connections must be
avoided. If a booster
booster battery is to be used, first
connect the positive (+) terminal of booster battery
 to the positive (+) terminal of discharged battery
 Under no circumstances allow
allow any sparks or and then connect the negative (-) terminal of
open flames around battery
battery.. No smoking. booster battery to engine or body ground (-)
Batteries produce a highly flammable gas (Refer to the
the decal below). Never cross polarity of
which could lead to battery explosion if the battery terminals. Disconnect cables in the
ignited. exact reverse order from above.
 Never check the battery by
by placing a metal
object across the battery posts.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-1

when engine is started. Once engine is acceler-

ated, the light should go out.

Alternator. The standard

standard alternator for the
Cummins QSB6.7 engine is a 130 amp alternator.
It should be expected 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 precautions
should be observed when working on or around
the alternator.
Avoid grounding the output wires or the field wires
between the alternator
alternator and the regulator. Never
run an alternator on an open circuit.
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Grounding an alternator’s output wires or termi-
nals, which are always hot regardless of whether
or not the engine is running or accidentally revers-
ing of the battery polarity, will destroy the diodes.
Grounding the field circuit will also result in the
destruction of the diodes. Some voltage regula-
tors provide protection against some of these cir-
cumstances; however, it is recommended that
extreme caution be used.
Never disconnect the battery while the alternator
is in operation. Disconnecting the
the battery will
result in damage to the diodes, caused by the
momentary high voltage and current induced by
the instantaneous collapse of the magnetic field
surrounding the field windings.

 Accidentally reversing the

battery polarity will destroy the diodes of the
alternator circuit.

NOTE: It is normal for alternator light to stay on

6-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 Illustration 6-1. Dash Panel

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-3

CB15 CB13 CB11 CB19 CB17

(10 AMP) (15 AMP) (30 AMP) (30 AMP) (20 AMP)
IGNITION SWITCH, ACCESSORY DEFROSTERS AIR RIDE, OPS & FRONT WIPERS
TICS DISPLA
D ISPLAY
Y (HIGH SPEED) SEAT BELT
MODULE, & LIGHT
SWITCHES

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 CB14 CB12 CB20 CB18 CB16
(15 AMP) (30 AMP) (10 AMP) (20 AMP) (20 AMP)
KILL ENGINE DEFROSTERS FUEL GAUGE, TOP & REAR ACCESSORY
POWER (HIGH SPEED) HORN, & PARKING WIPERS
BRAKE SWITCH

Illustration 6-2. Dash Circuit Breakers

6-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

CB21
(30 AMP)
A.C. / HEATER UNIT
FAN (HIGH SPEED)

CB22
(30 AMP)
A.C. / HEATER
UNIT FAN
(MEDIUM SPEED)

CB23
(30 AMP)
A.C. / HEATER
UNIT FAN
(LOW SPEED)

https://www.forkliftpdfmanuals.com/ CB24
(30 AMP)
 CONDENSER

CB25, CB26
(10 AMP)
ACCESSORY (CB,
RADIO, ETC.)

Illustration 6-3. Control Stand Circuit Breakers

Component Troubleshooting VDC, the alternator is defective and requires

replacing. Should the alternator output drop
Alternator. The alternator provides 13.8 - 14.4
below 12 VDC, the alternator is defective and
VDC at 130 amps of power for the electrical sys-
requires replacing.
tem and trickle charges the battery when the
engine is being operated. Perform the following procedures below for abnor-
mal charging system operation.
The most effective way to troubleshoot an alterna-
tor is with an ammeter on the output of the alter- 1. Insure
Insure that
that the under
undercha
charge
rged
d conditi
condition
on (below
(below
nator. Another good check is with a voltmeter 12 VDC) has not been caused by accessories
across the battery.
battery. With the engine operating at a having been left on for extended periods of
moderate speed, the voltmeter reading should time.
never exceed 15.5 VDC. If reading exceeds
exceeds 15.5
2. Check the drive
drive belt for proper
proper tensio
tension
n (refer
(refer to
to

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-5

Drive Belt Ten

Tension
sion in Section 1).
1). it trips. If the circuit breaker cannot maintain a
set state, perform the following troubleshooting
3. Ens
Ensure
ure that
that batt
battery
ery is
is good
good and capa
capable
ble o
off
procedures to troubleshoot the automatic circuit
holding a charge.
breaker.
4. Inspect
Inspect the wirin
wiring
g for defec
defects.
ts. Check all con-
1. Turn the
the ignit
ignition
ion key
key to the
the Off
Off positio
position.
n.
nections for tightness and cleanliness, includ-
ing the slip connectors at the alternator and 2. Remove
Remove allall wires
wires from
from the
the outpu
outputt side
side (load
(load
connections at the battery. side) of the circuit breaker.
5. With
With the ignit
ignition
ion switc
switch
h on and all
all wiring
wiring har-
har- 3. Turn
Turn the igniti
ignition
on key to the
the “Ignition
“Ignition”” position.
position.
ness leads connected, connect a voltmeter If the circuit breaker retrips, the circuit breaker
from: is defective and must be replaced.
a. alt
altern
ernato
atorr “BAT”
“BAT” term
terminal
inal to groun
ground
d 4. If the
the circuit
circuit break
breaker
er maintain
maintains s a set state,
state, one
of the output circuits
circuits is shorted. Reconnect
b. alt
altern
ernato
atorr #1 ter
termin
minal
al to
to groun
ground
d
the wires one by one to the output side (load
c. altern
alternato
atorr #2
#2 term
termina
inall to
to groun
ground
d side)
shoot until the circuit
the circuit breaker
of the trips.
wire, that Trouble-
tripped the
An infinity reading indicates an open circuit circuit breaker, for a short.
between the voltmeter connection and bat-
5. Isolat
Isolate
e and remov
remove
e the
the short
short from the circu
circuit.
it.
tery. Repair if required.
Single-Pole, Single-Throw 30 amp Relays
6. With all access
accessories
ories turne
turnedd off,
off, connect
connect a volt-
volt-
6-4). A relay is nothing more than an
(Illustration 6-4).
meter across the battery.
battery. Operate engine at
electrically controlled
controlled switch. Relays are always
moderate speed. If voltage is 15.5 VDC or
shown on electrical circuits in a de-energized
higher, replace the alternator.
state. The internal switch,
switch, common at pin 30,
Circuit Breakers. Circuit breakers are employed toggles between pins 87A (when de-energized)
in the electrical system and act similar to fuses, and 87 (when
(when energized). Pins 86 and 85 control
protecting the electrical circuits and valuable com- the coil of the relay.
ponents from overloads which could damage
The most effective way to troubleshoot the relay is
them. Perform the following troubleshooting pro-
with an ohmmeter.
ohmmeter. This can be accomplished by
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cedures to troubleshoot a circuit breaker.
removing the female spade connectors from pins
1. Tur
Turn
n the ignit
ignition
ion key
key to the Igniti
Ignition
on positio
position.
n. 30, 87, and 87A. In a de-energized state, ensure
that pins 30 and 87A have continuity between
2. If the
the circuit
circuit breake
breakerr is tripped
tripped,, reset
reset the
the circuit
circuit
them. With an ohmmeter,
ohmmeter, check the resistance
resistance
breaker.
between pins 30 and 87a. The ohmmeter should
3. If the circu
circuit
it breake
breakerr immediat
immediately
ely retrip
retrips,
s, indicate a reading of 0 - 40 ohms. Energize the
remove all wires from the output side (load relay and check the resistance between pins 30
side) of the circuit breaker. and 87. The ohmmeter should indicate a reading
of 0 - 40 ohms.
ohms. If these two checks are good, the
4. Reset the circu
circuit
it breake
breakerr. If the circu
circuit
it breake
breakerr
relay is good.
retrips, the circuit breaker is defective and
must be replaced. Single-Pole, Single-Throw
Single-Throw,, Maintain Contact
Switches. A switch is designed with with the purpose
5. If the
the circuit
circuit break
breaker
er maintain
maintains s a set state,
state, one
of controlling an electrical circuit by completing or
of the output circuits
circuits is shorted. Reconnect
opening the circuit. With an ohmmeter,
ohmmeter, check the the
the wires one by one to the output side (load
resistance between the contact points of the
side)
shoot until the circuit
the
the circuit breaker
of the trips.
wire, that Trouble-
tripped the switch. With the switch closed (completing the
circuit), the ohmmeter reading should indicate 0 -
circuit breaker, for a short.
40 ohms. With the switch open (opening the cir-
6. Isolat
Isolate
e and remov
remove
e the
the short
short from the circu
circuit.
it. cuit), the ohmmeter reading should be infinity.
infinity. If
the above checks
checks are good, the
the switch is good. If
Automatic 90 amp Circuit Breaker.
Breaker. The auto-
any of the above checks fail, the switch is bad and
matic 90 amp circuit breaker is located on the right
must be replaced.
side of engine. It will automatically
automatically reset itself if

6-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Normally Closed simplest way to prove the solenoid coil good is to

Contact (when relay energize the solenoid and then, with a metal
Common
Contact is de-energized) object, touch the nut that secures the coil to the
cartridge. The magnetic field generated when the
Normally Open coil becomes an electromagnet will be significant
Contact (when relay enough to pull the metal object to the nut (some
is de-energized) solenoids employ a metal nut encased in plastic
and will require removal in order to detect the
magnetic field). This will prove the coil coil good; how-
ever, the
the armature may be stuck. If the hydraulic
circuit is still defective at this point, remove the coil
and cartridge. Now energize the coil, the arma-
ture inside the cartridge should shift.
shift. If the arma-
arma-
ture inside the cartridge did not shift and the coil is
magnetized, replace the cartridge.
Exercise care not to reverse polarity because
some solenoids employ internal diodes which can
be destroyed when the polarity is reversed. The
solenoids employed on the transmission control
valve contain diodes. The black wire
wire of the coil
connects to the ground side of the circuit while the
red wire goes to the positive side of the circuit.
Diodes (Illustration 6-5).
6-5). Diodes are one-way
conductors that
that provide isolation. Current flow
Illustration 6-4. SPSP,, ST 30 amp
amp Relay through a diode is from anode to cathode.
cathode. They
are easily proven good by using an ohmmeter.
Single-Pole, Double-Throw, Momentary Rocker When using the ohmmeter, place the leads of the
Switches. This type of switch operates on the ohmmeter on the opposite ends of the diode.
principle that the circuit is closed only when the Observe the ohmmeter reading. Then reverse the
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ohmmeter leads on the ends of the diode.
switch
is is held
released, theincircuit
the closed state. This
will open. Once the switch
switch is Observe the ohmmeter reading. The ohmmeter
ohmmeter
 is released, the circuit will open. This switch is
checked like an On-Off switch with the exception readings should indicate a higher ohm resistance
that the switch must be held closed to complete in one direction opposed to the other direction
resistance checks. because the current generated by the ohmmeter
is sufficient enough to forward-bias the diode.
Solenoids. A solenoid is an electrical compo-
nent. When electricity is applied to the coil, the
the
solenoid will form an electromagnet. The magnet- Current Flow
ic field will pull or push an armature into the coil
(based on application). The armature can be con- con-
nected to a switch in electrical circuits to turn the
switch on or off.
off. An armature can also be used to
open or close valves.
Solenoids employed as electrical switches can be Cathode Anode
troubleshot with an ohmmeter.
ohmmeter. Remove the two
wires from the two larger posts of the solenoid. Illustration 6-5. Diode
Energize the solenoid. With an ohmmeter
ohmmeter,, check
the resistance between the two larger posts. The
ohmmeter should indicate between 0 - 40 ohms
nominally.
Solenoids employed as hydraulic switches are
used to open and close spools of valves. The

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-7

Refer to Illustrations 6-6 and 1-6 for component reference

Component Problem Correction

1. Battery 1. Lo
Low voltage. 1.
a. Low electrolyte
electrolyte level. Check
electrolyte level in battery, fill
with distilled water as required,
and recharge battery.
b. Alternator output is bad. Refer
to the Alternator troubleshoot-
ing section below.
c. Loose, broken, or corroded
wires. Repair or replace wires.
wires.
d. Ensure that low voltage condi-
tion has not been caused by
accessories having been left
on for extended periods of
time.

2. Alternat
ato
or 1. Low out
output
put vol
voltag
tage
e (volt
(voltage
age is 1.
below 12 VDC).
a. Ensure drive belts are tight.
b. Inspect the wiring for defects.
Check all connections for tight-
https://www.forkliftpdfmanuals.com/ ness and cleanliness, includ-
ing the slip connectors at the
 ing the slip connectors at the
alternator and connections at
the battery.
c. Defective alternator.
alternator. Replace
alternator.
2. High
High outp
output
ut vol
voltag
tage
e (vol
(voltag
tage
e 2. Defect
Defective
ive alt
altern
ernato
atorr. Rep
Replac
lace
e
exceeds 15.5 VDC). alternator.

3. Batt
Batter
ery
y Di
Disc
scon
onnec
nectt 1. When
When key
key swi
switc
tch
h is in the
the ON
ON 1. Remove
Remove wirwires
es fro
from
m the
the swit
switch,
ch,
Switch (if equipped) position, contact points of switch turn the switch on. With an ohm-
do not close. meter, check the resistance across
the contact
contact points. The ohmmeter
reading should indicate 0 - 40
Ohms.
2. When
When key
key swi
switc
tch
h is in
in the
the OFF
OFF 2. Rem
Remove
ove wir
wires
es fro
from
m the
the swit
switch,
ch,
position, contact points of switch turn the switch
switch off. With an ohm-
do not open. meter, check the resistance across
contact points. The ohmmeter
reading should indicate infinity.

6-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Component Problem Correction

4. Ig
Igni
niti
tion
on Sw
Swit
itch
ch 1. Igniti
Ignition
on switc
switch
h (S1, Illu
Illustr
strati
ation
on 6-6)
6-6) 1. On the
the back
back of
of the
the ignit
ignition
ion swi
switch
tch
does not close (accessory posi- (S1, Illustration 6-6), at the B ter-
tion). minal, you should see 12 VDC
straight from the battery, provided
that the truck is not equipped with
a battery disconnect switch. If
equipped with a battery discon-
nect switch, ensure that it is
turned on. Turn the key to the
ignition position, at the I terminal,
you should see 12 VDC, if not,
remove the wires from the I termi-
nal
VDCand recheck
is now voltage.
voltage.
present, If 12 a
you have
short. If 12 VDC is not present
and 12 VDC was present at the B
terminal, replace the ignition
switch (S1). To isolate short,
reconnect the wires to the I termi-
nal one at a time checking voltage
with each connection.
connection. When the the
voltage drops, the wire, that was
just connected, is shorted. Isolate
and remove short.
2. Igniti
Ignition
on switc
switch
h (S1, Illu
Illustr
strati
ation
on 6-6)
6-6) 2. The tru
truck
ck is
is equip
equipped
ped wit
with
h an anti
anti--
does not close (start position). restart ignition switch (S1).
https://www.forkliftpdfmanuals.com/ Should the truck fail to start on the
first attempt, the key must be
 turned fully off to reset the ignition
switch, allowing the B (Battery)
and S (Start) contacts to close.
This is a momentary position that
should only make contact when
the key is fully turned. On the
back of the ignition switch (S1,
Illustration 6-6), at the B terminal,
you should see 12 VDC straight
from the battery. Turn the key to
the start position. On the back of
the ignition switch (S1), at the S
terminal, you should see 12 VDC,
if not, remove the wire from the S
terminal.
(S1) to theTurn
startthe ignition
position switch
and
recheck for 12 VDC at the S termi-
nal. If the 12 VDC is now present,
the wire, just removed, is shorted.
Isolate and remove the short. If
12 VDC is not present and 12
(continued)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-9

Component Problem Correction

4. Igni
Igniti
tion
on Sw
Swit
itch
ch (Continued)
(Continued)
VDC was present at the B termi-
nal, replace the ignition switch
(S1).

5. Wires 1. Wire has lost continuity. 1. Isolate the wire from the circuit
(Ohm out the wire). Ohms will
vary according to the length of the
wire. Expect to see low Ohms if
wire is good.

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6-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

PLACE THE FOLLOWING ILLUSTRATIONS IN

FOLDER ENVELOPES:
Illustration 6-6 - 06-2485 SHT. 2 (Panel ANSI)
Illustration 6-7 - 06-2485 SHT. 3 (Bottom Cab ANSI)
Illustration 6-8 - 06-2485 SHT. 4 (Seat ANSI)
Illustration 6-9 - 06-2485 SHT. 5 (Frame ANSI)
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 Illustration 6-10 - 06-2485 SHT. 6 (Truck
ANSI)Electrical Box
Illustration 6-11 - 06-2485 SHT. 7 (Top Cab and
A-Frame ANSI)
ANSI)
Illustration 6-12 - 06L-0123 (Work Lights ANSI)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-11

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https://www.forkliftpdfmanuals.com/
https://www.forkliftpdfmanuals.com/
https://www.forkliftpdfmanuals.com/
https://www.forkliftpdfmanuals.com/
6-12 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Taylor Integrated Control System (TICS) Components

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TICS Display Module

The Taylor Integrated Control System (TICS) Display Module. The TICS Display Module is an
electronic display system
system for engine and equipment information. The display module is mounted
on the right side of the dash.

 The TICS system display modules should not be exchanged between trucks.
Each TICS module has been specifically programmed for each truck.

PIN #7

PIN #6

PIN #7
PIN #6

PIN #1 PIN #12

PIN #12 PIN #1

TICS Display Module Pin Assignments

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-13

LH MESSAGE WINDOW RH MESSAGE WINDOW

UP

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 DOWN

MEASURE /
BACK
ADJUST GROUPS
GROUPS
ENGINE COOLANT BATTERY
TEMPERATURE VOLTAGE
PARK BRAKE
SEAT BELT
ENGINE OIL SET
PRESSURE
LOW BRAKE
PRESSURE

STOP

Taylor Integrated Control System (TICS) Display Module Main Screen

The Taylor
Taylor Integrated Control System (TICS) 2. MPH - This
This indi
indicat
cates
es vehic
vehicle
le speed
speed in mile
miles
s
Display Module Main Screen. The main screen per hour.
of the TICS Display Module displays the status of
3. ACTIVE
ACTIVE MESMESSAG
SAGESES - Mess
Message
age text
text tha
thatt
the engine and equipment operating information
alerts the operator of the status of different
of the truck. The operating information that
functions of the truck or to check warnings dis-
appears on the main display screen is described
played on the Active Warnings screen.
as follows:
NOTE: The Active Warnin
Warnings gs screen is dis-
1. Shifter
Shifter Positio
Position
n - This indica
indicates
tes the elect
electric
ric played by depressing the F2 button.
shifter’s position.

6-14 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

ACTIVE MESSAGES DISPLAYED: 11. CORRECTIVE ACTIONS

ACTIONS - Message text that
Neutral Lock On - Indicates that the Neutral alerts the operator to take action before the
Lock safety feature is active. truck will allow continuation of truck operation.
Check Warnings - Indicates that the operator
CORRECTIVE ACTIONS DISPLA DISPLAYED:
YED:
should read the Active Warnings.
Check Engine - Indicates there is an engine
Forward Alarm Off - Indicates that the forward
related problem and that the engine needs to
alarm is disabled while in the Operator Con-
be checked.
trolled mode of operation. This message will
Please Sit Down - Indicates that the operator
only appear while the Forward Alarm is in the
needs to occupy the seat.
Operator Controlled mode and disabled.
Shift thru Neutral - This message will only
NOTE: Depressing the F3 button will enable
appear while the Forward Alarm is in the Oper-
the forward alarm. [Refer to the Forward
ator Controlled mode and disabled. NOTE:
Alarm System in the Operator’s Guide
(OG160) for detailed information.] Depressing
ward alarm. the F3 button
[Refer the will
to the enableAlarm
Forward the for-
4. - Thi
his
s ic
icon
on wil
illl cha
chang
nge
e fro
from
m whi
hite
te to re
red
d System in the Operator’s Guide (OG160) for
detailed information.]
when the engine coolant temperature Is great-
Service Required - Indicates that truck mainte-
er than 218 F (103 C). If thishttps://www.forkliftpdfmanuals.com/
icon changes to
nance needs to be performed.
 

red, stop the engine immediately and notify

 maintenance personnel. 12. F1 - Depress this button to view the
the Diagnos-
tics Select screen.
5. - This icon will change from white to red 13. F2 - Depress this button to view Active
when the engine oil pressure has fallen below Warnings.
10 psi (.7 bar) at 750 rpm or less than 40 psi
(2.8 bar) at 1,600 rpm. If this icon changes to 14. F3 - Depress this button to
to manually enable or
red, stop the engine immediately and notify disable the forward alarm while the forward
maintenance personnel. alarm is in the Operator Controlled Manual
mode of operation [refer to the Forward
6. - Th
This ic
icon wi
will ch
change fr
from wh
white to
to re
red Alarm System in the Operator’s Guide
when the battery voltage is less than 9 VDC or (OG160) for detailed information].
greater than 15 VDC. This icon will be white
white 15. F4 - Reserved for optional functions.
when the battery voltage is greater than 9
VDC or less than 15 VDC. If this icon changes 16. UP and DOWN - Depress either
either button to
to red, stop the engine immediately and notify make adjustments or scroll through menus.
maintenance personnel. NOTE: Adjustments should only be made by
Maintenance Personnel!!
7. - Thi
This
s ico
icon
n fla
flas
she
hes
s whe
when
n the
the se
seat
at be
belt
lt is 17. OK - Depress this button to select a high-
unfastened. lighted item.
8. - Th
This ic
icon ililluminates whe
when
n th
the pa
parking 18. Back - Depress this button to back up through
brake is applied. the display screens.
19. Measure / Adjust Groups - Depress this button
9. - Th
This ic
icon flashes wh
when a low hy
hydraulic to select measure groups, adjust groups, infor-
pressure problem (below 1,500 psi / 104 bar) mation screen or status page.
exists in the service brake apply circuit. NOTE: Adjustment groups will be Pin Code
protected. NOTE: Adjustments should only
10..
10 - Th
This
is ic
icon
on fl
flas
ashe
hes
s for
for 30 se
seco
cond
nds
s be
befo
fore
re be made by Maintenance Personnel!!
the engine ECM shuts down the truck due to
high transmission temperature.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-15

NOTE THE TYPE

OF MODULE IS
LABELED HERE
(XS2 OR XA2)

YELLOW / RED
RED
GREEN (POWER ON)
(STATUS) LED
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LED
TICS Module

TICS Module. The TICS Module status

status is indicated by the following LEDs:
1. Green LED - When this
this LED is illumin
illuminated,
ated, it indica
indicates
tes that
that the module
module is powered
powered on.
on.
2. Yellow / Red LED - When
When this LED is blinking
blinking the yellow
yellow color
color, the status of the module
module is normal.
normal.
When this LED is blinking the red color, there is an error and the TICS Display Module will display an
error message.

LED Indicator Showing Different XS2 and XA2 Modes

Status Flash

Normal operation (yellow)

Error Error Primary Flash (red) Secondary Flash (yellow)

code Error category Error description

1:n See note a

2:n See note a

3:1 CAN error

3:2 Address error

4:1 Memory error b

FE Fatal error

a. Error groups
groups 1:n and
and 2:n are controlled
controlled by the master
master..
b. FRA
FRAMM me
memor
moryy error
error..

6-16 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Suggested Actions For Specific Fault Codes

1:n / 2:n - Check the TICS main display for proper operation or any displayed
displayed error messages. Consult
factory.

3:1 - Check CAN communication wiring for continuity between module and TICS main display.
display. Consult
maintenance manual for wire schematics.

3:2 - Check address tag at module to make sure it is in place (refer to photo below).

4:1 and FE - Check the TICS main display for displayed error messages. Replace modules as required.
Consult factory.

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 ADDRESS TAG
TAG

PROTECTIVE
COVER

TICS Module Wire Harness Plug

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-17

PIN #42
PIN #29

PIN #28 PIN #15

PIN #14
PIN #1

TICS Module Pin Assignments (XA2)

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NOTE: The TICS system
system of this truck employs XA2 modules. Always replace each module with the
correct module. Refer to the following illustration for truck control module locations.

6-18 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

TICS MD3
DISPLAY MODULE

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 CAB MODULE
(XA2-A1)

CHASSIS MODULE
(XA2-A0)

TICS Control Module Locations On The Truck

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-19

Measure Groups
Measure groups are used to check the status of inputs, outputs and logic parameters within the truck con-
trol program. The measure groups are broken
broken into two subgroups, function groups and maintenance
groups. The function groups show all data
data related to a particular function within
within the truck control program.
Function groups are primarily used by TMW personnel during truck set up and troubleshooting. The
maintenance groups are set up to be used by the maintenance
maintenance personnel of the end user.
user. These groups
show the status of all inputs and outputs related to the noted
noted function. These groups are to be used to
aid the end user in diagnosing and solving any problems with daily operation of the truck.
To access the Maintenance Groups inside the Taylor Integrated Control System (TICS) display module,
perform the following procedures:

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 MEASURE /
ADJUST
GROUPS

Main Display Screen

1. From the
the Main Display
Display screen,
screen, depress
depress the
the Measure
Measure / Adjust
Adjust Groups button
button (≡). This will display
display the
the
Main Measure / Adjust screen.

6-20 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

MEASURE

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 Main Measure / Adjust Screen

2. At the Main
Main Measure
Measure / Adjust
Adjust screen,
screen, depress
depress the
the F2 (Measure)
(Measure) button.
button. This will
will display
display the Measure
Measure
screen.

DEPRESS UP OR
DOWN BUTTONS
SELECT GROUP;
DEPRESS OK
BUTTON TO
ENTER INTO
DESIRED GROUP
GR OUP..

DEPRESS THE
BACK ARROW
TO GO TO
DEPRESS PREVIOUS
F1 TO DISPLAY
RETURN TO
THE MAIN
DISPLAY

Measure Screen

3. Depress
Depress the UP or DOWN
DOWN button to to highlight
highlight the desired
desired maintenanc
maintenance
e group and depress
depress the
the OK
button to display the values of the
the selected group. Depress the F2 button to toggle
toggle between the Raw
and Scaled values (refer to description of values below). To exit out of the selected group values,
depress the ← button to return to the Measure Groups list display. NOTE: A list of the Measure and
Maintenance Groups is illustrated in this section.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-21

Sensor Status
Scaled Value
Value – Analog sensor
sensor values
values are displayed
displayed in program defined
defined units (PSI,
(PSI,
Degrees, etc.) while the Digital sensors are displayed as True (12 VDC
input to module from sensor) or False (no input to module from sensor).
Raw Value – Analog sensor values are displayed in Millivolts. Digital sensors are not
displayed.

Communication Status
OK – Indica
Indicates
tes that the
the sensor input
input to module
module connection
connection is functionin
functioning
g correctly
correctly..
!!! – Indic
Indicates
ates that there
there is
is a problem
problem with
with sensor
sensor input
input to
to module
module (See note below).
below).

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6-22 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

THESE WILL VARY BASED

ON THE NUMBER OF ACCESSORY
FUNCTIONS ACTIVA
ACTIVATED
TED
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Maintenance and Measure Groups

SENSOR COMMUNICATION
STATUS STATUS

DEPRESS TO TOGGLE BETWEEN

RAW AND SCALED VALUES

Hydraulic Maintenance Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-23

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Engine Maintenance Group

6-24 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Cab Maintenance Group

DEPRESS TO TOGGLE BETWEEN

RAW AND SCALED VALUES

Transmission Maintenance Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-25

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Brake Maintenance Group

DEPRESS TO TOGGLE BETWEEN

RAW AND SCALED VALUES

Fuel Usage Information Group

6-26 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

ACC1 Maintenance Group

NOTE: Additional accessory hydraulic

hydraulic maintenance groups (ACC2,
(ACC2, ACC3, etc.)
etc.) have the typical
typical values
as those listed in the ACC1 Maintenance
Maintenance Group above. However
However,, some values could be different from
those listed above.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-27

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Joystick Measure Group

6-28 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

(Continued)

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Joystick Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-29

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Engine Measure Group

6-30 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

(Continued)

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Engine Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-31

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Cab Measure Group

6-32 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Transmission Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-33

(Continued)

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Transmission Measure Group

6-34 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

(Continued)

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Transmission Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-35

(Continued)

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 DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Transmission Measure Group

6-36 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Display Data Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-37

(Continued)

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 DEPRESS TO TOGGLE BETWEEN
RAW AND SCALED VALUES

Display Data Measure Group

6-38 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

APC Interface Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-39

(Continued)

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 DEPRESS TO TOGGLE
BETWEEN RAW AND

SCALED VALUES

APC Interface Measure Group

6-40 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 (Continued)
DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Engine Fault Code Measure Group

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-41

(Continued)

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 DEPRESS TO TOGGLE
BETWEEN RAW AND
SCALED VALUES

Engine Fault Code Measure Group

6-42 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Valve Current Setting Adjustments

The valves (used to actuate the tilt and hoist functions)
functions) are controlled by output modules. There are four
settings that can be adjusted for each function and the range of values allowed is controlled by the soft-
ware. These parameters (minimum current, maximum
maximum current, start ramp time
time and stop ramp time) are
set by Taylor
Taylor personnel during the initial set up of the truck. It may be necessary to adjust these settings
over time due to component wear or replacement. These values are accessed accessed through the operational
display, via the adjust groups.
Perform the following procedures to adjust the settings:

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 MEASURE /
ADJUST
GROUPS

Operational Display

1. From the
the Main Display
Display screen,
screen, depress
depress the
the Measure
Measure / Adjust
Adjust Groups button
button (≡). This will display the
Main Measure / Adjust screen.

ADJUST

Main Select Screen

2. At the Main Measure / Adjust screen, depress F1 (Adjust). This will bring up the Adjust screen.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-43

DEPRESS UP OR
DOWN BUTTON
TO SELECT GROUP;
DEPRESS OK BUT-
TON TO ENTER
INTO DESIRED
GROUP.

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Adjust Groups Screen

3. Depress
Depress the UP or DOWN
DOWN button
button to highlight
highlight the
the desired
desired adjust
adjust group and depress
depress the
the OK
button to make setting adjustments to the selected group. The PIN code screen will appear.
appear. The cor-
rect PIN code must be entered before the software will allow any adjustments to be made. NOTE:
Taylor personnel will provide qualified maintenance personnel with the Pin Code necessary to make
adjustments within adjust groups.

DEPRESS UP OR
DOWN BUTTON
TO CHANGE DIGIT.
DEPRESS OK BUT-
TON TO ENTER
DIGIT.

PIN Code Screen

4. From the PIN PIN code screen,

screen, depress
depress the UP or DOWN
DOWN button
button until the
the first numeric
numeric digit
digit appears in
in the
first field. Depress the OK button to enter the numeric digit and advance to the next field. Repeat this
procedure until all four numeric digits have
have been entered. After the code has been entered, OK will be
highlighted; depress the OK button to enter PIN code.

6-44 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

DEPRESS UP OR
DOWN BUTTON TO
SELECT FUNCTION;
DEPRESS OK BUT-
TON TO ENTER
FUNCTION ADJUST
GROUP SCREEN.

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Lift / Tilt Adjust Group Screen

5. Depress
Depress the UP or DOWN button
button to select
select the function
function in which
which setting
setting adjustments
adjustments are to be made.
made.
With the function selected, depress the OK button to access the settings. Ensure that Lift is high-
lighted and depress the OK button.

DEPRESS UP OR
DOWN BUTTON TO
ADJUST;; DEPRESS
ADJUST
OK BUTTON TO
STORE ADJUST-
MENT.

Lift (Min Setting) Screen

6. This parameter
parameter is used
used to calibrate
calibrate the minimum
minimum amount
amount of current
current sent to
to the lift valve
valve when lifting.
lifting.
With the engine running, fully actuate the joystick toto the lift position. Slowly depress the UP or DOWN
button until the mast just begins to lift the carriage. Observe the value underneath the Min value value
parameter (upper right–hand of display). Add 50 counts to the value at which the mast just began to
creep upward (depress the UP button until the Min value is 50 counts higher than the count at which
the mast began to creep upward). Depress the OK button to store store the value into the processor and
advance to the Max )parameter of this screen by depressing the OK button again. NOTE: The Plus

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-45

funct
function
ion (, F3 button) extends the cylinder while the Minus function ( , F4
F4 but
butto
ton)
n) re
retr
trac
acts
ts th
the
e
cylinder.

DEPRESS UP OR
DOWN BUTTON TO
ADJUST; DEPRESS
OK BUTTON TO
STORE ADJUST-
MENT.

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Lift (Max Setting) Screen

7. The Max parameter

parameter of Lift
Lift is used
used to calibrate
calibrate the maximum
maximum amount
amount of current
current sent to
to the lift valve
valve
when lifting. The desired setting is the value that
that no noticeable increase in speed is obtained
obtained after the
value is exceeded. Ensure that the Max value is highlighted on the upper right side of the display
(depress the OK button if the Min value is highlighted). With the engine running, fully actuate
actuate the joys-
tick to speed
in the the lift at
upwhich
position. Slowly depress
the carriage
the moves. the UP or the
Depress DOWN button to
OK button until there
store theisvalue
no noticeable increase
into the proces-
sor and depress the ← button (back) to go back to the Adjust Groups screen.
8. Repeat these
these procedures
procedures for
for adjusting
adjusting the setting(s
setting(s)) of the other TICS
TICS system
system parameters.
parameters.

 The ignition switch should be turned to its Off position after maintenance
personnel have made setting adjustments within the TICS
TICS system. Failure to do so, gives
gives
Unauthorized personnel access to change settings within the TICS system.

Valve Current Default Settings

Adjustment Group Default Settings
Hoist - Up (+) / Down () Min - 800 / 600
Max - 151500
00 / 107
1075
5
Start - 250 / 0
Stop - 250 / 250
Tilt - Out (+) / In () Min - 750 / 750
Max - 15150000 / 135
1350
0
Start - 0 / 0
Stop - 250 / 250

NOTE: Depress the F2 button (Reset)

(Reset) to return the selected function
function back to its default setting.

6-46 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Percent Ground Speed Allowed Setting Procedure

The following procedure must be performed with the truck parked and the parking brake set.

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 Measure / Adjust
Groups Button

1. At the Main screen

screen of the TICS
TICS display
display module, depress
depress the
the the Measure
Measure / Adjust Groups
Groups button
button (≡)
as indicated by arrow above to access the Main Measure / Adjust screen.

Adjust Button

2. At the Main Measure / Adjust screen, depress the F1 button (as indicated by the arrow above) to access
the Adjust screen.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-47

UP Button

OK Button

Down Button

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3. Select the
the Percent
Percent Ground Speed
Speed Allowed
Allowed adjust group
group by depressi
depressing
ng the UP or Down
Down button (as
(as
indicated by the arrows above) and depress
depress the OK button to view the adjust group. The PIN code
screen will appear. The correct PIN code must be entered before the software
software will allow any adjust-
ments to be made.

UP Button

OK Button

Down Button

4. Depress
Depress the UP or Down buttonbutton (as indicated
indicated by the
the arrows above)
above) until
until the first
first numeric digit
digit appears
appears
in the first field. Depress the OK button to enter the numeric digit and advance to the the next field.
Repeat this step until all four numeric
numeric digits have been entered. After the code has been entered, OK
will be highlighted; depress the OK button to enter PIN code and view the Percent Ground Speed
Allowed adjust group.
group . Depress the OK button again to make adjustments.

6-48 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

UP Button

OK Button

Down Button

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5. Depress
Depress the UP or Down button
button (as indicated
indicated by the
the arrows above)
above) to adjust
adjust the percentage
percentage of
Allowed Ground Speed. Depress the OK button to accept the new Percent Ground Speed adjust-
ment. NOTE: The F2 button (Reset) may be depressed to reset the Allowed Ground Speed percent-
age back to 100% if necessary.

Measure / Adjust
Groups Button

6. Depres
Depresss the Meas
Measure
ure / Adjus
Adjustt Groups
Groups butto
button
n (≡) as indicated by arrow above to return to the Main
Display screen. NOTE: At the above screen,
screen, the Percent Ground Speed Allowed percentage is dis-
played on the right side.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-49

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7. Depres
Depress
s the F1 button (as indicate
indicated
d by arrow above)
above) to access the
the Select Diagnost
Diagnostic
ic Option screen.
screen.

8. Depress
Depress the F2 button
button (as indicated
indicated by arrow
arrow above) to access
access the Transm
Transmissio
ission
n Information
Information screen
to view the new Maximum Ground Speed allowed for truck travel.

6-50 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 BACK

9. After viewing
viewing the Maximum
Maximum Ground
Ground Speed (indicated
(indicated to the
the left of the arrow
arrow illustrated
illustrated on the above
above
screen), depress the BACK ( ← ) button to return to the Main Display screen.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-51

Resetting The Service Timer

The Service Timer
Timer should be reset after scheduled maintenance has been performed. Perform the follow-
ing procedures to reset the Service Timer:

The following procedure must be performed with the truck parked and the parking brake set.

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 DIAGNOSTICS
BUTTON

Main Display Screen

1. Turn
Turn the ignition
ignition key to its
its accessory
accessory position
position (first
(first click).
click). From the
the Main Display
Display screen,
screen, depress
depress the
F1 button (Diagnostics) to access the Diagnostics Select screen.

ENGINE
BUTTON

Diagnostics Select Screen

2. At the Diagnostics
Diagnostics Select
Select screen,
screen, depress the
the F1 button (Engine)
(Engine) to access the
the Engine Informatio
Information
n
screen.

6-52 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

RESET SERVICE
TIMER BUTTON
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Maintenance Timer Reset Screen

3. At the Engine Informat

Information
ion screen,
screen, depress the
the F3 button (Reset
(Reset Service
Service Timer)
Timer) to access
access the Mainte-
Mainte-
nance Timer Reset screen.

Maintenance Timer Reset Screen

4. At the Maintenance
Maintenance Timer
Timer Reset
Reset screen,
screen, enter each
each number of the Pin Code
Code by depressing
depressing the F1
through F4 buttons.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-53

OK BUTTON

DOWN
BUTTON

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Maintenance Timer Reset Screen

5. After the
the Pin Code number
number has been entered,
entered, depress
depress the
the Down Button
Button to reset the
the Maintenance
Maintenance
Timer.. Depress the OK button to exit the Maintenance Timer
Timer Timer Reset screen and return to the Engine
Information screen.

6-54 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

6
A
-
C
l
o
s
e
d
C
cir
u
ti
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a
 m
e
r
a
s
a
n
d
M
o
i
n
to
r
s

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 Section 6A

Closed Circuit TV Cameras and Monitors

Introduction. The camera system (if equipped) 4. Volume
Volume Buttons. Depress the upper button
button
gives the operator a vantage view from a remote to increase the volume of the monitor; depress
mounted camera, strategically placed, dependant the lower button to decrease the volume.
on operational requirements.
5. Brightness Buttons. Depress the upper but-
ton to increase the brightness of the monitor’s
display; depress the lower button to decrease
the brightness.

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 Monitor. The orientation of the image being dis-
dis-
played by the monitor is controlled by a magnetic
plug located in the rear of the camera (see Illustra-
tion 6A-1).
Monitor Operation (Illustration 6A-2).
6A-2). The follow-
ing describes the monitor’s controls.
1. Power Button. Depress this button to turn the
monitor on (button illuminated green).
Depress this button again to turn the monitor
off. This button will be illuminated red when
the monitor is on and in Standby mode.
2. Camera Select Button. Depress this button
to view the video from camera 1 (CA1).
Depress this button to view the video from
camera 2 (CA2).
3. Menu Button. Depress this button to display
the main menu of the monitor.
monitor. To navigate Illustration 6A-1. Camera
through the main menu, depress the Bright-
ness Buttons. To change the content
content of a
selected menu item, depress the Camera
Select Button. The main menu
menu consists of the 1
following adjustable items:
a. Color. Depress the Camera Select Button 2
3
to change the color depth of the displayed
images.
4
b. Contrast. Depress the Camera Select
Button to change the contrast level of the
displayed images. 5
c. Tint. Depress the Camera Select Button
to change the color coordination of the dis-
played images.
Illustration 6A-2. Monitor

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6A-1

Illustration 6A-3. Camera Circuit

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 06C-0108

6A-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 9

Transmission

FILLER
CAP

CHARGING
PUMP
BRAKE
PUMP

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 OIL MAIN / STEERING
DIPSTICK PUMP

CONTROL
VALVE

OIL SUMP
SCREEN DRAIN PLUG

Illustration 9-1. TC-32 Transmis

Transmission
sion

Introduction. The TC-32 transmission is a pow- mission’s converter charging pump draws trans-
ershift transmission which provides three speeds mission oil from the transmission sump through
forward and three speeds reverse. Both direction the oil sump screen and directs it through the
and speed range are controlled by a roll shift pressure regulating valve and oil filter.
filter. The pres-
mechanism attached to the steering column. sure regulating valve maintains pressure to the
transmission control valve for actuating the direc-
Operation. With the engine running, the trans-
tion and speed
speed clutches. This requires only a

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9-1

small amount of transmission oil. The remaining and are connected to the output shaft of the con-
oil is directed through the torque converter circuit verter either by direct gearing or drive shaft. The
to the transmission oil cooler and returns to the purpose of the directional or speed clutches is to
transmission for positive lubrication. After enter- direct the power flow through the gear train to pro-
ing the converter housing, the oil is directed vide the desired speed range. Refer to Section
through the stator support to the converter blade 9C for electrical operation of the transmission con-
cavity and exits in the passage between the tur- trol valve.
bine shaft and converter support. The oil then
Transmission Oil Level Check (Illustration 9-1).
9-1).
flows out of the
the converter to the oil cooler
cooler.. After
The oil level of the transmission should be
leaving the cooler, the oil is directed back to the
checked daily, with the oil at normal operating
transmission.
temperature [180 to 200F+ (82 to 93C+)] and
The torque
center. Theconverter turbine receives
reaction member oil at its
of the torque con- the engine
should operating
be up at low
to the FULL idle.onThe
mark theoil level
dipstick.
verter takes the oil which is exhausting from the The dipstick is located inside the engine hood, on
inner portion of the turbine and changeshttps://www.forkliftpdfmanuals.com/
its direc- the engine’s right side.
tion to allow correct entry for recirculation into the
impeller element.

Illustration 9-3. Transmiss

Transmission
ion Oil Filter

Transmission Oil Filter Replacement (Illustra-

tion 9-3).
line 9-3) . The
spring oil filter,
brake
brake, located
, should below the
be replaced drive
periodically
(refer to the Preventive Maintenance chart in the
Appendices for oil filter replacement interval).
Illustration 9-2. Transmission Control Valve
Valve The interval listed in the Appendices is based on
normal environmental condition, excessive dust
may require a more frequent filter replacement
Transmission Control Valve (Illustration 9-2).
9-2).
interval. Perform thethe following procedures to
The transmission control valve directs oil, under
change the filter:
pressure, to the desired directional and speed
clutch. The directional and speed clutch assem-
assem-
blies are mounted inside the transmission case  Death or serious injury could

9-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

result from a runaway

runaway truck. Park truck on a 3. Cle
Clean
an the
the oil
oil scree
screen
n thoro
thorough
ughly
ly..
hard, level surface, apply parking brake, block
wheels in both directions to prevent movement NOTE: An accumulation of sludge or soft dirt in
of truck and Lock Out & Tag Out truck before the sump should be removed with flushing oil.
servicing truck.
4. Use a new
new gasket
gasket and
and re-ins
re-instal
talll the oil
oil screen.
screen.
Tighten the oil screen to 10-15 ft-lbs (14-20
N⋅m).
 Dispose of transmission oil
and filter in accordance with federal and local 5. Refer to Transmission Oil Filter Replace-
regulations. ment for procedures to change the filter
element.

NOTE: Itafter
changed is recommended
100 hours of that the filters
operation be and
on new 6. Re-i
Re-ins
nsta
tall
ll the
the dra
drain
in plug
plug..
rebuilt or repaired transmissions. 7. Refer to Filling The Transmission,
Transmission , located
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below, for adding oil to the transmission.
1. Mak
Make
e certain
certain filt
filter
er is cool
cool to the
the touch,
touch, then
then
 8. Operat
Operate e the eng
engine
ine and
and check
check for
for leaks
leaks..
provide a suitable container to catch any When the transmission’s oil temperature
draining oil, and unscrew filter and dispose of reaches 180 to 200F+ (82 to 93F+), make a
filter properly
p roperly.. final oil check and add oil to bring the oil level
2. Apply
Apply an even
even film
film of
of fresh
fresh oil
oil to the
the gaske
gaskett to the FULL mark on the dipstick.
surface of the replacement filter and then Filling The Transmission (Illustration 9-1).
thread filter onto filter head. Perform the following procedures to fill the trans-
3. Hand
Hand tighte
tighten n filter
filter 3/4
3/4 turn
turn past
past point
point where
where mission with oil:
gasket first contacts filter head surface. 1. Wit
With
h the engine
engine shut
shut down,
down, fill
fill the
the transmi
transmis-
s-
4. Refer to Filling The Transmission for adding sion to the LOW mark on the dipstick.

oil to the transmission. 2. Operat

Operate e the eng
engine
ine and
and check
check for
for leaks
leaks..
Changing The Transmission Oil (Illustration When the transmission’s oil temperature
9-1).. The transmission oil should be changed
9-1) reaches +180F to +200 F (+82 F to +93F)
periodically (refer to the Preventive Maintenance and the engine operating at low idle, make a
chart in the Appendices for transmission oil final oil check and add oil to bring the oil level
change interval). to the FULL mark on the dipstick.
Cleaning The Transmission Breather. The
breather should be checked for restriction and
 Death or serious injury could cleaned periodically (refer to the Preventive
result from a runaway truck. Park truck on a Maintenance chart in the Appendices for trans-
hard, level surface, apply parking brake, block mission breather
breather cleaning interval). The preva-
wheels in both directions to prevent movement lence of dirt and dust will determine the frequency
of truck and Lock Out & Tag Out truck before at which the breather requires cleaning. Perform
servicing truck. the following procedures to clean the transmission
breather:

 Dispose of transmission oil 1. Clean

Clean the
the area
area around
around the
the breathe
breatherr before
before
and filter in accordance with federal and local removing it.
regulations.
NOTE: Care must be exercised when removing
Perform the following procedures to change the the breather to avoid damaging the breather.
transmission oil:
2. Re
Remo
move
ve th
the
e bre
breat
athe
herr.
1. Provid
Providee a suitabl
suitable
e contain
containerer and remov
remove
e the
3. Wash
Wash thethe breathe
breatherr thoroughl
thoroughly
y in solve
solvent
nt and
and
drain plug to drain the oil.
dry it with compressed air.
2. Rem
Remove
ove the oil scr
screen
een and gas
gasket
ket..
4. Re-
Re-ins
instal
talll the bre
breath
ather
er..

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9-3

General Information
Oil Pressure (low idle) 240 psi
(16.6 bar)
Oil Pressure (high idle) 300 psi
(20.7 bar)
Oil Temperature 180 - 200 F
(82 - 93C)
Oil Capacity 26 Quarts
(24.6 Liters)

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9-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

CLUTCH PRESSURE CHECK

POINT 240 PSI [16.6 bar (LOW IDLE)] -
INSTALL PRESSURE 300 PSI [20.7 bar (HIGH IDLE)]
GAUGE IN THIS LINE
FOR CONVERTER OUT
PRESSURE CHECK

TRANSMISSION

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 CONVERTER OUT TO
COOLER [25 PSI (1.7 bar) MIN. -
70 PSI (4.8 bar) MAX. AT
RATED RPM]

COOLER
TEMPERATURE
TRANSDUCER

IN FROM COOLER

Illustration 9-4. Transmiss

Transmission
ion Check Points
Points

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9-5

TRANSMISSION
FLUID FILTER

TRANSMISSION
FLUID COOLER
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 INDICATES FLUID FLOW

Illustration 9-5. Transmis

Transmission
sion Oil Flow

9-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Transmission Troubleshooting
Electrical / Mechanical Checks. Prior to check- 2. Work
Work the mach
machine
ine to brin
bring
g the oil temp
tempera
eratur
ture
e
ing any part of the system from a hydraulic stand- up to the operating range (refer to step 1.
point, the following electrical / mechanical checks above).
should be made.
NOTE: If the machine
machine cannot be worked, the con-
con-
1. Ensure
Ensure that
that the
the proper
proper sole
solenoi
noids
ds on cont
control
rol verter can be stalled to bring the temperature up
valve are energized. When the solenoids are to the operating range. Perform the following pro-
energized they become magnetized. A mag- cedures to stall the converter.
netic field can be checked at the nut that holds
the solenoid to the cartridge. Some solenoids 3. With
With the right
right serv
service
ice brak
brake
e pedal
pedal applied
applied,,
employ a metal nut, encased in plastic, which move the shifter to the forward position and
will require removal to detect a magnetic field. third gear selected.
An effective way to accomplish this is with a
metal wrench. 4. Con
Contin
tinue
ue to apply
apply the
the brakes
brakes and
and accel
accelera
eratete
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the engine approximately one-half to three-
2. Ens
Ensure
ure that
that the
the inchi
inching
ng valve
valve is
is not enga
engaged
ged
 2. Ensure
Ensure that
that the
the inchi
inching
ng valve
valve is
is not enga
engaged
ged quarter throttle for 30 seconds, let off accelera-
nor sticking. tor for 10 seconds.
Hydraulic Checks. Before checking the torque 5. Repeat
Repeat step
step 4. until
until the desir
desired
ed conver
converter
ter out-
out-
converter, transmission, and associated hydraulic let temperature is reached.
system for pressures and rate of flow, it is essen-
tial that the following preliminary checks be made.
 Full throttle stall speeds for an
NOTE: Do not attempt these checks
checks with cold oil.
oil. excessive length of time will overheat the
converter.
1. Check
Check the oil lev
level
el in
in the
the trans
transmis
missio
sion.
n. Thi
This
s
should be done with the oil temperature 6. Whe
When
n checkin
checking
g the press
pressure
ures,
s, alway
always
s check
check
between +180° F and +200° F (+82F to
+93F), and the engine operating at idle. the
first.charge pump and converter out pressures
Problem Cause Correction

1. Low clutch 1. Lo
Low
w oil
oil le
lev
vel
el.. 1. Fi
Fill
ll to pro
prope
perr le
leve
vel.
l.
pressure
2. Clutch
Clutch pre
pressu
ssure
re regu
regulat
lating
ing val
valve
ve 2. Cle
Clean
an val
valve
ve spo
spool
ol and hou
housin
sing.
g.
spool is stuck open.
3. Defect
Defective
ive cha
chargi
rging
ng pum
pumpp [240
[240 - 3. Re
Repl
plac
ace
e cha
charg
rgin
ing
g pum
pump.
p.
300 psi (16.6 - 20.7 bar) normal
operating pressure].
4. Broken
Broken or wor
wornn clut
clutch
ch sha
shaft
ft or 4. Replac
Replacee seali
sealing
ng rin
rings
gs or
or clut
clutch
ch
piston sealing rings. shaft.
5. Clutch
Clutch pis
piston
ton ble
bleed
ed valv
valve
e stuck
stuck 5. Cle
Clean
an blee
bleed
d valve
valves
s thor
thoroug
oughly
hly..
open.

2. Low
Low con
conv
ver
erte
terr 1. Lo
Low
w oil
oil le
lev
vel
el.. 1. Fi
Fill
ll to pro
prope
perr le
leve
vel.
l.
charging pump
output 2. Su
Suct
ctio
ion
n scre
screen
en plu
plugg
gged
ed.. 2. Cl
Clea
ean
n suc
sucti
tion
on sc
scre
reen
en..
3. Air leak
leaks
s at pum
pump
p intak
intake
e hose
hose and
and 3. Tigh
ighten
ten all
all connec
connectio
tions
ns or rep
replac
lace
e
connections or collapsed hose. hose if necessary
necessary..
4. De
Defe
fect
ctiv
ive
e char
chargi
ging
ng pum
pump.
p. 4. Re
Repl
plac
ace
e cha
charg
rgin
ing
g pum
pump.
p.
continued

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9-7

Problem Cause Correction

2. Low
Low con
conve
vert
rter
er 5. Clo
Clogge
gged
d trans
transmis
missio
sion
n filte
filterr. 5. Rep
Replac
lace
e trans
transmis
missio
sion
n filte
filterr.
charging pump
output (Continued) 6. Def
Defect
ective
ive pre
pressu
ssure
re regu
regulat
lator
or.. 6. Replac
Replacee or rebu
rebuild
ild pre
pressu
ssure
re
regulator.

3. No
Nois
isy
y co
conv
nver
erte
terr 1. Wo
Worn
rn co
coup
upli
ling
ng ge
gear
ars.
s. 1. Re
Repl
plac
ace
e coup
coupli
ling
ng gea
gears
rs..
2. Wo
Worn
rn ch
charg
argin
ing
g pu
pump
mp.. 2. Re
Repl
plac
ace
e cha
chargi
rging
ng pu
pump
mp..
3. Wo
Worn
rn or
or dama
damage
ged
d bear
bearin
ings
gs.. 3. A compl
complete
ete dis
disass
assemb
embly
ly will
will be
necessary to determine which
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bearing is faulty.
 4. Low cha
chargi
rging
ng pum
pump
p pre
pressu
ssure.
re. 4. Refe
Referr to
to Pro
Problem 2. of this trouble-
blem
shooting chart.
5. Excess
Excessive
ive int
intern
ernal
al leak
leakage
age in 5. Reb
Rebuil
uild
d or rep
replac
lace
e trans
transmis
missio
sion.
n.
converter.

4. Ov
Over
erhe
heat
atin
ing
g 1. Lo
Low
w oil
oil le
lev
vel
el.. 1. Fi
Fill
ll to pr
prop
oper
er le
leve
vel.
l.
2. Oil coo
cooler
ler ven
vents
ts are
are rest
restric
ricted
ted.. 2. Cl
Clea
ean
n oil
oil coo
coole
lerr.
3. Wo
Worn
rn tra
transm
nsmiss
ission
ion bear
bearing
ing.. 3. Rep
Replac
lace
e or rebu
rebuild
ild tra
transm
nsmiss
ission
ion..
4. Wo
Worn
rn oil
oil sea
seali
ling
ng rin
rings
gs.. 4. Remove
Remove,, disas
disassem
semble
ble,, and
and rebuil
rebuild
d
converter assembly
assembly..
5. Wo
Worn
rn ch
charg
argin
ing
g pu
pump
mp.. 5. Re
Repl
plac
ace
e cha
chargi
rging
ng pu
pump
mp..
6. Pum
Pump
p sucti
suction
on line
line tak
taking
ing in
in air
air. 6. Check
Check con
connec
nectio
tions
ns and tig
tighte
hten
n
securely.
7. Open cir
circui
cuitt betw
between
een the eng
engine
ine 7. Is
Isol
olat
ate
e and
and re
repa
pair
ir..
ECM (Electronic Control Module)
and transmission temperature
transducer.
8. Defect
Defective
ive tra
transm
nsmiss
ission
ion temp
tempera
era-- 8. Replac
Replacee trans
transmis
missio
sion
n temper
temperatu
ature
re
ture transducer
transducer.. transducer.

5. La
Lac
ck of po
powe
werr 1. Low en engi
gine
ne RPM
RPM at
at conv
conver
erte
terr 1. Tune engi
engine
ne and
and check
check gove
governo
rnorr.
stall.
2. Wo
Worn
rn oil
oil sea
seali
ling
ng rin
rings
gs.. 2. Remove
Remove,, disas
disassem
semble
ble,, and
and rebuil
rebuild
d
converter assembly
assembly..
3. Wo
Worn
rn ch
charg
argin
ing
g pu
pump
mp.. 3. Re
Repl
plac
ace
e cha
chargi
rging
ng pu
pump
mp..
4. Lo
Low
w oil
oil le
lev
vel
el.. 4. Fi
Fill
ll to pr
prop
oper
er le
leve
vel.
l.
5. Res
Restri
tricti
ction
on in hydr
hydraul
aulic
ic circ
circuit
uit.. 5. Re
Remo
move
ve res
restr
tric
icti
tion
on..

9-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Problem Cause Correction

6. No Fo
Forward 1. Defect
Defective
ive sol
solenoi
enoid
d or car
cartri
tridge
dge in 1. Swap
Swap thethe For
Forwar
wardd and
and Rev
Revers
ersee
control valve. cartridges and solenoids; if the
fault changes from Forward to
Reverse, the solenoid or cartridge
is defective. To determine which
is defective, switch the solenoids
only. If the fault did change,
replace the
the defective
defective solenoid. If
fault did not change, replace
cartridge.
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2. Revers
ersee clut
clutch
ch pac
pack
k plat
plates
es are 2. Pla
Place
ce the tra
transm
nsmiss
ission
ion in the
fused together. neutral position and rev up the
 engine. If the truck tries to move
in reverse, clutch plates are fused
together. Replace or rebuild
transmission.
3. Defect
Defective
ive reg
regula
ulator
tors
s in the mod
modu-
u- 3. Re
Repl
plac
ace
e the
the modul
modulat
ator
or val
valve
ve..
lator valve.
4. Spools
Spools are
are stick
sticking
ing in
in contro
controll valve
valve 4. Cl
Clean
ean or repl
replac
ace
e defect
defectiv
ive
e parts.
parts.
body.

7. No Reverse 1. Defect
Defective
ive
control solenoi
solenoid
valve. d or car
cartri
tridge
dge in 1. Swap
Swa p the
the For
cartridges Forwar
andward
d and
and Rev
Revers
solenoids; if erse
thee
fault changes from Reverse to
Forward, the solenoid or cartridge
is defective. To determine which
is defective, switch the solenoids
only. If the fault did change,
replace the
the defective
defective solenoid. If
fault did not change, replace
cartridge.
2. Forwar
Forwardd clut
clutch
ch pac
pack
k plat
plates
es are 2. Plac
Placee the tra
trans
nsmi
miss
ssio
ion
n in the
the neu-
fused together. tral position and rev up the engine.
If the truck tries to move in forward,
clutch plates are fused together.
Replace or rebuild transmission.
3. Defect
Defective
ive reg
regula
ulator
tors
s in the mod
modu-
u- 3. Re
Repl
plac
ace
e the
the modul
modulat
ator
or val
valve
ve..
lator valve.
4. Spools
Spools are
are stick
sticking
ing in
in contro
controll valve
valve 4. Cl
Clean
ean or repl
replac
ace
e defect
defectiv
ive
e parts.
parts.
body.

8. No For
orw
war
ard
d or
or 1. Parking brake is applied. 1. Release parking brake.
Reverse

continued

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9-9

Problem Cause Correction

8. No For
Forwa
ward
rd or 2. Parki
Parkingng brak
brakee switc
switch
h (S21,
(S21, 2. Rep
Replac
lace
e park
parking
ing brak
brake
e swit
switch.
ch.
Reverse Illustration 6-6) is defective.
(Continued)
3. Inch
Inchin
ing
g valv
valve
e is stu
stuck
ck or
or 3. Di
Dise
seng
ngag
age
e inch
inchin
ing
g valv
valve.
e.
engaged.
4. Low ch
char
arge
ge pum
pump
p pres
pressu
sure
re.. 4. Refer
Refer to
to Proble
Problemm 2. of this
this tro
troubl
uble-
e-
shooting chart.
5. Low con
conve
vert
rter
er out
out press
pressur
ure.
e. 5. Ref
Refer
er to
to Proble
Problem
m 2. of this
this tro
troubl
uble-
e-
shooting chart.
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9. Vibration 1. De
Defe
fect
ctiv
ive
e di
diff
ffer
eren
enti
tial
al.. 1. Re
Repa
pair
ir di
diff
ffer
erent
entia
ial.
l.
2. Output
Output sha
shaft
ft in
in trans
transmis
missio
sion
n is 2. Rep
Repair
air or tig
tighte
hten
n outp
output
ut sha
shaft.
ft.
loose.
3. Trans
ransmis
missio
sion
n moun
mountt is loo
loose.
se. 3. Repair
Repair or tigh
tighten
ten tra
transm
nsmiss
ission
ion
mount.
4. Eng
Engin
ine
e mou
mount
nt is lo
loos
ose.
e. 4. Rep
Repair
air or tig
tighte
hten
n engin
engine
e mount
mount..
5. Exc
Excess
essive
ive back
backlas
lash
h in differ
different
ential
ial.. 5. Re
Repa
pair
ir di
diff
ffer
erent
entia
ial.
l.
6. Plates
Plates ins
inside
ide tra
transm
nsmiss
ission
ion are 6. Repair
Repair or repl
replace
ace eng
engine
ine clu
clutch
tch
sticking or slipping. wear or plates.
7. De
Defe
fect
ctiv
ive
e inchi
inching
ng valv
valve.
e. 7. Re
Repl
plac
ace
e inc
inchi
hing
ng va
valv
lve.
e.
8. Def
Defect
ective
ive tor
torque
que con
conver
verter
ter.. 8. Rep
Repair
air or repl
replace
ace con
conver
verter
ter..
9. De
Defe
fect
ctiv
ive
e char
charge
ge pum
pump.
p. 9. Rep
Repair
air or rep
replac
lace
e char
charge
ge pum
pump.
p.
10. Drive shaft
shaft is out-of-phase.
out-of-phase. 10. Correc
Correctt drive shaft
shaft to be in phase.
11. Loose or missing universal
universal joints.
joints. 11. Ti
Tighten
ghten or replace.
replace.
12. Defec
Defective
tive universal
universal joints. 12. Replac
Replace
e universal
universal joints.
13. Brake / pilot / cooling
cooling pump, 13. Replac
Replace
e or tighten.
tighten.
located on the back of the trans-
mission, is cavitating or are loose.

14. Low oil

oil level.
level. 14. Add oil to the recommended
recommended level.
level.
15. Tr
Transmis
ansmission
sion is overhe
overheating.
ating. 15. Troubleshoot and repair transmis-
sion.
16. Drive axle
axle is loose.
loose. 16. Tighten and re-torque drive axle.
17. Tr
Tread
ead pattern
pattern on tires. 17. Change tread
tread pattern.
pattern.

9-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

9
A
-T
ar
n
s
m
si
s
oi
n
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 o
l
e
r

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 Section 9A

Transmission
Transmission Cooler

CHARGE AIR
COOLER

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 RADIATOR

TRANSMISSION
OIL COOLER

INDICATES HYDRAULIC FLUID FLOW

Illustration 9A-1. Transmiss

Transmission
ion Oil Cooler Hose Flow Diagram
Introduction. The transmission
transmission oil cooler failure requiring a new or rebuilt transmission,
employs a forced air cooled method of cooling the in order for warranty to be valid, the transmis-
transmission oil. sion oil cooler, transmission filter, and hoses
from the transmission to the transmission oil
Transmission Oil Cooler Maintenance. The
Transmission
cooler must be replaced. It is impossible
impossible to
transmission oil cooler should be cleaned exter-
back flush the transmission oil cooler to
nally as conditions warrant.
remove all contaminants from the core.

Whenever the cooler hoses have been discon-

 In the event of transmission

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9A-1

nected and then reconnected, operate the engine

up to normal operating temperature and check the
transmission oil cooler hoses connections for
leaks.

 Make certain used filter and

drained transmission oil are disposed of in
accordance with federal and local regulations.

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9A-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 9
C
-T
a r
n
s m
s i
s
o i
n
C
o
n
tr
o
s l

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 Section 9C

Transmission
Transmission Controls
shift lever and an automatic powershift control
module. The APC module interfaces with the
Taylor Integrated Control System’s MD3 module,
that is located in the instrument panel, to automat-
ically shift the transmission.

 Before servicing truck, park

the truck on level ground, apply parking brake
and block the wheels in both directions.

TICS Pin Code. Certain transmission control

functions can only be changed in the TICS system
by entering a Pin Code. The Pin Code is unique
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to each truck and is provided to the person desig-
 nated by the purchaser of the vehicle. The pin
code can be changed by authorized personnel.
Transmission
Transmission Shift Mode Selection (Illustrations
9C-6). Refer to the Transmission
9C-2 through 9C-6).
Operating Instructions in the Operator’s Guide
(OG160) for information on selecting the transmis-
sion shift mode. To select the mode of transmis-
sion shifting from within the TICS display module,
perform the following steps:
Illustration 9C-1. Electric Shifter 1. At the
the Main
Main Displa
Display
y screen
screen (Illu
(Illustrat
stration
ion 9C-2),
depress the Measure / Adjust Groups button
Introduction. This that
speed transmission truckisiscontrolled
equippedbywith
anaelectric
three ≡) to access the Main Measure / Adjust
(screen.

ADJUST

Illustration 9C-2. Main Measure / Adjust Screen

2. Depres
Depress
s the F1
F1 button
button (Adjust)
(Adjust) to
to access
access the
the Adjust
Adjust screen.
screen.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-1

DEPRESS UP OR
DOWN BUTTON TO
SELECT GROUP;
DEPRESS OK BUT-
TON TO ENTER
INTO DESIRED
GROUP.

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 Illustration 9C-3.
9C-3. Adjust Screen

3. At the Adjust screen

screen (Illustrati
(Illustration
on 9C-3), select
select Transmi
Transmission
ssion Adjust
Adjust Group by depressing
depressing the UP or
DOWN button to highlight the selection (if the selection is not already highlighted). NOTE: The cate-
gory is highlighted when a black box appears behind the selection (category text will be white).
Depress the OK button to access the Transmission
Transmission Adjust Group screen. The PIN code screen will
appear. The Pin Code must be entered before the software will allow any adjustments to be made.

DEPRESS UP OR
DOWN BUTTON
TO SELECT THE
NUMERIC DIGITS
OF THE PIN CODE.
DEPRESS OK BUT-
TON AFTER EACH
DIGIT IS ENTERED.

Illustration 9C-4. Pin Code Screen

4. From the PIN

PIN code screen
screen (Illustrat
(Illustration
ion 9C-4),
9C-4), depress
depress the UP or DOWN button
button until
until the first
first numeric
numeric
digit appears in the first field.
field. Depress the OK button to enter the numeric digit and advance
advance to the
second field. Repeat this procedure until all four numeric digits have been entered. After the code
has been entered, OK will be highlighted; depress the OK button to view the Transmission Adjust

9C-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Group screen.

DEPRESS UP OR
DOWN BUTTON TO
SELECT GROUP;
DEPRESS OK BUT-
TON TO ENTER
INTO DESIRED
GROUP.

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 Illustration 9C-5. Transmis
Transmission
sion Adjust Group Screen

5. At the Transmi
Transmission
ssion Adjust
Adjust Group screen,
screen, select Shift
Shift Mode Select (Illustrat
(Illustration
ion 9C-5) by depressing
depressing
the UP or DOWN button to highlight selection and depress the OK button to access the Shift Mode
Select screen.

DEPRESS UP OR
DOWN BUTTON TO
SELECT GROUP;
DEPRESS OK BUT-
TON TO ENTER
INTO DESIRED
GROUP.

Illustration 9C-6. Shift Mode Select Screen

6. At the Shift
Shift Mode Select
Select screen (Illust
(Illustration
ration 9C-6),
9C-6), depress
depress the UP or DOWN
DOWN button to select
select the shift
shift
mode of transmission operation. Selecting Locked / Auto activates the APC module to automatically
select the speed range (Locked / Auto Mode – operator cannot manually select speed range at the
electric shifter). Selecting Operator Controlled allows the operator choose whether the speed

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-3

range of the transmission is manually shifted or automatically shifted (Operator Controlled Mode, refer
to Operator Controlled Auto / Manual Selection in this section). Selecting Locked / Manual allows
the speed range to be manually selected by the
the operator at the electric shifter.
shifter. Once the desired
mode has been selected, depress the OK button once.
7. Depres
Depresss the
the Measur
Measure e / Adjus
Adjustt Groups
Groups (≡) button to return to the Main Display screen and turn the igni-
tion switch to its Off position.

 The ignition switch should be turned to its Off position after maintenance
personnel have made setting adjustments within the TICS
TICS system. Failure to do so, gives
gives
Unauthorized personnel access to change settings within the TICS system.

Operator Controlled Auto / Manualhttps://www.forkliftpdfmanuals.com/

Selection (Illustration 9C-7).
9C-7). To select whether the speed range is
automatically (Auto) or manually (Manual) selected while the Operator Controlled mode is enabled,
perform the following steps:
1. At the Main Display
Display screen (Illustr
(Illustration
ation 9C-7),
9C-7), depress
depress the Diagnostics
Diagnostics button
button (F1) to access the
the
Diagnostics Select screen.

DIAGNOSTICS
BUTTON

Illustration 9C-7. Main Display

Display Screen

2. At the Diagnostics
Diagnostics Select
Select screen (Illustrat
(Illustration
ion 9C-8), depress
depress the Transmi
Transmission
ssion button
button (F2) to access
the Transmission Information screen.

9C-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

TRANSMISSION
BUTTON
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 Illustration 9C-8. Diagnostics Select Screen

3. At the Transmi
Transmission
ssion Informati
Information
on screen (Illustrat
(Illustration
ion 9C-9), depress
depress the Shift Mode Select
Select button (F2)
to select the shift mode (Operator Controlled / Manual or Operator Controlled / Auto). Selecting Oper-
ator Controlled / Auto activates the APC module to automatically select the speed speed range. Selecting
Operator Controlled / Manual allows the speed range to be manually selected by the operator at the
electric shifter
shifter..

OPERATOR CONTROLLED MODE

OR

Illustration 9C-9. Transmiss

Transmission
ion Information Screen

4. Once the
the desired
desired mode
mode has
has been
been selected,
selected, depres
depress
s the ← button once to return to the Main Display
screen.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-5

Forward Alarm Mode Selection (Illustrations 9C-2 thru 9C-4, 9C-10 and 9C-11)
9C-11).. Refer to the Forward
Alarm System in the Operator’s Guide (OG160) for information on selecting the operating mode of the
forward alarm. To select the Automatic or Operator Controlled mode of forward alarm operation, perform
the following steps:
1. Fol
Follow
low ste
steps
ps 1.
1. thru
thru 4. of the Tr
of the Transmission
ansmission Shift Mode Selection found earlier in this section.

DEPRESS UP OR
DOWN BUTTON TO
SELECT GROUP;
DEPRESS OK BUT-
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INTO DESIRED
 GROUP.

Illustration 9C-10. Transmiss

Transmission
ion Adjust Group Screen

2. At the Transmi
Transmission
ssion Adjust
Adjust Group screen,
screen, select
select Forward Alarm
Alarm Control
Control (Illustration
(Illustration 9C-10)
9C-10) by
depressing the UP or DOWN button to highlight selection and depress the OK button to access the
Forward Alarm Control screen.

DEPRESS UP OR
DOWN BUTTON TO
SELECT GROUP;
DEPRESS OK BUT-
TON TO ENTER
INTO DESIRED
GROUP.

Illustration 9C-11.
9C-11. Forward Alarm Control Screen

3. At the Forward
Forward Alarm Control
Control screen (Illustr
(Illustration
ation 9C-1
9C-11), depress
depress the UP or DOWN button to select
select

9C-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

the mode of foward alarm operation. Selecting Automatic activates

activates the forward alarm every time the
truck is operated for forward travel (Automatic Mode – operator cannot choose when to use forward
alarm). Selecting Operator Controlled activates the forward
forward alarm only when the operator chooses toto
(Operator Controlled Mode, refer to Forward Alarm On / Off Selection in
turn the forward alarm On (Operator
this section). Once the desired mode has been selected, depress the OK button once.
4. Depres
Depresss the Mea
Measur
suree / Adjust
Adjust Gro
Groups
ups (≡) button to return to the Main Display screen and turn the igni-
tion switch to its Off position.

 The ignition switch should be turned to its Off position after maintenance
personnel have made setting adjustments
adjustments within the TICS system.
system. Failure to do so, gives
Unauthorized personnel access to change settings within the TICS system.
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Forward Alarm On / Off Selection (Illustration 9C-12).
9C-12). To turn the forward alarm On or Off while operat-
 ing the forward alarm in the Operator Controlled mode,
mode, depress the F3 button to enable or disable the
forward alarm. When the forward alarm is disabled, no audible sound will be emitted by the forward alarm
when the electric shifter is placed
placed in its Forward position. A Forward Alarm Off text
text message will be dis-
played on the Main Display screen (refer to Illustration
Illustration 9C-12) when the forward
forward alarm is disabled. When
the forward alarm is enabled, an audible sound will be emitted by the forward alarm once the electric shift-
er is placed in its Forward position.

FORWARD ALARM OFF

FORWARD ALARM ON

Illustration 9C-12. Main Display Screen (Forward Alarm Operation - Operator Controlled Mode)
Mode)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-7

Automatic Powershift Control (APC). The APC

module controls shifting
shifting parameters. The Taylor
Taylor
Integrated Control System (TICS) monitors the
APC module via CAN-bus. The TICS system will
signal the APC to go to Neutral Lock when the
operator vacates the seat or alternate idle is
activated.

 Should any truck equipped

with an APC module require welding on its
structural members, the RS connector must be
unplugged from the APC module prior to any
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welding. Failure to comply with this caution
may lead to damage to the APC module.
 APC Module

SPICER OFF–HIGHWAY
D M
E
F
S
APC

4
3 red 7–segment
status LED
LED lamps digits
(”D”,”E”,”F”)
2 push buttons ’M’ and ’S’ for display mode selection.

APC Front Display

The display is located on the APC front panel (or the Transmission Information screen displayed on the
TICS Display Module) and consists of:
The LED lamp labelled ’D’ is yellow and is used to indicate Diagnostic modes.
The LED lamp labelled ’E’ is yellow and is used to indicate Errors.
The LED lamp labelled ’F’ is red and is switched on when the APC is in the reset condition due to the
bootstrap or Fault mode.
After power up, the display defaults to the last display mode (if the display mode was not the error display)
selected when the controller was last powered down.
Typically, this will be the gear position mode. In this mode, the center left digit shows the actually
engaged direction and the center right digit shows the currently engaged range (gear).
Pressing the ’M’ switch (F3) changes the displayed information group while pressing the ’S’ switch (F4)
selects the item within the group.
While pushing the switch (about 0.5 seconds after it is released), the display shows which information is
about to be displayed.

9C-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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The second group shows the shift lever position and some other less used but nevertheless quite relevant
values (see below).
The third display accessed with the ’M’ button (F3) isn’t actually a group of screens but is used to inform
you about any current or previously active errors.
errors. The display normally shows ’ – – ’ to indicate
indicate there are
no faults, but if one or more faults are (or have been) detected, the most severe one is shown until you
press the ’S’ switch (F4). Doing so reveals the next error until
until no more errors are present, at which
which time
again the ’ – – ’ sign is shown.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-9

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APC User Interface On TICS Transmission Information Screen

Display mode Comment

GPOS Reflects the actually engaged transmission direction and range.
VSPD Shows vehicle speed
speed in km/h
km/h or MPH (parameter setting). Speeds are
shown with a 0.1 km/h or 0.1 MPH resolution.
DIST Shows the travelled distance in km
km or Miles (parameter setting). Distance is
shown with a 0.1 km or 0.1 Mile resolution. By pressing the “S” button (F4)
(F4)
during 3 seconds, the distance trip counter is reset to 0.
OPER Shows the total operating
operating time of the vehicle
vehicle (engine running). Operating time
is shown with a 1 hour resolution and has a range of 0 to 49,999 hours.
hours. The
number digits show the hours, the number of dots in between show the
number of times 10,000 hours needs to be added to the number shown:
1 2 3 4 = 1234 hours
1 2.3.4. = 31234 hours

CPOS Reflects the current shift lever direction and position.

ESPD Shows measured engine speed (RPM)
TSPD Shows measured turbine speed (RPM)
OSPD Shows measured output speed (RPM)
SRAT Reflects the current speed ratio (calculated as TSPD/ESPD
TS PD/ESPD [turbine speed /
engine speed]) and is an important factor in automatic shifting.
TQ I Measured turbine torque at transmission input side (Nm)
TTMP Shows transmission temperature in °C

9C-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

CTMP Shows cooler input temperature in °C

ERR The error display.

display. By pressing the “S” button (F4) you can scroll through the
errors codes. If an error code is blinking, this indicates that the error was
active in the past, but not active anymore.

When the controller detects an error, the

the ’E’ led blinks slowly to indicate this. You can always select the
error display mode (ERR) to view the nature of the problem. An overview of the error codes is included in
the back of this section (refer to APC Error Codes and Descriptions).
Descriptions).
Operating Modes
Normal Driving
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For detailed description see functional description.
 Diagnostic Mode
This mode is selected when the ‘S’ mode switch (F4) is pressed at power up.
Limp Home Mode
Defaulted to if either of following conditions occurs:
a single fault on a transmission control output is detected
a fault related to the engine speed sensor is detected
If one of the above conditions
conditions is present, the transmission
transmission is put in neutral. In order to continue driving,
neutral must first be selected on the shift lever.
lever. Once the shift lever has been put in neutral, the driver
can re–engage a direction. In this mode, the user cancan operate the transmission in either
either direction in 1st
and 2nd only. If the fault occurs at a higher gear position, the user is allowed to shift down manually.
manually.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-11

The controller uses default limits; all shifts use a default modulation curve.
The GPOS / CPOS display indicates the letters ‘LH’ on the left two digits of the direction/position
indication.

Shutdown Mode
This mode is activated
activated when a severe internal or external problem is detected. In this mode, the
transmission is forced in Neutral. This mode is selected only if an intolerable combination of faults exists.
In case of an intermitting problem, SHUTDOWN mode is exited and the controller enters the LIMP HOME
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mode.
Also when a fault, related to the parameter settings, located in FLASH memory is detected, the controller
reverts to shutdown mode.
The GPOS / CPOS display indicates the letters ‘Sd’ on the left two digits of the direction/position
indication.

Shifter Lever

The mainranges.
different interface with
The thelever
shift driveroutput
is thesignals
shift lever.
shift lever. It as
serve allows selecting
inputs for the the
for APC.driving direction and the
For automatic mode, the shift lever position will limit the gear in which the controller is allowed to shift to.
Mode Identification
The above modes are identified as follows:

Mode D–led E–led Display

Normal driving Off as per error

Self test On Off described in 4.18

Limp home Off Blinking

Shut Down Off Blinking

9C-12 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Diagnostics and Guidelines

Diagnostics and Maintenance
General
Principally there are no specific devices required for first level troubleshooting as the APC incorporates
several self–test features assisting
assisting in this process. Nevertheless, use of digital multi–meters and simple
tools such as an indicator lamp will be required to pinpoint exact causes of problems.
problems. More indepth
troubleshooting and system tuning involves use of a WIN95 Compatible PC with appropriate software and
FLASH parameter programming equipment. The APC allows recall and modification of non–volatile non–volatile
parameters through RS232. This way, way, customers can, given the necessary equipment, choose to adapt
certain parameters to suit their needs. From a maintenance point of view, view, this is relevant in so far that the
APC allows reading back the (modified) parameters along with serial number, part number and
modification date. Several PC hosted tools have been developed to ease the service service and troubleshooting
process. https://www.forkliftpdfmanuals.com/
 Self Diagnostic Functions
The APC has special circuitry to help verify its operation.
Six self–test groups are built into the APC control programs:
 Display test and Version

 Digital input test

 Analogue input test

 Speed sensor test

 Output test

 Voltage test

The ’D’ led is on while operating the APC in diagnostic mode.

NOTE: If during operation in a self–test mode a fault is detected, the E–led flashes to indicate the presence of the
fault. Pressing S–button (F4) for awhile, however in this case, will not reveal the fault code.

Self Test Operation

‘ S’ switch (F4) on the APC front panel while powering up the
Self–test mode is activated by pressing the ‘S’
APC.
Switching off the power of the APC is the only way to leave the self–test mode.

The available information is organized as groups of related displays.

Generally, each mode’s start display provides an overview of the status of all members of the group.
For instance, the start display of the input test mode cryptically shows the level of each input and the
speed sensor test mode shows the frequency of each sensor channel in kHz (kiloHertz).
Pushing the ‘M’ switch (F3) selects the next group in the order listed.
By pushing the ‘S’ switch (F4) a list of modes with more detailed information about the selected group can
be looked through.
When a new group is selected with the ‘M’ switch (F3), the display always reverts to the overview display
(i.e., the beginning of the mode–list).

Pressing a switch (M or S / F3 or F4) shortly reselects

reselects the current group or mode. This feature is
applicable in all diagnostic–groups.
After powering up, the display test is activated.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-13

Overview of Test Modes

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Display Test and Ver
Version
sion
When selecting this group, the display shows:

When pressing the S switch (F4), the display changes to:

Releasing the switch engages a scrolling text display that shows the part number and the version.
When pressing the S switch (F4), the display switches back to the display test mode, showing:

9C-14 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Followed by the program identification string (e.g. ECON C 1.5 r6).

After releasing the S switch (F4), the display again illuminates all segments.

Digital Input Test

When selecting this group, the display shows:

The display
Different shows which
segments can beinputs
can inputs are active.
switched Each segment
on simultaneously difof the display
if different
ferent indicates
inputs are a specific
activated logical input.
simultaneously. In
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total there are fourteen inputs: ten digital and four analog inputs (in this group treated as if they
they were
 digital pull to ground inputs).
Digital inputs numbered 0 – 9 are shown on the segments as shown below.
below. Analog inputs 0 – 3 are
shown on segments numbered 10 – 13 below.

The below example indicates that inputs 1, 4 and 5 are on. All others are off.
off.

By pressing the ‘S’ switch (F4) repeatedly, each individual input is shown in more detail.
While pressing the ‘S’ switch (F4), the display shows the logic–input number with the matching harness
wire. (– i.e., the below display corresponds with input one connected to wire A12).
A12).

Releasing the switch displays the input’s state (hi or lo).

NOTE: the analog inputs return ‘high’ when pulled to ground.

Pressing the S switch (F4) at the last analog input brings back the overview on the display.

Analogue Input Test

The APC has 4 analog resistance inputs. They measure the single–ended resistance of a sensor
connected between the input and signal ground B18.
When selecting this group the display shows:

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-15

Releasing the switch brings an overview of the 4 analog inputs on the display.
display. The values, displayed in
kΩ (kiloOhms), are separated by a dot.

The above display corresponds with a first input of 1 k Ω, a second of 2 kΩ and the last two of 0 kΩ..
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Values that are more accurate can be found while running through the input specific displays (S switch /
F4). While pressing the switch, similar
similar to the display of digital inputs, the left side of the display gives
information about which input is tested; the right side gives the matching wire. The displayed value, when
the S switch (F4) is released, is the resistance in Ω. (Ohms).

NOTE: Although the APC also has 4 current sense and 3 voltage sense inputs, these are not
directly accessible through diagnostic displays.
The current sense inputs are treated in combination with analog output test modes.
The voltage sense inputs are not yet supported by the diagnostic modes.

Speed Sensor Test

When selecting this mode, the display shows:

When releasing the ‘M’ switch (F3) again, an overview appears on the display.
display. The four values, displayed
in thousands of Hertz, are separated by a dot. Speeds below 1,000 Hz are shown as 0.
Using the ‘S’ switch (F4) more detailed
detailed information concerning the speeds is available. While pressing
the ‘S’ switch, the display shows the speed channel number on the left side of the display while the
matching wire is shown on the right.
Once released, the left digit indicates what type of speed sensor should be connected to this channel:
 c – for a current sensor (Magneto Resistive Sensor)

 i – for an inductive speed sensor

The three other digits and the dot represent the matching
matching speed in kHz (kiloHertz).
(kiloHertz). For instance in the
below examples, the left display indicates a current speed
speed sensor and a frequency of 933 Hz. The right
one indicates an inductive sensor generating about 1,330 Hz.

After the last channel is shown, another press on the ‘S’ switch (F4) re–selects the speed sensor
overview.

9C-16 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Output Test
When selecting this mode, the display shows:

The display shows which outputs are active. Similar to the digital input test overview screen, each
segment of the display indicates a specific input.
Different segments can be switched on simultaneously if different outputs are activated simultaneously.

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 A blinking segment indicates a fault at a certain output.
In total, there are 11 outputs:
 Outputs 0 – 6 are analog

 Outputs 7 – 9 are STP digitals outputs

 Output 10 is a STG digital output

Information that is more specific can be found while running through the different modes (S switch / F4).
While pressing the switch, the left side of the display gives information about which output channel is
tested; the right side gives the matching wire number.
When releasing the switch, the display shows either the actual current in mA (milliAmps), or the logic state
‘hi’’ or ’lo’).
of the output (either ‘hi
If an output is currently in fault, its respective
respective segment in the overview screen blinks slowly.
slowly. On the output
specific screen, the display alternates between the actual state (current value or logic state) and the fault
type (open / short / curr / oor).

Voltage Test
Test
When selecting this mode, the display shows:

The displayed value, after the M switch (F3) is released, is the PERMANENT VOLTAGE Vp in Volts as
measured on wire A01
A01..

The two other modes of this group are switched voltage (Vs) and sensor voltage (Vsen),
(Vsen), also
expressed in Vol
Volts
ts..

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-17

Vs is measured on wire B12. This power supply input is used to allow the the APC to control the power down
process, allowing it to save statistical information in FLASH before actually shutting down.
Vsen is measured off an internally generated voltage regulator and should be near 8.0V.
8.0V. It can be
measured on any unloaded analog input channel (e.g. ANI0 on A11). The Vsen voltage is used as a
reference for the analog inputs.

Connector layout :

Rear view on the

controller connector

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 J154 J155
APC Rear Connector

APC Module Harness Connector Pin and Wire Assignments (see Illustration above for Rear Harness
Connector Wiring Pin–out).

WIRE PIN FUNC TYPE DESCRIPTION TAYLOR WIRE

A01 A1 PPWR Pwr Permanent Battery Plus A01
A02 B1 VFS0+ Pwm 1st S
So
olenoid A02
A03 C1 VFS0– Sns Not Used
A04 D1 VFS1+ Pwm 2nd S
Soolenoid A04

A05 E1 VFS1– Sns Not Used

A06 F1 VFS2+ Pwm 3rd S
Soolenoid A06
A07 G1 VFS2– Sns Not Used
A08 H1 VFS3+ Pwm Not Used
A09 J1 VFS3– Sns Not Used
A10 K1 DO0 Stp Warning Lamp Not Used
A11
A11 A2 ANI0 Ptg Not Used
A12 B2 DIGIN0 Ptp A12
A13 C2 DIGIN1 Ptp A13
A14 D2 DIGIN2 Ptp Not Used
A15 E2 DO1 Stp Forward Solenoid A15
A16 F2 DO2 Stp Reverse Solenoid A16
A17 G2 DIGIN3 Ptp Not Used
A18 H2 DIGIN4 Ptp Not Used

A19
A20 J22
K D
DIO
G3IN5 P
Sttp
g A19
Not Used
A21 A3 GND Gnd Supply Ground A21
A22 B3 SS0 Sns Not Used
A23 C3 SS0 Gnd Not Used
A24 D3 SS1 Sns Drum speed sensor+ A24
A25 E3 SS1 Gnd Drum speed sensor – A25
A26 F3 SS2 Sns A26
A27 G3 SS2 Gnd
Gn A27
A28 H3 ANI1 Ptg Converter out temperature Not Used

9C-18 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

A29 J3 ANI2 Ptg Not Used

A30 K3 GND Gnd Signal Ground A30

WIRE PIN FUNC TYPE DESCRIPTION TAYLOR WIRE

B01 L1 VFS4+ HbrgA Not Used
B02 M1 ANI4 Sns 5V Reference voltage out Not Used
B03 N1 VFS5+ HbrgB Not Used
B04 P1 ANI5 Sns Not Used
B05 R1 VFS6+ Pwm Not Used
B06 S1 ANI6 Sns Not Used
B07 L2 CANL Comm CAN Lo B07
B08 M2 CANH Comm CAN Hi B08
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B09 N2 RXD Comm RS232 RXD B09
 B10 P2 TXD Comm RS232 TXD B10
B11 R2 SS3 Sns Not Used
B12 S2 SPWR Pwr Switched Battery Plus B12
B13 L3 DIGIN6 Ptp Not Used
B14 M3 DIGIN7 Ptp Not Used
B15 N3 DIGIN8 Ptp Not Used
B16 P3 DIGIN9 Ptp Not Used
B17 R3 ANI3 Ptg Not Used
B18 S3 SGND Gnd VFS Ground B18

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-19

APC Error Codes and Descriptions

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

00.50 S There is a problem Controller reverts to Stop machine & Hardware related Contact Spicer Off–
related to the internal a ”shut down” mode Contact mainte- fault – related to in Highway and inform
RAM (in CPU). and will force neutral nance for trouble- the internal RAM. the fault code and
0. shooting. the time that is was
active.

00.51 S There is a problem Controller reverts to Stop machine & Hardware related Contact Spicer Off–
related to the system a ”shut down” mode Contact mainte- fault – related to in Highway and inform
RAM (in CPU). and will force neutral nance for trouble- the system RAM. the fault code and
0. https://www.forkliftpdfmanuals.com/
shooting. the time that is was
active.
00.52 S There is a problem Controller reverts to Stop machine & Hardware related Contact Spicer Off–
related to the system a ”shut down” mode Contact mainte- fault – related to in Highway and inform
RAM. and will force neutral nance for trouble- the system RAM. the fault code and
0. shooting. the time that is was
active.

00.53 S There is a problem Controller reverts to Stop machine & Hardware related Contact Spicer Off–
related to the Flash a ”shut down” mode Contact mainte- fault – related to in Highway and inform
program memory. and will force neutral nance for trouble- the flash program the fault code and
0. shooting. memory. the time that is was
active.

30.04 S Power supply out of Controller will save Stop machine & Power supply to the Check power supply
range –> below all logged informa- Contact mainte- controller too low: cables to the control-
minimum. tion to flash, will pow- nance for trouble- APC 12V supply ver- ler. Check alternator,
erdown, and force all shooting. sion: < 9 V check the connec-
outputs off. APC 24V supply ver- tion cables between
sion: < 16V. the battery and the
alternator, check the
battery.

30.05 A Power supply out of The controller will Contact mainte- Power supply to the Check power supply
supply,,
range –> above have reduced pro- nance for trouble- controller too high: check if a jump start
maximum. portional control shooting. APC 12V supply ver- setup is still con-
accuracy due to sion: > 18 V nected.
reduced PWM duty APC 24V supply ver-
cycle. sion: > 32 V.

31.00 A Voltage supply for The controller will Contact mainte- Voltage supply for Check power supply
supply..
the sensors : Vsense have reduced sensor nance for trouble- the sensors : Vsense Check the controller.
(8V) is out of range signals. shooting. (8V) is below 7,2 V.
–> below minimum.
minimum.

31.01 A Voltage supply for The controller will Contact mainte- Voltage supply for Check power supply
supply..
the sensors : Vsense have reduced sensor nance for trouble- the sensors : Vsense Check the controller.
(8V) is out of range signals. shooting. (8V) is above 8,8 V.
–> above maximum.

40.06 A Invalid shift lever The controller will Contact mainte- The controller Check the wiring
direction detected. force neutral. nance for trouble- receives from the between the control-
shooting. shift lever a request ler and the shift lever
to engage forward concerning the for-
and reverse at the ward and the reverse
same time. signal.

9C-20 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

40.08 B Seat orientation input The controller will Stop the vehicle, put Seat orientation input Check the seat ori-
was changed while force neutral. the shift lever in neu- was changed while entation switch or
the parking brake tral and put the park- the parking brake train the driver to
was not active, or/ ing brake on until the was not active, or/ change the seat ori-
and the shift lever fault disappears. and the shift lever entation according to
was not in neutral, was not in neutral, the correct proce-
or/and the machine or/and the machine dure.
was not at standstill. was not at standstill.

41.06 A Invalid shift lever The controller will not Contact mainte- The controller Check the wiring
position detected. allow range shifting, nance for trouble- receives from the between the control-
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however driving is shooting. shift lever an ler and the shift lever
still possible. unknown range shift concerning the range
 pattern. signals.

42.04 S/A The actual transmis- Controller will flag Contact mainte- The transmission Check the transmis-
sion ratio is too low. the fault – this fault is nance for trouble- ratio measured by sion, in order to
indicating that one or shooting. the controller is more understand if and
more clutches are than 5% below the which clutch is slip-
slipping. value of what is ping. Check the
should be. transmission ratio
settings of the con-
troller.

42.05 S/A The actual transmis- Controller will flag Contact mainte- The transmission Check the transmis-
sion ratio is too high. the fault – this fault is nance for trouble- ratio measured by sion, in order to
indicating that one or shooting. the controller is more understand if and
more clutches are than 5% above the which clutch is slip-
slipping. value
shouldofbe.
what is ping. Check the
transmission ratio
settings of the con-
troller.

43.03 A The transmission Controller will flag Contact mainte- The converter out Check the wiring
converter out tem- the fault. nance for trouble- temperature sensor between the control-
perature sensor is shooting. is not connected or ler and the converter
out of range. shorted. out temperature sen-
sor. Check the con-
verter out tempera-
ture sensor.

43.07 A The transmission Controller will flag Take notice of the The controller mea- Check the converter
converter out tem- the fault – in order to fault, and try to bring sured a converter out temperature and
perature sensor > indicate the driver
driver of the converter tem- out temperature the converter out
100C. the warning level. perature to a lower between 100C and temperature sensor.
level. the allowed limit.

43.08 A The transmission The controller is pro- Stop machine, select The controller mea- Check the converter
converter out tem- tecting the transmis- neutral and apply full sured a converter out temperature and
perature sensor > sion and does not throttle (limited to 50 out temperature the converter out
125C. allow that the con- %) in order to cool above the allowed temperature sensor.
verter out tempera- the transmission oil limit.
ture exceeds its limit. below 100C (until
The controller will the fault 43.03 is
force the transmis- gone). Once the con-
sion to neutral, and if verter out tempera-
engine is controlled, ture is below 100C,
the engine will be continue driving the
limited 50 % of its machine.
maximum speed.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-21

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

45.06 B Invalid pattern for the The controller will Contact mainte- Invalid pattern for the Check the redundant
reduced vehicle limit the vehicle nance for trouble- reduced vehicle reduced vehicle
speed redundant speed to the reduced shooting. speed redundant speed switches and
digital inputs (2 speed. digital inputs (2 the wiring connected
inputs used). inputs used). from these switches
to the APC.

46.05 A The transmission The controller will Release the inching The transmission Release the inching
has exceeded the open or close the pedal and cycle the has exceeded the pedal and cycle the
maximum torque inching clutch shift lever via neutral maximum torque shift lever via neutral
during inching. depending of the back in the selected during inching. back in the selected
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GDE parameter direction in order to direction.
selection. get drive again.
47.06 B Invalid pattern for the The controller will Contact mainte- Invalid pattern for the Check the inching
inching mode digital select the mode ”no nance for trouble- inching mode digital mode selection
inputs (2 inputs inching allowed”. shooting. inputs (2 inputs switch and the wiring
used). used). connected from this
switch to the APC.

50.00 S Analog input 0 (wire Controller reverts to Contact mainte- The analog input Check the wiring
A11) related fault :
A11) a ”limp home” mode. nance for trouble- ANI0 is below 500 between the control-
analog input is shooting. ohm. ler and the pressure
shorted to ground. feedback sensor.
Check the pressure
feedback sensor.

50.01 S Analog input 0 (wire Controller reverts to Contact mainte- The analog input Check the wiring
A11)) related fault :
A11 a ”limp home” mode. nance for trouble- ANI0 exceeds 4000 between the control-
analog input is not shooting. ohm. ler and the pressure
connected. feedback sensor.
Check the pressure
feedback sensor.

51.00 A Analog input 1 (wire The controller will Contact mainte- The analog input Check the wiring
A28) related fault : limit the transmission nance for trouble- ANI1 is shorted
shorted to between the control-
analog input is temperature mea- shooting. ground. ler and the transmis-
shorted to ground. surement to the low- sion sump tempera-
est clipped value in ture sensor. Check
its settings, which the transmission
will result in a bad sump temperature
temperature com- sensor.
pensation.

51.01 A Analog input 1 (wire The controller will Contact mainte- The analog input Check the wiring
A28) related fault : limit the transmission nance for trouble- ANI1 is not con- between the control-
analog input is not temperature mea- shooting. nected. ler and the transmis-
connected. surement to the high- sion sump tempera-
est clipped value in ture sensor. Check
its settings, which the transmission
will result in a bad sump temperature
temperature com- sensor.
pensation.

9C-22 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

52.00 B Analog input 2 (wire Controller will flag Contact mainte- The analog input Check the wiring
A29) related
related fault : the fault, and will use nance for trouble- ANI2 is shorted
shorted to between the control-
analog input is the lowest clipped shooting. ground, or measured ler and the device
shorted to ground. value in its settings. input value is below connected to this
the minimum value analog input. Check
(corresponding with this device con-
0 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.
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52.01 B Analog input 2 (wire Controller will flag Contact mainte- The analog input Check the wiring
 A29) related
related fault : the fault, and will use nance for trouble- ANI2 is not con- between the control-
analog input is not the lowest clipped shooting. nected, or measured ler and the device
connected. value in its settings. input value is above connected to this
the maximum value analog input. Check
(corresponding with this device con-
100 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.

53.00 B Analog input 3 (wire Controller will flag Contact mainte- The analog input Check the wiring
B17) related fault : the fault, and will use nance for trouble- ANI3 is shorted
shorted to between the control-
analog input is the lowest clipped shooting. ground, or measured ler and the device
shorted to ground. value in its settings. input value is below connected to this
the minimum value
(corresponding with analog input.
this device Check
con-
0 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.

53.01 B Analog input 3 (wire Controller will flag Contact mainte- The analog input Check the wiring
B17) related fault : the fault, and will use nance for trouble- ANI3 is not con- between the control-
analog input is not the lowest clipped shooting. nected, or measured ler and the device
connected. value in its settings. input value is above connected to this
the maximum value analog input. Check
(corresponding with this device con-
100 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.

54.00 A Analog input 4 (wire Controller will flag Contact mainte- The reference power Check the refence
B02) related fault : the fault. The control- nance for trouble- supply (4.5 V ref.) for power supply of the
analog input is ler uses the analog shooting. the analog inputs analog inputs ANI2,
shorted to ground. input ANI4
ANI4 to have a ANI2, ANI3,
ANI3, ANI5
ANI5 & ANI3, ANI5
ANI5 and
reference power ANI6 is below
below 4 V ANI6.
supply for the analog
inputs ANI2, ANI3,
ANI5 and ANI6.
ANI6.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-23

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

54.01 A Analog input 4 (wire Controller will flag Contact mainte- The reference power Check the refence
B02) related fault : the fault.
fault. The con-
con- nance for trouble- supply (4.5 V ref.) for power supply of the
analog input is not troller uses the ana- shooting. the analog inputs analog inputs ANI2,
connected. log input ANI4 to ANI2, ANI3,
ANI3, ANI5
ANI5 & ANI3, ANI5
ANI5 and
have a reference ANI6 is above 4.95
4.95 ANI6.
power supply for the V.
analog inputs ANI2,
ANI3, ANI5
ANI5 and
ANI6.

55.00 B Analog input 5 (wire Controller will flag Contact mainte- The analog input Check the wiring
B04) related fault : https://www.forkliftpdfmanuals.com/
the fault, and will use nance for trouble- ANI5 is shorted
shorted to between the control-
analog input is the lowest clipped shooting. ground, or measured ler and the device
 shorted to ground. value in its settings. input value is below connected to this
the minimum value analog input. Check
(corresponding with this device con-
0 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.

55.01 B Analog input 5 (wire Controller will flag Contact mainte- The analog input Check the wiring
B04) related fault : the fault, and will use nance for trouble- ANI5 is not con- between the control-
analog input is not the lowest clipped shooting. nected, or measured ler and the device
connected. value in its settings. input value is above connected to this
the maximum value analog input. Check
(corresponding with this device con-
100 %). nected. Check
calibration if the
is done
correctly – recalibra-
tion of this analog
input.

56.00 B Analog input 6 (wire Controller will flag Contact mainte- The analog input Check the wiring
B06) related fault : the fault, and will use nance for trouble- ANI6 is shorted
shorted to between the control-
analog input is the lowest clipped shooting. ground, or measured ler and the device
shorted to ground. value in its settings. input value is below connected to this
the minimum value analog input. Check
(corresponding with this device con-
0 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.

56.01 B Analog input 6 (wire Controller will flag Contact mainte- The analog input Check the wiring
B06) related fault : the fault, and will use nance for trouble- ANI6 is not con- between the control-
analog input is not the lowest clipped shooting. nected, or measured ler and the device
connected. value in its settings. input value is above connected to this
the maximum value analog input. Check
(corresponding with this device con-
100 %). nected. Check if the
calibration is done
correctly – recalibra-
tion of this analog
input.

9C-24 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

60.00 S/A Speed channel 0 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire A22) related channel has a fail- nance for trouble- SPC0 is shorted to between the control-
fault : speed channel ure, and which is not shooting. ground. ler and the speed
is shorted to ground. the engine speed sensor connected to
channel, the control- speed channel 0.
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 0.
speed channels
have a failure, of the
engine speed chan-
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nel has a failure, the
controller reverts to a
 limp home mode.

60.01 S/A Speed channel 0 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire A22) related channel has a fail- nance for trouble- SPC0 is not con- between the control-
fault : speed channel ure, and which is not shooting. nected. ler and the speed
is not connected. the engine speed sensor connected to
channel, the control- speed channel 0.
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 0.
speed channels
have a failure, of the
engine speed chan-
nel has a failure, the
controller reverts to a
”limp home” mode.

60.03 S/A Speed chchannel 0,

0, When a speed chan- Contact mainte- Speed channel is not Check the speed
Invalid signal. nel has a failure, the nance for trouble- measuring. sensor installation.
controller will flag the shooting.
appropriate
appropria te error. If
the engine speed
channel has a fail-
ure, the controller
reverts to a ”limp
home” mode.

61.00 S/A Speed channel 1 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire A24) related channel has a fail- nance for trouble- SPC1 is shorted to between the control-
fault : speed channel ure, and which is not shooting. ground. ler and the speed
is shorted to ground. the engine speed sensor connected to
channel, the control- speed channel 1.
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 1.
speed channels
have a failure, of the
engine speed chan-
nel has a failure, the
controller reverts to a
”limp home” mode.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-25

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

61.01 S/A Speed channel 1 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire A24) related channel has a fail- nance for trouble- SPC1 is not con- between the control-
fault : speed channel ure, and which is not shooting. nected. ler and the speed
is not connected. the engine speed sensor connected to
channel, the control- speed channel 1.
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 1.
speed channels
have a failure, of the
engine speed chan-
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nel has a failure, the
controller reverts to a
 limp home mode.

61.03 S/A Speed chchannel 1,

1, When a speed chan- Contact mainte- Speed channel is not Check the speed
Invalid signal. nel has a failure, the nance for trouble- measuring. sensor installation.
controller will flag the shooting.
appropriate
appropri ate error. If
the engine speed
channel has a fail-
ure, the controller
reverts to a ”limp
home” mode.

62.00 S/A Speed channel 2 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire A26) related channel has a fail- nance for trouble- SPC2 is shorted to between the control-
fault : speed channel ure, and which is not shooting. ground. ler and the speed
is shorted to ground. the engine
channel, thespeed
control- sensor connected
speed channel 2. to
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 2.
speed channels
have a failure, of the
engine speed chan-
nel has a failure, the
controller.

62.01 S/A Speed channel 2 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire A26) related channel has a fail- nance for trouble- SPC2 is not con- between the control-
fault : speed channel ure, and which is not shooting. nected. ler and the speed
is not connected. the engine speed sensor connected to
channel, the control- speed channel 2.
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 2.
speed channels
have a failure, of the
engine speed chan-
nel has a failure, the
controller reverts to a
”limp home” mode.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

9C-26

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

62.03 S/A Speed chchannel 2,

2, When a speed chan- Contact mainte- Speed channel is not Check the speed
Invalid signal. nel has a failure, the nance for trouble- measuring. sensor installation.
controller will flag the shooting.
appropriate
appropria te error. If
the engine speed
channel has a fail-
ure, the controller
reverts to a ”limp
home” mode.

63.00 S/A Speed channel 3 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire B11) related https://www.forkliftpdfmanuals.com/
channel has a fail- nance for trouble- SPC3 is shorted to between the control-
fault : speed channel ure, and which is not shooting. ground. ler and the speed
 is shorted to ground. the engine speed sensor connected to
channel, the control- speed channel 3.
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 3.
speed channels
have a failure, of the
engine speed chan-
nel has a failure, the
controller reverts to a
”limp home” mode.

63.01 S/A Speed channel 3 When only 1 speed Contact mainte- Speed channel Check the wiring
(wire B11) related channel has a fail- nance for trouble- SPC3 is not con- between the control-
fault : speed channel ure, and which is not shooting. nected. ler and the speed
is not connected. the engine
channel, speed
the control- sensor connected
speed channel 3. to
ler will calculate what Check the speed
the missing speed sensor connected to
should be.be. If several
several speed channel 3.
speed channels
have a failure, of the
engine speed chan-
nel has a failure, the
controller reverts to a
”limp home” mode.

63.03 S/A Speed chchannel 3,

3, When a speed chan- Contact mainte- Speed channel is not Check the speed
Invalid signal. nel has a failure, the nance for trouble- measuring. sensor installation.
controller will flag the shooting.
appropriate
appropria te error. If
the engine speed
channel has a fail-
ure, the controller
reverts to a ”limp
home” mode.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-27

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

70.00 S/A Output 0 (wires A02 Action will depend

depend ”limp home” mode: – wires A02 & A03 If the output is con-
& A03) related fault: on the function Stop machine and configured as analog figured as an output
– wires A02 & A03 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. output wires are solenoid:
output: – critical output
output (eg. ”Limp home” mode shorted to each Check the wiring
output wires are transmission valve will result in reduced other,, or the sense
other between the control-
shorted to each control): the control- driving functionality. line is shorted to bat- ler and the VFS/
other, or the sense ler reverts to a ”limp Contact mainte- tery +, or the plus Selector solenoid 0,
line is shorted to bat- home” mode. nance for trouble- line is shorted to Check the VFS/
tery +, or the plus – non–critical feature
feature shooting.” ground.– wire A02 selector solenoid 0.
line is shorted to output: the controller configured as digital If the output is con-
ground. https://www.forkliftpdfmanuals.com/
will flag the fault, but output: the output is nected to an other
– wire A02 config-
config- no actions will be shorted to ground. device: Check the
 ured as digital out- taken. wiring between the
put: controller and the
the output is shorted other device, Check
to ground. the other device.”

70.01 S/A Output 0 (wires A02 Action will depend

depend ”limp home” mode: – wires A02 & A03 If the output is con-
& A03) related fault: on the function Stop machine and configured as analog figured as an output
– wires A02 & A03 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output wire is not solenoid:
output: – critical output
output (eg. ”Limp home” mode connected, or its Check the wiring
the output wire is not transmission valve will result in reduced plus line is shorted to between the control-
connected, or its control): the control- driving functionality. battery +. ler and the VFS/
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire A02 config-
config- Selector solenoid 0,
battery +. home” mode. nance for trouble- ured as digital out- Check the VFS/
– wire A02 config-
config- – non–critical feature
feature shooting. put: selector solenoid 0.
ured as digital out- output: the controller the output is shorted If the output is con-
put: will flag the fault, but to battery +. nected to an other
the output is shorted no actions will be device: Check the
to battery +,
+, or the
the taken. wiring between the
output is not con- controller and the
nected. other device, Check
the other device.

70.02 S/A Output 0 (wires A02 Action will depend

depend ”limp home” mode: – wires A02 & A03 If the output is con-
& A03) related fault: on the function Stop machine and configured as analog figured as an output
– wires A02 & A03 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current solenoid:
output: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. Check the wiring
the output current transmission valve will result in reduced between the control-
exceeds 1400 mA. control): the control- driving functionality. ler and the VFS/
ler reverts to a ”limp Contact mainte- Selector solenoid 0,
home” mode nance for trouble- Check the VFS/
– non–critical feature
feature shooting. selector solenoid 0.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

9C-28 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

70.03 S/A Output 0 (wires A0

A02 Action will depend
depend “limp home“ mode: – wires A02 & A03 If the output is con-
& A03) related fault: on the function Stop machine and configured as analog figured as an output
– wires A02 & A03 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current is solenoid:
output: – critical output
output (eg. ”Limp home” mode out of range, occurs Check the wiring
the output current is transmission valve will result in reduced when the load has between the control-
out of range, occurs control): the control- driving functionality. the incorrect imped- ler and the VFS/
when the load has ler reverts to a ”limp Contact mainte- ance. Selector solenoid 0,
the incorrect imped- home” mode. nance for trouble- Check the VFS/
ance. – non–critical feature
feature shooting. selector solenoid 0.
output: the controller
https://www.forkliftpdfmanuals.com/ If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
 taken. wiring between the
controller and the
other device, Check
the other device.

71.00 S/A Output 1 (wires A0 A04 Action will depend

depend “limp home“ mode: – wires A04 & A05 If the output is con-
& A05) related fault: on the function Stop machine and configured as analog figured as an output
– wires A04 & A05 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. output wires are solenoid: Check the
output: – critical output
output (eg. ”Limp home” mode shorted to each wiring between the
output wires are transmission valve will result in reduced other, or the sense controller and the
shorted to each control): the control- driving functionality. line is shorted to bat- VFS/Selector
VFS/Select or sole-
other,, or the sense
other ler reverts to a ”limp Contact mainte- tery +, or the plus noid 1, Check the
line is shorted to bat- home” mode. nance for trouble- line is shorted to VFS/selector sole-
tery +, or the plus – non–critical feature
feature shooting. ground. noid 1.
line is shorted to output: the controller – wire A04 config-
config- If the output is con-
ground. will flag the fault, but ured as digital out- nected to an other
– wire A04 config-
config- no actions will be put: the output is device: Check the
ured as digital out- taken. shorted to ground. wiring between the
put: controller and the
the output is shorted other device, Check
to ground. the other device.

71.01 S/A Output 1 (wires A0A04 Action will depend

depend “limp home“ mode: – wires A04 & A05 If the output is con-
& A05) related fault: on the function Stop machine and configured as analog figured as an output
– wires A04 & A05 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output wire is not solenoid:
output: – critical output
output (eg. ”Limp home” mode connected, or its Check the wiring
the output wire is not transmission valve will result in reduced plus line is shorted to between the control-
connected, or its control): the control- driving functionality. battery +. ler and the VFS/
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire A04 config-
config- Selector solenoid 1,
battery +. home” mode. nance for trouble- ured as digital out- Check the VFS/
– wire A04 config-
config- – non–critical feature
feature shooting. put: selector solenoid 1.
ured as digital out- output: the controller the output is shorted If the output is con-
put: will flag the fault, but to battery +. nected to an other
the output is shorted no actions will be device: Check the
to battery +, or the taken. wiring between the
output is not con- controller and the
nected. other device, Check
the other device.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-29

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

71.02 S/A Output 1 (wires A04 Action will depend

depend “limp home“ mode: – wires A04 & A05 If the output is con-
& A05) related fault: on the function Stop machine and configured as analog figured as an output
– wires A04 & A05 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current solenoid:
output: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. Check the wiring
the output current transmission valve will result in reduced between the control-
exceeds 1400 mA. control): the control- driving functionality. ler and the VFS/
ler reverts to a ”limp Contact mainte- Selector solenoid 1,
home” mode. nance for trouble- Check the VFS/
– non–critical feature
feature shooting. selector solenoid 1.
output:https://www.forkliftpdfmanuals.com/
the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
 taken. wiring between the
controller and the
other device, Check
the other device.

71.03 S/A Output 1 (wires A04 Action will depend

depend “limp home“ mode: – wires A04 & A05 If the output is con-
& A05) related fault: on the function Stop machine and configured as analog figured as an output
– wires A04 & A05 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current is solenoid:
output: – critical output
output (eg. ”Limp home” mode out of range, occurs Check the wiring
the output current is transmission valve will result in reduced when the load has between the control-
out of range, occurs control): the control- driving functionality. the incorrect imped- ler and the VFS/
when the load has ler reverts to a ”limp Contact mainte- ance. Selector solenoid 1,
the incorrect imped- home” mode. nance for trouble- Check the VFS/
ance. – non–critical feature
feature shooting. selector solenoid 1.

output:
will flag the
thecontroller
fault, but If the output
nected to an is con-
other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

72.00 S/A Output 2 (wires A06 Action will depend

depend “limp home“ mode: – wires A06 & A07 If the output is con-
& A07) related fault: on the function Stop machine and configured as analog figured as an output
– wires A06 & A07 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. output wires are solenoid:
output: – critical output
output (eg. ”Limp home” mode shorted to each Check the wiring
output wires are transmission valve will result in reduced other,, or the sense
other between the control-
shorted to each control): the control- driving functionality. line is shorted to bat- ler and the VFS/
other, or the sense ler reverts to a ”limp Contact mainte- tery +, or the plus Selector solenoid 2,
line is shorted to bat- home” mode. nance for trouble- line is shorted to Check the VFS/
tery +, or the plus – non–critical feature
feature shooting. ground. selector solenoid 2.
line is shorted to output: the controller – wire A06 config-
config- If the output is con-
ground. will flag the fault, but ured as digital out- nected to an other
– wire A06 config-
config- no actions will be put: the output is device: Check the
ured as digital out- taken. shorted to ground. wiring between the
put: controller and the
the output is shorted other device, Check
to ground. the other device.

9C-30 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

72.01 S/A Output 2 (wires A0A06 Action will depend

depend “limp home“ mode: – wires A06 & A07 If the output is con-
& A07) related fault: on the function Stop machine and configured as analog figured as an output
– wires A06 & A07 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output wire is not solenoid:
output: – critical output
output (eg. ”Limp home” mode connected, or its Check the wiring
the output wire is not transmission valve will result in reduced plus line is shorted to between the control-
connected, or its control): the control- driving functionality. battery +. ler and the VFS/
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire A06 config-
config- Selector solenoid 2,
battery +. home” mode. nance for trouble- ured as digital out- Check the VFS/
– wire A06 config-
config- – non–critical feature
feature shooting. put: selector solenoid 2.
ured as digital out-
put: https://www.forkliftpdfmanuals.com/
output:
will
the controller
flag the fault, but
the output is shorted
to battery +.
If the output is con-
nected to an other
the output is shorted no actions will be device: Check the
 to battery +, or the taken. wiring between the
output is not con- controller and the
nected. other device, Check
the other device.

72.02 S/A Output 2 (wires A0

A06 Action will depend
depend “limp home“ mode: – wires A06 & A07 If the output is con-
& A07) related fault: on the function Stop machine and configured as analog figured as an output
– wires A06 & A07 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current solenoid:
output: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. Check the wiring
the output current transmission valve will result in reduced between the control-
exceeds 1400 mA. control): the control- driving functionality. ler and the VFS/
ler reverts to a ”limp Contact mainte- Selector solenoid 2,
home” mode. nance for trouble- Check the VFS/
– non–critical feature
feature shooting. selector solenoid 2.

output:
will flag the
the controller
fault, but If the output
nected to an is con-
other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

72.03 S/A Output 2 (wires A0

A06 Action will depend
depend “limp home“ mode: – wires A06 & A07 If the output is con-
& A07) related fault: on the function Stop machine and configured as analog figured as an output
– wires A06 & A07 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current is solenoid:
output: – critical output
output (eg. ”Limp home” mode out of range, occurs Check the wiring
the output current is transmission valve will result in reduced when the load has between the control-
out of range, occurs control): the control- driving functionality. the incorrect imped- ler and the VFS/
when the load has ler reverts to a ”limp Contact mainte- ance. Selector solenoid 2,
the incorrect imped- home” mode. nance for trouble- Check the VFS/
ance. – non–critical feature
feature shooting. selector solenoid 2.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-31

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

73.00 S/A Output 3 (wires A08 Action will depend

depend “limp home“ mode: – wires A08 & A09 If the output is con-
& A09) related fault: on the function Stop machine and configured as analog figured as an output
– wires A08 & A09 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. output wires are solenoid:
output: – critical output
output (eg. ”Limp home” mode shorted to each Check the wiring
output wires are transmission valve will result in reduced other,, or the sense
other between the control-
shorted to each control): the control- driving functionality. line is shorted to bat- ler and the VFS/
other, or the sense ler reverts to a ”limp Contact mainte- tery +, or the plus Selector solenoid 3,
line is shorted to bat- home” mode. nance for trouble- line is shorted to Check the VFS/
tery +, or the plus – non–critical feature
feature shooting. ground. selector solenoid 3.
line is shorted to output:https://www.forkliftpdfmanuals.com/
the controller – wire A08 config-
config- If the output is con-
ground. will flag the fault, but ured as digital out- nected to an other
– wire A08 config-
config- no actions will be put: the output is device: Check the
 ured as digital out- taken. shorted to ground. wiring between the
put: controller and the
the output is shorted other device, Check
to ground. the other device.”

73.01 S/A Output 3 (wires A08 Action will depend

depend “limp home“ mode: – wires A08 & A09 If the output is con-
& A09) related fault: on the function Stop machine and configured as analog figured as an output
– wires A08 & A09 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output wire is not solenoid:
output: – critical output
output (eg. ”Limp home” mode connected, or its Check the wiring
the output wire is not transmission valve will result in reduced plus line is shorted to between the control-
connected, or its control): the control- driving functionality. battery +. ler and the VFS/
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire A08 config-
config- Selector solenoid 3,
battery +. home” mode. nance for trouble- ured as digital out- Check the VFS/
– wire A08 config-
config- – non–critical feature
feature shooting. put: selector solenoid 3.

ured as digital out-

put: output:
will flag the
thecontroller
fault, but thebattery
to output+.
is shorted If the output
nected to an is con-
other
the output is shorted no actions will be device: Check the
to battery +,
+, or the
the taken. wiring between the
output is not con- controller and the
nected. other device, Check
the other device.

73.02 S/A Output 3 (wires A08 Action will depend

depend “limp home“ mode: – wires A08 & A09 If the output is con-
& A09) related fault: on the function Stop machine and configured as analog figured as an output
– wires A08 & A09 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current solenoid:
output: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. Check the wiring
the output current transmission valve will result in reduced between the control-
exceeds 1400 mA. control): the control- driving functionality. ler and the VFS/
ler reverts to a ”limp Contact mainte- Selector solenoid 3,
home” mode. nance for trouble- Check the VFS/
– non–critical feature
feature shooting. selector solenoid 3.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

9C-32 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

73.03 S/A Output 3 (wires A0

A08 Action will depend
depend “limp home“ mode: – wires A08 & A09 If the output is con-
& A09) related fault: on the function Stop machine and configured as analog figured as an output
– wires A08 & A09 assigned to the out- go to neutral to be output: to a transmission
configured as analog put: able to drive again. the output current is solenoid:
output: – critical output
output (eg. ”Limp home” mode out of range, occurs Check the wiring
the output current is transmission valve will result in reduced when the load has between the control-
out of range, occurs control): the control- driving functionality. the incorrect imped- ler and the VFS/
when the load has ler reverts to a ”limp Contact mainte- ance. Selector solenoid 3,
the incorrect imped- home” mode. nance for trouble- Check the VFS/
ance. – non–critical feature
feature shooting. selector solenoid 3.
https://www.forkliftpdfmanuals.com/
output:
will
the controller
flag the fault, but
If the output is con-
nected to an other
no actions will be device: Check the
 taken. wiring between the
controller and the
other device, Check
the other device.

74.00 S/A Output 4 (wire B0

B01) Action will depend
depend “limp home“ mode: – wire B01 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog/digi- figured as an output
– wire B01 config-
config- assigned to the out- go to neutral to be tal output: to a transmission
ured as analog/digi- put: able to drive again. output wire is solenoid:
tal output: – critical output
output (eg. ”Limp home” mode shorted to ground. Check the wiring
output wire is transmission valve will result in reduced between the control-
shorted to ground. control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 4, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 4.

output:
will flag the
the controller
fault, but If the output
nected to an is con-
other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

74.01 S/A Output 4 (wire B0B01) Action will depend

depend “limp home“ mode: – wire B01 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B01 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output wire is not solenoid:
put: – critical output
output (eg. ”Limp home” mode connected, or its Check the wiring
the output wire is not transmission valve will result in reduced plus line is shorted to between the control-
connected, or its control): the control- driving functionality. battery +. ler and the Selector
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire B01 config-
config- solenoid 4, Check
battery +. home” mode. nance for trouble- ured as digital out- the selector solenoid
– wire B01 config-
config- – non–critical feature
feature shooting. put: 4.
ured as digital out- output: the controller the output is shorted If the output is con-
put: will flag the fault, but to battery +. nected to an other
the output is shorted no actions will be device: Check the
to battery +, or the taken. wiring between the
output is not con- controller and the
nected. other device, Check
the other device.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-33

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

74.02 S/A Output 4 (w

(wire B0
B01) Action will depend
depend “limp home“ mode: – wire B01 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B01 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output current solenoid:
put: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. Check the wiring
the output current transmission valve will result in reduced between the control-
exceeds 1400 mA. control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 4, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 4.
output:https://www.forkliftpdfmanuals.com/
the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
 taken. wiring between the
controller and the
other device, Check
the other device.

74.03 S/A Output 4 (w

(wire B0
B01) Action will depend
depend “limp home“ mode: – wire B01 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B01 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output current is solenoid: Check the
put: – critical output
output (eg. ”Limp home” mode out of range, occurs wiring between the
the output current is transmission valve will result in reduced when the load has controller and the
out of range, occurs control): the control- driving functionality. the incorrect imped- Selector solenoid 4,
when the load has ler reverts to a ”limp Contact mainte- ance. Check the selector
the incorrect imped- home” mode. nance for trouble- solenoid 4.
ance. – non–critical feature
feature shooting. If the output is con-

output:
will flag the
thecontroller
fault, but nected
device: to an other
Check the
no actions will be wiring between the
taken. controller and the
other device, Check
the other device.

75.00 S/A Output 5 (w

(wire B0
B03) Action will depend
depend “limp home“ mode: – wire B03 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog/digi- figured as an output
– wire B03 config-
config- assigned to the out- go to neutral to be tal output: to a transmission
ured as analog/digi- put: able to drive again. output wire is solenoid:
tal output: – critical output
output (eg. ”Limp home” mode shorted to ground. Check the wiring
output wire is transmission valve will result in reduced between the control-
shorted to ground. control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 5, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 5.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.”

9C-34 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

75.01 S/A Output 5 (wire B0

B03) Action will depend
depend “limp home“ mode: – wire B03 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B03 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output wire is not solenoid: Check the
put: – critical output
output (eg. ”Limp home” mode connected, or its wiring between the
the output wire is not transmission valve will result in reduced plus line is shorted to controller and the
connected, or its control): the control- driving functionality. battery +. Selector solenoid 4,
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire B03 config-
config- Check the selector
battery +. home” mode. nance for trouble- ured as digital out- solenoid 4.
– wire B03 config-
config- – non–critical feature
feature shooting. put: If the output is con-
ured as digital out-
put:
https://www.forkliftpdfmanuals.com/
output: the controller
will flag the fault, but
the output is shorted
to battery +.
nected to an other
device: Check the
the output is shorted no actions will be wiring between the
 to battery +, or the taken. controller and the
output is not con- other device, Check
nected. the other device.”

75.02 S/A Output 5 (wire B0

B03) Action will depend
depend “limp home“ mode: – wire B03 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B03 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output current solenoid: Check the
put: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. wiring between the
the output current transmission valve will result in reduced controller and the
exceeds 1400 mA. control): the control- driving functionality. Selector solenoid 4,
ler reverts to a ”limp Contact mainte- Check the selector
home” mode. nance for trouble- solenoid 4.
– non–critical feature
feature shooting. If the output is con-
output: the controller nected to an other
will flag thewill
no actions fault,
bebut device: Check the
wiring between the
taken. controller and the
other device, Check
the other device.”

75.03 S/A Output 5 (wire B0

B03) Action will depend
depend “limp home“ mode: – wire B03 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B03 config-
config- assigned to the out- go to neutral to be put: the output cur- to a transmission
ured as analog out- put: able to drive again. rent is out of range, solenoid: Check the
put: – critical output
output (eg. ”Limp home” mode occurs when the wiring between the
the output current is transmission valve will result in reduced load has the incor- controller and the
out of range, occurs control): the control- driving functionality. rect impedance. Selector solenoid 4,
when the load has ler reverts to a ”limp Contact mainte- Check the selector
the incorrect imped- home” mode. nance for trouble- solenoid 4.
ance. – non–critical feature
feature shooting. If the output is con-
output: the controller nected to an other
will flag the fault, but device: Check the
no actions will be wiring between the
taken. controller and the
other device, Check
the other device.”

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-35

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

76.00 S/A Output 6 (w

(wire B0
B05) Action will depend
depend “limp home“ mode: – wire B05 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog/digi- figured as an output
– wire B05 config-
config- assigned to the out- go to neutral to be tal output: to a transmission
ured as analog/digi- put: able to drive again. output wire is solenoid:
tal output: – critical output
output (eg. ”Limp home” mode shorted to ground. Check the wiring
output wire is transmission valve will result in reduced between the control-
shorted to ground. control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 6, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 6.
output:https://www.forkliftpdfmanuals.com/
the controller If the output is con-
will flag the fault, but nected to an other
 no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.”

76.01 S/A Output 6 (w(wire B0

B05) Action will depend
depend “limp home“ mode: – wire B05 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B05 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output wire is not solenoid:
put: – critical output
output (eg. ”Limp home” mode connected, or its Check the wiring
the output wire is not transmission valve will result in reduced plus line is shorted to between the control-
connected, or its control): the control- driving functionality. battery +. ler and the Selector
plus line is shorted to ler reverts to a ”limp Contact mainte- – wire B05 config-
config- solenoid 6, Check
battery +. home” mode. nance for trouble- ured as digital out- the selector solenoid
– wire B05 config-
config- – non–critical feature
feature shooting. put: 6.
ured as digital out-
put: output:
will flag the
thecontroller
fault, but thebattery
to output+.
is shorted If the output
nected to an is con-
other
the output is shorted no actions will be device: Check the
to battery +, or the taken. wiring between the
output is not con- controller and the
nected. other device, Check
the other device.”

76.02 S/A Output 6 (w

(wire B0
B05) Action will depend
depend “limp home“ mode: – wire B05 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B05 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output current solenoid:
put: – critical output
output (eg. ”Limp home” mode exceeds 1400 mA. Check the wiring
the output current transmission valve will result in reduced between the control-
exceeds 1400 mA. control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 6, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 6.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.”

9C-36 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

76.03 S/A Output 6 (wire B0

B05) Action will depend
depend “limp home“ mode: – wire B05 config-
config- If the output is con-
related fault: on the function Stop machine and ured as analog out- figured as an output
– wire B05 config-
config- assigned to the out- go to neutral to be put: to a transmission
ured as analog out- put: able to drive again. the output current is solenoid:
put: – critical output
output (eg. ”Limp home” mode out of range, occurs Check the wiring
the output current is transmission valve will result in reduced when the load has between the control-
out of range, occurs control): the control- driving functionality. the incorrect imped- ler and the Selector
when the load has ler reverts to a ”limp Contact mainte- ance. solenoid 6, Check
the incorrect imped- home” mode. nance for trouble- the selector solenoid
ance. – non–critical feature
feature shooting. 6.
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output: the controller If the output is con-
will flag the fault, but nected to an other
 no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

80.00 S/A Digital output 0 (w

(wire Action will depend
depend “limp home“ mode: Wire A10 is shorted If the output is con-
A10) related
related fault : on the function Stop machine and to ground. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
ground. put: able to drive again. solenoid:
– critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 7, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 7.
output:
will flag the
the controller
fault, but If the output
nected to an is con-
other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.”

80.01 S/A Digital output 0 (w

(wire Action will depend
depend “limp home“ mode: Wire A10 is shorted If the output is con-
A10) related
related fault : on the function Stop machine and to battery +. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
battery + or the out- put: able to drive again. solenoid:
put is not connected. – critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 7, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 7.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.”

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-37

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

81.00 S/A Digital output 1 (wire Action will depend

depend “limp home“ mode: Wire A15 is shorted If the output is con-
A15) related fault : on the function Stop machine and to ground. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
ground. put: able to drive again. solenoid:
– critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 8, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 8.
output:https://www.forkliftpdfmanuals.com/
the controller If the output is con-
will flag the fault, but nected to an other
 no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

81.01 S/A Digital output 1 (wire Action will depend

depend “limp home“ mode: Wire A15 is shorted If the output is con-
A15) related fault : on the function Stop machine and to battery +. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
battery + or the out- put: able to drive again. solenoid: Check the
put is not connected. – critical output
output (eg. ”Limp home” mode wiring between the
transmission valve will result in reduced controller and the
control): the control- driving functionality. Selector solenoid 8,
ler reverts to a ”limp Contact mainte- Check the selector
home” mode. nance for trouble- solenoid 8. If the
the
– non–critical feature
feature shooting. output is connected
output:
will flag the
thecontroller
fault, but to an other
Check device:
the wiring
no actions will be between the control-
taken. ler and the other
device, Check the
other device.

82.00 S/A Digital output 2 (wire Action will depend

depend “limp home“ mode: Wire A16 is shorted If the output is con-
A16) related fault : on the function Stop machine and to ground. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
ground. put: able to drive again. solenoid:
– critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 9, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 9.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

9C-38 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

82.01 S/A Digital output 2 (w

(wire Action will depend
depend “limp home“ mode: Wire A16 is shorted If the output is con-
A16) related
related fault : on the function Stop machine and to battery +. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
battery + or the out- put: able to drive again. solenoid:
put is not connected. – critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 9, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 9.
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output: the controller If the output is con-
will flag the fault, but nected to an other
 no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

83.00 S/A Digital output 3 (w

(wire Action will depend
depend “limp home“ mode: Wire A20 is shorted If the output is con-
A20) related
related fault : on the function Stop machine and to ground. figured as an output
output is not con- assigned to the out- go to neutral to be to a transmission
nected, or shorted to put: able to drive again. solenoid:
ground. – critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 10, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 10.
output:
will flag the
the controller
fault, but If the output
nected to an is con-
other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

83.01 S/A Digital output 3 (w

(wire Action will depend
depend “limp home“ mode: Wire A20 is shorted If the output is con-
A20) related
related fault : on the function Stop machine and to battery +. figured as an output
output is shorted to assigned to the out- go to neutral to be to a transmission
battery +. put: able to drive again. solenoid:
– critical output
output (eg. ”Limp home” mode Check the wiring
transmission valve will result in reduced between the control-
control): the control- driving functionality. ler and the Selector
ler reverts to a ”limp Contact mainte- solenoid 10, Check
home” mode. nance for trouble- the selector solenoid
– non–critical feature
feature shooting. 10.
output: the controller If the output is con-
will flag the fault, but nected to an other
no actions will be device: Check the
taken. wiring between the
controller and the
other device, Check
the other device.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-39

Fault
Code Type Explanation Controller’s Action Driver Action Fault Cause Troubleshooting

90.xx S/B/ System Error. Controller reverts to Contact mainte- Software related Contact Spicer Off–
– H a ”shut down” mode nance for trouble- fault. Highway and inform
99.xx and will force neutral shooting. the fault code and
0. the time that is was
active.

95.71 S Data in the APC is The controller reverts Download an APT Wrong APT file (data Download an APT
not compatible with to a ”shut down” file compatible with file) is in the APC file compatible with
the data expected by mode and will force the active firmware (typically after APC the active firmware
the APC firmware. neutral 0. into the APC. firmware upgrade). into the APC
https://www.forkliftpdfmanuals.com/ If the error code still
persists, the data
 flash may be corrupt
(contact Spicer Off–
Highway).

99.90 S Wrong firmware is The controller reverts Flash the correct Wrong firmware is Flash the correct
flashed into the APC. to a ”shut down” firmware into the flashed into the APC. firmware into the
mode and will force APC. APC.
neutral 0.

99.95 S CAN peak load Controller will reply No actio

action
n reques
requested
ted.. Overload
Overlo ad of
of incom
incom-- No action requested.
detected : APC tem- on the CAN mes- ing CAN messages
porarily could not sages which are to the APC.
process all incoming available in its buffer.
messages, due to an
excessive peak of
CAN requests.

The codes listed below are called ’Exceed Parameter’ codes and are not so much codes that report a problem, but rather
indicate a certain machine operating state.
These codes give an indication of the machine operating state in regard to some programmed limits that may be
exceeded.

Exceed
Code Type Explanation Controller’s Action Driver Action

E0.01 E The vehicle speed is too high to The controller will disable the down- The driver should slow down the
make the requested downshift. shift in order to protect the transmis- vehicle, in order that the requested
sion, until the vehicle speed comes downshiflt can be made.
below the downshift limit.

E1.01 E The vehicle speed is too high to The controller will not allow the The driver should slow down the
make the requested direction direction change to protect the vehicle, in order that the requested
change. transmission and will place the direction change can be made.
transmission in neutral, until the
vehicle speed comes below the
direction change vehicle speed
limit.

E2.01 E The engine speed is too high to The controller will not allow the The driver should slow down the
make the requested direction direction change or re–engagement engine, in order that the requested
change or the requested re–en- of the direction, until the engine direction change or direction re–en-
gagement of the direction. speed comes below the direction gagement can be made.
change or the direction re–engage-
ment engine speed limit.

9C-40 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Exceed
Code Type Explanation Controller’s Action Driver Action

E3.00 E The reduced vehicle speed limita- The controller is limiting the vehicle No action is requested, the vehicle
v ehicle
tion is active. speed to the reduced vehicle speed speed is limited due to request.
limit.

E3.01 E The reduced vehicle speed limita- The controller is limiting the vehicle The driver should slow down the
tion is active, however the vehicle speed to the reduced vehicle speed vehicle, in order that the vehicle
speed is above the limit. limit, but detects a higher vehicle speed comes below the reduced
speed. vehicle speed limit.

E3.02 E The vehicle

maximum vehicle is ahttps://www.forkliftpdfmanuals.com/
speedspeedbolimit.
ve the The controller
speed is limitingvehicle
to the maximum the vehicle The driver
vehicle, shouldthat
in order slow
thedown the
vehicle
speed limit, but detects a higher speed comes below the maximum
 vehicle speed. vehicle speed limit.

E4.00 E An abnormal deceleration is The controller detected an abnor- The driver should slow down, in
detected. mal deceleration, and will disable order that the wheels can not slip
the automatic shifting for a certain any more.
time.

E4.01 E An abnormal acceleration is The controller detected an abnor- The driver should slow down the
detected. mal acceleration, and will disable engine, in order that the wheels can
the automatic shifting for a certain not spin any more.
time.

E5.01 E Time in gear exceeded the time to The controller detected that the time The driver should contact mainte-
recalibrate the transmission. in gear exceeded the time to recali- nance to recalibrate the transmis-
brate the transmission. sion.

E6.00 E Operator is not seated with shift The controller detected that the The driver should take place in the
lever not in neutral and/or the park- operator is not seated with the shift operator seat and confirm his pres-
ing brake not activated. lever not in neutral and/or the park- ence (cycle the shift lever through
ing brake not activated. neutral and/or release the throttle
pedal).

E7.01 E Transmission lilimit ex

exceeded on
on tu
tur- Upshif
Upshiftt to decre
decrease
ase turb
turbine
ine spee
speed.
d. The driv
driver
er shoul
shouldd slow
slow down
down the
bine speed. vehicle, in order that the vehicle
speed comes below the maximum
transmission limit speed.

Type Severity of Effect Level Description

S High Severe Warning Vehicle inoperable, with loss of primary function / Vehicle operable, but at
reduced level of performance – customer dissatisfied.

A Moderate Warning Vehicle operable, but comfort / convenience

Vehicle convenience item(s) inoperable
inoperable – customer
customer
experiences discomfort.

B Low Info Vehicle operable, but comfort / convenience item(s) operable at reduced
level – customer experiences some dissatisfaction.

H Very Low Data Info Vehicle operable, defect not noticed by customer.

E None Exceed Parameter Info Driver is requesting an action which is protected by the controller.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-41

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9C-42 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

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 PLACE THE FOLLOWING ILLUSTRATION IN
A FOLDER
FOLDER ENVELOPE:
ENVELOPE:
Illustration 9C-13 - 09C-2343 (SHIFT ANSI)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-43

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https://www.forkliftpdfmanuals.com/
9C-44 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 11

Drive Shaft

TRANSMISSION
TO AXLE
DRIVE SHAFT

CROSS
ASSEMBLY

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Illustration 11-1. Transmiss
11-1. Transmission
ion to Axle Drive
Drive Shaft
 Introduction. The drive shaft connects the trans- shaft, must be aligned
align ed as shown in Illustration
mission to the drive axle. It is important to always 11-1. If the flanges are not aligned, reposition
reposition the
have the transmission in phase with the drive axle splines to bring the flanges into alignment.
(See the note below).
If this is not followed, the drive shaft will be out of
Lubrication (Illustration 11-1).
11-1). The drive shaft,
phase, and vibration and noise may occur.
universal joints and slip joints should be greased
periodically (refer to the Preventive Maintenance
chart in the Appendices for drive shaft compo- Drive Shaft
The bolts, Bolts
which Inspection
connect (Illustration
the drive the .
shaft to 11-1)
11-1).
nents lubrication interval). brake disc and drive axle, should be checked for
tightness periodically (refer to the Preventive
NOTE: When the transmission
transmission to axle drive shaft
Maintenance chart in the Appendices for drive
is installed, the cross assemblies, on the drive
shaft bolts inspection interval). If tightening is

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 11-1

required, apply a torque value of 110 ft-lbs (150

N⋅m) to the bolts.

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11-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 13

Steer Axle
Introduction. The steer axle is mounted to the Mounting Bolts Check (Illustration 13-1).
13-1). The
frame with two pivot pins. The pivot pins are an mounting bolts of the steer axle should be
integral part of the axle. Axle pivot bearings are checked for tightness periodically (refer to the
installed inside the front and rear steer axle pivot Preventive Maintenance chart in the Appen-
blocks. All routine maintenance can be accom- dices for steer axle mounting bolts inspection
plished with the steer axle connected to the frame. interval). If the mounting bolts require tightening,
torque bolts to 150 - 165 ft-lbs (200 - 225 N ⋅m)
Lubrication. Refer to the Lubrication section in
[405 - 450 ft-lbs (550 - 610 N ⋅m) TXH400L].
the Appendices for information on lubricating the
steer axle. Steer Cylinder Mounting Bolts (Illustration 13-1).
13-1).
The steer cylinder mounting bolts should be
checked for tightness periodically (refer to the
 Before checking or servicing Preventive Maintenance chart in the Appen-
the steer axle, park on level ground, apply the dices for steer cylinder mounting bolts inspection
parking brake, block the wheels in both interval). If there is any evidence of threading or
directions, shut down the engine, and Lock movement of the steer cylinder, then remove the
Out & Tag Out the truck. mounting bolts, clean bolts, apply Loctite  to the
threads of the bolts and torque bolts to 460 ft-lbs
(625 N⋅m) [900 ft-lbs (1,225 N⋅m) TXH400L].

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 STEER AXLE
MOUNTING BOLT
STEER CYLINDER
MOUNTING BOLT

Illustration 13-1. Steer Axle

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 13-1

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13-2 PRELIMINARY TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 14

Drive Axles

BLEEDER BRAKE COOLING

DRAIN VALVE INPUT PORT
PLUG
VENT
PLUG

POSITION PLUG BRAKE

HERE TO FILL OR COOLING
CHECK LEVEL OUTPUT
PORT

BRAKE
APPLY
PORT
POSITION PLUG
HERE TO DRAIN BRAKE COOLING
DRAIN PLUG

BREATHER

FILL
PLUG

DRAIN PLUG
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Illustration 14-1. Wet Disc Brakes Drive Axle (TX180S-360L, TXB180S-300L, TXH300L, TXH350L)
 Introduction. The drive axle is equipped with Preventive Maintenance chart in the Appen-
double reduction gearing. The first gear reduction dices for oil level inspection interval). Perform the
is a hypoid type ring gear and pinion. The second following procedures to check the oil level and
reduction is in the form of planetary gears inside service the differential and planetary hubs:
the hubs. This arrangement permits the axle
shafts and hypoid gearing to carry only a nominal
torsional load while providing the highest practical
gear reduction at the wheels. result Deathtruck.
from a runaway or serious
Park injury could
the truck on
a hard, level surface, apply the parking brake,
Checking Lube Oil Level (Illustrations 14-1 and block the wheels in both directions to prevent
14-2).. The oil in the differential and the planetary
14-2) movement of the truck and Lock Out & Tag Out
hubs should be checked periodically (refer to the the truck before servicing the drive axle.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 14-1

1. Di
Difffer
eren
enti
tial
al 1. Di
Difffer
eren
enti
tial
al
a. Park
Park the tructruckk on a hard
hard,, level
level surf
surface
ace,, a. Park
Park thethe truck
truck on a hard,hard, level
level surf
surface
ace,,
block the wheels in both directions, apply block the wheels in both directions, apply
the parking brake and Lock Out & Tag Out the parking brake and Lock Out & Tag Out
the truck. the truck.
b. Che
Check ck the
the oil
oil level
level in the the diff
differe
erenti
ntial
al by b. Pro
Providvide
e a suitabl
suitable e contain
container
er to catch
catch drain
drain--
removing the fill plug. ing oil. Then, remove the differential
differential drain
c. The oil
oil level
level shoul
should d be even
even with
with the
the bot-
bot- plug and fill plug.
tom of the fill plug hole. Add oil as c. Onc
Once e the oil
oil has comp
complet
letely
ely drai
drained
ned,, instal
installl
required. the differential drain plug and fill with
d. Re
Re-i-ins
nsta
tall
ll the
the fil
filll plug
plug.. recommended lubricant (refer to the Fuel
and Lubricant Specifications in the
2. Pl
Plan
anet
etar
aryy Hubs
Hubs Appendices)) even with the bottom of the
Appendices
a. Maneuv
Maneuver er the
the truck
truck unti
untill the drai
drain
n plug
plug on fill plug hole.
one of the planetary hubs is in the d. Re
Re-i -ins
nsta
tall
ll the
the fil
filll plug.
plug.
3 o’clock (PRC-785 drive axle) or 9 o’clock
(PRC-1756 drive axle) position of hub rota- 2. Pl
Plan
anet
etarary
y Hubs
Hubs
tion (see Illustrations 14-1 and 14-2). a. Pos
Positi
ition
on the
the truck
truck so that
that the
the drain
drain plug
plug
b. Par
Park k the tru
truck
ck on a hard,
hard, level
level surf
surface
ace,, for one of the planetary hubs is at the
block the wheels in both directions, apply 6 o’clock position of hub rotation.
the parking brake and Lock Out & Tag Out b. Par
Park k the
the truck
truck on a hard,
hard, level
level surf
surface
ace,,
the truck. block the wheels in both directions, apply
c. Rem
Removeove the dradrain
in plu
plug.
g. The oil levlevel
el the parking brake and Lock Out & Tag Out
should be even with the bottom of the the truck.
drain plug hole. Add oil as required. c. Pro
Provid
videe a suit
suitabl
able
e conta
containe
inerr to cat
catch
ch
d. Re
Re-i-ins
nsta
tall
ll the
the drai
drainn plug
plug.. draining oil and then remove the drain
plug.
e. Rep
Reposiositio
tionn the tru
truck
ck as nec
necess
essary
ary and
and
service the hub on the opposite end of the d. Onc
Once e the oil
oil has compl
complete
etely
ly drain
drained,
ed, posi-
posi-
axle by repeating the above procedures. tion the truck so that the drain plug is in the
3 o’clock or 9 o’clock position of hub rota-
Changing The Oil (Illustrations 14-1 and 14-2). 14-2). tion (see Illustrations 14-1 and 14-2). Fill
The oil in the differential and planetary hubs the hub with recommended oil (refer to the
should be changed periodically (refer to the Pre- Fuel and Lubricant Specifications in the
ventive Maintenance chart in the Appendices Appendices)) until the oil level is even
Appendices
for drive axle differential and planetary hubs oil with the bottom of the drain plug hole.
intervals). Refer to the Fuel and
change intervals). Re-install the drain plug.
Lubricant Specifications in the Appendices for e. Fol
Follow
low the
the above
above proced
procedure
uress for servi
servicin
cing
g
the type of oil to be used in the drive axle. Per- the hub on the other side of the drive axle.
form the following procedures to change https://www.forkliftpdfmanuals.com/
the oil in
the drive axle: Draining The Hydraulic Fluid From The Brake
 Housings (Illustrations 14-1 and 14-2).
14-2). The
brake housings should be drained after the first
 Death or serious injury could month or 200 - 250 hours of operation, whichever
result from a runaway truck. Park the truck on comes first, and when the hydraulic fluid is
a hard, level surface, apply the parking brake, changed (refer to Changing The Hydraulic Fluid
block the wheels in both directions to prevent in Section 22).
22). Perform the following procedures
movement of the truck and Lock OutO ut & Tag Out to change the hydraulic fluid from the brake

the truck before servicing the drive axle. housing:

 Death or serious injury could

 Dispose of used oil in accor- result from a runaway truck. Park the truck on
dance with federal and local regulations. a hard, level surface, apply the parking brake,
block the wheels in both directions to prevent

14-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

movement of the truck and

a nd Lock Out & Tag Out low, add fluid until fluid level is at the FULL
the truck before servicing the drive axle. mark on the dipstick of the hydraulic tank.
12. Bleed the brakes and check for correct
correct brake
operation (refer to Wet Disc Brake Bleeding
 Dispose of used hydraulic in Section 15).
15).
fluid in accordance with federal and local regu-
lations. Oil Capacities

1. Park
Park the truc
truck
k on a hard,
hard, leve
levell surfac
surface,
e, block
block TX180S-360L,TX180S-300L,
the wheels in both directions, apply the TXH300L,TXH350L (PRC-785):
parking brake and Lock Out & Tag Out the Differential 20 Quarts
truck. (18.9 Liters)
Planetary Hub (each) 2 Quarts
(1.9 Liters)
 Allow the wheel end brakes to
TXH400L (PRC-1756):
cool to ambient temperature (cool to the touch)
before draining
draining brake cooling fluid.
fluid. Wear Differential 22 Quarts
(20.8 Liters)
protective
in personalgloves. Failure
injury from to dobrake
heated so may result
cooling Planetary Hub (each) 7 Quarts
fluid. (6.6 Liters)

2. Provid
Provide
e a suitabl
suitable
e contain
container
er to catch
catch drain
drained
ed Mounting Bolts. The drive axle mounting
mounting bolts
hydraulic fluid. should be inspected periodically (refer to the
Preventive Maintenance chart in the Appen-
3. Remove
Remove the
the brake
brake cool
cooling
ing hose
hosess from
from the
the dices for drive axle mounting bolts inspection
brake housing and quickly cap hoses. interv
int erval).
al). If there
there is any evidenc
evidence
e of threading
threading or
4. Remove
Remove the
the brake
brake cooli
cooling
ng drain
drain plug
plug from
from the movement of the drive axle, then loosen the lock-
hub. nuts, clean threads, apply Loctite  to threads and
torque the locknuts on the mounting bolts to 700
5. Clean
Clean the
the drain
drain plug and
and apply
apply silic
silicone
one seala
sealant
nt ft-lbs (950 N⋅m).
to the threads of the plug. Re-install plug and
tighten to 25-35 ft-lbs (34-47 N⋅m). Additional Drive Axle Servicing. Should more
detailed service of the drive axle components be
6. Re-con
Re-connec
nectt the brak
brake
e coolin
cooling
g hoses
hoses to the
the
brake housing. required, refermanual.
maintenance to the manufacturers drive axle
7. Repeat
Repeat proce
procedur
dures
es 1. thru
thru 6. for
for the oppos
opposite
ite
brake housing.
8. Remove
Remove the
the vent
vent plug
plug in the top
top of the brak
brake
e
housing and the plug from the unused brake
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cooling output port of both brake housings.
 When the housing is filled, the vent plug port
permits air to be removed.
9. Fill
Fill the hydr
hydrauli
aulic
c tank
tank with
with the spec
specifi
ified
ed
amount of fluid (refer to Changing The
Hydraulic Fluid in Section 22) 22) until hydraulic
fluid flows from the brake cooling output port
of the brake housings.
10. Re-install the vent plug and brake cooling out-
put plug. Tighten both to a torque value
value of
60-75 ft-lbs (80-100 N⋅m).
11. Place the transmission
transmission in Neutral and start the
engine. When the hydraulic fluid level goes

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 14-3

DRAIN
PLUG BRAKE COOLING
INPUT PORT BRAKE APPLY
PORT
POSITION PLUG
HERE TO FILL OR
CHECK LEVEL

POSITION PLUG

HERE TO DRAIN

BRAKE COOLING BRAKE COOLING

OUTPUT PORT DRAIN PLUG

VENT
PLUG

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 BREATHER

BLEEDER
DRAIN PLUG VALVE

Illustration 14-2. Wet Disc

Disc Brakes Drive Axle (TXH400L)
(TXH400L)

14-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Drive Axle Troubleshooting

Troubleshooting

Problem Cause Correction

1. Dif
Diffe
fere
rent
ntia
iall 1. Lo
Low
w oil
oil le
lev
vel
el.. 1. Fill
Fill to cor
correc
rectt level
level wit
with
h recom
recom--
overheats mended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
Appendices ).
2. Inc
Incorr
orrect
ect typ
type
e and
and grade
grade of oil.
oil. 2. Drain,
Drain, flus
flush,
h, and
and refil
refilll with
with reco
recom-
m-
mended oil.
3. Inc
Incorr
orrect
ect bea
bearin
ring
g adju
adjustm
stment
ent.. 3. Adjust
Adjust bea
bearin
rings.
gs. Rep
Replac
lace
e any tha
thatt
are damaged or excessively worn.
4. Breath
Breather
er in dif
differ
ferent
ential
ial hous
housing
ing is
is 4. Rep
Replac
lace
e brea
breathe
therr ifif dam
damage
aged.
d.
plugged.

5. Oi
Oill lev
level
el is to
too
o high
high.. 5. Drain
Dra
levelininoil
oilthe
down
down to the
the chec
check
differential. k plug
plug

2. Loss
Loss of oi
oill out
out of 1. Dama
Damaged
ged oror badly
badly wor
worn
n pinio
pinion
n 1. Replac
Replacee oil
oil seal
seal and che
check
ck for
the differential shaft oil seal. loose pinion bearings or pinion nut.
2. Loo
Loose
se car
carrie
rierr moun
mountin
ting
g bolt
bolts.
s. 2. Check
Check and
and tigh
tighten
ten mou
mounti
nting
ng bolt
bolts.
s.
Replace gasket if damaged or bro-
ken.
3. Breath
Breather
er in dif
differ
ferent
ential
ial hous
housing
ing is
is 3. Rep
Replac
lace
e brea
breathe
therr ifif dam
damage
aged.
d.
plugged; forcing oil by the seals.

3. No
Nois
isy
y di
diff
ffer
eren
enti
tial
al

a. No
Nois
ise
e on
on dri
driv
ve a. Ri
Ring
ng gear
gear and
and pin
pinio
ionn adjus
adjust-
t- a. Adjust.
ment is too loose (excessive back-
lash).
1) Dri
Drive
ve sha
shaft
ft is out
out-of
-of-ph
-phase
ase 1) Whe
Whenn the
the tran
transmi
smissi
ssion
on to
to axle
axle
drive shaft is installed, the flanges
on the drive shaft, must be aligned
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11-1. If the
flanges are not aligned, reposition
 the splines to bring the flanges into
alignment. If this is not followed,
the drive shaft will be out of phase,
and vibration and noise may occur.
b. No
Nois
ise
e on
on coa
coas
st b. Ri
Ring
ng gear
gear and
and pin
pinio
ion
n adjus
adjust-
t- b. Adjust.
ment is too tight (insufficient back-
lash).
c. Co
Cons
nsta
tant
nt no
nois
ise
e c. 1) Wor ornn be
bear
arin
ings
gs.. c. 1) Re
Repl
plac
acee be
bear
arin
ings
gs..
2) Ch
Chip
ippe
pedd gea
gearr te
teet
eth.
h. 2) Re
Repl
plac
acee ge
gear
ar..
d. No
Nois
ise
e on
on tur
turns
ns d. Wo
Worn
rn or dam
damaged
aged dif
differ
ferent
ential
ial d. Rep
Replac
lace
e dif
differ
ferent
ential
ial par
parts.
ts.
pinion gears, side gears, or pinion
journals.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 14-5

Problem Cause Correction

4. Nois
Noisy
y fina
finall driv
drives
es 1. Lo
Low
w oil
oil le
leve
vel.
l. 1. Fill
Fill to cor
correc
rectt level
level wit
with
h recom
recom--
(Planetary Axles) mended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
Appendices ).
2. Worn
Worn bear
bearing
ings
s in whe
wheels
els or plan
planet
et 2. Re
Repl
plac
ace
e bear
bearin
ings
gs..
gears.
3. Ch
Chip
ippe
ped
d gear
gear tee
teeth
th.. 3. Re
Repl
plac
ace
e gear
gears
s.

5. Fina
Finall driv
drives
es ove
over-
r- 1. Lo
Low
w oil
oil le
leve
vel.
l. 1. Fill
Fill to cor
correc
rectt level
level wit
with
h recom
recom--
heat (Planetary mended oil.
Axles)
2. Incorr
Incorrect
ect typ
type
e and
and gra
grade
de of 2. Drain,
Drain, flu
flush,
sh, and refi
refillll with
with oil
oil of
of
oil. recommended specifications.
3. Incorr
Incorrect
ect lub
lubric
ricant
ant for ope
operat
rating
ing 3. Instal
Installl the corr
correct
ect lubr
lubrica
icant
nt speci
speci--
temperature. fied for temperature range.
4. Whee
Wheell beari
bearing
ngs
s impro
imprope
perl
rly
y 4. Adjust
Adjust whe
wheel
el bear
bearing
ings
s to
to recom
recom--
adjusted. mended preload.
5. Sc
Scor
ored
ed pla
plane
nett pins
pins.. 5. Inspec
Inspectt and
and rep
replac
lace
e defe
defecti
ctive
ve
parts.

6. Loss
Loss of oioill out
out of 1. Damage
Damaged d or
or brok
broken
en whe
wheel
el dri
driver
ver 1. Re
Repl
plac
ace
e ga
gask
sket
et..
final drives gasket.
(Planetary Axles)
2. Dama
Damage
gedd or br
brok
oken
en hub
hub cap
cap 2. Re
Repl
plac
ace
e ga
gask
sket
et..
gasket.
3. Damage
Damaged d or
or exce
excessi
ssivel
vely
y wor
worn
n 3. Replac
Replacee oil
oil seals
seals and adj
adjust
ust whe
wheel
el
wheel oil seals. bearings properly.
4. Lo
Loos
ose
e whe
wheel
el bea
beari
ring
ngs.
s. 4. Adjust
Adjust whe
wheelel bear
bearings
ings pro
proper
perly
ly and
and
replace oil seal.

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7. Br
Brak
ake
e flui
fluid
d lev
level
el is
is 1. Bra
Brake
ke pis
piston
ton sea
seals
ls are pos
possib
sibly
ly 1. Re
Repl
plac
ace
e seal
seals
s.
 continuously low leaking.
with no signs of
external leakage

8. Gear
Gear oi
oill lev
level
el in 1. Seal
Seal betw
between
een brak
brake
e hous
housing
ing and 1. Re
Repl
plac
ace
e sea
seal.
l.
hub is continuous- wheel hub may be leaking.
ly too high
2. Coo
Coolin
ling
g fluid
fluid pres
pressur
sure
e is too
too high.
high. 2. Have
Have brake
brake coo
coolan
lantt press
pressure
ure rel
relief
ief
valve cartridge replaced.

9. Sign
Signs
s of
of ext
exter
erna
nall 1. Clean
Clean surf
surface
ace and the
then
n deter
determin
mine
e 1. Re
Repl
plac
ace
e seal
seals
s.
leakage exist location of leakage.

14-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 15

Brake Control System

Introduction. The brake control system controls parking brake control is pulled out, the hydraulic
the slowing down and stopping of the truck. pressure is released and the parking brake is
Hydraulic pressure is controlled by the foot oper- applied.
ated brake valves (pedals) and is sent to the
brake housings of the drive axle to apply the ser-
vice brakes. The parking brake control applies
and releases the spring applied, drive line parking
brake.
Major Components (Illustration 15-2).
15-2). The brake
control system consists of a main pump, manifold,
two accumulators, brake valves, shuttle valve,
drive axle service brakes, parking brake control,
and parking brake. Refer to the illustrations as
indicated for identification of parts.
Manifold. Refer to Section 22 for operation of
the manifold.
Accumulators (Illustration 15-8).
15-8). There are two
accumulators connected
connected to the main valve. They
store a volume of oil at pressure for brake applica-
tion. These accumulators are hydro-pneumatic
piston type and are precharged with dry nitrogen
to 1,250 psi (86 bar) and 500 psi (35 bar). Refer
to Section 22E for procedures for checking the Illustration 15-1. Parking Brake Control
precharge and charging the accumulator.
Brake Valves (Illustration 15-3).
15-3). There are two Parking Brake (Illustration 15-4).
15-4). The parking
brake valves used to stop the truck. Both brake brake is spring applied and hydraulically released.
valves actuate the service brakes of the drive axle
when either brake pedal is applied. The LH brake
valve can independently disengage the transmis-  Do not attempt to remove
sion (inching) when the brake pedal is applied. spring(s), they are not serviceable. Do not cut,
saw, torch or
or modify this chamber.
chamber. Serious
When either brake valve is applied, its P and B injury or death could result.
ports will be connected to send hydraulic pressure
to apply the service brakes. When the service Parking Brake Linings. The parking brake
brake lin-
brakes are released, the B port is connected to ings should be checked for wear periodically (refer
the T port to vent hydraulic flow back to the to the Preventive Maintenance chart in the
hydraulic tank. Appendices for parking brake linings wear
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inspection). The parking brake linings should be
Inching Operation. When the LH brake pedal is
depressed, the transmission will be disengaged replaced before the brake lining friction material
and wheel end brakes applied. This allows for reaches a thickness
thickness of .031 inch (.8 mm). The
high engine speeds for greater hydraulic pump parking brake linings must be replaced in pairs.
output while reducing travel speed.
Shuttle Valve (Illustration 15-8).
15-8). The shuttle
valve is used to isolate the hydraulic flow from the
two brake valves.
Parking Brake Control (Illustration 15-1).
15-1). The
parking brake control is located on the instrument
panel and when pushed in, it energizes the park-
ing brake solenoid valve which supplies hydraulic
pressure to release the spring applied parking
brake, disengaging the parking brake. When the

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-1

MAIN PUMP
(Illustration 22-9)
(Illustration

PARKING BRAKE
CONTROL
(Illustration
(Illustration 15-1)

BRAKE VALVES
(Illustration 15-3)

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 MANIFOLD
(Illustration 15-4)
(Illustration
ACCUMULATORS
ACCUMULATORS
(Illustration
(Illustration 22-19)

PARKING BRAKE
(Illustration
(Illustration 15-4)

Illustration 15-2. Brake Control System Components

Components Identification

15-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

RH

LH

INDICATES HYDRAULIC FLUID FLOW

Illustration 15-3. Brake Valves

Parking Brake Linings (Illustration 15-4).

15-4). The & Tag Out the truck.
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parking brake linings should be checked for wear
1. Park the truck
truck on a hard, level surfac
surface,
e, block
block
 periodically (refer to the Preventive Maintenance
chart in the Appendices for parking brake linings the wheels of the truck in both directions,
wear inspection interval). The parking brake lin- place the parking brake in the released posi-
ings should be replaced when the thickness of the tion and Lock Out &Tag Out the truck.
brake lining friction material is .031 inch (.8 mm) or 2. Remove
Rem ove plu
plug
g (5)
(5) and
and scre
screww (17)
(17)..
less. The parking brake linings must be replaced 3. With
Wit h the parki
parking
ng brake
brake releas
released,
ed, loose
loosen
n the
in pairs. Perform the following procedures to coupling nut (27) and back off setscrew (6)
replace the parking brake linings: until end of piston (12) is flush with the
exposed end of piston (9).
 Death or serious injury could 4. Apply
App ly the
the parking
parking brake
brake,, Lock
Lock Out &Tag&Tag Out
result from a runaway truck. Park the truck on the truck, and remove the worn brake lining
a hard, level surface, block the wheels in both carrier assemblies (19).
directions to prevent movement, and Lock Out 5. Instal
Installl new brake
brake lining
lining carri
carrier
er assemb
assemblie lies.
s.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-3

Illustration 15-4. Parking Brake Assembly

6. Instal
Installl screw
screw (17)
(17) into
into torqu
torque
e plate
plate (1)
(1) and a hard, level surface, block the wheels in both
thread it into the nuts (18). Tighten the nuts directions to prevent movement, and Lock Out
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(18) against each other to a torque value of & Tag Out the truck.
 30-35 ft-lbs (41-48 N⋅m).
1. Park
Park the truck
truck on a hard,
hard, level
level surf
surface
ace,, block
block
7. Pos
Positi
ition
on the
the truck
truck with
with a rate
rated
d load
load on a
the wheels of the truck in both directions,
15 percent grade (15 feet rise over 100 feet
place the parking brake in the released posi-
distance). Apply the parking brake to ensure
tion and Lock Out &Tag Out the truck.
that it will hold the truck with a rated load on a
15 percent grade. 2. Rem
Remove
ove the
the plug (see
(see Illu
Illustr
strati
ation
on 15-5).
15-5).
Parking Brake Adjustment (Illustrations 15-4 3. Loosen the coupli
coupling
ng nut
nut (see
(see Illust
Illustration
ration 15-6).
thru 15-6). the
15-6).
adjustment Perform thebrake:
parking following procedures to 4. Set runni
running
ng clear
clearanc
ance
e betwee
betweenn the disc
disc and
and
the lining surface by turning the set screw until
a 0.020 - 0.030 inch (0.51-0.76 mm) thick shim
 Death or serious injury could just fits between the lining and the disc surface
result from a runaway truck. Park the truck on when the opposite lining is in contact with the
disc.

15-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

5. Torque the
the coupling
coupling nut to
to 50-55
50-55 ft-lbs
ft-lbs (68-75 Illustration 15-4). Loosen the outer hex nut
N⋅m), while holding the set screw in position. (18) and place a 0.010 - 0.015 inch thick shim
6. Re-ins
Re-instal
talll the plug
plug and torq
torque
ue to 45-50
45-50 ft-lb
ft-lbs
s between the lining and the disc surface.
Adjust the socket head cap screw (17) until
u ntil
(61-68 N⋅m).
the clearance between the shim is eliminated.
8. Tigh
ighten
ten the
the outer
outer hex nuts
nuts (18)
(18) to
to comple
complete
te
the centering operation. Torque the two hex
nuts (18) against each other to a torque rating
of 30-35 ft-lbs (41-48 N ⋅m).
9. Re-adj
Re-adjust
ust the
the brake
brake when
when the
the running
running clea
clear-
r-
ance reaches a total of 0.100 inch (2.5 mm).
Wet Disc Brake Bleeding (Illustrations 14-1 and
14-2).. Bleeding the wet disc brake system
14-2)
requires two servicemen; one to operate the ser-
vice brake pedal, and another to open and close
the bleeder valves on the drive axle. Perform the
following procedures to bleed the service brakes:

 Death, serious injury or

property damage could result from not
bleeding the wet disc brakes.
brakes. The wet disc
disc
PLUG brakes must be bled to remove all air from the
system when any brake system hydraulic
connection has
has been loosened. Air can
Illustration 15-5. Parking Brake (Plug Installed) prevent hydraulic pressure from applying the
brakes correctly and can increase stopping
distance.

SETSCREW  Death or serious injury could

result from a runaway truck. Park the truck on
a hard, level surface, apply parking brake and
block the wheels of the truck in both directions
to prevent movement.

 Do not reuse used hydraulic

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fluid. Used hydraulic fluid can be contami-
 nated and can cause incorrect operation.
Damage to components can result.
1. Park
Park the truc
truck
k on a hard,
hard, leve
levell surfac
surface,
e, apply
apply
parking brake and block the wheels of the
truck in both directions to prevent movement.
COUPLING 2. With
With the engin
enginee running
running,, have
have someone
someone appl
apply
y
NUT one of the service brake pedals and hold it
down.
Illustration 15-6. Parking Brake (Plug Removed) 3. Ope
Open n the blee
bleeder
der valv
valve
e about
about 1/2
1/2 turn
turn on the
the
left front wheel brake housing, allowing air and
7. Even
Even up the
the runnin
running
g cleara
clearance
nce 0.01
0.010
0 - 0.015
0.015 oil to vent into a suitable container.
inch (0.25-0.38 mm) on each side of the disc
by adjusting the socket head cap screw (17,

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-5

MANUAL
OVERRIDE KNOB

Illustration 15-7. Parking Brake Solenoid

4. Close
Close the
the bleede
bleederr valve
valve and
and then
then releas
release
e the enough pressure is available by the accumulators.
brake pedal.
To return to normal parking brake operation, fully
5. Repeat
Repeat proc
procedu
edures
res 2.,
2., 3.,
3., and 4.
4. until
until a
bubble-free flow of fluid is observed while con- turn
wise.the manual override knob out counterclock-
tinuing to check the level of fluid in the hydrau-
lic tank. Drive Axle Service Brakes Servicing
6. Repeat
Repeat proc
procedu
edures
res 2.
2. throug
through
h 5. to bleed
bleed the
the
right service brake.
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 Death, serious injury or pro-
Parking Brake Solenoid (Illustration 15-7).
15-7). The perty damage may occur from improperly
parking brake solenoid of the manifold can be maintaining the service brakes. Improper
manually activated to release the parking brake. maintenance procedures may lead to decreas-
ed service life, decreased performance, or
brake failure. Always follow proper proce-
proce-
 Death or serious injury could dures for inspection, maintenance, and service
result from a runaway truck. Park the truck on of the brake system as outlined in this manual.
a hard, level surface if possible, block the
wheels in both directions to prevent move-
The brakes should be disassembled and inspect-
ment, and Lock Out & Tag Out the truck. ed every 10,000 hours (or 5 years), whichever
To release the parking brake, fully turn the manual occurs first, or when any of the following condi-
override knob in clockwise to release the parking tions, listed below,
below, occur.
occur. The suggested brakes
brake. inspection interval is based on normal operating
conditions and may be increased or decreased
NOTE: The parking brake will only be released if based on actual operating experience.
experience.

15-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

1. Brakes
Brakes have
have overh
overheat
eated
ed and
and / or hydra
hydrauli
ulic
c more service brakes - such as grinding or
tank level has run low. metal-to-metal contact.
2. Dir
Dirty
ty or cont
contami
aminat
nated
ed hydrau
hydraulic
lic flui
fluid.
d. 5. Abnorm
Abnormall
ally
y long
long pedal
pedal stroke
stroke,, even
even with
with
hydraulic tank fluid level full.
3. Clogge
Cloggedd or dirty
dirty hydraul
hydraulic
ic return
return filte
filterr with
(apparently) fibrous material. 6. Servic
Service
e brakes
brakes pulling
pulling to one
one side
side or the other
other..
4. Out
Out-of
-of-th
-the-o
e-ordi
rdinar
nary
y brake
brake noise
noise from one
one or

Brake Control System Troubleshooting

Troubleshooting

Problem Cause Correction

1. No or we
weak
ak se
serv
rvice 1. Ai
ice Airr in
in bra
brake
ke sy
syst
stem
em.. 1. Bleed
Bleed the
the brak
brake
e syste
system
m (ref
(refer
er to
to
brakes Wet Disc Brake Bleeding in this
section).

2. Defect
Defective
ive ser
servic
vice
e brake
brake val
valve.
ve. 2. Replac
Replace e serv
service
ice bra
brake
ke val
valve.
ve.
3. Lea
Leak
k in lin
line
e betwe
between
en the
the mani
manifol
fold
d 3. Ins
Inspec
pectt hydra
hydrauli
ulic
c hoses
hoses and
and repai
repairr
and brake housings. if needed.
4. De
Defe
fect
ctiv
ive
e pisto
piston
n seal
seals.
s. 4. Refer
Refer to
to the
the drive
drive axle
axle manu
manufac
factur
tur--
er’s manual for isolation of defec-
tive piston seals (which side) and
repairs.
5. Worn
Worn or
or damag
damaged
ed disc
disc(s)
(s) ins
inside
ide 5. Refer
Refer to
to the
the drive
drive axle
axle manu
manufac
factur
tur--
brake housing. er’s manual for repairs.
6. Br
Brak
akes
es are
are ove
overh
rhea
eati
ting.
ng. 6. Refe
Referr to Pr
Prob
oble
lem the Wet
m 1. of the
Disc Brakes Cooling System
Troubleshooting chart in Section
15C.
7. Defe
Defect
ctiv
ive
e ma
maninifo
fold
ld.. 7. Re
Repa
pair
ir ma
mani
nifo
fold
ld..
8. Ref
Refer
er also
also to Pro
Proble
blem m 7.
7. of the
Hydraulic System Troubleshoot-
ing chart in Section 22. 22.
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 2. Brak
Brakes
es wi
will
ll no
nott 1. Def
Defect
ective
ive ser
servic
vice
e brake
brake valv
valve(s
e(s).
). 1. Rep
Replac
lace
e servi
service
ce brak
brake
e valve
valve(s)
(s)..
release
2. Worn
Worn or
or damag
damaged
ed disc
disc(s)
(s) in brak
brake
e 2. Refer
Refer to
to the
the drive
drive axle
axle manu
manufac
factur
tur--
housing. er’s service manual for repairing
procedures.

continued

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-7

Problem Cause Correction

2. Brak
Brakes
es wi
will
ll no
nott 3. High
High press
pressure
ure brak
brake-a
e-appl
pply
y port
port of
of 3. Remove
Remove bloblocka
ckage
ge fro
from
m the
the hig
highh
release the brake housing is blocked. pressure brake-apply port of the
(Continued) brake housing.
Loosen the bleeder valve to allow
trapped oil to escape.
escape. Remove the the
high pressure brake-apply hose
from the brake housing. Then with
a paper clip, insert a paper clip in
the port to remove the blockage,
reassemble and perform the Wet
Disc Brake Bleeding procedures
located in this section.
4. Pin
Pinche
ched,
d, crim
crimped
ped,, or def
defect
ective
ive 4. Is
Isol
olat
ate
e and
and re
repa
pair
ir..

hydraulic hose.

3. Noi
oisy
sy br
brak
akes
es 1. Wrong
Wrong typ
type
e of hyd
hydrau
raulic
lic flu
fluid
id is
is 1. Use onl
onlyy appro
approved
ved flu
fluid
id (ref
(refer
er to
to
being used. the Fuel and Lubricant Specifica-
tions).
tions ).
2. Br
Brak
akes
es are
are ove
overh
rhea
eati
ting
ng.. 2. Refe
Referr to Pr
Probl
oblem
em 1.
1. of the Wet
the
Disc Brakes Cooling System
Troubleshooting chart in Section
15C.
3. Intern
Internal
al failu
failure
re insid
inside
e the driv
drive
e axle
axle 3. Refer
Refer to
to the dri
drive
ve axle
axle manuf
manufact
actur-
ur-
wheel end. er’s manual for repairs.

4. Park
Parkin
ing
g bra
brak
ke 1. Def
Defect
ective
ive par
parkin
king
g brake
brake swi
switch
tch.. 1. Rep
Replac
lace
e parki
parking
ng bra
brake
ke swi
switch
tch..
does not apply
2. Loo
Loose,
se, bro
broken
ken,, or sho
shorte
rted
d wire(
wire(s).
s). 2. Is
Isol
olat
ate
e and rep
repai
airr wire(
wire(s)
s)..
3. De
Defe
fect
ctiv
ive
e ma
mani
nifo
fold
ld.. 3. Re
Repa
pair
ir ma
mani
nifo
fold
ld..
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4. De
Defe
fect
ctiv
ive
e mai
main
n pum
pump.
p. 4. Re
Repl
plac
ace
e mai
main
n pump.
pump
5. Park
Parkin
ing
g bra
brak
ke 1. Def
Defect
ective
ive par
parkin
king
g brake
brake swi
switch
tch.. 1. Rep
Replac
lace
e parki
parking
ng bra
brake
ke swi
switch
tch..
does not release
2. Loo
Loose,
se, bro
broken
ken,, or sho
shorte
rted
d wire(
wire(s).
s). 2. Is
Isol
olat
ate
e and rep
repai
airr wire(
wire(s)
s)..
3. De
Defe
fect
ctiv
ive
e ma
mani
nifo
fold
ld.. 3. Re
Repa
pair
ir ma
mani
nifo
fold
ld..

4. Defe
Defect
ctiv
ive
e ma
mainin pump. 4. Re
Repl
plac
ace
e mai
main
n pump.
pump
5. Ref
Refer
er also
also to Pro
Proble
blem
m 8. of the
Hydraulic System Troubleshoot-
ing chart in Section 22.
22.

15-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

PLACE THE FOLLOWING ILLUSTRATION IN

A FOLDER
FOLDER ENVELOPE:
ENVELOPE:
Illustration 15-8 - 15-2495 SHT. 2 (ANSI)

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-9

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15-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 1
5
C
-W
C
oli e
tD
n i
g s c
S B
y r
s a
te k
mes

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 Section 15C

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 Wet Disc Brakes Cooling System
Introduction. The brakes cooling system
system main-
tains a safe operating temperature by cooling the
hydraulic fluid in the wet disc brake system.
Major Components (Illustration 22-1).
22-1). The brake
cooling system consists of an auxiliary pump,
manifold, cooling check valve, various hoses and
fittings.
Auxiliary Pump (Illustration 15-8).
15-8). The auxiliary
pump is a two section pump with gear sets of
equal size. The flow of one gear set is sent
sent to
port B1 of the cooling check valve while the flow
of the other gear set is sent to port P3 of the man-
ifold valve (refer to Brake / Brake Cooling Logic
in Section 22 for a detailed description of man-
ifold flow dedicated to service brake cooling).

COOLING
CHECK VALVE

Illustration 15C-1.
15C-1. Cooling Check Valve

Cooling Check Valve (Illustrations 15C-1 and

15-7). The cooling check valve sends cooling fluid
15-7).
to the service
service brakes. This valve receives flow
from the auxiliary pump at port B1 and the fluid is
sent out port P1 to cool the right side drive axle
brake. The cooling check valve
valve also receives flow
from the manifold at port P2 and the fluid is sent
out port B2 to cool the left side drive axle brake.
This valve also sends fluid from the service brakes
back to the hydraulic tank. In addition, the cooling
check valve contains two 15 psi (1 bar) check
valves that limit the drive axle wheel ends from
seeing no more than 15 psi (1 bar) of pressure,
protecting the wheel end face seals.
Manifold. Refer to Section 22 for operation of
the manifold.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15C-1

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Wet Disc Brakes Cooling System Troubleshooting
Troubleshooting

Problem Cause Correction

1. Br
Brak
akes
es Ov
Over
erhe
heat
at 1. Lo
Low
w cool
coolin
ing
g fluid
fluid fl
flow
ow.. 1. Refer
Refer to
to Probl
Problem
em 2.
2. of thi
this
s troub
trouble-
le-
shooting chart.

2. Im
Impr
prop
oper
er hydr
hydraul
aulic
ic flui
fluid.
d. 2. Use
Fuelspe
specif
andcified
ied flu
fluid
id (ref
Lubricant (refer
er to
to the
the
Specifica-
tions in the Appendices
Appendices). ).
3. Hydrau
Hydraulic
lic sys
system
tem coo
cooler
ler fins
fins are 3. Cle
Clean
an the
the hydrau
hydraulic
lic syst
system
em coole
coolerr.
plugged.
4. Excess
Excessive
ive dut
dutyy cycle
cycle (ex
(exces
cessiv
sive
e 4. Allow
Allow hydr
hydraul
aulic
ic flui
fluid
d to coo
cooll and
and
application of brakes). adjust duty cycle.
5. Brakes
Brakes at wheel
wheel end
ends
s are
are not
not fully
fully 5. Refe
Referr to
to Prob
Proble
lem 2. in the Brake
m 2.
releasing. Control System Troubleshooting
chart in Section 15.
15.

2. Low
Low Coo
Cooli
ling
ng Fl
Flui
uid
d 1. Low hyd
hydrau
raulic
lic flu
fluid
id sup
supply
ply.. 1. Fill
Fill hydrau
hydraulic
lic tan
tank
k to the pro
proper
per
Flow fluid level.
2. Plugge
Plugged d hydra
hydrauli
ulic
c tank
tank brea
breathe
therr 2. Rep
Replac
lace
e bre
breath
ather
er fil
filter
ter..
filter.
3. Air leak
leak in sucti
suction
on hose
hose to
to auxili
auxiliary
ary 3. Lo
Loca
cate
te lea
leak
k and
and repai
repairr.
pump.
4. De
Defe
fect
ctiv
ive
e auxil
auxilia
iary
ry pump
pump.. 4. Re
Repl
plac
ace
e the
the pu
pump
mp..
5. Fluid
Fluid is byp
bypass
assing
ing the
the check
check val
valves
ves 5. Cle
Clean
an the che
check
ck val
valves
ves.. If cle
cleani
aning
ng
in cooling check valve. does not resolve the problem,
replace the check valves.

3. One
One Sid
Side
e of
of Dri
Drive
ve 1. Defect
Defective
ive che
checks
cks in cool
cooling
ing che
check
ck 1. Re
Repl
plac
ace
e defect
defectiv
ive
e check
checks.
s.
Axle Overheats valve.

15C-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 16

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 Steering System
Introduction. The steering system provides guid-
ance control of the truck.
Major Components (Illustration 16-1).
16-1). The steer-
ing system consists of the main pump, manifold,
steering valve, steer cylinder, hoses and various
fittings.
Main Pump. Refer to Section 22 for operation of
the main pump.
Manifold. Refer to Section 22 for operation of
the manifold.
Steering Orbitrol. Refer to Section 22 for opera-
tion of the steering orbitrol.
Steer Cylinder (Illustration 16-1).
16-1). The steer cylin-
der is a double-acting cylinder that turns the steer
tires.
Steering Logic. Refer to Section 22 for steering
logic information.
Steering System Tr
Troubleshooting.
oubleshooting. Refer to
Hydraulic System Tr
Troubleshooting
oubleshooting chart in
Section 22.
22.
Setting Hydraulic Pressures. Refer to Setting
Hydraulic Pressures in Section 22 for proce-
dures to set the pressures for the steering system.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 16-1

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Hoist Circuit
16-2 PRELIMINARY TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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Hoist Circuit
 Hoist Circuit

PLACE THE FOLLOWING ILLUSTRATION IN

A FOLDER
FOLDER ENVELOPE:
ENVELOPE:
Illustration 16-1 - 16-2364 SHT. 2 (ANSI)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 16-3

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 Hoist Circuit

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16-4 PRELIMINARY TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 17

Tires and Wheels

Introduction. This section contains safety warn-  Bias and radial constructions
constructions must never be
ings that must be adhered to to prevent serious mixed on dual pair.
personal injury or death when servicing tires and
wheels. Also included are procedures for properly Tire Inflation. The tire pressure should
should be
torquing the wheel nuts. checked on a daily basis (refer to the serial data
plate, located on the left side of the truck in front
of the steer tire, for proper tire pressure).
 Under no circumstances
should anyone mount or demount tires without
proper training as required in OSHA Rules and  Maintain the proper tire
Regulations 1910.177 “Servicing multi-piece inflation pressures listed on the truck serial
and single piece rim wheels.” Follow all pro- data plate.
cedures and safety instructions. Tire Overinflation. Overinflation results in high
cord stress even when the tire isn’t overloaded.
Tires. Tires
expenses may represent
of equipment one of the
operation. major
Refer direct
to the Stress reduces resistance to blowouts from
Goodyear Tire Maintenance Manual for proper impacts. It also increases the danger of the tire
maintenance and repair of tires for optimal tire life. being cut. The problem can be compounded by
The Goodyear Tire Maintenance Manual is a poorly maintained working terrain.
generic tire maintenance manual covering tire Tire Underinflation. An underinflated
underinflated tire
tire will
will
maintenance that apply to all brands of tires. deflect too much.
much. It also leads to excessive side-
Check the tires and valve caps daily for any wall flexing. It is very important, in wheel ends
damage. employing dual tire pairs, that each tire have the
correct air pressure.
pressure. This prevents one tire from
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carrying more of the load than the other tire.
tire. Flex-
 ing of an underinflated tire in a dual pair could
  All tire related safety warnings in the Safety lead to the underinflated tire rubbing the other tire
Check 2nd Edition booklet and this section which could lead to premature tire
tire failure. Tires
must be understood before performing any with radial cracks indicate continuous underinfla-
tire maintenance.
 Inflate tire in a safety cage. Use safety tion operation.
operat
include theion. Other underinflated indications
following: indications
chains or equivalent restraining devices dur- 1. Sp
Spot
otty
ty or
or unev
uneven
en tre
tread
ad wea
wearr
ing inflation.
inflation. Misassembled parts
parts may fly
apart with explosive force during inflation. 2. Pl
Ply
y sepa
separa
rati
tion
on
 Never sit on or stand in front of a tire and rim
rim 3. Loo
Loose
se or
or broken
broken cor
cords
ds insi
inside
de the
the tire
tire
assembly that is being inflated. Use a clip-
clip-
on chuck, an in-line pressure gauge, and 4. Fa
Fabr
bric
ic ca
carc
rcas
ass
s fat
fatig
igue
ue
make sure the inflation hose is long enough Rims. The rims hold the tires on the hub. The
to permit the person inflating the tire to wheels and mounts require a run-in period. The
stand to the side of the tire, not in front or in torque of the wheel nuts must be checked every
back of the tire assembly. 10 hours of operation until rim is fully seated. Per-
 Keep tires free of grease and oil. Grease form the Torquing Procedure to tighten the
and oil are highly damaging to tires. If wheel nuts of each hub each time tires are
grease or oil are allowed to remain on tires removed from the
the drive or steer axle. Inspect the
for extended periods of time, rubber deterio- wheel studs daily
daily..
ration may occur.
 Tire assemblies
assemblies operated as a dual pair must  If one wheel stud has broken
have the same outside diameter, be from the off, a significant reduction of the rim’
rim’s
s clamp-
same manufacturer
manufacturer,, be of the same type ing force will be lost. Remove machine from
(industry code) and be of the same construc- service and repair immediately.
tion (both bias or both radials).

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 17-1

1
WHEEL NUT TORQUE VALUE
Drive Axle.............490 - 510 ft-lbs 10
(670 - 695 N⋅m) 8
 This value is located on the truck
truck
serial plate for reference.

3
6

5
4

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 7
9

Illustration 17-1. Drive Axle Wheel Nuts Torquing

Torquing Sequence (TX180S - 360L)

Torquing Procedure (Illustrations 17-1 through Inspection

17-4).. Perform the following procedures to torque
17-4)
the wheel nuts:

 Mixing parts of one manufacturer’s
manufacturer’s rims with
 Every time the wheels are those of another is potentially dangerous.
removed, a run-in period
period is required. The Always check manufacturer for approval.
wheel nuts must be re-torqued every 10 hours  Do not be
be careless or take chances. If you
of operation until rims are fully seated. are not sure about the proper mating of rim
and wheel parts, consult a wheel and rim
1. Start
Start at posit
position
ion #1 and
and tighte
tighten
n the wheel
wheel nut
nut expert. This may bebe the tire man who is
is
to the specified torque value listed. Proceed servicing your fleet or the rim and wheel
in the wheel
other illustrated
nuts.numerical order to torque the distributor in your area.
1. Multi-piece
Multi-piece rims and all rim compo
components
nents must
2. Repeat
Repeat proce
procedur
dure
e 1. until
until no wheel
wheel nut
nut moves
moves
be inspected before re-assembly each time
when the proper torque value is applied. Pro-
the tire is removed from the rim for repair and
cedure 1. may have to be repeated several
each time the tire is replaced. Rims and all rim
times to tighten the wheel nuts to the proper
components should be inspected annually (or
torque value.
every 3,000 hours) otherwise.

17-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

WHEEL NUT TORQUE VALUE

Drive Axle.............490 - 510 ft-lbs
(670 - 695 N⋅m)
 These value is located
located on the truck
serial plate for reference.

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 Illustration 17-2. Drive Axle Wheel Nuts Torquing Sequence (TXH400L)

2. Any rim
rim or rim
rim compo
component
nent whi
which
ch is bent out of
of 6. Rims
Rims have
have a useful
useful servic
service
e life that
that is depe
depen-
n-
shape, pitted from corrosion, broken, or dent on variables such as over / under inflation
cracked must not be used. It must be marked pressures, duty cycle, yard conditions, and
or tagged as unserviceable and removed from overloading from
from example. Although actualactual
the service area and discarded. When part rim life will vary from one application to anoth-
condition is in doubt, replace it. er, replacement after 10,000 hours of service
life is recommended. These rims should be
3. Ensure
Ensure that
that all part
parts
s correc
correctly
tly matc
match
h the type
type
tagged as unserviceable and removed from
of wheel being assembled. Check with the
the service area and discarded.
manufacturer if there is any doubt.
Tire / Wheel Jacking
4. Rim bases,
bases, rim flanges
flanges,, rim gutte
gutters,
rs, lock
lock rings,
and bead seat bands must be free of any dirt,
surface rust, scale or loose / flaked rubber 
buildup prior to re-assembly.
re-assembly. All dirt and rust  Never rely solely upon jacks or or hoists to
must be removed from the lock ring gutter. support the lift truck while removing tire /
Clean and repaint rims to stop the detrimental wheel.
effects of corrosion.
 Before placing jack in position,
position, block tire
tire
5. Air infla
inflatio
tion
n equipme
equipment
nt should
should have
have a filter
filter in and wheel on the other side of the truck.
the air line cable of removing moisture from
 Always place oak or other
other hardwood block
the air.
air. This will help in preventing
preventing corrosion.
cribbing under the load after the jack or

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 17-3

hoist has lifted the load. Make sure the crib- tool about 10° to keep it firmly in place. If it
bing is large enough to have sufficient con- slips off, it can fly with enough force to kill.
tact with the supported load to be stable. Always stand to one side when you apply
 Never get under
under,, near or between heavy hydraulic pressure.
objects that are supported only by a jack or  Never force or hammer rim components,
hoist. especially rim components under pressure.
 Always use hardwood blocks
blocks under jack.  Never attempt to weldweld on an inflated
inflated tire / rim
assembly.
 Do not under
under any circumstances,
circumstances, attempt to
rework, weld, heat or braze any rim compo-
nents 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.
 Do not hammer
hammer on rims
rims or components
components with
steel hammers. Use rubber,
rubber, lead, plastic,
plastic, or
brass faced mallets, if it is necessary, to tap
components together.
 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.
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 Make sure to remove the valve corecore to
exhaust all air from the tire.
tire. Remove both
 cores from a dual assembly.
 Check the valve stem by running
running a piece
piece of
wire through the stem to make sure it is not
plugged.
WHEEL NUT TORQUE VALUES Mounting And Inflation
Steer Axle........340 - 360 ft-lbs (375 - 405 N ⋅m)
 These values are on the truck
truck serial plate 
for reference.  Inflate tire in a safety cage. Use safety
chains or equivalent restraining devices dur-
Illustration 17-3. Steer Axle Wheel Nuts Torquing
Torquing ing inflation.
inflation. Misassembled parts may fly
Sequence (TX180S-360L) apart with explosive force during inflation.
 Do not seat rings by by hammering while the
Demounting tire is being inflated. If a part is tapped,
tapped, it or
the tool can fly out with explosive force.
 Never sit on or stand in front of a tire and rim
 assembly that is being inflated. Use a clip-
clip-
 Do not let anyone mount or demount tires
without proper training as stated in OSHA on chuck,
make sureanthein-line pressure
inflation gauge,
hose is and
long enough
Rules and Regulations 1910.177 “Servicing to permit the person inflating the tire to
multi-piece and single piece rim wheels.” stand to the side of the tire, not in front or in
 Do not stand in front of the tire during back of the tire assembly.
deflation.  Mixing parts of one manufacturer’s
manufacturer’s rims with
 Demounting tools apply pressure to rim rim those of another is potentially dangerous.
flanges to unseat tire beads. Keep your Always check manufacturer for approval.
fingers clear.
clear. Slant the demounting bead  Do not be
be careless or take chances. If you

17-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

are not sure about the proper mating of rim mended rim for the tire.
and wheel parts, consult a wheel and rim  Never run a vehicle
vehicle on one tire
tire of a dual
expert. This may be the tire man who is assembly. The carrying
carrying capacity of the
servicing your fleet or the rim and wheel dis- single tire and rim is dangerously exceeded
tributor in your area. and operating a vehicle in this manner can
 Do not inflate the tire before all side and lock result in damage to the rim and tire.
rings are in place. Double check to make  Do not reinflate
reinflate a tire that has been run flat
sure all components are properly seated. without first inspecting the tire, rim and
1. Refer to Illust
Illustration
ration 17-5 for hardw
hardware
are and
and its
its wheel assembly. Double check the lock ring
orientation for wheel mounting. for damage; make sure that it is secure in
the gutter before inflation.
2. Check
Check compo
componennents
ts for
for proper
proper assemb
assembly ly again
again
after inflating to approximately 5 psi (.3 bar).  Excessive turning of the steering
steering axle tires,
tires,
when the truck is stopped, should be
avoided. It can cause excessive wear (flat
5
spots) to develop.
1
Servicing Tire And Rim On Vehicle
9
8 
Block the other tires of
 of the vehicle before
you place the jack in position.
3  Regardless of how
how hard or firm the ground
ground
12 appears, put hardwood blocks under the
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jack. Always crib up vehicle with
with blocks just
just
in case the jack should slip.
  Remove the bead seat band slowly to pre-
pre-
11 vent it from dropping off and crushing your
4 toes. Support the band on your thigh and
roll
youritback
slowly
andto toes.
the ground.
ground. This will protect
protect
 When using a cable sling, stand clear; it
7
might snap and lash out.
10
Compressor Precautions
6 2
There have been instances of tires exploding vio-
lently while on vehicles. The forces involved
involved in
WHEEL NUT TORQUE VALUES
this type explosion are sufficient enough to cause
Steer Axle........340 - 360 ft-lbs (375 - 405 N ⋅m) serious personal injury to anyone in the immediate
 These values are on the truck
truck serial plate vicinity.. Some of these explosions are believed to
vicinity
for reference. have been caused by flammable vapors entering
the tire during inflation. When the machine is
operating, the temperature of the air and vapor
Illustration 17-4. Steer Axle Wheel Nuts Torquing mixture inside the tire will increase. The tempera-
Sequence (TXH400L)
ture inside
increase in the tire will
ambient also increase
temperature andwith
whenansub-
Operation jected to direct sunlight. If the vapor and air mix-
ture inside the tire are within the ratio limits that
will support combustion, and any or all of the
 above heat increasing factors cause the tempera-
 Do not overload rims or over-inflate
over-inflate tire / rim ture to rise, an explosion
explosion may occur.
occur. The follow-
assembly. Check your rim manufacturer
manufacturer if ing are some warnings that can prevent flam-
special operating conditions are required. mable vapors from entering the compressor and
 Do not use undersized
undersized rims. Use recom-
recom- subsequently being entrapped in tires.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 17-5

flammable agents in the compressor to pre-

 vent freezing of the condensation inside the
 Do not locate the compressor
compressor in a utility compressor. Drain thethe compressor
compressor tank
room used for storing flammable solvents, frequently or locate the compressor inside to
paints, thinners,
thinners, etc. The flammable
flammable vapors eliminate the freezing problem.
will be sucked into the compressor intake  Do not locate
locate the compressor
compressor near a battery
while the compressor is charging. charger. Batteries emit hydrogen gas, which
 Do not clean the
the compressor air filter with a is highly flammable, during the charging pro-
flammable solvent. Use a non-flammable cess, and could be sucked into the compres-
solvent, such as carbon tetrachloride. sor intake.
 Do not use alcohol,
alcohol, methanol,
methanol, or other

5
1. DRIVE AXLE
2. RIM
6 3. NUT
4. RIM
5. SIDE RING
6. LOCK RING

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 2
1

NOTE: TO OPERATOR

Wheel and mounts require run in period on a new machine and after each tire change.

Refer to serial plate on the side of machine for torque specifications before machine is put in service
and re-torque nuts each 10 hours until clamps are seated.

Care should be taken to keep grease and other foreign material from rim seating surfaces.

Illustration 17-5. Wheel Mounting

Mounting Hardware
Hardware

17-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 18

Chassis
Introduction (Illustration 18-1).
18-1). The chassis is hangers, drive axle mounts, tilt cylinder anchors
carefully engineered and ruggedly constructed, and steer axle mounts.
although welded steel structures always contain
undetectable cracks, especially welded joints.
When these joints are subject to fluctuating  Periodic inspection is
stresses of significant magnitude, these cracks will required to detect fatigue cracks that have
grow. This is known as fatigue
fatigue crack growth. No grown to a significant size in order to avoid
matter how low the stress levels are kept, some serious failure of the structural weldment.
fatigue crack growth will occur in all welded struc- When a crack is found, the truck must be
tures. immediately taken out of service and repaired.

Structural Inspection, Reporting, and Repair

Procedure (Refer to SIRR in the Appendices
Appendices)).  Under no circumstances,
Follow the OSHA rules, 29 CFR, 1910.178 (Q)(1), without prior written approval from Taylor
Machine Works, Inc. Engineering Department,
(5),
daily&before
(7) which require
being inspecting
placed in service,industrial
removing trucks should the chassis be modified, i.e. adding of
trucks from service if cracks are found, and mak- additional counterweights. As per OSHA 29
ing repairs only if authorized by the manufacturer. CFR1910.178 (a) (4).
If trucks are used on a round-the-clock basis, they
shall be examined after each shift.
shift. OSHA 29 CFR  If the fatigue crack is allowed
1910.178 (p)(1) requires that trucks in need of to grow, catastrophic failure could occur in the
repair be taken out of service.
service. Areas to be chassis or other welded components, causing
inspected on the truck chassis include mast serious injury to personnel and / or property.
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Chassis Troubleshooting
 Problem Cause Correction

1. Cr
Crac
ack
ks in
in wel
welds
ds 1. Me
Meta
tall fa
fati
tigu
gue.
e. 1. Have
Have crac
cracks
ks in weld
welds
s repa
repaire
ired
d
(Refer to SIRR in the immediately.
Appendices))
Appendices 2. Over
Overlo
load
adining.
g. 2. Refer
Refer to
to Corre
Correcti
ction
on 1.
1. abov
above
e and
and
Notify Taylor avoid overloading the truck.
Machine Works, 3. Ro
Roug
ugh h terr
terrai
ain.
n. 3. Refer
Refer to
to Corre
Correcti
ction
on 1. abo
above
ve and,
and, if
Inc. for proper possible, avoid operating truck on
repair procedures. rough terrain.
4. Trav
ravell
elling
ing with
with load
load in
in an unrec
unrecom-
om- 4. Ref
Refer
er to
to Corre
Correcti
ction
on 1.
1. abov
above
e and
and
mended travel position (excessive the Operator’s Guide for proper
height and / or fully side-shifted, travelling positions.
one side or the other).
5. Se
Seve
vere
re du
duty
ty cy
cycl
cles
es.. 5. Ref
Refer
er to Cor
Correc
rectio
tion
n 1.
1. abov
above.
e.

2. Engi
Engine
ne or tr
tran
ans-
s- 1. En
Engi
gine
ne vib
vibra
rati
tion
on.. 1. Refe
Referr to Pr
Prob
oble
lem
m 17.
17. in th
the
e
mission support Engine Troubleshooting chart in
mounts broken Section 1.1.
2. Tra
rans
nsmi
miss
ssion
ion vibra
vibrati
tion
on.. 2. Refe
Referr to Pr
Prob
oble
lem the Trans-
m 9. in the
mission Troubleshooting chart in
Section 9.9.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 18-1

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 Note: Photocopy this sketch to identify fatigue cracks or
structural damage to
to the chassis. Be very descriptive
descriptive of
damage to the chassis, i.e. location, depth, length.

Illustration 18-1. Chassis

18-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 20

Cab

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 Illustration 20-1. Cab

Introduction (Illustration 20-1).

20-1). The cab has 6. The door latch must always funct
function
ion properl
properly
y.
been carefully designed with the operator’s safety
7. The tilt
tilt steeri
steering
ng must
must lock firml
firmly
y into
into position
position..
and comfort in mind. The components in the cab
have been laid out for easy access.
Cab Maintenance Checks. The following checks  Failure to adhere to any of the
must be performed before operating the truck. above could lead to personal injury, death or
property damage.
1. Steps
Steps and opera
operator’
tor’s
s compar
compartme
tment
nt must
must be
free of oil, grease and trash.
 Avoid stepping on the top
2. All glas
glass
s and mirr
mirrors
ors of
of the cab
cab shoul
should
d be Lexan cover while servicing the truck.
cleaned
impaired.daily to keep vision from being
 Always use approved ladders,
3. Under
Under no circu
circumst
mstanc
ancee should
should objec
objects
ts be stands, or manlifts to reach high places on the
allowed in the cab which would restrict the truck.
operator’s vision or exit.
4. The seat
seat must
must lock
lock firm
firmly
ly into
into posit
position
ion..  The top Lexan cover is a part
5. The seat
seat belt
belt must
must alwa
always
ys be inta
intact
ct and
and of the OSHA mandated FOPS (Falling Object
operable. Protective Structure).
Structure). Do not remove or

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20-1

replace cover with glass.

Troubleshooting
1. Should
Should abnorm
abnormalal vibra
vibratio
tion
n or shifti
shifting
ng of cab
cab
structure occur, check mounting bolts for tight-
ness and ensure that rubber mounts are not
damaged.
2. Should
Should leak
leak occur
occur fro
from
m the
the seals
seals of the
glasses, repair seal.
Lubrication. The grease fittings, on the door
hinges, should be greased periodically (refer to
the Preventive Maintenance chart in the
Appendices for door hinge lubrication interval).

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20-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

2
0
A
S -A
y i
s r
te C
mo
n
d
tii
o n
in
g

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https://www.forkliftpdfmanuals.com/
 Section 20A

Air Conditioning System

Introduction. The air conditioning / heating sys- warm, high pressure liquid (to the expansion
tem provides the operator with a comfortable valve). The drier is equipped with a binary switch
operating environment. which protects the compressor.
Major Components (Illustration 20A-2).
20A-2). The air The binary switch is normally closed when the
conditioning system consists of a wall-mounted air system pressure is within operating specifications.
conditioner / heater unit, condenser, compressor, The binary switch will open when the system pres-
four 30 amp circuit breakers, and a heater shut-off sure exceeds 312 psi (22 bar). The binary switch
switch
valve. will not close again until the pressure has dropped
below 225 psi (16 bar). When the pressure drops
Air Conditioner / Heater Unit (Illustration 20A-1).
20A-1).
below 2 psi, the binary switch
switch will open. The
The floor-mounted air conditioner / heater unit is
binary switch will not close again until the pres-
capable of delivering 36,000 BTUs (37,980 kJ) of
sure is above 28 psi (2 bar). The binary switch
cooling capacity, 38,700 BTUs (40,830 kJ) of
can be replaced without recovering the refrigerant.
heating capacity, and is powered by 12 VDC from
30 amp circuit breakers (CB21, CB22 and CB23). The binary
unit on the switch
the is located
high pressure
press in the
ure side. Theairfitting
conditioner
that
The air conditioner / heater unit is a three speed
holds the binary switch is equipped with a check
unit with a preset thermostat. The air conditioner /
valve, that prevents the high pressure coolant
heater unit has a cool / heat switch that allows the
from exhausting if the switch is removed.
operator to select for cooling or heating of the cab.
The air conditioning system is charged with Evaporator / Heater Coil. The evaporator / heat-
approximately 4.25 lbs. (1.9 kg) of R134a Freon. er coil is located inside the air conditioner / heater
unit. The evaporator and heater coils are inte-
NOTE: The Clean Air Act, passed in 1992, speci- grated into one unit. The evaporator coil changes
fies that anyone who works on vehicle air condi-
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the warm, metered pressure liquid refrigerant
tioning systems must be certified by an EPA (from the expansion valve) into a cold, low pres-
approved agency
agency.. sure gas. The cold, low pressure gas is sent back
into the expansion
expansion valve. The temperature of this
Compressor. The compressor is belt driven and low pressure gas is what controls the expansion
circulates the refrigerant through the air condition- valve. The colder the gas, the closer a ball will
ing system
a cool, when its clutch
low pressure clut
gasch is engaged.
and It receives
pumps a hot, high seat and restrict the refrigerant into the evaporator
coil.
pressure gas to the condenser.
condenser. When the thermo-
stat signals for cooling, an electrical signal is sent The heater coil is the medium by which heat is
to the compressor clutch, engaging the clutch and transferred from the engine coolant to the opera-
driving the compressor. tor’s compartment. A heater shut-off
shut-off valve is
located on the air conditioner / heater unit and
NOTE: Any time repairs are made to the air con- when opened, allows the heat transfer to occur.
ditioning system which require the recovery of the When operating the air conditioner, close the
refrigerant, it is recommended that the drier be heater shut-off valve for maximum cooling
changed and 4 ounces (118 milliliters) of AC ester efficiency.
lubricating oil be added to the dryer. Circuit Breakers. Refer to Circuit Breakers in
the Component Troubleshooting of Section 6
Condenser. The condenser,
condenser, mounted on the
for troubleshooting of circuit breakers.
back of the cab, changes the refrigerant from a
hot, high pressure gas (from the compressor) to a Air Conditioner / Heater Maintenance. The
warm, high pressure liquid (to the drier) by cooling remote mounted condenser of the air conditioning
the refrigerant. The condenser is powered by system should be cleaned every 3 months to
12 VDC from a 30 amp circuit breaker (CB24). remove debris. The condenser can be cleaned
with a fin comb, air hose and nozzle, or soap and
Drier. The drier stores a volume of refrigerant.
water. The evaporator / heater
heater coils in the air con-
Additionally, it filters and removes moisture from
ditioner / heater unit should be cleaned every
the refrigerant. The drier receives
receives a warm, high
3 months with compressed air.
pressure liquid (from the condenser) and sends a

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20A-1

HEATER
SHUT-OFF VALVE

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 FASTENERS

COVER
FILTER

Illustration 20A-1. Air Conditioner / Heater Unit

Heater Shut-off Valve (Illustration 20A-1).

20A-1). The air conditioner filters should be cleaned every
heater shut-off valve controls the circulation of 3 months or as conditions warrant. The filters
heated coolant through the air conditioning / heat- must be replaced yearly or as conditions warrant.
er unit. Additionally
Additionally,, there are two
two shut-off valves, If filters are not cleaned regularly, they may
located on the engine, that control the circulation become partially clogged with lint, dirt, grease or
of heated coolant through the heating / defrosting other debris. The filters should be cleaned
cleaned or
circuit. All three shut-off
shut-off valves must be fully open changed as conditions warrant. Perform the fol-
for
are maximum heating.
closed, there will beIf no
anycirculation
of the shut-off valves
of heated lowing procedures to remove filters for cleaning or
replacement:
coolant through the heating system.
1. Remove
Remove filter
filter cover
covers
s from
from the
the air
air condition
conditioner
er /
Refrigerant Hoses. Periodically check the hoses heater unit’s housing by removing fasteners.
and fittings for chafing or cracking. Replace as
2. Remove
Remove filters
filters from filte
filterr covers
covers and
and clean
clean with
conditions require.
low pressure air. air. Replace old filters with new
Cleaning and / or Changing The Air Condition- filters if filters are damaged.
er / Heater Unit Filters (Illustration 20A-1).
20A-1). The

20A-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

3. Install
Install the filter
filters
s in the
the filter
filter covers
covers and sec
secure
ure engage the clutch of the compressor (refer to
filter covers to air conditioner / heater unit with Drier in this section).
fasteners.
7. Check
Check the
the air condit
condition
ioning
ing hoses
hoses and
and fittin
fittings
gs
Inspection. In the event of a cooling problem, for leaks. If a leak is detected, the refrigerant
perform the following inspection procedures. must be recovered prior to making repairs.

NOTE: The Clean Air Act, passed in 1992, speci-

 Death or serious injury could fies that anyone who works on vehicle air condi-
result from a runaway truck. Park the truck on tioning systems must be certified by an EPA
a hard, level surface, apply the parking brake approved agency
agency..
and block the wheels in both directions to
prevent movement of the truck. 8. For any
any further
further repair
repairs,
s, contac
contactt a certi
certified
fied air
conditioning repair technician.

 Rotating fan and belts can

cause severe injury. Stay clear of fan and
belts when engine is running.
1. Check
Check the
the compre
compresso
ssorr drive
drive belt tens
tension
ion and
and
pulley alignment. Tension on the drive belt
should be such that a firm push with the thumb
at a point midway between the two pulleys will
deflect the belt approximately 3/8” (9.5
(9.5 mm). If
the deflection of the belt is more than 3/8” (9.5
mm), adjust the belt tension. https://www.forkliftpdfmanuals.com/
 2. Check
Check the
the conden
condenser
ser for
for debris
debris and
and clean
clean if
required.
3. Check
Check all elect
electric
rical
al connec
connectio
tions
ns and ensure
ensure
that the circuit breakers are set.
4. Checki
Checkingng the compr
compress
essoror clutch
clutch will
will requir
requiree
starting the engine. When 12 VDC is sent
from the thermostat through the binary switch
to the compressor, the compressor’s clutch will
pop towards the compressor pulley (this will be
heard). The clutch will then begin to rotate
rotate
with the pulley (this will be seen).
5. Ensure that the evapor
evaporator
ator coil, locat
located
ed inside
inside
the air conditioner / heater unit (and ceiling-
mounted air conditioner unit), is not iced up.
The thermostat’s capillary should be posi-
tioned in the center of the evaporator coil fins.
If the thermostat is functioning properly when
the fins ice up, the thermostat will remove the
12 VDC to the compressor
compressor.. This will allow the
compressor pulley to free-spin and no refriger-
ant will be circulated to the evaporator coil.
The ambient temperature will then defrost the
evaporator coil fins.
6. The 12
12 VDC sign
signal
al from
from the
the thermo
thermosta
statt must
must
pass through a binary switch, which monitors
low pressure and high pressure in order to

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20A-3

Air Conditioner / Heater Unit Troubleshooting (Illustration 20A-2)

Problem Cause Correction

1. Air
Air con
condi
diti
tion
onin
ing
g 1. Circui
Circuitt break
breaker(
er(s)
s) (CB2
(CB21,
1, CB22
CB22 or 1. Reset
Reset or repl
replace
ace circ
circuit
uit brea
breaker
ker(s)
(s)..
unit does not CB23) is tripped or defective. Refer to Circuit Breakers of the
power up Component Troubleshooting in
Section 6.
6.
2. Harnes
Harnesss conne
connecto
ctorr is disc
disconn
onnect
ected
ed 2. Con
Connec
nectt or tig
tighte
hten
n harn
harness
ess
or loose. connector.
3. Loo
Loose
se pin
pin in
in harne
harness
ss conn
connect
ector
or.. 3. Is
Isol
olat
ate
e and
and re
repa
pair
ir..
4. Br
Brok
oken
en or
or shor
shorte
ted
d wire
wires.
s. 4. Trou
rouble
blesho
shoot,
ot, isola
isolate
te and repai
repairr.

2. Fan
Fan blo
blows
ws li
limi
mite
ted
d 1. Hea
Heater
ter shut
shut-of
-offf valv
valve
e is ope
open.
n. 1. Clo
Close
se hea
heater
ter shu
shut-o
t-off
ff val
valve.
ve.
or no cold air
2. Compre
Compresso
ssorr clutc
clutch
h is sli
slippi
pping
ng or
or 2. Tigh
ighten
ten driv
drive
e belt
belt or repla
replace
ce clutc
clutch.
h.
defective.
3. Lo
Low
w Fre
Freon
on ch
char
arge
ge.. 3. Have
Have certif
certified
ied tech
technic
nician
ian rech
recharg
arge
e
air conditioning system.
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4. Th
Ther
ermo
most
stat
at is def
defec
ecti
tive
ve.. 4. Re
Repl
plac
ace
e th
ther
ermo
most
stat
at..
 5. Ev
Evap
apor
orat
ator
or coi
coill is ice
iced
d up.
up. 5. Thermo
Thermosta
statt is def
defect
ective
ive.. Rep
Replac
lace
e
thermostat.
6. The con
conden
denser
ser fan is sei
seized
zed or 6. Uns
Unseiz
eize
e fan,
fan, repl
replace
ace or chec
check
k wir-
wir-
defective. ing to fan motor.
7. The eva
evapor
porato
atorr / heat
heater
er c
coil
oils
s are
are 7. Cle
Clean
an wit
with
h comp
compres
ressed
sed air or
dirty or stopped up. remove restriction.
8. Fil
Filter
ter is dirt
dirty
y or sto
stoppe
pped
d up.
up. 8. Cl
Clea
ean
n or rep
repla
lace
ce fil
filte
terr.
9. Binary
Binary swi
switch
tch in conde
condense
nserr is 9. Is
Isol
olat
ate
e and
and re
repa
pair
ir..
defective.
10. Circu
Circuit
it breaker(s)
breaker(s) is tripped or 10. Isola
Isolate
te and repair.
repair.
defective.
11. The heat / air switch of the air con- 11. Place the heat
heat / air switch in the air
ditioner / heater unit is in the heat position.
position.
12. Defec
Defective
tive heat / air switch
switch of air 12. Replac
Replace
e heat / air switch.
switch.
conditioning unit.
13. Harne
Harness
ss connector(s)
connector(s) is discon- 13. Connec
Connectt or tighten harness
harness
nected or loose. connector(s).
14. Air conditioner
conditioner compresso
compressorr is 14. Contact certified technician to
defective. repair or replace.

20A-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Problem Cause Correction

3. Air
Air con
condiditi
tion
onin
ing
g 1. Dra
Draina
inage
ge hose
hoses
s are
are rest
restric
ricted
ted.. 1. Rem
Remove
ove res
restri
tricti
ction
on from
from hos
hoses.
es.
unit is leaking
water in the cab 2. Draina
Drainage
ge hos
hoses
es hav
have
e shif
shifted
ted 2. Reposi
Repositio
tion
n the
the dra
draina
inage
ge hose
hoses.
s.
upwards. The drainage hoses should run
downward to prevent water from
standing in the hoses.
3. Drain
Drain ven
ventt in
in drai
drainag
nage
e pan
pan is 3. Rem
Remove
ove rest
restric
rictio
tion
n from
from drain
drain vent.
vent.
restricted.

4. Fan blow no 1. Hea

Heater
ter shut
shut-of
-offf valv
valve
e is
is open
open.. 1. Clo
Close
se hea
heater
ter shu
shut-o
t-off
ff val
valve.
ve.
heated air
2. Engine-
Engine-mou
mounte
nted
d shu
shut-o
t-off
ff val
valve(
ve(s)
s) is 2. Op
Open
en shut
shut-o
-off
ff va
valv
lve(
e(s)
s)..
closed.
3. Hea
Heater
ter hos
hoses
es kink
kinked
ed or res
restri
tricte
cted.
d. 3. Unkink
Unkink or remo
remove
ve rest
restric
rictio
tion
n from
from
hoses.
4. Defect
Defective
ive engi
engine
ne therm
thermost
ostat
at (stuc
(stuck
k 4. Re
https://www.forkliftpdfmanuals.com/ Repl
plac
ace
e engine
engine ther
thermo
most
stat
at..
open).
 5. Lo
Low
w coo
oola
lant
nt.. 5. Ch
Chec
eck
k and
and fill
fill rad
radia
iato
torr.
6. Engine
Engine did not ris
rise
e to
to opera
operatin
ting
g 6. Allow
Allow engi
engine
ne enou
enough
gh time
time to reac
reach
h
temperature. operating temperature.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20A-5

Hoist Circuit

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20A-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

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PLACE THE FOLLOWING ILLUSTRATION IN
 A FOLDER
FOLDER ENVELOPE:
ENVELOPE:
Illustration 20A-2 - 20A-2367 SHT. 1 (A.C. ANSI)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20A-7

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https://www.forkliftpdfmanuals.com/
20A-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

2
0
H
-H
e
a
ti
n
g
S
y
s
te
m

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https://www.forkliftpdfmanuals.com/
 Section 20H

Heating System
Introduction. The heating system provides a cleaned or changed. Perform the following proce-
comfortable working environment in a cold climate dures to remove filters for cleaning or replace-
and is essential in removing condensation from ment:
the windshield in which otherwise would impair
1. Remov
Remove
e filter
filter cover from the heater
heater / defroster
defroster
vision. Provided the
the engine-mounted shut-off
valves are open, the engine coolant flows through unit’s housing by removing screws.
the heater coils of the heater / defroster units, air 2. Remove
Remove filte filterr from filt
filter
er cover
cover and clean
clean with
with
conditioner / heater unit (if equipped), and returns low pressure air. air. Replace old filter with new
back to the engine block. filter if filter is damaged.
Major Components (Illustration 20H-2).
20H-2). The 3. Install
Install filter
filter in the filter
filter cover
cover and
and secu
secure
re to
to
heater system consists of two heater / defroster heater / defroster unit with screws.
units, two 30 amp circuit breaker (CB11 and
CB12), air conditioner / heater unit, shut-off valves
and hoses.
Heater / Defroster Units (Illustration 20H-1).
20H-1). The
heater / defroster units are powered by 12 VDC
from two 30 amp circuit breaker (CB11 and CB12),
employ a two speed switch (S24), two relays (K12
and K13) and are rated at 15,300 BTUs (16,140
kJ).
SCREWS
Circuit Breakers. Refer to Circuit Breakers in
the Component Troubleshooting of Section 6
for troubleshooting of circuit breakers.
Shut-off Val
Valves
ves (Illustration 20H-2).
20H-2). The shutoff
valves [one is located in the air conditioning /
heater unit (see Illustration 20A-1) and one is FILTER
engine mounted] control the flow of heated cool-
ant to the heater / defroster circuits. They must
Illustration 20H-1. Heater / Defroster Unit Filter
be fully open for maximum operation. If any of the
shut-off valves are closed, there will be no flow of
heated coolant to circulate in the heating / defrost-
ing circuit.
Hoses. Periodically check the hoses and elbows
for chafing or cracking. Replace as conditions
require.

 Severe injury may occur from

burns. Always shut down engine and allow to
cool before servicing or inspecting heater
hoses.

Cleaning and / or Changing The Heater /

Defroster Unit Filter (Illustration 20H-1).
20H-1). The
heater / defroster unit’s filter should be cleaned
every 3 months
months or as conditions warrant. The fil-
ter must be replaced once a year or as conditions
warrant. If the filter is not cleaned regularly,
regularly, it may
become partially clogged with lint,https://www.forkliftpdfmanuals.com/
dirt, grease or
other debris. A clogged filter
filter will produce a loss of
 air volume and therefore the filter should be

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20H-1

Heating System
Sy stem Troubleshooting
Troubleshooting (Illustration 20H-2)

Problem Cause Correction

1. Heat
Heater
er / de
defr
fros
oste
terr 1. The hea
heater
ter / defro
defroste
sterr switc
switch
h (S5)
(S5) 1. Rep
Replac
lace
e heater
heater / def
defros
roster
ter swi
switch
tch..
fan is not turning is defective.
2. Circui
Circuitt break
breaker
er (CB1
(CB11
1 or CB12
CB12)) is 2. Re
Rese
sett circ
circui
uitt brea
breake
kerr.
tripped.
3. Circui
Circuitt break
breaker
er (CB1
(CB11
1 or CB1
CB12)
2) 3. Circui
Circuitt is sho
shorte
rted.
d. Trou
rouble
blesho
shoot,
ot,
keeps tripping. isolate and repair short.
4. Circui
Circuitt break
breaker
er (CB1
(CB11
1 or CB 12)
12) is
is 4. Rep
Replac
lace
e cir
circui
cuitt bre
breake
akerr.
defective.
5. Def
Defect
ective
ive rel
relay
ay (K1
(K12
2 or
or K13)
K13).. 5. Re
Repl
plac
ace
e rel
relay
ay..
6. De
Defe
fect
ctiv
ive
e fan
fan mot
motor
or.. 6. Re
Repl
plac
ace
e fan
fan mo
moto
torr.
7. Loose
Loose or brok
broken
en wire
wires
s / plu
plugs
gs / 7. Trou
rouble
blesho
shoot,
ot, isol
isolate
ate and
and repla
replace
ce
pins between any of the compo- wire.
nents.

2. Heat
Heater
er / de
defr
fros
oste
terr 1. The engi
engine-
ne-mou
mounte
ntedd shut-o
shut-off
ff val
valve
ve 1. Op
Open
en shut
shut-o
-off
ff va
valv
lve(
e(s)
s)..
fan is turning, but or air conditioning / heater unit
no warm air is shut-off valve is closed.
present
2. Hea
Heater
ter hose
hoses
s kinke
kinked
d or rest
restric
ricted
ted.. 2. Unkink
Unkink or
or remove
remove rest
restric
rictio
tion
n from
from
hoses.
3. Defect
Defective
ive engi
engine
ne therm
thermost
ostat
at (stuc
(stuck
k 3. Rep
Replac
lace
e eng
engine
ine the
thermo
rmosta
stat.
t.
open).
4. Lo
Low
w co
cool
olan
ant.
t. 4. Ch
Chec
eck
k and
and fill
fill radi
radiat
ator
or..
5. Engine
Engine is not
not at
at opera
operatin
ting
g tempe
tempera-
ra- 5. All
Allow
ow engi
engine
ne enou
enough
gh time
time to rea
reach
ch
ture. operating temperature.

3. Heat
Heater
er / de
defr
fros
oste
terr 1. Defect
Defective
ive heat
heater
er / defro
defroste
sterr switch
switch 1. Rep
Replac
lace
e heater
heater / def
defros
roster
ter swi
switch
tch..
operates in only (S5).
one speed
2. Def
Defect
ective
ive rel
relay
ay (K1
(K12
2 or
or K13)
K13) 2. Re
Repl
plac
ace
e rel
relay
ay..
3. Loose
Loose or brok
broken
en wire
wires
s / plu
plugs
gs / 3. Trou
rouble
blesho
shoot,
ot, isola
isolate
te and repai
repairr.
pins between any of the compo-
nents.

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20H-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

PLACE THE FOLLOWING ILLUSTRATION IN

A FOLDER
FOLDER ENVELOPE:
ENVELOPE:
Illustration 20H-2 - 20A-2367 SHT. 2 (Defroster ANSI)

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20H-3

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20H-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 22

Hydraulic System
Steering Logic (Illustration 22-20 and 22-14).
22-14). tank return from one outlet port to force fluid
Hydraulic flow from the larger of the two gear sets through a hydraulic cooler located behind the
in the main pump enters the manifold at port P1. radiator. The check acts as a bypass valve for
Flow is then directed to the main relief valve (RV1) cold fluid startup as well as increased flow to tank
and the two steering logic controls (LC2 and LC3). as the mast is being lowered.
If there is no demand from steering, LC2 sends
Brake / Brake Cooling Logic (Illustration 22-20).
22-20).
flow to the orbitrol until 150 psi (10.4 bar) standby
The auxiliary pump is a two section pump with
pressure can maintained in the line causing LC2
gear sets of equal size. Flow from one gear set
to close. The flow opens LC3 and is then directed
enters the manifold
manifold at port P3. Flow is blocked by
valves. Whenhttps://www.forkliftpdfmanuals.com/
to the hoist and tilt valves. steering, load
logic element (LC1) and must pass through orifice
sense pressure builds from the orbitrol, which
causes LC2 to open and LC3 to close enough to ORF1 and check
lator charging valve (CK1)
process. to startbuilds
As pressure the accumu-
in the
satisfy the steering flow requirement (Load sense
charge circuit, the pressure reducing valve (PRV1)
pressure can be measured at port LSM). Excess
supplies pilot fluid for accessory valve and hoist /
flow is available for use by the hoist and tilt.
tilt valve operation. When the PRV1 valve setting
When load sense (steering) pressure reaches the
is reached, it closes off and all flow through the
setting of relief valve [RV2 (which must be set at a
circuit is directed to the parking brake and service
pressure equal to or lower than RV1)], RV2 opens
brake accumulators.
accumulators. When both accumulators
causing LC3 to open as well. Pump flow is then
reach full pressure, determined by the unloader
tilt. (Refer to the HYDRAULIC
sent to hoist and tilt.
valve (UNL1), the pilot to the spring chamber of
PRESSURE SETTINGS in the Appendices for
logic element (LC1) is drained and pump flow is
RV1 and RV2 pressure settings.)
directed to the drive axle to cool the left side drive
Hydraulic Logic (Illustration 22-20).
22-20). Hydraulic axle brake. Flow from the other gear set cools the
flow from the secondary gear set of the main fluid of the
the right side drive axle brake.
brake. As pres-
pump enters at the inlet of the accessory valve. sure falls in the accumulators, the pressure signal

Flow then the

joins with passes through
flow from thethe manifold
primary pump.where
Theit to UNL1
itself. fallsvalve
Relief and closes
(RV3) it.
itprotects
. The process repeats
the pump from
combined flows then enter the hoist and tilt valve. over-pressurization and acts as a thermal relief
Pump flow from the secondary gear set is always also. The parking brake is electrically applied and
available for accessory functions such as side released by solenoid SOL1. Pressure must be
shifter and fork positioners if the truck is so held on the spring-applied / hydraulic-released
equipped. Pump flow from the primary pump parking brake (located on the transmission out-
must satisfy steering requirements first, but put). Both brake pedals are supplied
supplied from pres-
pres-
excess flow is always available for hoist and tilt sure and flow stored in accumulator
accumulator (ACC2). The
functions. The total flow from both pumps is avail- LH foot pedal inches the transmission and applies
able to hoist and tilt if there is no requirement from the wheel brakes. The RH foot pedal applies the
steering or accessory functions.
functions. Flow returns to only. (Refer to the HYDRAULIC
wheel brakes only.
the tank from the hoist and tilt valve outlet. The PRESSURE SETTINGS in the Appendices for
outlet is equipped with two returns. An inline pressure settings.)
check valve has been installed at the hydraulic

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-1

MAIN PUMP
(Illustrations 22-9 and 22-10) AUXILIARY PUMP
AUXILIARY
(Illustration 22-11)

JOYSTICK https://www.forkliftpdfmanuals.com/
CONTROLLER HYDRAULIC
 SYSTEM COOLER
(Illustration 5-3)

ORBITROL
(Illustration 22-14)
(Illustration

HYDRAULIC
TANK
(Illustration
(Illustration 22-16)

PILOT FILTER
(Illustration
(Illustration 22-13)

MANIFOLD
(Illustration 22-6)
ACCUMULATORS
ACCUMULATORS
(Illustration
(Illustration 22-12)
COOLING
CHECK VALVE
(Illustration
(Illustration 22-20)

Illustration 22-1. Hydraulic System

System Components
Components Identification
Identification

22-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Side Illustrated

Side Illustrated

CK1
COOL https://www.forkliftpdfmanuals.com/
 PRV1
PB
ACC2

P3 RV1
LC3

O ORF3
LC2
RV3 PPM
RV2

PARKING BRAKE SOLENOID

Illustration 22-2. Manifold (Engine Side) Illustration 22-3. Manifold (Mast Side)

PB - (Parking Brake) Supply connection to the LC2 - (Logic Control) Controls flow to steering.
parking brake chamber.
LC3 - (Logic Control) Controls flow to steering and
Cool - (Service brake cooling) Cooling fluid supply hoist/tilt functions.
to one of the service brake.
PRV1 - (Pressure Reducer) Controls maximum
CK1 - (Check Valve) Isolates higher brake pres- pilot pressure.
sure circuits from lower pump pressure.
RV2 - (Pressure Relief) Controls maximum steer
P3 - (Auxiliary Pump Port) Supply connection from pressure.
primary pump.
PPM - (Pilot pressure measure) Gauge port to
ACC2 - (Accumulator Port) Service brake accumu- check pilot pressure.
lator supply.
ORF3 - (Orifice #3) This orifice stabilizes the
RV3 - (Pressure Relief) Thermal relief for ACC2 unloader valve (UNL1).
accumulator.
RV1 - (Pressure Relief) Primary pump relief
Parking Brake Solenoid - Controls parking brake
apply / release.
O - (Orbitrol Port) Supply port to steering orbitrol.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-3

Side Illustrated flow/pressure signals to the accumulator charge

circuit. The check valves isolates the parking and
service brake circuits from lower brake cooling
pressures.
LC1 - (Logic Control Number one) Logic control
for accumulator circuit.
LSO - (Load sense) Steering load sense connec-
PBM tion from orbitrol.
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LSM - (Load Sense Measure) Port for load sense
 ORF4 pressure check.
PP - (Pilot Pressure) Pilot pressure check port.
ACCM
ORF2
P1M UNL1 - (Unloader Valve number one) Controls
accumulator charge pressure high and low limits.

CK1 &
LC1
ORF1
P1
LSO

UNL1
PP Side Illustrated
LSM

Illustration 22-4. Manifold (Top

(Top Side)

B - (Service brake Port) Supply pressure to the

service brake pedals.
ORF4 - Currently not used.
ACCM - (Accumulator measure port) Port for park
brake pressure check. ACC1

ORF2 - (Orifice2) Controls parking brake

release rate.
PBM - Port to monitor parking brake pressure.
P1M - (Pump One Measure) Pressure check port
for primary pump.
P1 - (Pump One / Main Pump) Primary pump
Illustration 22-5. Manifold (Bottom Side)
inlet to manifold.
CK1 & ORF1 - (Check valve number one and
ACC1 - (Accumulator #1) This port provides the
orifice number one) Orifice number dampens the
connection to the parking brake accumulator.

22-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

TILT OUT
PORT RELIEF
FORK POSITIONERS
PORT RELIEFS
TILT
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 LIFT

MANIFOLD

SIDE SHIFT PORT

RELIEFS

ACCESSORY MANUAL
MAIN RELIEF OVERRIDE

Illustration 22-6. Accessory / Manifold / Lift / Tilt Valves

Manual Override during servicing or inspection of the main and

accessory valves. Always use access panels
Each of the end caps solenoids is equipped with a
located on the side of the truck and the cab
manual override in the event of an electrical fail-
floorboard to access valves. Do not stand or
ure. By depressing the override button of the
respective solenoid, the internal pilot spool is allow others
the mast andto stand under
carriage. elevated
Ensure parts
area is clearof
manually moved into position, allowing pilot pres-
before activating the manual overrides of the
sure to move the work
work section’s main spool. This
main or accessory valves.
feature is extremely useful in troubleshooting.
Should a function fail to operate, depressing the
override switch will override all the electrical actu-
ated functions of the manifold.

 Death or serious injury may

occur from being trapped between moving
parts of the lift truck. Never put yourself or
any body parts between the cab and mast

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-5

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 BOLTS
TORQUE
TO 75 FT-
LBS. 9/16”
SOCKET

Illustration 22-7. Valve Bank Through Bolts (Lift / Tilt Side)

BOLTS
TORQUE
TO 32 FT-
LBS. 9/16”
SOCKET

Illustration 22-8. Valve Bank Through Bolts (Accessory

(Accessory Side)

22-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

FLOW RATE @ 2200 RPM = 22 GPM / 83 LPM

FLOW RATE @ 750 RPM = 7 GPM / 26 LPM

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 FLOW RATE @ 2200 RPM = 46 GPM / 174 LPM FLOW RATE @ 2200 RPM = 4.8 GPM / 18 LPM
FLOW RATE @ 750 RPM = 15 GPM / 57 LPM FLOW RATE @ 750 RPM = 1.6 GPM / 6 LPM

Illustration 22-9. TXH 400L / Main Pump Illustration 22-11.

22-11. Auxiliary Pump

FLOW RATE @ 2200 RPM = 22 GPM / 83 LPM

FLOW RATE @ 750 RPM = 7 GPM / 26 LPM

FLOW RATE @ 2200 RPM = 40 GPM / 151 LPM

FLOW RATE @ 750 RPM = 13 GPM / 49 LPM

Illustration 22-10. TX (H) 180-360 Main Pump

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-7

SERVICE BRAKE
ACCUMULATOR
ACCUMULA TOR
PRE-CHARGED TO
1,250 PSI (1 GALLON)
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 PARKING BRAKE
PARKING
ACCUMULATOR
ACCUMULA TOR PRE-
CHARGED TO 500 PSI
(1/2 GALLON)

Illustration 22-12. Accumulators

and unfiltered pilot fluid will enter the pilot pas-

RETURN
FILTER sages of the
the main valve. The pilot filter should be
replaced periodically (refer to the Preventive
ELEMENT Maintenance chart in the Appendices for pilot
filter replacement interval). Perform the following
procedures to replace the pilot filter:

50 PSI
 Death or serious injury could
(3.5 bar)
result from a runaway truck. Park the truck on
BYPASS
a hard, level surface, apply the parking brake,
block the wheels in both directions to prevent
movement of the truck and Lock Out & Tag Out
FILTER the truck.
HEAD

FILTER 
accordance withDispose of fluid
federal and and
local filter in
regulations.
BOWL
1. Park the
the truck
truck on a hard,
hard, level
level surf
surface
ace,, block
block
the wheels in both directions, apply the park-
ing brake and Lock Out & Tag Out the truck.
Illustration 22-13. Pilot Filter
2. Ensure
Ensure filt
filter
er is cool
cool to
to the touc
touch
h and prov
provide
ide a
Pilot Filter Replacement (Illustration 22-13).22-13). The suitable container to catch any draining fluid.
pilot filter filters the pilot pressure fluid.
fluid. The filter 3. Drain the filter
filter bowl if equipped
equipped with drain bolt.
head contains a 50 psi (3.5 bar) bypass. When a
pressure differential exists of greater than 50 psi 4. Loos
Loosen
en and rem
remove
ove fil
filter
ter bow
bowl.
l.
through the filter element, the bypass will open 5. Remov
Remove
e filter
filter by pulling
pulling downw
downward
ard with
with a sligh
slightt

22-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

twisting motion. Discard properly of filter.

filter. vent hydraulic fluid aeration. Refer to the Service
Capacities in the Appendices for the working
6. Check
Check bowl
bowl O-rin
O-ring
g for dama
damage
ge and
and replace
replace ifif
and total refill capacities of the hydraulic tank.
necessary.
Temperature Switch. When the temperature of
7. Lubricate
Lubricate the
the O-ring
O-ring of
of the
the new filte
filterr with
with clean
clean
the fluid in the hydraulic tank exceeds 180F
hydraulic fluid. Place new filter on post in filter
(82C), a normally closed (NC) switch will open.
head.
This will signal the TICS (Taylor
(Taylor Integrated Control
8. Insta
Installll filter
filter bowl and tighten
tighten to a torque value System) of a high hydraulic fluid temperature con-
of 15-20 ft-lbs (20-27 N ⋅m). https://www.forkliftpdfmanuals.com/
dition. A High Hydraulic
Hydraulic Temperature
Temperature active
warning will appear on the TICS display module.
 9. Ensure
Ensure filt
filter
er is cool
cool to
to the touc
touch
h and provi
provide
de a
suitable container to catch any draining fluid. Checking The Fluid Level (Illustration 22-15).
22-15).
10. Apply an even film of fresh hydraulic fluid on The hydraulic fluid level can be checked on the
the gasket surface of the replacement filter. fluid level dipstick.
dipstick. Ensure the carriage
carriage is fully
lowered and the mast is fully tilted back before
11. Unscrew filter and dispose of properly.
properly. checking the hydraulic fluid level. Refer to the
12. Thread the new filter onto filter head. Fuel and Lubricant Specifications in the
Appendices for the type of fluid to be used.
13. Hand tighten filter
filter 3/4 turn
turn past point where
gasket first contacts filter head surface. Add hydraulic fluid until
un til the fluid level is even with
the FULL mark
mark on the dipstick. The fluid level level
must be maintained between the FULL and ADD
STEERING marks on the dipstick.
COLUMN

 Not adhering to the above pro-

cedure can
tank. As lead tohydraulic
a result, overfillingfluid
of the
willhydraulic
be forced
forced
through the breather
breather..

Breather Filter (Illustration 22-16).

22-16). Replace the
breather filter periodically (refer to the Preventive
Maintenance chart in the Appendices for breath-
er filter replacement interval).
interval). More frequent
replacement may be necessary if the machine is
being operated under extremely dusty conditions.
Hydraulic Return Filter Replacement (Illustra-
T - TANK 22-16). The hydraulic return filter
tions 22-15 and 22-16).
R - RIGHT STEERING is made up of 10 micron glass fiber media and is
L - LEFT VALVE non-reusable. This filter should be replaced peri-
LS - LOAD SENSE odically (refer to the Preventive Maintenance
chart
ment in
interv Appendices
theal).
interval). for following
Perform the return filter replace-
proc
procedures
edures
Illustration 22-14. Steering Orbitrol
to replace the hydraulic return filter:
Servicing The Hydraulic System
Hydraulic Operation. All hydraulic functions  Used return hydraulic filters
should be checked daily for free operation [refer to should be disposed of according to federal
Daily Checks in the Operator’s Guide (OG160)]. and local regulations.
Hydraulic Tank (Illustration 22-16).
22-16). The tank is 1. Lo
Loos
osen
en th
the
e 6 bol
bolts
ts..
equipped with a return filter
filter.. All air entering the
tank is filtered through a disposable breather. 2. Twist the cover count
countercloc
erclockwise
kwise and lift
lift to
This tank also contains a diffuser which helps pre- remove cover.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-9

3. Rem
Remove
ove retu
return
rn filt
filter
er asse
assembl
mbly
y. the truck.
4. Re
Remo
move
ve ret
retur
urn
n filt
filter
er..
5. Inspect
Inspect the
the gromme
grommett for
for service
serviceable
able condit
condition
ion  Dispose of drained hydraulic
and replace if necessary. fluid in accordance with federal and local
regulations.
6. In
Inst
stal
alll new
new fi
filt
lter
er..
7. Place
Place cover
cover over
over bolts
bolts until
until cove
coverr seats
seats
against head and twist cover clockwise.
clockwise. Tight-  The lift and tilt cylinders
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en bolts to a torque value of 10-12 ft-lbs should be fully retracted to keep dilution of the
new hydraulic fluid to a minimum.
 (14-16 N⋅m).

 Plug all hoses when they are

COVER disconnected to prevent foreign matter from
entering the hydraulic system.
1. Park the
the truck
truck on a hard,
hard, level
level surf
surface
ace,, block
block
the wheels in both directions, apply the park-
RETURN ing brake and Lock Out & Tag Out the truck.
FILTER
2. Provide
Provide a suitabl
suitable
e cont
container
ainer,, remove
remove the drain
plug and drain the hydraulic fluid.
3. Remove
Remove the
the acces
access
s cap from
from the
the hydra
hydrauli
ulic
c
BOLT
tank.
4. Rem
Remove
ove the bre
breath
ather
er fil
filter
ter..
5. Remove
Remove the
the retur
return
n filte (referr to Hydraulic
filterr (refe
FILTER
Return Filter Replacement for removal pro-
HEAD / BOWL
cedures).
ASSEMBLY
ASSEMBL Y 6. Remove
Remove thethe suction
suction strai
strainer
ners
s from the
the hydrau
hydrau--
lic tank and clean in solvent. Dry with com-
com-
pressed air.
7. After
After all
all the flui
fluid
d has been
been drain
drained
ed from
from the
the
Illustration 22-15. Hydraulic Return Filter tank, remove the access cover(s) and
O-ring(s).
Changing The Hydraulic Fluid (Illustration
22-16).. The hydraulic fluid should be changed
22-16) 8. Steam clean the interi
interior
or of
of the
the hydraulic
hydraulic tank.
periodically (refer to the Preventive Maintenance
chart in the Appendices for hydraulic fluid change
interval). The hydraulic fluid must also be  Do Not clean the interior of
the hydraulic tank with a flammable solvent;
changed
hydraulic in the event ofRefer
component. a catastrophic
to the Fuelfailure
and of a this can create a serious fire hazard.
Lubricant Specifications chart in the Appen- 9. Ins
Instal
talll new
new ret
return
urn fil
filter
ter..
dices for the proper type of fluid to be used and
perform the following procedures to change the 10. Re-ins
Re-install
tall suction strainers.
strainers.
hydraulic fluid: 11. Re-install access
access cover(s) and O-ring(s).
Inspect O-ring(s) and replace if necessary.
 Death or serious injury could 12. Re-ins
Re-install
tall the drain
drain plug.
result from a runaway truck. Park the truck on
13. Install new breather filter.
filter.
a hard, level surface, apply the parking brake,
block the wheels in both directions to prevent 14. Slowly fill tank with hydraulic fluid from the filler
movement of the truck and Lock-Out & Tag Out filter port (see Illustration 22-16) while inspect-

22-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

ing for leaks (pay particular attention to the leaks. Tighten connections / bolts as required.
access covers). If a leak is detected, repair
Hydraulic Hose Assemblies and Fittings. All
before adding additional hydraulic fluid. If
hydraulic hose assemblies should be checked
there are no leaks detected, fill the hydraulic
daily for chaffing
chaffing or cracking. Check daily to
tank to the FULL mark on the fluid level dip-
ensure that there are no loose fittings on the
stick (see Illustration 22-16).
hydraulic connections.
15. Inspect hydraulic tank fittings and hoses for

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 FILLER CAP
w/DIPSTICK

STRAINER

RETURN FILTER
(10 MICRON)

BREATHER
FILTER
(10 MICRON)

HYDRAULIC
FLUID TEMPERA-
TURE SENDER

Illustration 22-16. Hydraulic Tank

Tank

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-11

truck with the manual lowering valve open.

Close valve before attempting to raise the
carriage.

STEM
SCREW

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 COLLAR

LOCK
PLATE

VALVE
Illustration 22-17. Detecting Hydraulic Leaks STEM

 Do Not use hands to check

for hydraulic
hydraulic leaks. Because the hydraulic
system is under high pressure, leaks could
develop that can not be seen, but will pene-
trate the skin and possibly cause other serious
injuries. When checking for hydraulic
hydraulic leaks,
wear heavy gloves and safety goggles, and
use a piece of cardboard or wood to find leaks
(See Illustration 22-17).

Manual Lowering Valve Operation

The manual lowering valve should only be opened Illustration 22-18. Manual Lowering Valv
Valve
e
when normal lowering methods cannot be per-
formed. Opening The Manual Lowering Valve (Illustration
22-18). Perform the following procedures to open
the manual lowering valve:
 Death or serious injury could
result from being crushed. Do not allow
allow 1. Rem
Remove
ove the
the stem
stem scr
screw
ew and
and colla
collarr.
anyone near the lift truck - certainly not 2. Re
Remo
move
ve th
the
e loc
lock
k pla
plate
te..
walking, standing under, or beside the load or 3. Make
Make sure
sure no one
one is und
under
er / near
near the
the mast,
mast,
lifting mechanism.
carriage, or load lifting mechanism.
4. Turn
Turn the
the valve
valve stem count
countercloc
erclockwise
kwise 1/4 turn
 Death or serious injury could
until the notches on top of the valve stem align
result from a runaway truck. Apply the parking
parking
with the hydraulic fittings of the valve block
brake, block the wheels in both directions to
(note position of valve stem in Illustration
prevent movement of the truck and Lock Out &
22-19)..
22-19)
Tag Out the truck.
NOTE: The only way to stop the lowering
lowering of the
 Death or serious injury could load is by closing the manual lowering valve.
result from being crushed. Do not operate the
5. Aft
After
er the
the load has
has been
been fully
fully lower
lowered,
ed, clos
close
e

22-12 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

the manual lowering valve (refer to Closing when setting pressures, allow any portion of
The Manual Lowering Valve). your body to be positioned in front of the
relief. It is possible
possible that the relief could be
Closing The Manual Lowering Valve (Illustration
blown loose with great force which could
22-18).. The manual lowering valve must be
22-18)
cause severe bodily injury or death.
closed and locked before operating the lift truck.
Perform the following procedures to close the
manual lowering valve:  Fluid passing over a relief
1. Tu
Turn
rn the valve stem clock
clockwise generates heat; should a relief be blown loose,
wisehttps://www.forkliftpdfmanuals.com/
1/4 turn
turn until
until the
the
notches, located on top of the valve stem, hot, pressurized fluid will be forced from the
open port. This could cause severe bodily
bodily
 point toward the sides of the valve block (note open port. This could cause severe bodily
bodily
position of valve stem in Illustration 22-19). injury.
2. Instal
Installl the lock
lock plate
plate over
over the
the valve
valve stem.
stem. Prior to setting any hydraulic pressures, these pro-
Ensure that the notch of the lock plate is secu- cedures must be performed first:
red by the stud on the valve block (see Illustra- 1. Par
Park
k the
the truck
truck on a hard,
hard, level
level surf
surface
ace..
tion 22-19).
2. Ap
Appl
ply
y the
the park
parkin
ing
g brak
brake.
e.
3. Ins
Instal
talll coll
collar
ar over
over val
valve
ve ste
stem.
m.
3. Block
Block the
the wheels
wheels in both
both direc
directio
tion
n to preven
preventt
4. Ins
Instal
talll stem
stem scr
screw
ew and
and tigh
tighten
ten.. movement of the truck.
Steering (Illustration 22-20)
1. Instal
Installl an operat
operate
e pressur
pressure
e gauge
gauge into
into the
pressure check at port (LSM).

FULLY 2. Ensure
Ensure thethe tire
tire pivot
pivot area
area and engin
engine
e compar
compartt
is clear.
OPEN
3. Start
Start the
the truc
truck.
k. Ste
Steer
er and
and dead
dead-he
-head
ad the
the stee
steerr
cylinder.
4. Observ
Observee the
the pre
pressu
ssure
re gaug
gauge.
e. The gau
gauge
ge ind
indi-
i-
cations should be as specified in the
STUD 1/4 turn HYDRAULIC PRESSURE SETTINGS chart in
the Appendices
Appendices.. If not,
not, perform the remaining
procedure to set the steer pressure.
FULLY CLOSED
5. Loosen
Loosen the jam nut on RV2.
RV2. Turn the set
screw clockwise to increase the pressure or
Illustration 22-19. Closing and Opening The
counterclockwise to decrease the pressure.
Lowering Valv
Valve
e
6. When
When the
the speci
specifie
fied
d press
pressure
ure has bee
been
n
Setting Hydraulic Pressures achieved, tighten the jam nut.

Hydraulic pressures
engine speed. must be set
The hydraulic fluidatshould
recommended
be at Lift and Tilt Back (RV1) (Illustration 22-20)
1. Ins
Instal
talll an operat
operate
e pressur
pressure
e gauge
gauge into
into the
operating temperature before adjusting hydraulic pressure check at port (HPC1).
pressures.
2. Start the truck
truck.. Ti
Tilt
lt back and dead-h
dead-head
ead the tilt
cylinders.
 Death or serious injury could
result from a runaway truck. Park the truck on 3. Observ
Observee the
the pre
pressu
ssure
re gaug
gauge.
e. The gau
gauge
ge ind
indi-
i-
a hard, level surface, apply the parking brake cations should be as specified in the
and block the wheels in both directions to HYDRAULIC PRESSURE SETTINGS chart in
prevent movement of the truck. the Appendices
Appendices.. If not,
not, perform the remaining
procedures to set the pressure of RV1.
 Under no circumstances, 4. Turn the eng
engine
ine of
off.
f. Loos
Loosen
en the
the jam
jam nut
nut on

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-13

the main relief valve located in the inlet section 2. Start the truck
truck.. Side shift in either direct
direction
ion
of the accessory
accessory valve (if equipped). Turn the and dead-head the cylinder.
set screw 1/4 quarter turn clockwise to
3. Observ
Observee the
the pre
pressu
ssure
re gau
gauge.
ge. The gau
gauge
ge indi
indi--
increase the pressure setting of this relief.
cations should be as specified in the
NOTE: The main relief in the inlet section of the HYDRAULIC PRESSURE SETTINGS chart in
accessory valve is in parallel with RV1. the Appendices
Appendices.. If not, perform the remaining
procedures to set the pressure of the accesso-
5. Loosen
Loosen the
the jam nut
nut on RV1
RV1 (r
(reli
elief
ef valve
valve,, ry main relief.
located in the manifold). https://www.forkliftpdfmanuals.com/
4. Turn the
the engin
engine
e off.
off. Loo
Loosen
sen the jam nut on
 the port relief located on the A port side of the
6. Turn
Turn the
the set
pressure screw clock
clockwise
wise to
or counterclockwise to increas
idecrease
ncrease
e the
ththe
e inlet section of the accessory valve.
pressure. 5. Turn
Turn the
the set screw clock
clockwise
wise to increas
increase
e the
the
7. When
When the speci
specifie
fied
d pressur
pressure
e has been
been achei-
achei- pressure or counterclockwise to decrease the
ved, tighten the jam nut. pressure.
8. Turn
Turn the set screw
screw of the
the main
main relief
relief in the inlet
inlet 6. When
When the
the speci
specifie
fied
d pressu
pressure
re has
has been
been
section of the accessory valve 1/4 turn coun- achieved, tighten the jam nut.
terclockwise to return this relief to it’s correct Side Shift and Fork Positioners Port Reliefs
setting (reverse of procedure 4.). 22-20). The port reliefs of the side
(Illustration 22-20).
9. Remove
Remove the
the pressu
pressure
re gauge
gauge instal
installed
led in proc
proce-
e- shift and fork positioners work sections are factory
dure 1. set and non-adjustable.
Tilt Out (Illustration 22-20) Hydraulic System Troubleshooting
1. Ins
Instal
talll an operat
operate
e pressu
pressure
re gauge
gauge into
into the
the Troubleshooting Common Steering Problems
pressure check at port (HPC1). (Illustration 22-20)
2. Start the truck
truck.. Ti
Tilt
lt out and dead-h
dead-head
ead the tilt 1. Instal
Installl a gaug
gauge
e in por
portt HPC3
HPC3.. Sta
Start
rt the engi
engine
ne
cylinders. and dead-head the steer cylinder in both
3. Observ
Observe e the
the pres
pressur
sure
e gaug
gauge.
e. The gau
gauge
ge indi
indi-- directions. Refer to the HYDRAULIC PRES-
cations should be as specified in the SURE SETTINGS chart in the Appendices for
HYDRAULIC PRESSURE SETTINGS chart in the steer pressure. The pressure
pressure should
the Appendices
Appendices.. If not, perform the remaining reach the specified value while dead-headed
procedures to set the pressure of the port in either direction.
relief located on the A port side of the tilt 2. Turn the
the steeri
steering
ng wheel
wheel in one dire
directi
ction
on until
until
valve. the steer cylinder dead-heads. The steering
4. Turn the
the engin
engine
e off.
off. Loo
Loosen
sen the jam nut on wheel should come to a near stop. Repeat in
the port relief located on the A port side of the the other direction.
direction. If the wheel does not stop
tilt valve. in one or the other direction while dead-head-
ing, the most likely component failure will be
5. Turn
Turn the
the set
pressure screw clock
clockwise
wise to
or counterclockwise to increas
idecrease
ncrease
e the
ththe
e the steer cylinder packing. Repack the steer
cylinder.
pressure.
3. Instal
Installl a pressur
pressure
e gauge
gauge (5,000
(5,000 psi
psi / 345 bar)
bar)
6. When
When the
the speci
specifie
fied
d pressu
pressure
re has
has been
been into pressure check (HPC3) of the manifold.
achieved, tighten the jam nut. Tilt back and dead–head the tilt cylinders. At
Accessory Main Relief (Illustration 22-20) high and low engine rpm, observe the pres-
sure gauge. Refer to HYDRAULIC PRES-
The port reliefs of the side shift and fork position- SURE SETTINGS chart in the Appendices for
ers work sections are factory set and non-adjust- specified pressure. This check indicates that
able. the main pump and the main relief (RV1) is
1. Instal
Installl an operat
operate
e pressu
pressure
re gauge
gauge into
into the
the operating correctly
correctly..
pressure check at port (HPC2).

22-14 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

4. With
With the tilt
tilt cylinde
cylinders
rs dead-h
dead-head
eaded
ed back,
back, not faulty, install a 3,000 psi (207 bar) pres-
attempt to steer thethe machine. If able to steer,
steer, sure gauge into port HPC5. The gauge indica-
the most probable failed component is logic tions should be approximately what is dis-
control (LC3). Replace LC3. played by the TICS module.
5. If repla
replacem
cement
ent of
of LC3 did
did not
not correc
correctt the prob
prob-- 4. If the
the pressur
pressure
e indicat
indicated
ed is pulsa
pulsatin
ting,
g, then
then
lem, replace logic control (LC2). there is a leak in the brake circuit.
circuit. The pulsa-
tion of pressure is caused by the unloader
6. If repla
replacem
cement
ent of
of LC2 did
did not
not correc
correctt the prob
prob--
valve (UNL1) and the logic control (LC1) cycl-
lem, replace Steer Relief (RV2). https://www.forkliftpdfmanuals.com/
ing on and off, charging the brake circuit.
7. If steerin
steering
g is not restor
restored
ed at this point, replac
replace
e
 5. Shut
Shut the truck
truck off
off and
and turn the
the igniti
ignition
on switc
switch
h
the orbitrol. to it’s ignition position (1st click). Continue to
Troubleshooting Common Brake Problems. monitor the brake pressure from the TICS
Should brake pressure drop below 1,500 psi (104 module display
display..
bar), a warning will be generated by the TICS.
Should the brake pressure continue to drop at
1,000 psi (69 bar), the parking brake will automati-  Death or serious injury could
cally apply.
apply. The parking brake is spring-applied result from removal of a component under
and hydraulic pressure to release (1,250 psi / 86 pressure. The brake circuits store
store pressure
bar minimum). after the engine
engine has been shut down. Always
bleed the brake pressure to 0 psi prior to
1. St
Star
artt th
the
e tru
truck
ck.. removal of any brake component.
2. The Brak
Brake
e pressu
pressure
re can
can be obtai
obtained
ned from
from the
the
TICS module display (refer to the Trans- 6. Shut off the engine
engine.. Tu
Turn
rn the igniti
ignition
on switc
switch
h to
to
mission Measure Group list illustration of TICS it’s ignition position (1st click). Bleed the brake
in Section 6).
6). pressure to zero by repeatedly depressing one
3. To ensure
ensure the
the pressure
pressure transd
transducer
ucer,, which
which of the service brake pedals and monitoring the
brake pressure at the TICS module display.
communicates brake pressure to the TICS, is
Problem Cause Correction

1. No LiLift
ft / Lo
Lowe
werr / 1. Operat
Operator
or is
is not
not seat
seated
ed in
in the
the oper-
oper- 1. Ret
Return
urn to the oper
operato
ators
rs sea
seat.
t.
Tilt in / Tilt out ators seat.
2. Lo
Low
w pilo
pilott pres
pressu
sure
re.. 2. Is
Isol
olat
ate
e and rep
repai
airr.

3. No hyd
hydra
raul
ulic
ic flu
fluid
id flo
flow
w. 3. Is
Isol
olat
ate
e and rep
repai
airr.

4. Inc
Incorr
orrect
ect pre
pressu
ssure
re setti
setting
ng of the 4. Adjust.
main relief (RV1).
5. Defect
Defective
ive mai
main
n reli
relief
ef (R
(RV1)
V1).. 5. Replace.
6. Incorr
Incorrect
ect pre
pressu
ssure
re sett
setting
ing of
of the
the 6. Adjust.
accessory valve’s main relief.
7. Defect
Defective
ive acce
accesso
ssory
ry valve
valve’s
’s mai
main
n 7. Replace.
relief.
8. Def
Defect
ective
ive Log
Logic
ic Cont
Control
rol (LC
(LC3).
3). 8. Replace.
9. De
Defe
fect
ctiv
ive
e mai
main
n pum
pump.
p. 9. Replace.

continued

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-15

Problem Cause Correction

1. No Lif
Liftt / Lo
Lowe
werr / 10. Loose or broken
broken plugs / pins
pins / 10. Isola
Isolate
te and repair.
repair.
Tilt in / Tilt out wires between the TICS compo-
(Continued) nents (i.e. display / modules / joys-
tick / solenoids).

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2. Sl
Slow
ow or No Lif
Liftt / 1. Ope
Operat
rator
or not
not is
is seate
seated
d in the ope
oper-
r- 1. Ret
Return
urn to the ope
operat
rators
ors sea
seat.
t.
 Lower ators seat.
2. Defect
Defectiveive sol
soleno
enoid
id or car
cartri
tridge
dge on 2. Activa
Activatio
tion
n of the
the manu
manualal overri
override
de
the lift valve. switch will confirm defective sole-
noid. Replace.
3. Lif
Liftt valve’
valve’s
s main
main spoo
spooll is stuc
stuck.
k. 3. Remove
Remove maimainn spoo
spool,
l, cle
clean
an and
re-assemble. Inspect valve hous-
ing for debris.
4. Center
Centering
ing spr
spring
ing(s)
(s) of the
the lift
lift 4. Replace.
valve’s main spool is broken.
5. Defect
Defective
ive pac
packin
king
g in one
one of the lif
liftt 5. Isolat
Isolate
e cylin
cylinder
der and repl
replace
ace the
cylinders. packing.
6. Defect
Defectiveive flo
flow
w contr
control
ol in one of
of the
the 6. Replace.
lift cylinders.
7. TICS
TICS (Tayl
(Taylor
or Integr
Integrate
ated
d Control
Control 7. Calibrate.
System) LIFT operation is mis-cali-
brated.
8. Loose
Loose or bro
broken
ken plu
plugs
gs / pins
pins / 8. Is
Isol
olat
ate
e and
and repa
repair
ir
wires between the TICS compo-
nents (i.e. display / modules / joys-
tick / solenoids).
9. Inner
Inner mast
mast or carr
carriag
iage
e is shi
shimme
mmed
d 9. Refer to Slide Bearing Blocks
too tight. Shimming in Section 27 and prop-
erly shim the mast.

3. Sl
Slow
ow or No Til
iltt Out
Out 1. Operat
Operator
or not
not is
is seate
seated
d in the ope
oper-
r- 1. Ret
Return
urn to the ope
operat
rators
ors sea
seat.
t.
ators seat.
2. Defect
Defective
ive flo
flow
w contr
control
ol in one of
of the
the 2. Replace.
Tilt cylinders
3. Tilt valv
valve’
e’s
s main
main spool
spool is stu
stuck.
ck. 3. Remove
Remove maimainn spoo
spool,
l, cle
clean
an and
re-assemble. Inspect valve hous-
ing for debris.
4. Center
Centering
ing spr
spring
ing(s)
(s) of the
the lift
lift 4. Replace.
valve’s main spool is broken.
5. Mis-ad
Mis-adjus
justed
ted tilt
tilt out port
port rel
relief
ief (A
(A 5. Ad
Adju
just
st til
tiltt out
out port
port rel
relie
ieff
port).
continued

22-16 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Problem Cause Correction

3. Slow
Slow or No Til
iltt Out
Out 6. Defect
Defectiveive til
tiltt out
out port
port reli
relief.
ef. 6. Replace.
(Continued)
7. Def
Defect
ective
ive sol
solenoenoid
id or
or cartr
cartridg
idge
e on 7. Activa
Activatio
tion
n of the man
manual
ual ove
overri
rride
de
the tilt valve. switch will confirm defective sole-
noid. Replace.
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8. TICS
TICS (Taylor
(Tayl or Integr
Integrate
ated
d Control
Control 8. Calibrat
ate
e.
System) tilt out operation is mis-
 calibrated.
9. Loos
Loose e or bro
broke
kenn plug
plugs
s / pins
pins / 9. Is
Isol
olat
ate
e and
and Re
Repa
pair
ir..
wires between the TICS compo-
nents (i.e. display / modules / joys-
tick / solenoids).

4. Sl
Slow
ow or no Til
iltt In
In 1. Operat
Operator
or is
is not
not seat
seated
ed in
in the
the oper-
oper- 1. Ret
Return
urn to the oper
operato
ators
rs sea
seat.
t.
ators seat.
2. Defect
Defectiveive flo
flow
w contr
control
ol in
in one of the
the 2. Replace.
tilt cylinders.
3. Tilt valv
valve’s
e’s mai
main
n spool
spool is stuc
stuck.
k. 3. Remove
Remove maimainn spoo
spool,
l, cle
clean
an and
re-assemble. Inspect valve hous-
ing for debris.
4. Center
Centering
ing spr
spring
ing(s)
(s) of the lif
liftt 4. Replace.
valve’s main spool is broken.
5. Defect
Defectiveive sol
soleno
enoid
id or
or cartr
cartridg
idge
e on 5. Activa
Activatio
tion
n of the man
manual
ual ove
overri
rride
de
the lift valve. switch will confirm defective sole-
noid. Replace.
6. TICS
TICS (Tayl
(Taylor
or Integr
Integrate
ated
d Control
Control 6. Calibrat
ate
e.
System) tilt in operation is mis-cali-
brated.
7. Loos
Loose e or bro
broke
kenn plug
plugs
s / pins
pins / 7. Is
Isol
olat
ate
e and rep
repai
airr.
wires between the TICS compo-
nents (i.e. display / modules / joys-
tick / solenoids).

5. No or slow 1. Steer
Steer cyli
cylinde
nderr piston
piston pac
packin
king
g is 1. Re
Re-p
-pac
ack
k steer
steer cyli
cylind
nder
er..
steering defective.
2. Logic
Logic Cont
Control
rol (LC2
(LC2)) is rest
restric
ricted
ted by
by 2. Remove
Remove and cleclean
an LC2
LC2.. Ins
Inspec
pectt
debris (stuck closed). LC2’s port for debris.
3. Log
Logic
ic Cont
Control
rol (LC
(LC2)
2) is def
defect
ective
ive.. 3. Replace.
4. Logic
Logic Cont
Control
rol (LC3
(LC3)) is rest
restric
ricted
ted by
by 4. Remove
Remove and cleclean
an LC3
LC3.. Ins
Inspec
pectt
debris (stuck open). LC3’s port for debris.
continued 5. Log
Logic
ic Cont
Control
rol (LC
(LC3)
3) is def
defect
ective
ive.. 5. Replace.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-17

Problem Cause Correction

5. No or slow 6. Steer
Steer Relie
Relieff (RV2)
(RV2) is rest
restric
ricted
ted by 6. Remove
Remove and cleclean
an RV
RV2.
2. Ins
Inspec
pectt
steering debris (stuck open). RV2’s port for debris.
(Continued)
7. Ste
Steer
er Reli
Relief
ef (RV
(RV2)
2) is def
defect
ective
ive.. 7. Replace.
8. Main
Main relief
relief (RV
(RV1)
1) is res
restri
tricte
cted
d by 8. Rem
Remove
ove and cle
clean
an RV
RV1.
1. Ins
Inspec
pectt
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debris (stuck open) RV1’s port for debris.
 9. Mai
Main
n relie
relieff (RV1)
(RV1) is
is defec
defectiv
tive.
e. 9. Replace.
10. Wor
Worn
n or defective
defective pump. 10. Rep
Replac
lace.
e.
11.. Defec
11 Defective
tive orbitrol.
orbitrol. 11. Rep
Replac
lace.
e.

6. No or weak 1. Logic
Logic Cont
Control
rol (LC1
(LC1)) is rest
restric
ricted
ted by 1. Remove
Remove and cleclean
an LC1
LC1.. Ins
Inspec
pectt
service brakes debris (stuck open). LC1’s port for debris.
2. Log
Logic
ic Cont
Control
rol (LC1
(LC1)) is defe
defecti
ctive.
ve. 2. Replace.
3. Unload
Unloader
er va
valve
lve (UNL
(UNL1)
1) is res
restri
tricte
cted
d 3. Rem
Remove
ove and cle
clean
an UNL
UNL1.1. Ins
Inspec
pectt
by debris (stuck open). UNL1’s port for debris.
4. Unl
Unload
oader
er valve
valve (UNL
(UNL1)
1) is defe
defecti
ctive.
ve. 4. Replace.
5. Thermo
Thermo reli
relief
ef (RV3)
(RV3) is
is restri
restricte
cted
d by 5. Remove
Remove and cleclean
an RV
RV3.
3. Ins
Inspec
pectt
debris (stuck open) RV3’s port for debris.
6. The
Thermo
rmo rel
relief
ief (R
(RV3)
V3) is
is defect
defective
ive.. 6. Replace.
7. The ser
servic
vice
e brake
brake acc
accumu
umulat
lator
or has
has 7. Cha
Charge
rge the ser
servic
vice
e brake
brake acc
accumu
umu--
lost it’s pre-charge. lator to 1,250 psi with dry-nitrogen.
8. The ser
servic
vice
e brake
brake acc
accumu
umulat
lator
or is
is 8. Replace.
defective.
9. Def
Defect
ective
ive ser
servic
vice
e brake
brake ped
pedal.
al. 9. Replace.
10. Debri
Debriss is in the internal passages
passages 10. Clean. If cleaning does not resolve
of the manifold. the problem, replace the manifold.
11.. Crack
11 Cracked
ed manifold.
manifold. 11. Rep
Replac
lace.
e.
12. Refer also
also to Problem 1. of the
Brake Control System Trouble-
shooting chart in Section 15.
15.

7. Park
Parkin
ing
g brak
brakes
es wil
willl 1. Log
Logic
ic Cont
Control
rol (LC1
(LC1)) is defe
defecti
ctive.
ve. 1. Remove
Remove and cleclean
an LC1
LC1.. Ins
Inspec
pectt
not release LC1’s port for debris.
2. Unload
Unloader
er va
valve
lve (UNL
(UNL1)
1) is res
restri
tricte
cted
d 2. Replace.
by debris (stuck open).
3. Unl
Unload
oader
er valve
valve (UNL
(UNL1)
1) is defe
defecti
ctive.
ve. 3. Remove
Remove and cle
clean
an UNL
UNL1.1. Ins
Inspec
pectt
UNL1’s port for debris.
continued

22-18 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Problem Cause Correction

7. Park
Parkin
ing
g brake
brakes
s wi
will
ll 4. The
Thermo
rmo reli
relief
ef (RV3)
(RV3) iis
s restri
restricte
cted
d by 4. Replace.
not release debris (stuck open).
(Continued)
5. The
Thermo
rmo rel
relief
ief (R
(RV3)
V3) is defect
defective
ive.. 5. Remove
Remove and cleclean
an RV
RV3.
3. Ins
Inspec
pectt
RV3’s port for debris.
6. Thehttps://www.forkliftpdfmanuals.com/
servic
ser vice
e brake
brake acc
accumu
umulat
lator
or has
has 6. Replace.
lost it’s pre-charge.
 7. The par
parkin
king
g brake
brake acc
accumu
umulat
lator
or is
is 7. Charge
Charge the par
parkin
kingg brake
brake acc
accumu
umu--
defective. lator to 500 psi with dry-nitrogen.
8. Def
Defect
ective
ive ser
servic
vice
e brake
brake ped
pedal.
al. 8. Is
Isol
olat
ate
e and rep
repla
lace
ce..
9. Parkin
Parkingg brake
brake sol
soleno
enoid
id is
is ener-
ener- 9. Defect
Defective
ive park bra
brake
ke swi
switch
tch..
gized. Replace.
10. Defective parking brake solenoid. 10. Rep
Replac
lace.
e.
11. Defective parking brake chamber.
chamber. 11. Rep
Replac
lace.
e.
12. Debris is in the internal
internal passages
passages 12. Clean. If cleanin
cleaning
g does not resolve
resolve
of the manifold. the problem, replace the manifold.
13. Crack
Cracked
ed manifold.
manifold. 13. Rep
Replac
lace.
e.
14. Refer also
also to Problem 5. of the

Brake Control
shooting chart System Trouble-
Tr
in Section ouble-
15.
15.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-19

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22-20 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Hoist Circuit

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 PLACE THE FOLLOWING ILLUSTRATION IN
A FOLDER
FOLDER ENVELOPE:
ENVELOPE:
Illustration 22-20 - 22-2896 SHT. 2 (Main Hyd. ANSI)

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22-21

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https://www.forkliftpdfmanuals.com/
22-22 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

2
2
E
-A
c
c
u
m
u
a l
to
r

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https://www.forkliftpdfmanuals.com/
 Section 22E

Accumulator
Introduction. The accumulator acts as a shock Charging The Accumulator (Illustration 22E-1).
22E-1).
absorber
en member in the hydraulic
of the system.
hydraulic systemWhen
stopsthe driv-
sudden- Perform the following procedures to charge the
accumulator.
ly, it creates a pressure wave that travels back
through the system.
system. This shock wave can devel-
op peak pressures several times greater than nor- 
mal working pressures and can be the source of  Use only dry
dry nitrogen to charge the
system failure. The gas cushion in an accumula- accumulator.
tor will minimize this shock, protecting expensive  When precharging,
precharging, the initial
initial 50 psi (3.5 bar)
hydraulic components. of dry nitrogen should be introduced slowly
Accumulators. There are two two accumulators
accumulators into the accumulator
accumulator..
connected to the manifold valve. They store a 1. Install
Install the
the chargin
charging
g kit (Illu
(Illustrat
stration
ion 22E-1)
22E-1) as
volume of oil at pressure for brake application. explained in the Checking Precharge proce-
These accumulators are hydro-pneumatic piston dures above.
type and are precharged with dry nitrogen to
1,250 psi (86 bar) and 500 psi (35 bar). 2. Con
Connec
nectt the charg
charging
ing kit
kit to a nitrog
nitrogen
en bottle
bottle

Checking Precharge. The precharge check with the charging hose (8).
should be performed periodically (refer to the 3. Inflat
Inflate
e the accumu
accumulat
lator
or to the predet
predeterm
ermine
ined
d
Preventive Maintenance chart in the Appen- pressure by opening the valve on the nitrogen
dices for precharge check interval). Follow the bottle slowly, closing it occasionally to allow
procedures listed below to check precharge (a the needle of the pressure gauge (2) to settle
charging kit is available from Taylor,
Taylor, part number into position giving an accurate pressure read-
1000-503). See Illustration 22E-1 for charging kit. ing.
1. To read andand adjust
adjust the
the gas pres
pressur
sure
e or “pre-
“pre- 4. When
When thethe proper
proper prec
prechar
harge
ge press
pressure
ure is
is
charge” pressure, all the hydraulic fluid must reached, close the valve on the nitrogen
be drained from the fluid side of the accumula- bottle.
tor to zero hydraulic pressure. To accomplish
this, let the lift cylinder down and hold lever in 5. To release
release press
pressure
ure in exces
excesss of the desired
desired
DOWN position for approximately one minute. precharge, slowly open the bleeder valve (6)
until the pressure drops to the desired level.
2. Rem
Remove
ove the
the valv
valve
e guard
guard and
and cap fro
from
m the
6. Rotate
Rotate the
the bar handle
handle count
counterc
ercloc
lockwi
kwise
se to the
the
accumulator. full stop position, then disconnect the swivel
3. Ensure
Ensure that
that the
the shaft
shaft of
of the air
air chuck
chuck (4)
(4) is (7) from the adapter (3).
fully retracted by turning the bar handle coun-
terclockwise until it stops. 7. Rem
Remove
ove the
the air chuc
chuck
k (4) from
from the
the accumu
accumula-
la-
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tor valve stem.
4. Do not
not have
have the char
charging
ging hose
hose (8)
(8) conne
connecte
cted
d
 to the gauging head assembly (1) unless free 8. Check
Check the
the valve
valve stem
stem for
for leaks
leaks with
with a soap
soapy
y
end of charging hose is plugged. water solution or oil. If the core is leaking,
depress it quickly, once or twice, to reseat the
5. Mount
Mount the
the swivel
swivel of
of the air
air chuck
chuck (4)
(4) on the
the core. It may be necessary to to further tighten or
accumulator’s valve stem and hand tighten to replace the core if leakage persists.
compress the gasket in the swivel to prevent
gas leakage. 9. Install
Install the
the accumu
accumulator
lator valve stem cap, then
tighten 1/2 turn beyond hand tight.
6. Turn
Turn the
the bar
bar handle
handle clock
clockwise
wise until the shaft
depresses the valve stem core of the accumu- 10. Insta
Installll the accumulator
accumulator valve guard.
lator. The precharge pressure
pressure should now be
indicated by the pressure gauge (2). 11. for
Recheck precharge
pressure loss. one week after charging

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 22E-1

Accumulator Part PSII Se

PS Sett
ttin
ing
g BAR
BAR Se
Sett
ttin
ing
g
Number / Size
2 2215-121 / 1 qt. 1,000 psi 69 bar
2788-970 / 1 qt. 1,000 psi 69 bar

3 2215-124 / 1 qt. 1,500 psi 104 bar

BAR
7 1 2788-955 / 1 qt. 1,500 psi 104 bar
HANDLE
2788-975 / 1 qt. 1,000 psi 69 bar
4
2788-940 / 1 gal. 65 psi 4.5 bar
2788-960 / 1 gal. 800 psi 55 bar
5
8 2788-949 / 1 gal. 1,250 psi 86 bar
2788-950 / 1 gal. 1,000 psi 69 bar
2788-951 / 1 gal. 1,500 psi 104 bar
2788-952 / 1 gal. 1,500 psi 104 bar
2788-961 / 1 gal. 1,500 psi 104 bar
6 ACCUMULATOR
ACCUMULATOR 2788-965 / 2-1/2 gal. 800 psi 55 bar
2788-966 / 2-1/2 gal. 1,500 psi 104 bar
9 11
10
We have a charging kit available. Taylor part
number 1000-503.

NITROGEN
BOTTLE

Charging Kit
1. GAUGING
GAUGI NG HEA
HEAD
D AS
ASSE
SEMB
MBL
LY
2. PRES
PR ESSU
SURE
RE GA
GAUG
UGE
E
3. ADAPTER https://www.forkliftpdfmanuals.com/
4. AIR CHUCK
 5. TANK VAL
ALVE
VE ASS
ASSEMB
EMBL
LY
6. BLEE
BLEEDE
DERR VAL
VALVE
VE
7. SWIV
SW IVEL
EL CONN
CONNECECT
TOR
8. CHA
HARG
RGIING HOS
HOSEE
9. COUPLING
10..
10 GLAN
GL AND
D
11. GLAN
GL AND
D NUT
NUT

Illustration 22E-1. Charging Accumulator

22E-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 27

ULTRA-VU Mast Assembly

Introduction. The mast assembly, in conjunction Maintenance / Inspections. There are several
with the carriage
and lowering and forks, is responsible for lifting
loads. inspectional
daily.requirements
formed daily. which must
These inspections must be per-
include
Major Components. The mast consists of the checking all welds and structural members for
inner mast, outer mast, two hydraulic lift cylinders, cracks. Check all mast
mast mounting hardware
hardware and lift
main rollers, slide bearing blocks, chain rollers, chains for damage or loose bolts. Hydraulic
and two multiple leaf lift chains. hoses and fittings must be checked for leaks and
signs of wear or damage.
Structural Inspection, Reporting, and Repair
Procedure (Refer to SIRR in the Appendices
Appendices)).
Follow the OSHA rules, 29 CFR, 1910.178 (Q)(1),  Do not climb on the mast of
(5), & (7) which require inspecting industrial trucks the forklift, on top of the cab, or on other high
daily before being placed in service, removing places of the truck while performing
trucks from service if cracks are found, and mak- maintenance.
ing repairs only if authorized by the manufacturer.
If trucks are used on a round-the-clock basis, they  Always use approved ladders,
shall be examined after each shift.
shift. OSHA 29 CFR
1910.178 (p)(1) requires that trucks in need of stands,
truck. or manlifts to reach high places on the
repair be taken out of service.
service. Refer to Safety
Check 2nd Edition for OSHA rules.
 Never ride on the forks of the
Mast Assembly Structure. This is an ULTRA-VU,
truck.
nested channel type mast with two multiple leaf lift
chains and two lift cylinders that are located behind
the mast
mast rails. The mast assembly is careful
carefully
ly  Do not use a material han-
engineered and ruggedly constructed, although dling forklift as a means to elevate personnel.
welded steel structures always contain undetect-
able cracks, especially welded joints. When these Main Rollers (Illustration 27-4).
27-4). The main
main rollers
joints are subject to fluctuating stresses of signifi- employ greaseable, shielded, tapered roller bear-
cant magnitude, these cracks will grow.
grow. This is ings. The main rollers must be greased periodi-
known as fatigue
fatigue crack growth. No matter how cally (refer to the Preventive Maintenance chart
low the stress levels are kept, some fatigue crack in the Appendices for inner mast main rollers
growth will occur in all welded structures. lubrication interval). To access the grease fittings
for the main rollers, the inner mast must be raised
so that the grease fitting of each main roller aligns
 Periodic inspection is with the grease holes located in the outer mast.
required to detect fatigue cracks that have The main rollers should be inspected for flat spots
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grown to a significant size in order to avoid or evidence of sliding any time the inner mast is
 serious failure of the structural weldment. taken apart from the outer mast.
When a crack is found, the truck must be
immediately taken out of service and repaired.
 The roller assemblies must not
be over lubricated. Excess grease inside the
 Under no circumstances, mast rails may cause the rollers to slide when
without prior written approval from Taylor subjected to a heavy load. If this happens,
happens, a
Machine Works, Inc. Engineering Department, flat spot will be worn on the rollers and the
should the mast assembly be modified.
modified. As per rollers will continue to slide until replaced with
OSHA 29 CFR1910.178 (a) (4). new rollers.

Chain Rollers
use sealed ball (Illustration 27-4).the
27-4).
bearings. Check
bearings. The chain
chain rollers
rollers
 If the fatigue crack is allowed
to grow, catastrophic failure could occur in the for looseness, cracks or flat spots.
mast assembly or other welded components Lift Chains. The lift chains must be lubricated
causing serious injury to personnel and / or every 500 hours of operation (refer to Leaf Chain
property.

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 27-1

PROCEDURE 2

PROCEDURE 3

PROCEDURE 1
PROCEDURE 4

PROCEDURE 5

Illustration 27-1. Mast Slide Bearing Shimming Procedure

Care, Maintenance, and Replacement section in install shims in the outer mast slide bearings.
the back ofSpecifications
Lubricant this manual). Refer
for the the Fuel
totype and
of lubricant The carriage
secured and inner
in position mast
by an should then
appropriate be
means
to be used to lubricate the lift chains. or they can be lowered to a height where they
Tilt Cylinder and Mast Hanger Pins. The tilt cyl- can more easily be blocked in position and
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shimmed. Shim the outer mast until the clear-
inder and mast hanger pins must be greased peri-
odically (refer to the Preventive Maintenance ance is 1/16 to 1/32 inch (1.6 to
to .8 mm). (See
chart in the Appendices for lubrication interval). NOTE below procedure 5.)
Lubrication. Refer to the Lubrication section in 2. Raise
Raise the carr
carriage
iage unti
untill the top
top carriag
carriage
e slide
slide
the Appendices for information on the lubrication bearings are aligned with the outer mast slide
of the mast assembly. bearings. Pry the carriage from side to side
and measure the movement.
movement. The carriage
Slide Bearing Blocks Shimming (Illustration and inner mast should then be secured in
27-1).. The slide bearing block life depends on the
27-1) position by an appropriate means or they can
duty cycle and operation of the truck.
truck. Periodically
Periodically,, be lowered to a height where they can more
the slide bearing blocks may require shimming to easily be blocked in position and shimmed.
adjust for wear.
inner mast wear
on a. telescopic
To preventmast
undue flexing ofit the
assembly, is Calculate the thickness of the shims needed
by subtracting 1/32 inch (.8 mm) from the dis-
essential for all slide bearings to be properly tance the carriage moved and shim the top
shimmed. The correct procedure is outlined here. carriage slide bearings. (See NOTE below
This method is to be used for fork lifts equipped procedure 5.)
with Ultra-Vu telescopic masts.
3. Rai
Raise
se the carr
carriag
iage
e until
until the bottom
bottom carri
carriage
age
1. Rai
Raise
se the
the carria
carriage
ge to allo
allow
w enough
enough room
room to

27-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

slide bearings are aligned with the outer mast

slide bearings.
side and measure
measurePrythe
themovement.
carriage from
Theside
car-to inner 
mast slide Do Not attempt
bearing slack intoprocedures
eliminate 4.
riage and inner mast should then be secured and 5. by adding shims to the carriage slide
in position by an appropriate means or they bearings. This can result in broken slide bear-
can be lowered to a height where they can ings.
more easily be blocked in position and
shimmed. Calculate the thickness of the Back Rest Slide Blocks (Illustration 27-2).
27-2). The
shims needed by subtracting 1/32 inch (.8 back rest slide block life depends on the duty
mm) from the distance the carriage moved and cycle and operation of the truck. Periodically
Periodically,, the
shim the bottom carriage
carriage slide bearings. (See back rest slide blocks may require shimming to
NOTE below procedure 5.) adjust for wear. Perform the following procedures
to shim the back rest slide blocks:
4. Align
Align the bott
bottom
om carri
carriage
age slide
slide beari
bearings
ngs and
and
the inner mast top slide bearings. Pry the 1. Raise
Raise the
the carria
carriage
ge and note
note the
the positi
position
on of the
the
inner mast from side to side (this must be inner mast when the distance between it and
done from the rear of the mast) and measure the back rest slide block is the least amount.
the movement. Calculate the thickness of the Shims should be added at this position.
shims needed by subtracting 1/32 inch (.8 2. Shim the back rest slide block
blocks
s until
until the
the slide
slide
mm) from the distance the inner mast moved. blocks just touch the inner mast.
Raise the carriage to allow access to the inner
mast top slide bearings. The carriage and NOTE: Replace any back
back rest slide blocks that
inner mast should then be secured in position become cracked, damaged or worn to 3/4 inch
by supporting with an appropriate means. (19.1 mm) thickness.
(See NOTE below procedure 5.)
5. Align
Align the bott
bottom
om carri
carriage
age slide
slide beari
bearings
ngs and
and
the inner mast bottom slide bearings. Pry the
inner mast from side to side (this must be
done from the rear of the mast) and measure
the movement. Calculate the thickness of the
shims needed by subtracting 1/32 inch (.8
mm) from the distance the inner mast moved.
Raise the carriage to allow access to the inner
mast bottom
bottom slide bearings. The carriage and
inner mast should then be secured in position
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by supporting with an appropriate means.
(See NOTE below)
 NOTES:
 Clearance at each position should be between
1/16 inch (1.6 mm) and 1/32 inch (.8 mm).
Repeat the above procedure if the clearance is
not as specified. Shims should be divided as
evenly as possible between the slide bearings.
 Replace any slide bearing blocks that become
cracked, damaged, or worn to 1 - 3/4 inches
(44.5 mm) thickness (See Illustration 27-3).

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 27-3

Troubleshooting

Problem Cause Correction

1. Crac
Cracks
ks in we
weld
lds,
s, 1. Met
etal
al fat
fatig
igue
ue.. 1. Have
Have crack
cracks
s in
in weld
welds
s repa
repaired
ired
especially at the immediately.
point where the
mast is pinned to 2. Over
Overlo
load
adin
ing.
g. 2. Refer
Refer to
to Corre
Correcti
ction
on 1.
1. and
and avoid
avoid
the chassis. overloading the truck.
(Refer to SIRR in the 3. Rou
ough
gh ter
terra
rain
in.. 3. Refer
Refer to
to Corre
Correcti
ction
on 1.
1. and,
and, ifif pos-
pos-
Appendices))
Appendices sible, avoid operating truck on
rough terrain.
Notify Taylor
Machine Works, 4. Trav
ravell
elling
ing with
with load
load in
in an unrec
unrecom-
om- 4. Ref
Refer
er to
to Corre
Correcti
ction
on 1.
1. and
and the
the
Inc. for proper mended travel position (excessive Operator’s Guide for proper travel-
repair procedures. height and / or fully side-shifted, ling positions.
one side or the other).
5. Seve
Severe
re du
duty
ty cy
cycl
cles
es.. 5. Re
Refe
ferr to
to Cor
Corre
rect
ction
ion 1.

INNER MAST

OUTER MAST

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 BACK REST
SLIDE BLOCK

Illustration 27-2. Back Rest Slide Blocks

27-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

SHIM
SLIDE
BEARING
HOUSING

SLIDE
BEARING
BLOCK

1-3/4” (44.5 mm)

MINIMUM
REPLACE BEARING BLOCKS WORN

TOTHAT
1-3/4”ARE
(44.5 mm) THICK
CRACKED OROR BLOCKS
BROKEN

Illustration 27-3. Slide Bearing Block Replacement

Replacement
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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 27-5

CHAIN OUTER MAST

ROLLER SLIDE BEARING
BLOCK

LIFT
CYLINDER

INNER
MAST

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MAIN
 ROLLERS

SLIDE
BEARING
BLOCKS

OUTER
MAST

Illustration 27-4. Mast Assembly Components

27-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

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 Note: Photocopy this sketch to
to identify fatigue cracks or structural damage to the mast. Be very
descriptive of damage to the mast, i.e. location, depth, length.

Illustration 27-7. Mast Assembly

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 27-7

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27-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Section 28

Carriage
Introduction. Described in this section is the main- Check 2nd Edition for OSHA rules.
tenance required
optional fork for the standard
positioning, “C” carriage,
and optional side shift
carriage.  Periodic inspection is
required to detect fatigue cracks that have
NOTE: Some trucks may be equipped with both grown to a significant size in order to avoid
fork positioning and side shifting capabilities. serious failure of the structural weldment.
When a crack is found, the truck must be
Major Components. The carriage consists of two immediately taken out of service and repaired.
forks, fork pin, main rollers, slide bearing blocks,
and two fork positioner cylinders / side shift cylin-
der (if equipped).  Under no circumstances,
without prior written approval from Taylor
Structural Inspection, Reporting, and Repair Machine Works, Inc. Engineering Department,
Procedure (Refer to SIRR in the Appendices
Appendices)). should the carriage assembly be modified.
modified. As
Follow the OSHA rules, 29 CFR, 1910.178 (Q)(1), per OSHA 29 CFR1910.178 (a) (4).
(5), & (7) which require inspecting industrial trucks
daily
trucksbefore being placed
from service in service,
if cracks removing
are found, and mak-  If the fatigue crack is allowed
ing repairs only if authorized by the manufacturer. to grow, catastrophic failure could occur in the
If trucks are used on a round-the-clock basis, they mast assembly or other welded components
shall be examined after each shift.
shift. OSHA 29 CFR causing serious injury to personnel and / or
1910.178 (p)(1) requires that trucks in need of property.
repair be taken out of service. Refer to the Safety

MAIN
ROLLER

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 SLIDE BEARING
BLOCKS

Illustration 28-1. Standard Carriage

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 28-1

MAIN
ROLLERS

SLIDE BEARING
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BLOCKS
 Illustration 28-2. Optional Carriage With Side Shift and Fork Positioners

Maintenance / Inspection. There are several grease fittings for the main rollers can be found on
inspectional requirements which must be per- the inside of the carriage plate. The main rollers
formed daily.
daily. These inspections must include should be inspected for flat spots or evidence of
checking all welds and structural members for sliding any time the carriage is taken out of the
cracks. Check all carriage mounting hardware for inner mast.
damage or loose bolts. The hydraulic fork posi-
tioner cylinders and hydraulic hoses should be
 The roller assemblies must not
checked for leaks and functional operation. be over lubricated. Excess grease inside
inside the
Main Rollers (Illustrations 28-1 through 28-3).
28-3).
mast rails may cause the rollers to slide when
The main rollers employ greaseable, shielded,
subjected to a heavy load. If this happens, a
tapered roller bearings
bearings for increased
increased durability
durability.. The
flat spot will be worn on the rollers and the
main rollers must be greased periodically (refer to
rollers will continue to slide until replaced with
the Preventive Maintenance chart in the Appen-
new rollers.
dices for the main rollers lubrication
lubrication interval). The

28-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Slide Bearing Blocks (Illustrations 28-1 through check for cracks (refer to the Fork Inspection,
28-3). The slide bearing block life depends on the
28-3). Repair, and Testing in the Appendices
Appendices). ).
duty cycle and operation of the truck. Periodically, Carriage. The carriage’s
carriage’s welds and structural
the slide bearing blocks will require shimming to members must be checked for cracks (refer to the
adjust for wear.
wear. It is essential
essential for all slide bearings Structural Inspection, Reporting, and Repair
to be properly shimmed. For proper shimming Procedure at the front of this section).
procedures refer to Section 27.27.
Lubrication. Refer to the Lubrication section in
Forks. The forks must be inspected daily to the Appendices for information on the lubrication
assure proper carriage operation. Forks must be of the carriage.
magnetic particle tested (magnafluxed) annually to

FORK
PIN CAP

FORK
PIN CYLINDER
PINS

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 MAIN
ROLLERS

SLIDE BEARING
BLOCKS

Illustration 28-3. Optional Carriage With Fork Positioners

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 28-3

Troubleshooting

Problem Cause Correction

1. Cra
rack
cks
s in wel
elds
ds 1. Met
etal
al fat
fatig
igue
ue.. 1. Have
Have crack
cracks
s in
in weld
welds
s repa
repaired
ired
(refer to SIRR in the immediately.
Appendices))
Appendices 2. Ov
Over
erlo
load
adin
ing.
g. 2. Refer
Refer to
to Corre
Correcti
ction
on 1.
1. and
and avoid
avoid
Notify Taylor overloading the truck.
Machine Works, 3. Rou
ough
gh ter
terra
rain
in.. 3. Refer
Refer to
to Corre
Correcti
ction
on 1.
1. and,
and, ifif pos-
pos-
Inc. for proper sible, avoid operating truck on
repair procedures. rough terrain.
4. Trav
ravell
elling
ing with
with load
load inin an unrec
unrecom-
om- 4. Ref
Refer
er to
to Corre
Correcti
ction
on 1.
1. and
and the
the
mended travel position (excessive Operator’s Guide for proper travel-
height and / or fully side-shifted, ling positions.
one side or the other).
5. Se
Seve
vere
re du
duty
ty cy
cycl
cles
es.. 5. Hav
Have e crack
cracks
s in
in weld
weldss repa
repaired
ired
immediately.
6. Tryi
rying
ng to use
use fork
fork posit
positione
ioners
rs while
while 6. Use for
fork
k posit
position
ioners
ers onl
only
y when
when
loaded. forks have no load.

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28-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Contents

Appendices

Page

SIRR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Fork Inspection, Repair, and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17

Leaf Chain Care, Maintenance, and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25

Torque Chart - Nuts and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33

Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-39

Hydraulic Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-41

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43

Fuel and Lubri

Lubricant
cant Speci
Specificatio
fications
ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TX / TXH / TXB 180S - 400L ( /07)

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 Section 1

Section Title

SIRR
Structurall Inspectio
Structura Inspection,
n, Reporting, And Repair
For Powered Industrial Trucks

This document contains information of vital importance concerning the

inspection, reporting, and repair of fatigue
fatigue cracks. If fatigue cracks
cracks are
not corrected they can lead to a catastrophic failure causing serious
injury to personnel and / or property.

It is important that the machine

machine be inspected regularly.
regularly. Any existing
fatigue cracks should be reported to the Taylor Machine Works, Inc.
engineering department immediately
immediately.. Repairs must be made in
accordance with AWS methodologies.

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TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-1

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A-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

These symbols are in accordance with AWS

 A2.4-76, “Symbols for Non-Destructive Testing.”
Testing.”
Dangerous Action. Operating a powered indus-
trial truck without inspecting, identifying, and  Periodic inspection is
repairing fatigue cracks in the mast, carriage, required to detect fatigue cracks that have
attachment, steer axle, and frame weldments. grown to a significant size in order to avoid
serious failure of the structural weldment.
What Can Happen. If the fatigue crack is allowed
When a crack is found, the truck must be
to grow, catastrophic failure could occur in the
immediately taken out of service and repaired.
mast or other welded components causing serious
injury to personnel and / or property. Restoring the weld to its original condition by com-
How To Avoid The Danger. Follow the OSHA plete penetration welding is usually acceptable.
rules, 29 CFR, 1910.178 (q)(1), (5), & (7) which Sometimes this is not practical and a change in
require inspecting industrial trucks daily before geometry by means of cutting, grinding or adding
being placed in service, removing trucks from ser- additional material is more economical; however
however,,
the user must be cautioned that OSHA 29 CFR
vice if cracks are
as authorized found,
by the and making
manufacturer. Ifrepairs
manufacturer. trucksonly
are 1910.178 (a)(4) requires manufacturer’s prior
used on a round-the-clock basis, they shall be written approval for modifications and additions
examined after each shift. OSHA 29 CFR which affect capacity and safe operation.
1910.178 (p)(1) requires that trucks in need of Cracking may occur due to overloading, rough
repair be taken out of service. operation, poor yard conditions, severe duty
Structural Inspection and Reporting Proce- cycles, failing to keep lift chains properly adjusted,
dure. The information enclosed in this procedure improper shimming of mast rails, carrying the
is directed to the structural weldments of the truck loads too high or not properly centered, using
assembly. Areas that should be included for attachments that clamp the load to the forks, etc.
inspection on the front end of the truck are the If such cracking is found, a review of the operation
mast and carriage. Areas to be inspected on the should be made to see if any of the above listed
truck chassis include mast hangers, drive axle problems are occurring and if so, a change in the
mounts, A-frame connections, and steer axle operation should be made to avoid future prob-
mounts. lems. Some cracking may be due to geometry,
geometry,
Inspection for Fatigue Cracks. Welded steel modifications
the structure. or
If due to the
this is the case,
attachments welded to
the geometry
structures always contain undetectable cracks, may have to be changed, the modification cor-
especially at welded joints. When these joints are
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subject to fluctuating stresses of sufficient magni-
rected, or the attachment changed or relocated to
correct the cracking problem. OSHA requires that
 tude, these cracks will grow.
grow. This is known as you have prior written approval of the manufac-
fatigue crack growth. No matter how low the turer for such changes.
stress levels are kept some fatigue crack growth
will occur in all welded structures. Test Procedures
Eventually, these fatigue cracks will become large 1. Visual (VT). Dirt and grease should be
enough to be detectable by nondestructive testing removed from the surface by wiping with a rag.
methods, i.e. VT, MT, DPT, or UT. One should look for cracked paint and rust
showing through the paint. Also, look for
Abbreviations. Basic Testing Symbols movement at bolted joints, irregular lines in
welds or dents, or deformations in the materi-
Type of Test Symbol al. Proper lighting is required in order to
Visual VT obtain satisfactory results.
Magnetic Particle MT 2. Magnetic Particle (MT). The test surface
Dye-Penetrant DPT must be free of loose rust, scale, moisture,
and painted surfaces must be cleaned at all
Ultrasonic UT points of electrode contact.
contact. Grinding, brush-

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-3

ing, or blasting do not affect results of this two years or 6,000 hours, whichever is sooner,
method of testing in most instances. thereafter. These inspections
inspections should be per-
formed by qualified maintenance personnel.
A magnetic field can be applied to the test
material with: NOTE: Duty cycles vary from extremely severe
a. Perm
Permananen
entt magn
magnet
et.. (capacity loads, high frequency of loading, rough
b. Yoke whic
whichh is an elect
electrom
romagn
agnet
et type
type of yards, etc.) to very light (partial capacities, few
device. load cycles, good yard conditions, etc.). Duty
cycle directly affects product life and maintenance
c. Pas
Passin
singg high
high amper
amperage age curr
current
ent thr
throug
ough
h
requirements. Depending on the quality and thor-
the part.
oughness of the daily inspections and the service
3. Dye-Penetrant (DPT).
(DPT). The test
test surface
surface must experience of the vehicle, the three-month visual
be thoroughly cleaned and dried. This can be inspection interval and the full-scale inspection
done with chemical solvents, vapor degreas- interval may be adjusted (increased or decreased)
ing, or by mechanical methods. However
However,, to levels appropriate for an individual vehicle duty
cleaning mechanically, such as grinding, blast- cycle.
ing, or wire-brushing, might prove detrimental
to the test because surface discontinuities can
be masked by cold working of the surface. 
 
 
  


 


 



Therefore, mechanical cleaning methods must 

 

 




 



 


 





be kept to a minimum.  


One of the following type penetrants should be
used in conjunction with the proper procedure Reporting Procedure. Taylor Machine Works,Works,
to get satisfactory results: Inc. should receive reports of the results of any
inspections.
a. Watater
er sol
solub
ublele pene
penetr
tran
antt
b. Pos
Postt emu
emulsilsifia
fiable
ble pen
penetr
etrant
ant Photocopy a sketch from your maintenance manu-
al, make your own sketch, or photograph, and
c. So
Solv
lven
entt remov
removab able
le pene
penetr tran
antt show indication of crack if any are evident, stating
Follow the directions supplied with the dye- the following:
penetrant for best results.
1. Location
Location (right,
(right, left,
left, inner
inner,, outer
outer,, machine
machine side
side
4. Ultrasonic (UT). Testing should be done in etc.);
accordance with AWS D1.1 approved meth-
ods. 2. Si
Size
ze of cra
rack
ck;;
3. Ex
Exte
tent
nt of cr
crac
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Frequency of Inspection. There are three (3) ack;
k;
levels of inspection: a. In toe of wel
eld;
d;
1. Daily.
Daily. Mandatory daily examination
examination of the b. Pro
Propag
pagati
ating
ng into
into the bas
base e metal
metal;;
truck as required by OSHA. (See Operator’s c. Ot
Othe
herr des
descr
crip
ipti
tion
on,, etc
etc..
Guide and Safety Check 2nd Edition for 4. Met
Method
hod of
of testi
testing
ng to det
detect
ect cra
cracks
cks..
details.) This examination
examination is usually per-
formed by the operator (or other designated If no cracks are found by yearly inspections,
person). please confirm by a fax or a short letter.
2. Three-month inspection. A thorough visual Repair Procedure
inspection (VT) following the guidelines shown 1. Con
Contac
tactt Tayl
Taylor
or Machi
Machine
ne Works
Works,, Inc.
in this procedure should be made every three
2. If rewel
reweldin
ding
g is sugges
suggested
ted,, use AWS
AWS approve
approved
d
months (refer
inspections to sketches
should for details).
be performed These
by qualified welding procedures.
maintenance personnel. 3. If design
design modifica
modification
tion is
is indicated,
indicated, conta
contact
ct Tay-
Tay-
3. 6,000 Hour Inspection. Full-scale inspection lor Machine Works, Inc. OSHA 29 CFR
(FS) including all examinations outlined in this 1910.178 (q)(5) requires that replacement
procedure (VT, MT, and DPT) should be made parts be equivalent as to safety with those
after the first year of operation and then every used in the original design. Different steel

A-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

grades are used for different components. Dif-

ferent steel grades require different welding
procedures, pre-heatings, rods, etc.
Inspection Locations. The following illustrations
are a representative set for the general welds
used on Taylor
Taylor Machine
Machine Works
Works trucks.
trucks. They are
used as a reference for specific details, but do not
necessarily represent exact details used in the
construction of your truck. The inspection method
for both the three-month inspection (3), and the
full-scale inspection (FS), are shown.

 The areas being inspected

must be properly cleaned prior to performing
the inspection. If not properly cleaned poten-
tially dangerous cracks may not be detected.

 Never go under a raised mast,

carriage or forks unless proper blocking has
been securely placed to prevent the mast, car-
riage or forks from falling in event of hydraulic
failure or drift. See Safety Check 2nd Edition.

List of Illustr
Illustrations
ations

Illust
Illustra
rati
tion
on.. 1. Innerr and
Inne and Ou
Oute
terr Mas
Mastt Arr
Arranangegemement nt . . . A-
A-6
6
Illustration. 2. I nner Mast Details 1 and 2 . . . . . . . . . . A-7
In
Illustration. 3. Outer Mast Detail 3 . . . . . . . . . . . . . . . . A-8
Illustration. 4. Outer Mast Detail 4 . . . . . . . . . . . . . . . . A-9
Illustration. 5. Carriage Detail . . . . . . . . . . . . . . . . . . . A-10
Illustration. 6. Chassis Arrangement . .https://www.forkliftpdfmanuals.com/
Ch . . . . . . . . . . . . A-11
Illustration. 7. Chassis Detail 1 . . . . . . . . . . . . . . . . . . A-12
Illustration. 8. Chassis Detail 2 . . . . . . . . . . . . . . . . . . A-13
Illustration. 9. Chassis Detail 3 . . . . . . . . . . . . . . . . . . A-14
Illustration. 10. Chassis Detail 4 . . . . . . . . . . . . . . . . . A-15
Illustration. 11. Chassis Detail 5 . . . . . . . . . . . . . . . . . A-16

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-5

Inner and Outer Mast Arrangement

Detail 2

Detail 3

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 Detail 1

Detail 4

Illustration 1. Inner and Outer Mast Arrangement

A-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Inner Mast Details

Detail 2

VT (3)
MT (FS)

Detail 1
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 VT (3)
MT (FS)

Illustration 2. Inner Mast Details 1 and 2

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-7

Outer Mast Details

VT (3)
MT (FS)

VT (3)
MT (FS)

VT (3)
MT (FS)

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 VT (3)
MT (FS)

Detail 3

Illustration 3. Outer Mast Detail 3

A-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Outer Mast Details

VT (3)
Detail 4 MT (FS)

VT (3) VT (3)
MT (FS) MT (FS)

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 Illustration 4. Outer Mast
Mast Detail
Detail 4

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-9

Carriage Detail

VT (3)
MT (FS)

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 VT (3)
MT (FS)

Illustration 5. Carriage Detail

A-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Chassis Arrangement

Detail 5
Detail 4

Detail 3

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 Detail 2

Detail 1

Illustration 6. Chassis Arrangement

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-11

A-11

Chassis Details

Detail 1 VT (3)
MT (FS)

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 VT (3)
MT (FS)

Illustration 7. Chassis Detail 1

A-12 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Chassis Details

VT (3)
Detail 2
MT (FS)

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 VT (3)
MT (FS)

Illustration 8. Chassis Detail 2

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-13

Chassis Details

Detail 3

VT (3)
MT (FS)

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 Illustration 9. Chassis Detail 3

A-14 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Chassis Details

VT (3)
MT (FS)
Detail 4

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 VT (3)
MT (FS)

Illustration 10. Chassis Detail 4

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-15

Chassis Details

Detail 5

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 VT (3)
MT (FS)

Illustration 11.
11. Chassis Detail
Detail 5

A-16 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Fork Inspection, Repair

Repair,, and Testing

Forks in use shall be visually inspected daily and Any fork that has a deviation of greater than 3 

must be magnetic particle tested (magnafluxed) fork angle from the original specification shall not
for cracks at intervals of not more than 2400 hours be returned to service.
or whenever any defect or permanent deformation
The difference in height of one set of forks when
is detected. Severe applications will require more
mounted on the fork carrier shall
shall be checked. If
frequent inspection.
the difference in tip heights exceeds 3% of the
When forks are used in pairs, the rated capacity of length of the blade, the set of forks shall not be
each fork shall be at least half of the manufactur- returned to service until repaired.
er’s rated capacity of the truck, and at the rated
It shall be confirmed that the positioning lock is in
load center distance shown on the lift truck name-
good repair and correct working order.
order. If ant fault
plate.
is found, the fork shall be withdrawn from service
Fork inspection shall be carried out carefully by until satisfactory repairs have been effected.
trained personnel with the aim of detecting any
The fork blade and shank shall be thoroughly
damage, failure, deformation, etc., which might
checked for wear, special attention being paid to
impair safe use. Any fork which shows such a
the vicinity of the heel. If the thickness
thickness is reduced
reduced
defect
not be shall be withdrawn
returned to service from service,
unless and shall
it has been sat- to 90% of the original thickness, the fork shall not
be returned to service.
isfactorily repaired.
The support face of the top hook and the retaining
faces of both hooks shall be checked for wear,
 Do not weld on forged forks. crushing, and other local deformations. If these
Failure to follow this warning could lead to are apparent to such an extent that the clearance
seriously weakened forks that could fail pre- between the fork and the fork carrier becomes
maturely under
under normal loads. When neces- excessive, the fork shall not be returned to service
sary, the welding of fork bushings should only until repaired.
be done by qualified welders knowledgeable of
the appropriate welding practice. If the fork marking is not clearly legible, it shall be
renewed. Marking shall be renewed per instruc-
The fork shall be thoroughly examined visually for tions from original supplier.
cracks and if considered necessary, subjected to a Each fork shall be clearly stamped with its individ-
nondestructive crack detection process, special
attention being paid to the heel and welds attach- ual loadtorating
subject wear.in an area readily visible and not
ing all mounting components to the fork blank.
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This inspection for cracks must also include any Only the manufacturer of the fork or an expert of
special mounting mechanisms of the fork blank to equal competence shall decide if a fork may be
 the fork carrier including bolt type mountings and repaired for continued use, and the repairs shall
forged upper mounting arrangements for hook only be carried out by such parties.
and shaft type carriages. The forks shall not be It is not recommended that surface cracks or wear
returned to service if surface cracks are detected. be repaired by welding. When repairs necessitat-
The straightness of the upper face of the blade ing resetting are required, the fork shall subse-
and the front face of the shank shall be checked. quently be subjected to an appropriate heat treat-
If the deviation from straightness exceeds 0.5% of ment, as necessary.
the length of the blade and/or the height of the A fork that has undergone repairs shall only be
shank, respectively, the fork shall not be returned returned to service after being submitted to, and
to service until it has been repaired. passing, the test procedures. The test load shall

(Rev. 3/96) A-17

correspond to 2.5 times the rated capacity marked

on the fork.

F D

Illustration 1. Ty
Typical
pical Fork
Fork

Fork strength shall permit the following loading

and method of test.
1. The test
test load
load F shal
shalll be applie
applied
d to it at the
the
applicable distance
fork arm shank (seeDIllustration
from the front
1). face of the
2. The fork
fork arm
arm shall
shall be
be restra
restraine
ined https://www.forkliftpdfmanuals.com/
d in a manne
mannerr
identical to that used on the forklift truck.
3. The test
test load shall be applied
applied twic
twice,
e, graduall
gradually
y
and without shock, and maintained for 30
seconds each time.
4. The fork
fork arm
arm shall
shall be
be checke
checked
d before
before and
and
after the second application of the test load.
It shall not show any permanent deformation.

A-18 (Rev.. 3/96)

(Rev

Leaf Chain Care, Maintenance, and Replacement

The leaf chain (or chains) on your Taylor material handling equipment was selected based on thou-
sands of hours of safe operation over many years of fork lift trucks working in various types of material
handling operations.
The entire chain system, including chain anchors, anchor supports, bearings, and chain rollers, is

sized for the basic model capacity and load center shown on the serial plate.
The utility of fork lift truck type material handling equipment requires it to operate under a wide variety
of load conditions. These vary from a few low lifts lifts to a very large number of high lifts per operating
hour.
The leaf chain is subjected to all the variations of environment, such as moisture, chemicals, tempera-
ture extremes, abrasives, and eveneven salt water in some applications. The chain cannot have the bene-
fit of a protective coating (paint) and must depend on proper lubrication for combating the effect of
these conditions. The lubrication program greatly affects
affects chain life.
The utility of the lift truck requires it to operate with a variety of attachments, such as forks, coil rams,
paper roll clamps, containers, marinas, and other attachments, all of which will place different dynamic
loads and load requirements on the hoist chains.
This wide variety of variables makes it impossible for Taylor to accurately predict an exact service life
Taylor material handling equipment. Therefore, the following procedure of
of the leaf chain on the Taylor
inspection and replacement is recommended to avoid sudden failure.

Maintenance and Replacement of the Leaf Chain

In addition to the daily walk-around inspections, at each 500 hours of operation, the chain should be
thoroughly cleaned and inspected for elongation, pin rotation and protrusion, cracked plates, enlarged
holes, worn contour and worn
worn surfaces on outside links
links or pin heads. If any of the above
above are
observed, replace the entire length of both chains. (Illustrations are on the following pages under
Modes of Chain Failure.)
Careful visual inspection of both inside and outside of the chain links where possible will reveal
some of these early indications of chain failure which may result in total chain breakage if left in ser-
vice.

NOTE: A hand-held mirror can aid tremendously in hard to see areas.

Particular attention should be given to that part of the chain which passes over the chain roller the
most frequently when under load.
It will be necessary to move the carriage to several locations and block it to prevent any possibility of
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falling to gain the best possible visual access to the greatest number of pitches of chain.
 After the chain is inspected and found to be serviceable, relubricate and place back in service.

 Utilize proper safety precautions when blocking.

At 2,000 hours,
hours, disassemble the leaf chain from the vehicle in accordance with the shop service
manual (page 27A-1). Thoroughly clean the chain and visually inspect for possible failure modes
as listed for the 500 hour interval
interval adding to that procedure the following. Articulate each joint of the
chain in both directions where the entire radius around each pin can be inspected for cracks.
Particular attention should be given to that length of chain which passes over the rollers.
If the 2,000 hour inspection does not reveal any apparent excess wear or chain damage, relubricate
and install the chain in its original position on the machine.
At each 500 hours after the leaf chain is reinstalled, inspect and relubricate and follow the same pro-
cedure as on a new machine.
At 4,000 operating hours remove and discard the leaf chain and replace with a new and lubri-
cated chain.
Taylor’s recommendation to replace the chain at 4,000 hours is based on typical service duty cycles.
Experience in a specific application may allow this interval to be increased or may require that it be
decreased. Any change should be based on thorough inspection procedures outlined in this manual.

TX / TXH / TXB 180S - 400L (4/07) A-19

Modes of Chain Failure — See Illustrations on the following two pages

1). Normal Wear – Chain Elongation. This is the result of wear when the load chain articu-
lates over the
the chain rollers. See illustration No.
No. 1 for explanation of wear limits. When a
theoretical length of 12-in. (305 mm) new chain has elongated from wear to a length of
12.360-in. (314 mm) [3%], it has exceeded the allowable wear limit. The wear should be
measured in the area that passes
passes over the roller most often. If the length in the
the articulat-
ing section exceeds allowable wear limits (see text), replace entire length of both
chains.

2). Chain Stretch. This can be caused by a combination of chain wear and overload. This
(overload) can show up as elongation of plates which do not pass over the rollers. If
there is any significant (1%) elongation in the area which does not pass over the rollers,
replace the entire length of both chains.
chains. Cracked chain plates (illustration no. 3) and
enlarged holes (illustration no. 7) can also result from chain stretch.
stretch. The entire length of
both chains must be replaced if either of these conditions are found.

3). Plate / Pin Rotation and / or Plate / Pin Lateral Movement. This is generally caused caused
by the plate seizing the pin at articulation which indicates lack of lubrication where the
joint rotates over the roller. (See illustration No. 2.) This can result in pin breakage in
extreme cases. If any evidence rotation is noted, replace entire length of both
evidence of pin rotation
chains.

4). Plate / Pin Cracks. Cracks result from fatigue, stress

stress corrosion, corrosion fatigue. (See
illustrations No. 3, 4, and 5.) If any cracks are observed of any kind on any link, replace
entire length of chain.
5). Chain Joint Stiffness. (See illustration No. 6.) Lack of lubrication. Check the chain for
other modes of failure. If none are observed, lubricate thoroughly and place back in ser-
vice. If stiffness
stiffness remains, the chain
chain may have been damaged and require replacement.
replacement.

6). Edge Wear of Plates. (See illustration No. 8.) Edge wear can occur at extended
extended hours
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of service and if sliding of chain occurs because of chain roller bearing problems. If wear
 exceeds 5% of plate height of unused plate, replace entire length of chain.

7). Worn Outside Links or Pin Heads. (See illustration

illustration No. 9.) Check for misalignment
misalignment of
the chain roller.
Replace the chain if wear is significant. Check (see Check Procedure) the chain for all
modes of failure. If none are found, eliminate the misalignment and place back into ser-
vice.

A-20 TX / TXH / TXB 180S - 400L (4/07)

Modes of Chain Failure

Appearance and/or Symptom Probable Cause Correction

1. Excessive Length (elongation)
Measure section of chain that runs
over sheaves.
3% wear elongation is maximum. Normal Wear

Replace chain immediately

Permanent deformation and eliminate the source
(stretch) from overload of overloads.

12 in. / 305 mm (New)

12.3 in. / 314 mm (Worn)

2. Abnormal Protrusion or Turned Pins

Excessive friction from high

loading and inadequate lubrica-
tion
Replace chain and
lubricate more frequently

3. Cracked Plates
(Fatigue)
Loading beyond chain’s capac-
ity (dropping load and catching Replace chain and eliminate
it) dynamic (impulse)
overloading

4. Arc-like Cracked Plates (Stress Severe rusting or exposure to

Corrosion) acidic or caustic medium, plus
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static stress at press fit Replace chain and protect
between pin and plate. (No from hostile environment by
 from hostile environment by
cyclic stress necessary) lubricating more frequently

5. Cracked Plates (Corrosion Fatigue)

Perpendicular to Pitch Line, plus rust
or other evidence of chemical
corrosion Corrosive environment and
cyclic motion (chain under Replace chain and protect
cyclic operation) from hostile environment by
lubricating more frequently

TX / TXH / TXB 180S - 400L (4/07) A-21

Appearance and/or Symptom Probable Cause Correction

6. Tight Joints
Dirt or foreign substance
packed in joints
Clean and relube
Corrosion and rust
Replace chain
Bent pins Replace chain

7. Enlarged Holes

High overload, dropping and

catching load Replace chain and correct
cause of overload

8. Worn Contour (Edge Wear)

Replace chain when wear
reaches 5% of H.
Normal wear on sheave bearing
area
H Abnormal wear, rubbing on Replace chain and correct
roller cause of overload

5% of H Check chain roller bearing

9. Worn Surfaces on Outside Links

or Pin Heads

Misalignment, rubbing on roller

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flanges Check alignment of
anchors, chain rollers
 and chain roller pin.



I. Use
Use pro
prope
perr saf
safet
ety
y pre
preca
caut
utio
ions
ns..
a. Always
Always lower the mast
mast and carriage
carriage to its lowest
lowest position
position before
before inspecting
inspecting the leaf
leaf chain,
unless the mast and carriage are securely blocked.

b. Always
Alway s useremoving,
inspecting, OSHA approved
appro ved support
suppo
or servicing rt chains.
lift means (man
(ma n lift,turn
Always scaffolding,
scaffo
offlding,
off ladder, Do
ladder,
the engine. or platform)
platform) when
not allow anyone
to touch the controls while people are near the upright.
II. Use Lockout
Lockout / Tagout
Tagout Procedure
Procedure to reduce
reduce causes
causes of possible
possible injury
injury.
III. Use only assembled
assembled chain. Do not build lengths from individual components.
IV.. Do not attempt
IV attempt to rework damaged chains by replacing only the
the components obviously
obviously faulty.
faulty. The
entire chain may be compromised and should be discarded.

A-22 TX / TXH / TXB 180S - 400L (4/07)

V. Do not weld
weld any chain
chain or componen
component.
t. Weld
Welding
ing spatter
spatter should
should never be allowed
allowed to come
come in contact
contact
with chain or components.

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 TX / TXH / TXB 180S - 400L (4/07) A-23

Appendix

Welding Precautions
Introduction. Once a crack is found in the truck trical connectors that must be disconnected
structure, it is advisable that you contact Taylor before welding include the TICS control modules
Machine Works, Inc. for proper welding proce- on the truck (refer to Illustration 2), TICS MDL dis-
dures. Your machine is comprised of different play, joystick control lever, forward and / or
metals, each requiring its own unique repair pro- reverse cameras & monitors (if equipped), engine
cedure. electrical connector, transmission cooler tempera-
ture transducer, accelerator pedal and APC
Welding Precautions. It is possible for damage
module.
to occur when welding during maintenance. Cur-
rent passed from the electrode through a pin,
bearing, cylinder piston or other part, seeking the
ground, can cause damage to parts.
Illustrated in Illustration 1 are some of the parts
on lift trucks subject to damage by the passage of
welding current.
Care and common sense are the best guides to
avoid such damage to the components.

 Death or serious injury could

result from a runaway truck. Park the truck on
a hard, level surface, apply the parking brake,
block the wheels in both directions to prevent
movement of the truck and Lock Out & Tag Out
the truck before performing maintenance.


 Before welding on
on any of the truck’s or
or
attachment’s structural members, the
electrical connector connected to the Taylor
Integrated Control System (TICS) control
modules must be unplugged prior to any
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welding. Failure to disconnect the electrical
 connectors from these components may
lead to damage.
 Should any truck equipped with an APC
APC
module require welding on its structural
members, the RS connector must be
unplugged from the APC module prior to any
welding. Failure to comply with this caution
may lead to damage to the APC module.
 Always connect the ground (closest to the
area to be welded, as possible, to provide
the shortest path for welding current flow) to
the part or welded assembly that is to be
welded.
Disconnection of Electrical Components.
Some electrical components on the truck must be
disconnected before attempting to weld on the
truck. If the electrical components are not discon-
discon-
nected before welding, damage
damage may occur.
occur. Elec-

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-25

TILT CYLINDER ENDS

AND ALL INTERNAL
COMPONENTS
CHAIN ROLLERS

LIFT CHAINS
AND MAST ENGINE
ROLLERS GEARS AND
BEARINGS
WHEEL
AND
SPINDLE
BEARINGS

CARRIAGE Á Á Á Á Á Á Á Á

ROLLERS Á Á Á Á Á Á Á Á

AND PINS
Á Á Á Á Á Á Á Á

Á Á Á Á Á Á Á Á

AXLE BEARINGS TRANSMISSION

UNIVERSAL
AND GEARS GEARS AND STEER AXLE PIVOT
JOINT
BEARINGS
BEARINGS

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1. Some Truck Parts Subject ToTo Damage
A-26 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

TICS MD3
DISPLAY MODULE

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 CAB MODULE
(XA2-A1)

CHASSIS MODULE
(XA2-A0)

Illustration 2 TICS Control Module and Main Display Locations

Locations On The Truck
Truck

TX / TXH / TXB 180S - 400L (Rev. 4/23/07) A-27

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A-28 TX / TXH / TXB 180S - 400L (Rev. 4/23/07)

Torque Chart - Nuts and Bolts

Force - 100 lbs. Force - 200 lbs.

(100 N) (200 N)
12” or 1’ 6” or 1/2’
(1 m) (1/2 m)
Graphic Illustration
of Torque
Lever Arm or Wrench Handle Lever Arm or Wrench Handle

Torque - 100 ft-lbs. or 1200 in-lbs. Torque - 100 ft-lbs. or 1200 in-lbs.
(100 N⋅m) (100 N⋅m)

NOTE: These charts are intended as a guide for the same SAE grade as the bolts on the chart.
the wrench torque that should be applied to tight- When nuts and bolts are of different grades, use
ening nuts and bolts, studs, or capscrews when the torque value for the lower of the two grades.
no torque is specified on the assembly print or
These charts are not intended for use in seating a
separate instructions. A steady pressure should
stud in a housing. The torque values, listed in the
be applied to the torque wrench until the torque
value is obtained.
obtained. A jerking action on the
the torque charts,
values. are
To the maximum
convert and minimum
dry torque
torque values to dry torque
lubricated
wrench may not yield the proper torque value.
torque values, multiply the max. or min. dry torque
When tightening a bolt with a slotted nut, torque to value by 75% (.75). Lubricated is defined as oil-
the lower value shown on the applicable chart. coated bolts, Loctite coated bolts, plated bolts or
Then continue to tighten until the hole in the bolt bolts used with hardened flatwashers.
and the slot in the nut line up. Nuts must be of
Recommended Torque, Foot-pounds (ft-lbs) / Newton meters (N m)  

SAE Grade 5 SAE Grade 8 12pt Ferry Head Capscrew

NF Threads Torque Torque Torque
ft-lbs (N m)
 ft-lbs (N m)
 ft-lbs (N m)


1/4 - 28 9 - 10 (12 - 13) 13 - 14 (18 - 19) 15 - 17 (20 - 23)

5/16 - 24 17 - 19 (23 - 26) 23 - 25 (31 - 34) 31 - 34 (42 - 46)
3/8 - 24 32 - 35 (43 - 48) 45 - 50 (61 - 68) 59 - 65 (80 - 88)
7/16 - 20 50 - 55 (68 - 75) 72 - 80 (98 - 109) 92 - 102 (125 - 138)
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1/2 - 20 81 - 90 (110 - 122) 108 - 120 (146 - 163) 135 - 150 (183 - 203)
 9/16 - 18 108 - 120 (146 - 163) 153 - 170 (208 - 231) NA
5/8 - 18 162 - 180 (220 - 244) 216 - 240 (293 - 325) 271 - 301 (367 - 408)
3/4 - 16 270 - 300 (366 - 407) 378 - 420 (513 - 570) 482 - 536 (654 - 727)
7/8 - 14 423 - 470 (574 - 637) 594 - 660 (805 - 895) 793 - 881 (1075 - 1195)
1 - 14 657 - 730 (891 - 990) 918 - 1020 (1245 - 1383) 1130 - 1255 (1532 - 1702)
1-1/8 - 12 792 - 880 (1074 - 1193) 1296 - 1440 (1757 - 1953) NA
1-1/4 - 12 1116
1116 - 1240 (1513 - 1681) 1800 - 2000 (2441 - 2712) NA
1-3/8 - 12 1512 - 1680 (2050 - 2278) 2448 - 2720 (3320 - 3688) NA
1-1/2 - 12 1980 - 2200 (2685 - 2983) 3200 - 3560 (4339 - 4827) NA
NC Threads
1/4 - 20 7 - 8 (10 - 11) 11 - 12 (15 - 16) 14 - 15 (19 - 20)
5/16 - 18 15 - 17 (20 - 23) 23 - 25 (31 - 34) 28 - 31 (38 - 42)
3/8 - 16 28 - 31 (38 - 42) 41 - 45 (56 - 61) 52 - 58 (71 - 79)
7/16 - 14 45 - 50 (61 - 68) 63 - 70 (86 - 95) 83 - 92 (113 - 125)
1/2 - 13 68 - 75 (92 - 102) 99 - 110 (134 - 149) 120 - 133 (163 - 180)
9/16 - 12 99 - 110 (134 - 149) 135 - 150 (183 - 203) NA
5/8 - 11 135 - 150 (183 - 203) 198 - 220 (268 - 298) 240 - 266 (325 - 361)
3/4 - 10 234 - 260 (317 - 353) 342 - 380 (464 - 515) 432 - 480 (586 - 651)
7/8 - 9 387 - 430 (525 - 583) 540 - 600 (732 - 814) 671 - 746 (910 - 1012)
1-8 576 - 640 (781 - 868) 810 - 900 (1098 - 1220) 940 - 1044 (1275 - 1416)

TX / TXH / TXB 180S - 400L (4/07) A- 29

SAE Grade 5 SAE Grade 8 12pt Ferry Head Capscrew

NF Threads Torque Torque Torque
ft-lbs (N m)  ft-lbs (N m)
 ft-lbs (N m)

1-1/8 - 7 720 - 800 (976 - 1085) 1152 - 1280 (1562 - 1736)

1152 NA
1-1/4 - 7 1008 - 1120 (1367 - 1519) 1638 - 18
1820
20 (2221 - 2468)
2468) NA
1-3/8 - 6 1314 - 1460
1460 (1782 - 1980)
1980) 2142 - 2380
2380 (2905 - 3227)
3227) NA
1-1/2 - 6 1746 - 194
1940
0 (2368 - 2631)
2631) 2844 - 31
3160
60 (3856 - 4285)
4285) NA

Recommended Torque for Metric Bolts

Torque
Class 8.8 (Equiv. to Grade 5) Classs 10.9 (Equiv. to Grade 8)

Bolt Size ft-lbs (N m) ft-lbs (N m)



M6-1.00 7 - 8 (10 - 11) 10 - 11 (14 - 15)

M8-1.25 17 - 19 (23 - 26) 24 - 27 (33 - 37)

M10-1.50 33 - 37 (45 - 50) 48 - 53 (65 - 72)

M12-1.75 59 - 65 (80 - 88) 83 - 92 (113 - 125)

M16-2.00 144 - 160 (195 - 217) 207 - 230 (281 - 312)

M20-2.50 279 - 310 (378 - 420) 405 - 450 (549 - 610)

M24-3.00 486 - 540 (659 - 732) 690 - 775 (936 - 1051)

M30-3.50 970 - 1078 (1315 - 1462) 1386 - 1540 (1

( 1879 - 2088)

Taylor Engineering Standards Recommended

Flathead BoltsTorque for Countersunk
with Internal Hex Drive
Tightening procedure for countersunkhttps://www.forkliftpdfmanuals.com/
flathead (these torque values applies only to hold caps
bolts with internal hex drive used for holding caps on tapered Timken  bearings found on the
on tapered Timken  bearings (found on the mast mast and carriage main roller assemblies)
and carriage main rollers):
Torque
1. The bolt
bolts
s and tappe
tappedd holes
holes must
must be clea
clean
n and
free of oil. (This can be done by using a spray Min. Max.
degreaser (Zep Aerosolve or equivalent) and Bolt Size ft-lbs (N m) ft-lbs (N m)
drying with compressed air.)
 

2. Ap
Appl
ply
y Loc
Locttit
ite
e to bolt threads. 5/16 - 18 7.5 10 8.5 12

3. Gradual
Graduallyly tight
tighten
en the bolt
bolts
s using
using a crossi
crossing
ng 3/8 - 16 14 19 16 22
pattern.
7/16 - 14 24 33 26 35
4. Repeat Step 3 until
until bolts
bolts hold at
at least
least the
the mini-
mini-
mum torque value indicated in the torque chart 1/2 - 13 38 52 42 57
below. Stake head at three places with
with a cen-
5/8 - 11 74 100 81 110
ter punch.
5. When
When bearing
bearingss are remov
removed,
ed, it is
is necess
necessary
ary to
to 3/4 - 10 135 183 150 203
run a tap in the threaded holes and a die on
the bolts to remove Loctite res
residue.
idue. If a die
is not available, use new bolts.

A- 30 TX / TXH / TXB 180S - 400L (4/07)

Torque Chart - Nuts and Bolts

Tightening procedure for Grade 8 countersunk torque value as indicated in the torque chart
flathead bolts with internal hex drive used for below.
retaining the slide bearing block housings (found
4. In order
order to
to achiev
achieve
e torque
torque valu
values
es of this
this mag-
mag-
on the mast and carriage):
nitude, a high quality hex bit driver tool should
1. Do Not
Not use star
starwas
washer
hers
s or any
any other
other type
type of be used.
“locking” washer with grade 8 bolts.
5. In order
order to
to minimi
minimize
ze bendi
bending
ng stres
stresses
ses in
in the
2. Genero
Generousl
usly
y lubric
lubricate
ate the
the head
head and thre
threads
ads of
of tool and thereby increase its life, the length of
the bolt with oil before installing. the hex bit should be as short as possible
(e.g., Snap-On “Stubby” length).
3. Gradua
Gradually
lly tight
tighten
en the bolt
bolts
s using
using a crossin
crossing
g
pattern until they hold at least the minimum

Recommended Torque
Torque for Countersunk Flathead Bolts with Internal Hex Drive
(these torque values applies only to those bolts used to retain
the slide bearing block housings)
Torque
Minimum Maximum

Bolt Size Hex Bit Size ft-lbs (N m)

 ft-lbs (N m)


5/16 - 18 3/16 13 18 15 20
3/8 - 16 7/32 20 27 22 30
7/16 - 14 1/4 30 41 32 43
1/2 - 13 5/16 65 88 70 95
5/8 - 11 3/8 110 149 115 156
3/4 - 10 1/2 265 359 265 366

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