Beruflich Dokumente
Kultur Dokumente
3374 715
CAUTION
Observe The Following Precautions For Maximum Safety Of Machine Operation
1. Only trained and responsible operators shall be permitted to handle loads with this truck.
2. Operate the truck from the operators seat only. Do not allow riders.
3. Test hydraulic controls for proper response before using the machine.
4. Know your load. Do not attempt to lift or transport loads in excess of rated capacity.
5. When the load obstructs the view, operate the truck in the reverse range.
6. Do not stand or work under an elevated load.
7. Transport the load low and tilted back.
8. Avoid sudden stops with a load.
9. Evenly distribute the weight of the load on both forks.
10. Back down a ramp in excess of 10 percent when loaded.
11. Do not move the truck until the air system reaches recommended pressure. Air pressure is
required for the service brakes.
12. Have defects repaired immediately. Do not operate a truck with damaged or defective systems.
13. When leaving truck, lifting mechanism shall be fully lowered, controls shall be neutralized, power shut off, parking brake set, and key removed. Block wheels if on incline.
LIMITED WARRANTY
Products manufactured by Taylor Machine Works, Inc. (Taylor) and sold are warranted by Taylor to be free from
defects in material and workmanship, under normal use and service, when Taylor products are operated at or
below rated capacity* in accordance with 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, Taylor
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.** If a defect in material and workmanship is found during the twelve
(12) months and/or two thousand (2000) hours whichever occurs first of the warranty period, Taylor will replace
lubricating oil, filters, antifreeze, and other service items made unusable by the defect. Only genuine Taylor parts
provided by Taylors Sudden Service, Inc. will be used during the warranty period.
NOTE:
All International warranty parts shipments are F.O.B. point of debarkation, duties, 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 for ninety (90) days to be free from defects in material or 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 center is the rated lift capacity at less than
load center. That is, a machine rated at 20,000 pounds at 24-inch load center connotes 20,000 pounds
is the maximum lift capacity even though the load center may be less than 24-inches. Subjecting Taylor
products to conditions or loads exceeding those stipulated is justification for immediate cancellation of
warranty for products involved.
**Travel reimbursement will be limited to six (6) hours maximum paid per claim, or to the nearest Taylor
Machine Works dealer location in the assigned territory in which the truck is based.
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
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 exclusion of others. Each rule must be 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 maintenance 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 Dealer or Taylor
Machine Works, Inc. if you have questions about the proper service techniques.
WARNING: 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, trained, and skilled personnel who have proper tools and knowledge, and
3. in accordance with the Operators Guide, Maintenance Manual and Safety Check booklet.
Maintenance Manual
OperatorsGuide
.
!
Regularly Scheduled maintenance, lubrication, and safety inspections will help ensure a safe and
productive work life for the machine and the operator(s).
WARNING: Do not operate the truck if it is in need of repair. Remove the ignition key and
attach a Lock-out tag.
WARNING: Do not attempt to perform maintenance procedures unless you have been
thoroughly trained and you have the proper tools.
Intro-1
WARNING: Use only genuine 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:
Intro-2
Safety
Safety First
Important Safety Instructions
Observe these rules. They are recognized as
practices that reduce the risk of injury to yourself
and others, or damage to the lift truck or load.
This manual contains maintenance and service
procedures for filling, lubricating, removing, repairing, and installing various components comprising
a heavy duty industrial lift truck. Because of the
size and weight of the lift truck, and high pressures in some of the components and systems,
improperly performing service on the truck can be
dangerous.
Warnings and cautions are included to reduce the
probability of personal injury, when performing
maintenance 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.
No single rule in the booklet can be followed to
the exclusion of others. Each rule must be considered in light of the other rules, the knowledge
and training of the man (operator / maintenance),
the limitations of the machine, and the workplace
environment.
Report all mechanical problems to mechanics and
supervisors.
Proper Training:
Taylor Machine Works, Inc. publishes Safety
Check, TMW-072 a booklet citing some safety
precautions to observe during lift truck operation.
One copy is shipped with each lift truck; additional
copies are available at a nominal fee from the
authorized Taylor dealer from which the equipment was initially purchased.
Minimum Required Personnel Safety
Equipment
1. Hard Hat
2. Safety Shoes
3. Safety Glasses
4. Heavy Gloves
5. Hearing Protection
6. Reflective Clothing
Failure to follow the safety precautions outlined in
this manual can create a dangerous situation.
Safety-1
Safety-2
Safety-3
Safety-4
LIFT CHAIN
CHAIN ROLLER
TILT CYLINDER
ANCHOR
TILT CYLINDER
RADIATOR
HYDRAULIC
RESERVOIR
STEER AXLE
PIVOT
STEER LINK
MAST
MAIN ROLLER
CARRIAGE
MAIN ROLLER
FORK PIN
STEER
AXLE HUB
SPINDLE
(UPPER AND (FRONT AND
BACK)
LOWER)
FORK
MAST
HANGER PIN
ENGINE
TRANSMISSION
PLANETARY HUB
DRIVE SHAFT
DIFFERENTIAL
1-2
(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
Engine Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A
Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wet Disc Brakes Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15C
Air Dryer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15D
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20A
Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20H
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Side Shift and Fork Positioners Carriage Hydraulic Circuits . . . . . . . . . . . . . . . . . . . 22A
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22E
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Type C Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Appendices
Section 1
Engine
OIL
DIPSTICK
OIL
FILLER
CAP
OIL
FILTER
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1-1
S
S
WARNINGS:
Do not use ether to start an engine equipped
with an electric heater starting aid. Use of
ether to start an engine equipped with an
electric heater starting aid may cause explosion and severe injury.
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.
Avoid touching exhaust components while
changing the oil. Severe burns may occur.
Some state and federal agencies in the
United States have determined that used
engine oil can be carcinogenic and can
cause reproductive toxicity. Avoid inhalation of vapors, ingestion and prolonged
contact with used engine oil.
CAUTIONS:
S Dispose of oil and filter in accordance with
federal and local regulations.
S Do not use a strap wrench to tighten the oil
filter. Mechanical over-tightening may
distort the threads or damage the filter
gasket.
S Never operate the engine with the oil level
below the ADD mark or above the FULL mark
on the oil dipstick.
1. The engine should be at operating temperature before the oil is changed.
2. Place a suitable container under the drain plug
of the oil pan. Remove the drain plug (or open
drain valve if equipped) to drain the oil.
3. When the oil has completely drained, re-install
the O-ring and drain plug (or close drain valve
if equipped) on the Cummins engine and apply
a torque value of 60 ft-lbs to tighten the drain
plug.
4. Unscrew the spin-off type oil filter (see Illustration 1-1). It should be possible to unscrew the
oil filter by hand; however, a band type filter
wrench may be used if necessary. Discard the
used oil filter.
1-2
5. Clean the area on the filter base that will contact the gasket on the new oil filter.
6. Fill the new filter with clean engine oil before
installation.
7. Apply a light film of engine oil on the gasket of
the new filter. Screw the new filter onto the
filter base until the gasket comes in contact
with the filter base and then tighten filter 1/2 to
3/4 turn by hand only.
8. Remove the oil fill cap and fill crankcase with
oil to the FULL mark on the oil dipstick (see
Illustration 1-1).
9. Start the engine and allow to idle. Visually
check the drain plug and oil filter for leaks.
10. Shut down the engine and wait 15 minutes for
the oil to drain back into the oil pan. When the
engine has cooled, recheck the oil level and
add oil as necessary to bring the oil level to
the FULL mark on the oil dipstick.
Drive Belts (Illustration 1-2). Visually inspect the
drive belt daily. Check the belt for intersecting
cracks. Transverse cracks (across the belt width)
are acceptable. Longitudinal cracks (direction of
belt length) that intersect with transverse cracks
are not acceptable. Replace the drive belt if belt
is frayed or has pieces of material missing. Adjust
drive belts that have a glazed or shiny surface
which indicates belt slippage. Correctly installed
and tensioned drive belts will show even pulley
and belt wear. After installation of a new drive
belt, check the tension and adjust if necessary.
NOTE: Ensure each rib of the drive belt is properly aligned in the corresponding grooves of each
pulley or damage to the belt will occur.
Drive belt damage can be caused by:
S Incorrect tension
S Incorrect size or length
S Pulley misalignment
S Incorrect installation
S Severe operating environment
S Oil or grease on the belts
Drive Belt Tension. Proper drive belt tension is
automatically maintained by a belt tensioner
supplied with the engine. Refer to the engine
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
OEM
PLUG
CUMMINS
PLUG
Oil Pressure
30 - 55 psi
Oil Capacity
(includes filter change)
15 Quarts
2350 rpm
750 rpm
Diagnostic Lights (Illustration 1-4). The diagnostic lights, located on the right side of the dash, are
used to alert the operator of engine related problems. At initial power up, all 3 lights will be illuminated for 2 seconds. After 2 seconds, the yellow
light will turn off. After 2.5 seconds, the red light
will turn off. After 3 seconds from power up, the
NOTES:
S Setting high rpms under no load conditions to
2350 rpm ensures that the engine will have
2200 rpms under a loaded condition.
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1-3
is restarted. There are no limits on the number of times the engine may be restarted.
NOTES:
S The engine should be shut off as soon as it
can be shut off safely. The engine should not
be run until the fault is corrected.
S
YELLOW
LIGHT
RED
LIGHT
d. Flip the diagnostic switch to the ON position for less than 3 seconds and then flip it
to the OFF position.
e. Flip the diagnostic switch to the ON position for less than 3 seconds and then flip it
to the OFF position.
f.
Flip the diagnostic switch to the ON position for more than 3 seconds and then flip
it to the OFF position.
1-4
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
04/04)
TT180S
180S--360L
360L(Rev.
(10/02)
02/04)
1-5
Failure Description
Failure Results
111* - Yellow
115* - Yellow
122 - Yellow
123 - Yellow
131 - Yellow
Engine idles when idle validation switch indicates idle and ramps up to a default set speed
when the idle validation switch indicates offidle.
132 - Yellow
Engine idles when idle validation switch indicates idle and ramps up to a default set speed
when the idle validation switch indicates offidle.
133 - Yellow
134 - Yellow
135 - Yellow
High voltage detected at the oil pressure signal pin 33 of the engine harness.
141 - Yellow
143 - Yellow
144 - Yellow
High voltage detected at the coolant temperature signal pin 23 of the engine harness.
145 - Yellow
Low voltage detected at the coolant temperature signal pin 23 of the engine harness.
146 - Yellow
151 - Red
153 - Yellow
Default value used for intake manifold temperature. No engine protection for intake manifold
temperature.
154 - Yellow
Default value used for intake manifold temperature. No engine protection for intake manifold
temperature.
155 - Red
191 -
1-6
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Failure Description
Failure Results
234 - Red
235 - Blue
241 - Yellow
242 - Yellow
243 - None
245 - None
Electronic Control Module (ECM) can not control the engine cooling fan. Fan will remain on
or off.
261* - Yellow
Power derate.
264 - Yellow
High or low voltage detected at the fuel temperature sensor signal circuit inside the VP44
pump controller.
278* - Yellow
283 - Yellow
284 - Yellow
297 - Yellow
319 - Blue
Power to the real time clock has been interrupted and its setting is no longer valid.
349 - Yellow
352 - Yellow
361 - Red
TT180S
180S--360L
360L(Rev.
(10/02)
08/04)
1-7
Failure Description
Failure Results
362 - Yellow
363 - Yellow
364* - Yellow
365 - Yellow
Low voltage detected at VP44 fuel pump controller supply voltage circuit.
366 - Yellow
367 - Red
368 - Yellow
369 - Yellow
372 - Yellow
373 - Red
374* - Yellow
375 - Yellow
376* - Red
377 - Yellow
381* - Yellow
382* - Yellow
385 - Yellow
1-8
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Failure Description
Failure Results
386 - Yellow
387 - Yellow
391 - Yellow
415 - Red
418 - ????
419 - Yellow
An error in the intake manifold pressure sensor signal was detected by the ECM.
422 - Yellow
429 - Yellow
No water-in-fuel protection.
431 - Yellow
432 - Yellow
Idle validation signal at pin 26 of the OEM harness indicates the throttle is at the idle position
when the throttle position signal at pin 30 of
the OEM harness indicates the throttle is not
at the idle position when the throttle position
signal at pin 30 of the OEM harness indicates
the throttle is at the idle position.
433 - Yellow
Boost pressure signal indicates boost pressure is high when other engine parameters
(i.e., speed and load) indicate boost pressure
should be low.
434* - Yellow
441 - Yellow
442 - Yellow
None on performance.
443 - Yellow
Low voltage detected at throttle position sensor +5 VDC supply pin 29 of the OEM harness.
Engine idles when idle validation switch indicates idle and ramps up to a default set speed
when idle validation switch indicates off-idle.
TT180S
180S--360L
360L(Rev.
(10/02)
1/04)
1-9
Failure Description
Failure Results
444 - Yellow
488 - Yellow
Intake manifold air temperature signal indicates intake manifold air temperature is above
the minimum engine protection threshold.
489 - Yellow
515 - Yellow
516 - Yellow
517 - Yellow
524 - Yellow
527* - Yellow
528 - Yellow
529* - Yellow
The device controlled by the Dual Output Driver B signal will not function properly.
551 - Yellow
611* - None
No effect.
768 - Yellow
1-10
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
08/04)
Engine Troubleshooting
The following chart includes some of the problems
that an operator may encounter during the service
life of a Cummins diesel engine. Always check the
easiest and obvious things first, such as the master
disconnect switch, the neutral start switch, an empty
fuel tank, closed fuel shut off, dead battery or corroded terminals. Study the problem thoroughly
before starting to work on the engine. Ask yourself
the following questions.
1. What were the warning signs preceding the
trouble?
Problem
1. Engine will not
crank or cranks
slowly
continued
TT180S
180S--360L
360L(Rev.
(10/02)
08/04)
Cause
Correction
1-11
Problem
Cause
Correction
2. Engine difficult to
start or will not
start (no exhaust
smoke present)
1-12
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
Cause
3. Engine difficult to
start or will not
start (exhaust
smoke present)
continued
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
Correction
1-13
Problem
Cause
Correction
5. Engine speed
surges at low or
high idle
1. Engine is cold.
1-14
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
7. Engine runs rough
or misfires
Cause
1. Engine is cold.
2. Electronic fault codes are active.
3. Air is in the fuel system.
4. Incorrect fuel grade is being used
or fuel quality is poor.
5. Fuel leak.
6. Fuel filter is restricted.
7. Fuel supply is restricted.
8. Fuel lift pump is malfunctioning.
9. Engine mounts are worn or
damaged.
10. Moisture is in the wiring harness
connectors.
8. Lubricating oil
pressure is low
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
Correction
1. Refer to Correction 1. of Problem
6. in this troubleshooting chart.
2. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
3. Refer to Correction 9. of Problem
2. in this troubleshooting chart.
4. Use correct grade of fuel.
5. Check the fuel lines, fuel connections, and fuel filters for leaks.
6. Replace fuel filter.
7. Check fuel lines for restrictions.
8. Refer to Correction 9. of Problem
3. in this troubleshooting chart.
9. Replace engine mounts.
10. Dry the connectors with an electronics cleaner.
1-15
Problem
9. Lubricating oil
pressure is high
Cause
1. Engine coolant temperature is too
low.
2. Oil pressure switch, gauge, or
sensor is malfunctioning.
3. Oil does not meet specifications.
4. Electronic fault codes are active.
1-16
Correction
1. Refer to Problem 15. of this troubleshooting chart.
2. Check the oil pressure switch,
gauge, or sensor for correct operation.
3. Refer to Correction 2. of Problem
8. in this troubleshooting chart.
4. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
12. Coolant temperature is above normal (Gradual
Overheat)
Cause
1. Charge air cooler fins, radiator fins, 1. Inspect the charge air cooler, radiaor air conditioner condenser fins
tor, and air conditioner condenser
are damaged or obstructed with
fins. Clean if necessary.
debris.
2. Coolant level is low.
2. Inspect the engine and cooling system for external coolant leaks.
Repair if necessary. Add coolant.
3. Electronic fault codes are active.
3. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
4. Fan shroud is damaged or missing, 4. Inspect the shroud and recirculaor the air recirculation baffles are
tion baffles. Repair, replace, or
damaged or missing.
install if necessary.
5. Incorrect oil level.
5. Add or drain engine oil.
6. Oil is contaminated with coolant or 6. Refer to Problem 11. in this troublefuel.
shooting chart.
7. Radiator hose is collapsed,
7. Inspect the hoses and replace any
restricted, or leaking.
defective hoses.
8. Incorrect coolant mixture of anti8. Verify the concentration of antifreeze and water.
freeze in the coolant. Add antifreeze or water to bring concentration to the proper mixture. Refer to
Coolant in Section 5 for the correct coolant concentration.
9. Oil level is above or below proper
9. Check the oil level. Add or drain oil
level.
if necessary.
10. Coolant temperature gauge is mal- 10. Test the temperature gauge.
functioning.
Replace the gauge if necessary.
11. Fan drive belt is loose, tight, or not 11. Check belt tension and tighten /
correctly aligned.
loosen if necessary. Replace drive
belt if necessary.
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
Correction
1. Inspect the engine and cooling system for external coolant leaks.
Repair if necessary. Add coolant.
2. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
3. Inspect and vent the cooling system. Refer to Filling The Cooling
System in Section 5.
4. Replace drive belt.
5. Replace radiator cap(s).
6. Inspect the hoses and replace any
defective hoses.
1-17
Problem
Cause
Correction
13. Coolant tempera7. Coolant temperature gauge is mal- 7. Test the temperature gauge.
ture is above norfunctioning.
Replace the gauge if necessary.
mal (Sudden Over- 8. Charge air cooler fins, radiator fins, 8. Inspect the charge air cooler, radiaheat)
or air conditioner condenser fins
tor, and air conditioner condenser
(Continued)
are damaged or obstructed with
fins. Clean if necessary.
debris.
14. Coolant loss
7. Engine is overheating.
1-18
1. Inspect the engine and cooling system for external coolant leaks.
Repair / replace damaged cooling
components. Add coolant.
2. Inspect the engine for coolant leaking 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. Repair / replace damaged components.
3. Replace radiator cap(s).
4. Inspect the hoses and replace any
defective hoses.
5. Check the coolant fill line for
restrictions or obstructions.
6. Drain and flush the cooling system.
Fill with correct mixture of antifreeze and water (refer to Coolant
in Section 5 for the correct coolant
concentration).
7. Refer to Problems 12. and 13. in
this troubleshooting chart.
1. Test the temperature gauge.
Replace the gauge if necessary.
2. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
3. Check the fan drive and controls.
4. Check the thermostat for the correct part number and for correct
operation.
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
Cause
5. Turborcharger is malfunctioning.
Correction
1. Refer to Correction 6. of Problem
14. in this troubleshooting chart.
2. Check the transmission oil cooler
and torque converter cooler for
coolant leaks.
3. Check the oil cooler for coolant
leaks and cracks.
4. Check the cylinder head gasket.
Replace if necessary.
1. Check for loose wires and verify
that the fuel shutoff valve is functioning properly.
2. Inspect the air intake ducts.
Locate and isolate the source of
the fumes. Make repairs as
needed.
3. Check the fuel lines, fuel connections, and fuel filter for leaks using
a combustible gas detector service
tool.
1. Check the air intake system for
restriction.
2. Remove the turbocharger drain line
and check for restriction. Clean or
replace the drain line.
3. Check the turbocharger oil seal for
leaks and condition of seal.
1. Use lower gear.
2. Refer to Correction 9. of Problem
2. in this troubleshooting chart.
3. Check air filter for restrictions.
Replace air filter if required.
4. Check the intake and exhaust systems for loose or damaged piping
connections and / or missing pipe
plugs. Check the turbocharger and
exhaust manifold mounting.
5. Monitor the turbocharger boost
pressure with an electronic service
tool.
continued
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1-19
Problem
19. Exhaust smoke
excessive under
load
(Continued)
Cause
6. Engine is cold.
1-20
Correction
6. Allow the engine to warm to operating temperature. If the engine
will not reach operating temperature, refer to Problem 15. in this
troubleshooting chart.
7. Check the AFC for leaks. Repair
any leaks found. Check and clean
AFC tubing and fittings for obstructions.
1. Check the fan hub, alternator, and
air conditioner compressor for
interference. Isolate belt-driven
accessories and check for vibration.
2. Refer to Problem 31. in this troubleshooting chart.
3. Verify the correct idle speed setting. Increase the idle speed with
the idle increment switch or an
electronic service tool.
4. Replace engine mounts.
5. Check the fan. Replace fan if
blade is missing or fan is damaged.
6. Refer to Problem 7. in this troubleshooting chart.
7. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
8. Inspect the vibration damper.
Replace if necessary.
9. Clean and replace the alternator.
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
22. Engine will not
reach rated speed
(rpm)
Cause
1. Electronic fault codes are active.
2. Truck speed is too low for
adequate cooling with high engine
load.
3. Tachometer is not calibrated or is
malfunctioning.
Correction
1. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
2. Reduce the engine load. Increase
the engine (fan) rpm by downshifting.
3. Compare the tachometer reading
with a handheld tachometer or an
electronic service tool reading.
Calibrate or replace the tachometer
as required.
4. Tighten the fittings, repair plumbing, or replace wastegate diaphragm.
5. Inspect the charge air cooler for
internal and external restrictions.
6. Remove restriction from fuel
supply.
7. Measure and correct if back pressure is above specification.
8. Refer to Correction 9. of Problem
3. in this troubleshooting chart.
9. Check the truck brakes for dragging, transmission malfunction,
cooling fan operation cycle time,
and engine-driven units.
10. Refer to Problem 23. in this troubleshooting chart.
1. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
2. Use correct grade of fuel.
3. Engine power decreases above
recommended altitude. Operate
this engine in altitudes under
11,000 feet.
4. Refer to Correction 3. of Problem
22. in this troubleshooting chart.
5. Check the intake and exhaust systems for restrictions. Inspect the
intake air filter and replace as
required.
6. Refer to Correction 4. of Problem
19. in this troubleshooting chart.
continued
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1-21
Problem
23 Engine power output is low
(Continued)
Cause
7. Air leak between the turbocharger
and intake manifold.
Correction
7. Check for leaks in the air crossover
tube, charge air cooler connections, hoses, or through holes in
the manifold cover and repair or
replace if necessary.
8. Inspect the charge air cooler for air
restrictions or leaks.
9. Check the fuel lines, fuel connections, and fuel filter(s) for leaks.
Check the fuel lines to the fuel
tank.
10. Refer to Correction 9. of Problem
2. in this troubleshooting chart.
11. Remove restriction from fuel
supply.
12. Inspect the fuel return lines for
restrictions.
13. Replace fuel filter.
14. Check the overflow valve. Replace
if necessary.
15. Refer to Correction 9. of Problem
3. in this troubleshooting chart.
16. Refer to Correction 9. of Problem
22. in this troubleshooting chart.
17. Check the oil level. Verify the oil
pan capacity. Drain excess oil if
necessary. Fill the system to the
specified level.
continued
1-22
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
Cause
Correction
1. Fan drive belt is loose, tight, or not 1. Check belt tension and tighten /
correctly aligned.
loosen if necessary. Replace drive
belt if necessary.
2. Oil is thin or diluted.
2. Use proper quality engine oil (refer
to the Fuel and Lubricant Specifications in the Appendices for the
proper type of oil to be used).
3. Vibration damper is damaged.
3. Inspect the vibration damper.
Replace if necessary.
4. Air intake or exhaust leaks.
4. Refer to Correction 4. of Problem
19. in this troubleshooting chart.
5. Air filter is restricted.
5. Check air filter for restrictions.
Replace air filter if required.
6. Coolant temperature is above
6. Refer to Problems 12. and 13. in
normal.
this troubleshooting chart.
7. Engine mounts are worn or
7. Replace engine mounts.
damaged.
8. Air conditioner compressor noise is 8. Isolate component and check for
excessive.
noise.
9. Fan is loose, damaged, or has
9. Check the fan. Replace fan if
excessive hub bearing end play.
blade is missing or fan is damaged.
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1. Tighten pulley.
2. Check the condition of the batteries. Replace batteries if required.
3. Check battery cables and connections.
4. Install an alternator with a higher
capacity.
5. Test the alternator output. Replace
the alternator or voltage regulator if
required.
6. Reset circuit breakers, repair wires,
or make good connections.
1-23
Problem
Cause
continued
1-24
Correction
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
Cause
Correction
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1-25
Problem
Cause
Correction
1. Fill fuel tank.
2. Replace fuel filter.
3. Tighten all fuel fittings and connections between the fuel tanks and
the fuel pump.
4. Check and repair the standpipe if
necessary.
5. Refer to Correction 9. of Problem
3. in this troubleshooting chart.
1. Fill fuel tank.
2. Refer to Correction 9. of Problem
22. in this troubleshooting chart.
3. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
4. Check the fuel lines, fuel connections, and fuel filters for leaks.
5. Refer to Problem 42. in this troubleshooting chart.
6. Inspect the charge air cooler for air
restrictions or leaks.
7. Refer to Correction 4. of Problem
19. in this troubleshooting chart.
8. Refer to Correction 9. of Problem
2. in this troubleshooting chart.
9. Check air filter for restrictions.
Replace air filter if required.
10. Use the correct grade of fuel.
11. Replace fuel filter.
12. Refer to Correction 9. of Problem
3. in this troubleshooting chart.
1. Refer to Problems 2. and 3. in this
troubleshooting chart.
2. Fill fuel tank.
3. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
4. Check the time limit on idle shutdown with an electronic service
tool.
5. Dry the connectors with an electronics cleaner.
continued
1-26
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
37. Engine shuts off
unexpectedly or
dies during deceleration
(Continued)
Cause
6. Battery voltage supply to the electronic control module (ECM) is low,
interrupted, or open.
7. Air is in the fuel system.
8. Fuel shutoff is malfunctioning.
Correction
6. Check the battery connections.
7. Refer to Correction 9. of Problem
2. in this troubleshooting chart.
8. Refer to Correction 1. of Problem
17. in this troubleshooting chart.
1. Fill fuel tank.
2. Refer to Correction 4. of Problem
2. in this troubleshooting chart.
3. Dry the connectors with an electronics cleaner.
4. Refer to Correction 9. of Problem
2. in this troubleshooting chart.
5. Replace fuel filter.
6. Refer to Correction 9. of Problem
22. in this troubleshooting chart.
7. Use the correct grade of fuel.
40. Fault code warning 1. Ignition switch is in the OFF posilamps do not illution.
minate
2. Battery voltage supply to the electronic control module (ECM) is low,
interrupted, or open.
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
1-27
Problem
42. Intake manifold air
temperature is
above normal
Cause
1. Charge air cooler fins, radiator fins, 1. Inspect the charge air cooler, radiaor air conditioner condenser fins
tor, and air conditioner condenser
are damaged or obstructed with
fins. Clean if necessary.
debris.
2. Fan drive belt or water pump belt is 2. Check the fan drive belt and water
broken.
pump belt. Replace belts if
required.
3. Fan shroud is damaged or missing, 3. Refer to Correction 4. of Problem
12. in this troubleshooting chart.
or the air recirculation baffles are
damaged or missing.
4. Truck speed is too low for
4. Reduce the engine load. Increase
adequate cooling with high engine
the engine (fan) rpm by downshifting.
load.
5. Verify that the engine and truck
5. Truck cooling system is not
adequate.
cooling systems are using the correct components.
1-28
Correction
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
45. Lubricating oil
sludge in the
crankcase is
excessive
46. Turbocharger
leaks engine oil or
fuel
Cause
1. Bulk oil supply is contaminated.
2. Coolant temperature is below
normal.
3. Crankcase ventilation system is
plugged.
4. Incorrect fuel grade is being used
or fuel quality is poor.
5. Oil does not meet specifications.
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
Correction
1. Refer to Correction 2. of Problem
41. in this troubleshooting chart.
2. Refer to Problem 15. in this troubleshooting chart.
3. Check and clean the vent tube.
4. Use the correct grade of fuel.
5. Refer to Correction 2. of Problem
8. in this troubleshooting chart.
1-29
English
Metric
50
345
10
69
260
127
13 / 12.3
12.3 / 11.6
15
14.2
25
6.2
15
3.7
3.0
10.1
30.6
17
27
14
20
68
176
80
190
88
46
174
10.4
9.8
15
103
212
100
160
71
180
82
200
93
Air System
Air inlet restriction,
f ll load maximum
full
ma im m
Fuel System
Maximum fuel inlet restriction
Cooling System
Coolant flow
Thermostats
*The lubricating oil temperature range is based on the temperature measurement in the oil gallery. When measuring the oil temperature in the pan, it will normally be approximately 10F higher than the oil gallery temperature.
1-30
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
11/05)
Hoist Circuit
TT180S
180S--360L
360L(Rev.
(10/02)
11/05)
1-31
1-32
Section 2
BLEED
SCREW
DRAIN VALVE
CAUTIONS:
S Dispose of used fuel filters and drained
fuel in accordance to federal and local
regulations.
S Mechanical tightening of the fuel filters may
result in seal and / or cartridge damage.
Tighten the filters by hand only.
1. Provide a suitable container to catch drained
fuel and use a strap wrench to remove the filters from the adapter.
2. Clean the area around the filter heads.
3. Fill the new filters with clean fuel and lubricate
the O-ring seals with clean oil.
4. Lubricate the seal on the fuel filters with clean
fuel.
5. Install filters and tighten them 1/2 turn after the
seals contact the adapter.
Changing The In-line Fuel Filter (Illustration 2-3).
The in-line fuel filter, located in the suction fuel
line, should be changed every 6 months or 1500
hours, whichever comes first, or more often if
conditions warrant.
CAUTION: Dispose of used fuel filter in
accordance to federal and local regulations.
TT180S
180S -- 360L
360L (Rev.
(10/02)
02/04)
FUEL
FILTER
DRAIN
VALVE
FUEL / WATER
SEPARATOR
2-1
IN-LINE
FUEL
FILTER
LEVER
3. Operate the lever on the fuel lift pump (Illustration 2-4) until the fuel flowing from the fitting is
free of air.
4. Tighten the bleed screw to a torque value of
7 ft-lbs.
General Information
Fuel Capacity:
T180S - 220S
T250S - 360L
2-2
35 Gallons
50 Gallons
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
FILLER
NECK
FUEL LEVEL
SENDING UNIT
FILLER CAP
FUEL
STRAINER
DRAIN PLUG
2-3
Section 3
SAFETY
FILTER
AIR
CLEANER
HOUSING
VACUATOR
PRECLEANER CAP
PRIMARY
FILTER
COVER
LATCH
IF EQUIPPED
3-1
cleaner housing.
S
3-2
Cause
2. Replace vacuator.
1.
a. Replace filter.
1. Damaged filter(s).
1. Replace filter(s).
180S--360L
360L(Rev.
(10/02)
TT180S
08/03)
Correction
1. Remove restriction.
5. Tighten connections.
3-3
Section 4
Exhaust System
Introduction. The exhaust system is responsible
for venting exhaust gases, generated by the
engine, to the atmosphere. It also provides noise
suppression.
WARNINGS:
S Do not service exhaust system until exhaust
system is cool. Failure to do so may result
in severe burns.
S Keep all flammable materials away from
exhaust components.
S Avoid breathing toxic exhaust fumes.
S All internal combustion engines produce
carbon monoxide, which can become concentrated in enclosed areas. Exposure to
carbon monoxide can result in serious injuries or health hazards, including death.
Properly ventilate work areas, vent exhaust
fumes, and keep shop clean and dry.
(A) Initial symptoms of carbon monoxide
poisoning include headaches, dizziness, and nausea. The smell of lift truck
exhaust means carbon monoxide is
present.
(B) If you experience initial symptoms, shut
off the lift truck engine, notify your
employer, and obtain medical attention.
S Never rely on a control device to reduce carbon monoxide output. Carbon monoxide
levels can change depending on maintenance. Make sure carbon monoxide level
testing is included in regular maintenance
procedures and that ventilation is used as
the primary control for emissions.
Maintenance. There is minimal maintenance
required on the standard exhaust system.
1. Check for leaks at all pipe connections.
2. Check for holes in the muffler and exhaust
piping.
3. Keep muffler guard clean and in place.
4. Keep guard clean and in place.
5. Keep handle clean and in place.
6. Keep exhaust system free of debris.
Exhaust Purifier (if equipped). The exhaust purifier converts up to 90% of the harmful diesel
exhaust gases, such as carbon monoxide and
hydrocarbons, into harmless carbon dioxide and
water vapor by forcing the exhaust gases to pass
through a porous ceramic honeycomb configured
catalyst. This design promotes uniform gas flow
through the catalyst element while generating only
minimal back pressure.
CAUTION: Avoid using fuel and oil additives which contain lead, sodium, arsenic,
phosphorus, mercury, antimony, zinc, copper,
tin, iron, nickel, and chrome. These additives
will poison the exhaust purifier and reduce its
useful life.
Exhaust Purifier Maintenance (Illustration 4-1).
If the diesel engine is allowed to idle for long periods of time, the exhaust purifier may accumulate
deposits of soot. These deposits can block the
effectiveness of the exhaust purifier and gradually
reduce the engines power. The exhaust purifier
can be removed and cleaned using the procedures listed below.
1. Remove the clamps to remove the exhaust
purifier from the exhaust system.
2. Remove clamps to remove the end cones to
expose the catalyst.
3. Wash the exhaust purifier by using steam or
high pressure water (not greater than 100 psi),
keeping the tip of the nozzle at least 2 inches
away from the face of the catalyst. Do not use
detergents. Wash the exhaust purifier through
both the inlet and outlet ends. Continue the
washing operation until the water, coming from
the exhaust purifier, is clear or almost clear.
4. Dry the exhaust purifier with compressed air
(no greater than 100 psi), keeping the nozzle
at least 2 inches away. The purpose of this
operation is to remove as much water from the
exhaust purifier as possible. The exhaust purifier should now be clean.
5. Place the exhaust purifier back into the
exhaust system and operate the engine. Be
sure to tighten all clamps and fittings as
necessary.
4-1
CLAMPS
4-2
Section 5
Cooling System
Introduction. The engine cooling system cools
the engine. Refer to Section 9A for transmission
cooling system and Section 15C for the wet disc
brakes cooling system (if equipped) to find more
detailed cooling information on these particular
cooling systems.
Cooling Requirements. The following requirements must be followed for trouble-free operation
of the cooling system.
TT180S
180S -- 360L
360L (Rev.
(10/02)
12/03)
5-1
9 Gallons
5-2
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
RADIATOR
15 PSI
PRESSURE CAP
OVERFLOW
TANK
TRANSMISSION
FLUID COOLER
FAN
PLATE
SHROUD
TT180S
180S -- 360L
360L (Rev.
(10/02)
12/03)
5-3
Hoist Circuit
5-4
COOLANT RECOVERY
BOTTLE
DEAERATION
LINE
UPPER
RADIATOR
HOSE
RADIATOR
LOWER
RADIATOR
HOSE
CUMMINS QSB5.9-C155
ENGINE
COOLANT FLOW
TT180S
180S -- 360L
360L (Rev.
(10/02)
11/05)
05-2351
5-5
Section 6
Electrical System
Introduction. This machine incorporates a
12-volt DC electrical system. Optional equipment
selected by the customer will determine the electrical equipment to be installed in addition to the
standard electrical system.
Major Components. The 12 volt electrical system consists of a battery, battery charging alternator, voltage regulator, starter switch, starter, and
starter solenoid. The remainder of the electrical
system consists of lights and / or gauges,
switches, circuit breakers, and accessory circuits.
The above items are included as standard equipment in the electrical system. Refer to Illustrations
6-1 through 6-14 for location of components and
wiring diagrams.
Battery. The machine is equipped with an industrial type, long life battery. The battery is perishable and requires servicing on a regular basis.
Batteries that are properly cared for can be
expected to give long trouble-free service. Perform the following procedures to maintain the battery in a serviceable condition.
WARNINGS:
S Under no circumstances allow any sparks or
open flames around battery. No smoking.
Batteries produce a highly flammable gas
which could lead to battery explosion if
ignited.
S Never check the battery by placing a metal
object across the battery posts.
CAUTION: Overfilling cells of the battery
can cause poor performance or early failure.
1. Check the level of the electrolyte regularly.
Add distilled water if necessary to bring the
electrolyte level to 3/8 inch above the separator plates. Do not overfill.
2. Keep the top of the battery, terminals, and
cable clamps clean. When necessary, wash
them with a solution of baking soda and water,
and rinse with clean water.
CAUTION: Do not allow the soda and
water solution to enter the battery cells.
3. Inspect the cables, clamps, and hold down
bracket regularly. Replace any damaged
parts. Clean and re-apply a light coating of
TT180S
180S--360L
360L(Rev.
(10/02)
04/04)
DANGER
6-1
06-2443 SHT. 01
6-2
T 180ST-180S
360L-(Rev.
360L11/05)
(10/02)
CB5 CB6
20
15
AMP AMP
HORN &
WORK
LIGHTS
CB7
15
AMP
FUEL
HEATER
CUTOFF
VALVE
CB8
20
AMP
CB9
10
AMP
DEFROSTER ELECTRIC
SHIFTER
POWER
&
APC
AUTO /
MANUAL
SWITCH
AIR RIDE
SEAT
POWER
CB1
10
AMP
TOP &
REAR
WIPER
IGNITION
SWITCH
POWER
6-3
6-4
6-5
Component Troubleshooting
Alternator. The alternator provides 13.8 - 14.4
VDC at 100 amps of power for the electrical system and trickle charges the battery when the
engine is being operated.
The most effective way to troubleshoot an alternator is with an ammeter on the output of the alternator. Another good check is with a voltmeter
across the battery. With the engine operating at a
moderate speed, the voltmeter reading should
never exceed 15.5 VDC. If reading exceeds 15.5
VDC, the alternator is defective and requires
replacing. Should the alternator output drop
below 12 VDC, the alternator is defective and
requires replacing.
Perform the following procedures below for abnormal charging system operation.
1. Insure that the undercharged condition (below
12 VDC) has not been caused by accessories
having been left on for extended periods of
time.
2. Check the drive belt for proper tension (refer to
Drive Belt Tension in Section 1).
3. Ensure that battery is good and capable of
holding a charge.
4. Inspect the wiring for defects. Check all connections for tightness and cleanliness, including the slip connectors at the alternator and
connections at the battery.
5. With the ignition switch on and all wiring harness leads connected, connect a voltmeter
from:
a. alternator BAT terminal to ground
b. alternator #1 terminal to ground
c. alternator #2 terminal to ground
An infinity reading indicates an open circuit
between the voltmeter connection and battery. Repair if required.
6. With all accessories turned off, connect a voltmeter across the battery. Operate engine at
moderate speed. If voltage is 15.5 VDC or
higher, replace the alternator.
Circuit Breakers. Circuit breakers are employed
in the electrical system and act similar to fuses,
protecting the electrical circuits and valuable components from overloads which could damage
6-6
in most cases, is always the hot side. Either signal can be sent to the relay to energize it. Ensure
that pin 85 is properly grounded, when required,
and / or that 12 VDC is present at pin 86 when it is
required.
When the relay is de-energized, the internal
switch connects pins 30 and 87A completing the
circuit of the two pins. When the relay is energized, the coil shifts the switch, connecting pins
30 and 87 completing the circuit of the two pins.
The most effective way to troubleshoot the relay is
with an ohmmeter. This can be accomplished by
removing the female spade connectors from pins
30, 87, and 87A. In a de-energized state, ensure
that pins 30 and 87A have continuity between
them. With an ohmmeter, check the resistance
between pins 30 and 87a. The ohmmeter should
indicate a reading of 0 - 40 ohms. Energize the
relay and check the resistance between pins 30
and 87. The ohmmeter should indicate a reading
of 0 - 40 ohms. If these two checks are good, the
relay is good. If one of these checks fails and 12
VDC required at pin 86 was or was not present, or
ground signal at pin 85 was or was not present,
dependant on the desired state of relay (ener-
Common
Contact
Normally Closed
Contact (when relay
is de-energized)
Normally Open
Contact (when relay
is de-energized)
6-7
1
5
14
13
9
4
8
14
13
6-8
12
T 180S
T 180S
- 360L- (Rev.
360L (10/02)
07/03)
14
13
12
6-9
2
4
The most effective way to troubleshoot the proximity switch is with an ohmmeter. This can be
accomplished by disconnecting the weatherpack
connector (located approximately 3 foot from the
proximity switch), jumpering the red wires at each
end and jumpering the black wires at each end.
Target the proximity switch (the red L.E.D. should
illuminate) and check the continuity of the white
and orange wires located on the proximity switch
side of the weatherpack. The ohmmeter should
indicate a reading of 0 - 40 ohms. Remove the
target from the proximity switch and with an ohmmeter, check the continuity between the white and
orange wires. The ohmmeter should now read
infinity If these two checks are good, the proximity
switch is good. If one of these checks fails, the
proximity switch is bad and must be replaced. Do
not rely on the red L.E.D. as a sole indicator that
the internal switch did, in fact, close. Always
check the continuity between the white and
orange wires as described above.
6
14
13
9
10
L.E.D.
12
6-10
RED
BLUE
WHITE
BLACK
ORANGE
NC
COM.
NO
Cathode
Anode
6-11
Problem
1. Low voltage.
Correction
1.
a. Low 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 troubleshooting section below.
c. Loose, broken, or corroded
wires. Repair or replace wires.
d. Ensure that low voltage condition has not been caused by
accessories having been left
on for extended periods of
time.
2. Alternator
1.
a. Ensure drive belts are tight.
b. Inspect the wiring for defects.
Check all connections for tightness and cleanliness, including the slip connectors at the
alternator and connections at
the battery.
c. Defective alternator. Replace
alternator.
3. Battery Disconnect
Switch (if equipped)
6-12
Component
4. Ignition Switch
continued
Problem
Correction
6-13
Component
Problem
(Continued)
12 VDC was present at the B terminal, replace the ignition switch
(S1).
4. Ignition Switch
(Continued)
5. Wires
6-14
Correction
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
11/05)
TT180S
180S--360L
360L(Rev.
(10/02)
11/05)
6-15
6-16
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Cause
Correction
1. Replace alternator.
1. Refer to the Component Trouble4. Seat Belt light (DS4) 1. Seat belt relay (K2, Illustration
6-12) is defective.
shooting earlier in this section.
is illuminated with
the seat belt fas2. Wire #35 from Seat Belt light
2. Isolate and repair short.
tened.
(DS4) to seat belt relay (K2) has a
short on it.
3. Wire #38 is open.
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
6-17
Problem
7. Low Air light (DS7)
is illuminated and
buzzer (LS5) is
energized.
Cause
Correction
continued
6-18
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
Problem
Cause
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
Correction
3.
a. Find leak and repair.
b. Replace the pressure relief
valve of the pilot pump.
6-19
6-20
Hoist Circuit
TT180S
180S--360L
360L(Rev.
(10/02)
11/05)
6-21
6-22
Section 6A
2
3
4
5
6
7
6A-1
06C-0032 SHT. 01
6A-2
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
08/04)
Section 9
Transmission
FLUID
DIPSTICK
PILOT
PUMP
CHARGING
PUMP
MAIN / STEERING
PUMP
INCHING
CYLINDER
FILLER
CAP
CONTROL
VALVE
OIL SUMP
SCREEN
DRAIN PLUG
transmission control valve for actuating the direction and speed clutches. This requires only a
small amount of transmission fluid. The remaining
fluid is directed through the torque converter circuit to the transmission fluid cooler and returns to
the transmission for positive lubrication. After entering the converter housing, the fluid is directed
through the stator support to the converter blade
cavity and exits in the passage between the turbine shaft and converter support. The fluid then
flows out of the converter to the fluid cooler. After
9-1
9-2
General Information
240 psi
300 psi
Oil Temperature
180 - 200_F
(82.2 - 93.3_C)
Oil Capacity
26 Quarts
9-3
COOLER
TEMPERATURE SWITCH
(245_ N.O.)
CONVERTER OUT
TO COOLER
(25 PSI MIN. - 70 PSI MAX.
AT RATED RPM)
TRANSMISSION
INSTALL PRESSURE
GAUGE IN THIS LINE
FOR CONVERTER OUT
PRESSURE CHECK
IN FROM COOLER
9-4
TRANSMISSION
FLUID FILTER
TRANSMISSION
FLUID COOLER
9-5
Transmission Troubleshooting
Electrical / Mechanical Checks. Prior to checking any part of the system from a hydraulic standpoint, the following electrical / mechanical checks
should be made.
1. Ensure that the proper solenoids on control
valve are energized. When the solenoids are
energized they become magnetized. A magnetic field can be checked at the nut that holds
the solenoid to the cartridge. Some solenoids
employ a metal nut, encased in plastic, which
will require removal to detect a magnetic field.
An effective way to accomplish this is with a
metal wrench.
2. Ensure that the inching valve is not engaged
nor sticking.
Hydraulic Checks. Before checking the torque
converter, transmission, and associated hydraulic
system for pressures and rate of flow, it is essential that the following preliminary checks be made.
NOTE: Do not attempt these checks with cold fluid.
1. Check the fluid level in the transmission. This
should be done with the fluid temperature
between +180 F and +200 F, and the engine
operating at idle.
Problem
1. Low clutch
pressure
2. Work the machine to bring the fluid temperature up to the operating range (refer to step 1.
above).
NOTE: If the machine cannot be worked, the converter can be stalled to bring the temperature up
to the operating range. Perform the following procedures to stall the converter.
3. With the right service brake pedal applied,
move the shifter to the forward position and
third gear selected.
4. Continue to apply the brakes and accelerate
the engine approximately one-half to threequarter throttle for 30 seconds, let off accelerator for 10 seconds.
5. Repeat step 4. until the desired converter outlet temperature is reached.
CAUTION: Full throttle stall speeds for an
excessive length of time will overheat the
converter.
6. When checking the pressures, always check
the charge pump and converter out pressures
first.
Cause
Correction
3. Replace pump.
2. Low converter
charging pump
output
continued
9-6
Problem
Cause
Correction
2. Low converter
charging pump
output (Continued)
3. Noisy converter
4. Overheating
5. Lack of power
6. No Forward
continued
5. Remove restriction.
9-7
Problem
6. No Forward
(Continued)
7. No Reverse
8. No Forward or
Reverse
Cause
Correction
4. Place the transmission in the neutral position and rev up the engine.
If the truck tries to move in forward,
clutch plates are fused together.
Replace or rebuild transmission.
continued
9-8
Problem
8. No Forward or
Reverse
(Continued)
9. Vibration
Cause
Correction
1. Defective differential.
1. Repair differential.
5. Repair differential.
9-9
9-10
9A-Transmission Cooler
Section 9A
Transmission Cooler
FROM TRANSMISSION
TO COOLER
TRANSMISSION
TO TRANSMISSION
FROM COOLER
TRANSMISSION
FLUID COOLER
9A-1
9A-2
9C-Transmission Controls
Section 9C
9C-1
Light should not illuminate. If it does illuminate, ground to the coil is missing.
d. If 12 VDC plus ground is present at the
solenoid and it does not energize, the solenoid is bad and needs replacing.
7. The energized solenoids for Forward First
Gear are Forward, First, and Second.
8. If all three of the solenoids are energized,
place the shifter in Forward Second and
repeat procedure 6. again for Forward
Second.
NOTE: Electrical operation of all the solenoids is
easily confirmed when the magnetic field is
detected by touching the nut that secures the coil
to the cartridge of the desired solenoid.
9C-2
2. No Reverse
Cause
Correction
3. Replace solenoid.
5. Defective shifter.
3. Replace solenoid.
5. Defective shifter.
9C-3
Problem
3. No Forward or
Reverse
Cause
1. Parking brake is applied.
8. Defective shifter.
8. Replace shifter.
continued
9C-4
Correction
Problem
Cause
Correction
5. Truck Stays in
Third Gear Only
6. No First Gear
4. Defective shifter.
continued
9C-5
Problem
6. No First Gear
(Continued)
7. No Second Gear
9C-6
Cause
Correction
4. Defective shifter.
Problem
8. No Third Gear
TT180S
180S--360L
360L(Rev.
(10/02)
08/04)
Cause
Correction
1. Defective shifter.
9C-7
Hoist Circuit
9C-8
09C-2272
9C-9
9C-10
PIN WIRE#
A1
B1
C1
D1
1
2
3
4
E1
F1
G1
H1
J1
K1
8
9
10
A2
B2
11
12
C2
13
D2
14
E2
15
F2
G2
H2
J2
K2
A3
16
17
18
19
20
21
B3
C3
22
23
D3
E3
24
25
F3
G3
H3
J3
K3
26
27
28
29
30
FUNCTION
BATTERY PLUS (wire #301)
BATTERY GROUND (wires #11)
Shift Fail Light (wire #308)
Transmission Valve Solenoid #1 (wire
#304)
Transmission Valve Solenoid #2 (wire
#305)
Transmission Valve Forward Solenoid
(wire #306)
Transmission Valve Reverse Solenoid
(wire #307)
Not Used In This Truck
Not Used In This Truck
12 VDC supply to Shift Fail Light (cab
wire #310)
BATTERY PLUS (cab wire #301)
Signal Ground for sensors (cab wire
#348)
Shift lever Forward Input (cab wire
#312)
Shift lever Reverse Input (cab wire
#319)
Shift lever selection wire (active in 1st
and 2nd gear, wire #315)
Not Used In This Truck
Not Used In This Truck
Not Used In This Truck
Not Used In This Truck
Not Used In This Truck
Engine speed hot (inductive pickup,
wire #321)
Not Used In This Truck
Transmission speed (inductive pickup,
wire #323)
Not Used In This Truck
Shift lever selection wire (active in 1st
gear, wire #314)
Not Used In This Truck
Not Used In This Truck
Not Used In This Truck
Manual / automatic switch (wire #309)
Not Used In This Truck
T 180S
T 180S
- 360L
- 360L
(Rev.
(10/02)
7/05)
Normal Display
showing gear position
and error messages
Speed Display
expressed in
turbine RPM
Speed Display
expressed in km/h
YELLOW (T)
LED
Input monitoring
reflects the inputs
TT180S
180S--360L
360L(Rev.
(10/02)
7/05)
9C-11
9C-12
T 180S
T 180S
- 360L
- 360L
(Rev.
(10/02)
7/05)
Diagnostic Codes
APC 70 Normal Display (Transmission Status)
The normal display shows information for the driver about the status of the transmission.
If the vehicle is in a certain gear, the gear position is displayed on the right digit. The gear
direction is shown on the left digit.
FWD 1st
transmission
is in fwd 1st
gear
NEUT 1st
transmission
is in net. 1st
gear
REV 1st
transmission
is in rev 1st
gear
FWD 2nd
transmission
is in fwd 2nd
gear
NEUT 2nd
transmission
is in net. 2nd
gear
REV 2nd
transmission
is in rev 2nd
gear
FWD 3rd
transmission
is in fwd 3rd
gear
NEUT 3rd
transmission
is in net. 3rd
gear
REV 3rd
transmission
is in rev 3rd
gear
TT180S
180S--360L
360L(Rev.
(10/02)
7/05)
9C-13
9C-14
FWD 1st
shift lever is
in fwd 1st
position
NEUT 1st
shift lever is
in net. 1st
position
REV 1st
shift lever is
in rev 1st
position
FWD 2nd
shift lever is
in fwd 2nd
position
NEUT 2nd
shift lever is
in net. 2nd
position
REV 2nd
shift lever is
in rev 2nd
position
FWD 3rd
shift lever is
in fwd 3rd
position
NEUT 3rd
shift lever is
in net. 3rd
position
REV 3rd
shift lever is
in rev 3rd
position
T 180S
T 180S
- 360L
- 360L
(Rev.
(10/02)
7/05)
Turbine Speed
In order to get the turbine speed display, the mode button must be depressed once. After
releasing the mode button, the display will show the turbine speed RPM (input RPM of the
transmission). If no dot is visible on the display, the value must be multiplied by 10 in order to
get the correct value. If a dot is visible, the value must be multiplied by 100 in order to get the
correct value.
Possible codes:
this segment is illuminated when the turbine speed has been selected
indicated turbine
speed is 630 RPM
indicated turbine
speed is 1400 RPM
Engine Speed
In order to get the engine speed display, the mode button must be depressed once after the
turbine speed was displayed. After releasing the mode button, the display will show the engine
speed RPM. If no dot is visible on the display, the value must be multiplied by 10 in order to
get the correct value. If a dot is visible, the value must be multiplied by 100 in order to get the
correct value.
Displayed Mode:
this segment is illuminated when the engine speed has been selected
The possible codes for the engine speed are identical to the possible codes for turbine speed.
TT180S
180S--360L
360L(Rev.
(10/02)
7/05)
9C-15
turbine speed
<1
engine speed
Displayed Modes:
this segment is illuminated
when the speed ratio has
been selected
turbine speed
<1
engine speed
Displayed Modes:
this segment is illuminated
when the speed ratio has
been selected
Battery Voltage
In order to get the battery voltage display, the mode button must be depressed once after the
downshift speed ratio was displayed. After releasing the mode button, the display will show
the battery voltage displayed in Volts. If no dot is visible on the display, the value displayed will
have a fractional amount from below .5 V. If a dot is visible, the value displayed will have a
fractional amount above .5 V.
Possible codes:
this segment is illuminated when the battery voltage has been selected
9C-16
T 180S
T 180S
- 360L
- 360L
(Rev.
(10/02)
7/05)
this segment is illuminated when the input test has been selected
Possible codes:
FWD Input
this segment is illuminated when the roll shifter is in the fwd position,
12 VDC will be present on wire 312 and on pin C2 of the metri-pack
connector to the APC 70
REV Input
this segment is illuminated when the roll shifter is in the rev position,
12 VDC will be present on wire 319 and on pin D2 of the metri-pack
connector to the APC 70
TV1 Input
this segment is illuminated when the shifter is in 1st gear, 12 VDC will be
present on wire 314 and on pin E3 of the metri-pack connector to the
APC 70
TV2 Input
this segment is illuminated when the shifter is in 2nd gear, 12 VDC will
be present on wire 315 and on pin E2 of the metri-pack connector to the
APC 70
Manual / Automatic Switch
this segment is illuminated when the operator has requested manual
shifting, 12 VDC will be present on wire 326 and on pin J3 of the
metri-pack connector to the APC 70
TT180S
180S--360L
360L(Rev.
(10/02)
7/05)
9C-17
Output 2
wire 307 for
TVR is good
Output 3
wire 304 for
TV1 is good
Output 1
wire 306 for
TVF is
shorted
Output 2
wire 307 for
TVR is
shorted
Output 3
wire 304 for
TV1 is
shorted
Output 1
wire 306 for
TVF is open
Output 2
wire 307 for
TVR is open
Output 3
wire 304 for
TV1 is open
NOT USED
Output 8
wire 308 for
shift fail light
is good
NOT USED
Output 8
wire 308 for
shift fail light
is shorted
NOT USED
Output 8
wire 308 for
shift fail light
is open
Output 4
wire 305 for
TV2 is good
Output 4
wire 305 for
TV2 is
shorted
Output 4
wire 305 for
TV2 is open
9C-18
T 180S
T 180S
- 360L
- 360L
(Rev.
(10/02)
7/05)
Fault Codes
In order to find out which fault was last detected, hold down the mode button M button for more than
2 seconds. The display will then show, alternately the fault area and the fault type. If several faults
coexist, only the severest one is shown. When this fault display is active, the T-LED will be blinking to
focus the drivers attention of the current problems.
Listed below are the faults listed in the order of severity (severest fault on top) along with displayed
codes:
Fault
Fault Area
Fault Type
TT180S
180S--360L
360L(Rev.
(10/02)
7/05)
9C-19
Fault
Fault Area
Fault Type
9C-20
T 180S
T 180S
- 360L
- 360L
(Rev.
(10/02)
7/05)
6/05)
Hoist Circuit
TT180S
180S--360L
360L(Rev.
(10/02)
7/05)
9C-21
9C-22
Section 11
Drive Shaft
TRANSMISSION
TO AXLE
DRIVE SHAFT
CROSS
ASSEMBLY
CROSS
ASSEMBLY
CENTERLINES MUST
BE PARALLEL
11-1
Section 13
Steer Axle
Introduction. The steer axle is mounted to the
frame with two pivot pins. The pivot pins are an
integral part of the axle. Pivot pin bushings are
installed on the front and rear pivot pins. All routine maintenance can be accomplished with the
steer axle connected to the frame.
STEER AXLE
MOUNTING BOLT
STEER CYLINDER
MOUNTING BOLTS
LOCK NUT
13-1
Section 14
Drive Axles
AXLE HOUSING FLUID
LEVEL CHECK / FILL PLUG
AXLE HOUSING
DRAIN PLUG
HUB CHECK /
DRAIN PLUG
14-1
14-2
T 180S -T360L
180S(Rev.
- 360L
02/24/04)
(10/02)
BLEEDER
VALVE
BRAKE
COOLING
INPUT PORT
BRAKE
COOLING
OUTPUT PORT
AXLE HOUSING
FLUID LEVEL
CHECK / FILL PLUG
HIGH
PRESSURE
BRAKE APPLY
PORT
BRAKE
COOLING
DRAIN PLUG
HUB CHECK /
DRAIN PLUG
AXLE HOUSING
DRAIN PLUG
POSITION PLUG
HERE TO FILL
OR CHECK LEVEL
180S--360L
360L(Rev.
(10/02)
TT180S
02/24/04)
plug is in the 9 oclock position of hub rotation. Fill the hub with recommended lubricant (refer to the Fuel and Lubricant
14-3
16 Quarts
5 Quarts
PRC-775P:
Differential
Planetary Hub (each)
22 Quarts
2.5 Quarts
14-4
T 180S -T360L
180S(Rev.
- 360L
02/24/04)
(10/02)
Cause
Correction
1. Fill to correct level with recommended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
1. Replace seals.
4.
4.
1. Differential
overheats
4. Noisy differential
a. Noise on drive
b. Noise on coast
c. Constant noise
d. Noise on turns
180S--360L
360L(Rev.
(10/02)
TT180S
02/24/04)
a. Adjust.
b. Adjust.
c.
1) Replace bearings.
2) Replace gears.
d. Replace differential parts.
14-5
Problem
5. Final drives overheat (Planetary
Axles)
14-6
Cause
Correction
1. Fill to correct level with recommended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
1. Replace gasket.
2. Replace gasket.
1. Fill to correct level with recommended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
2. Replace bearings.
3. Replace gears.
T 180S -T360L
180S(Rev.
- 360L
02/24/04)
(10/02)
Cause
Correction
1. Fill to correct level with recommended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
3. Noisy differential
a. Noise on drive
b. Noise on coast
c. Constant noise
d. Noise on turns
180S--360L
360L(Rev.
(10/02)
TT180S
02/24/04)
a. Adjust.
1) When the transmission to axle
drive shaft is installed, the flanges
on the drive shaft, must be aligned
as shown in Illustration 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. Adjust.
c.
1) Replace bearings.
2) Replace gear.
d. Replace differential parts.
14-7
Problem
4. Noisy final drives
(Planetary Axles)
Cause
Correction
1. Fill to correct level with recommended oil (refer to the Fuel and
Lubricant Specifications in the
Appendices).
2. Replace bearings.
3. Replace gears.
1. Replace gasket.
2. Replace gasket.
1. Replace seals.
1. Replace seal.
9. Signs of external
leakage exist
1. Replace seals.
14-8
T 180S -T360L
180S(Rev.
- 360L
02/24/04)
(10/02)
Section 15
SET
SCREW
COVER
INSTRUMENT PANEL
AIR PRESSURE GAUGE
NUT
TT180S
180S--360L
360L(Rev.
(10/02)
01/03)
15-1
AIR PRESSURE
GAUGE
(Illustration 15-1)
PARKING BRAKE
VALVE
(Illustration 15-5)
SERVICE
BRAKE VALVE
(Illustration 15-4)
AIR GOVERNOR
(Illustration 15-1)
INCHING BRAKE
VALVE
(Illustration 15-4)
AIR INCHING
CYLINDER
(Illustration 15-9)
DOUBLE CHECK
AND QUICK
RELEASE VALVES
(Illustration 15-6)
BRAKE
ACTUATORS
(Illustrations 15-10
and 15-12)
BRAKE RELAY
VALVE
(Illustration 15-7)
AIR DRAIN
CABLES
(Illustrations 15-15
and 15-16)
PARKING BRAKE
CHAMBER
(Illustration 15-8)
AIR TANK
(Illustration 15-3)
15-2
CHECK
VALVE
SAFETY
VALVE
BAFFLE
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
15-3
RH
LH
LOW AIR
SWITCH (S14)
SYSTEM AIR
D - DELIVERY
S - SOURCE
INDICATES AIR FLOW
15-4
PARKING BRAKE
VALVE (PP1)
PARKING BRAKE
SWITCH (S12)
(30 PSI)
15-5
QUICK RELEASE
VALVE
DOUBLE CHECK
VALVE
15-6
WARNINGS:
S Death or serious injury could result from a
runaway truck. Park the truck on a hard,
level surface, block the wheels in both
PARKING
BRAKE CHAMBER
NUT
CLEVIS
CLEVIS PIN AND
COTTER PIN
BRAKE
CALIPER
INSIDE LINK
BOLT
OUTSIDE LINK
BRAKE
ACTUATION LEVER
Illustration 15-8. Parking Brake Actuation Adjustment and Friction Pad Replacement
15-7
Parking Brake Pads (Illustration 15-8). The parking brake pads should be checked for wear every
6 months or 1500 hours, whichever comes first. If
the parking brake actuator adjustment cannot be
made, because the parking brake pads are worn,
then the brake pads must be replaced. The parking brake pads should be replaced when the thickness of the brake pad friction material is 1/16 or
less. The parking brake pads must be replaced in
pairs.
Perform the following procedures to replace the
parking brake pads:
WARNING: 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, and Lock Out & Tag-Out the truck.
1. Park the truck on a hard, level surface, block
the wheels of the truck in both directions,
place the parking brake in the released position and Lock Out &Tag Out the truck.
2. Disconnect the outside and inside links from
the brake actuation lever.
3. Remove both mounting bolts and spacers from
the brake caliper.
4. Remove the brake caliper from the brake disc
on the transmission.
5. Using a flat-bladed screwdriver, pry out the
brake pads from the brake caliper. Care
should be used in removing the lever side
brake pad. Do not to break off the plastic center snap tabs off the plastic brake actuator
cover.
6. Before replacing the brake pads, clean out the
existing pad glue from the pad compartment.
7. Install the new lever side brake pad.
NOTE: If the plastic center snap tabs are gone,
dab some silicone gasket adhesive around the
back edge of the lever side brake pad.
8. Place a layer of silicone gasket adhesive all
along the back edge of the new carrier brake
pad and install pad.
9. Install the brake caliper on the brake disc of
the transmission. Place spacers between the
transmission and the brake caliper. Then,
15-8
TRANSMISSION
DISENGAGED
5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
BOLT
BELLCRANK STOP BRACKET
CLEVIS
BELLCRANK
CLEVIS PIN
CLEVIS ASSEMBLY
INCHING VALVE SPOOL
CLEVIS PIN
ROD END
AIR INCHING CYLINDER
CLEVIS PIN
BELLCRANK MOUNTING
BRACKET
13. JAM NUT
14. JAM NUT
15. GREASE FITTING
15
3-3/16
Procedures 4. & 5.
6
8
1/2
13
10
11
5
12
9
14
6
7
TRANSMISSION
DISENGAGED
TRANSMISSION
ENGAGED
180S--360L
360L(Rev.
(10/02)
TT180S
08/03)
15-9
15-10
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
11/05)
PUSH
ROD
MANUAL
SLACK
ADJUSTER
CLEVIS
PIN
RELEASED
2.62 + 0.125
BRAKE
ACTUATOR
APPLIED
5.12 + 0.125 (PRC425Q)
4.87 + 0.125 (PRC775P)
(MAXIMUM ALLOWABLE STROKE)
ADJUSTING LOCK
SLEEVE
SCREW
PUSH ROD
CLEVIS
SPRING
SLACK
ADJUSTER
15-11
PUSH ROD
DUST PLUG
15-12
RELEASE
STUD
WASHER
RELEASE
STUD NUT
15-13
AIR PRESSURE
GAUGE
(Illustration 15-1)
PARKING BRAKE
VALVE
(Illustration 15-5)
SERVICE
BRAKE VALVE
(Illustration 15-4)
AIR GOVERNOR
(Illustration 15-1)
INCHING BRAKE
VALVE
(Illustration 15-4)
AIR INCHING
CYLINDER
(Illustration 15-9)
POWER
CLUSTER
(Illustration 15-14)
BREATHER
(Illustration 15-14)
DOUBLE CHECK
AND QUICK
RELEASE VALVES
(Illustration 15-6)
BRAKE COOLING
VALVE
(Illustration 15C-2)
BRAKE RELAY
VALVE
(Illustration 15-7)
BRAKE
RESERVOIR
(Illustration 15-14)
AIR TANK
(Illustration 15-3)
BRAKE
MANIFOLD VALVE
(Illustration 15C-1)
AIR DRAIN
CABLES
(Illustrations 15-15
and 15-16)
PARKING BRAKE
CHAMBER
(Illustration 15-8)
Illustration 15-13. Optional Wet Disc Brakes Control System Components Identification
15-14
23
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
HOSE ASSEMBLY
ELBOW
HOSE ASSEMBLY
STRAIGHT FITTING
BREATHER
STRAIGHT FITTING
BUSHING
COUPLING
HOSE ASSEMBLY
HOSE ASSEMBLY
ELBOW
QUICK PRESSURE CHECK
TEE
TEE
BUSHING
AIR HOSE ASSEMBLY
ELBOW
BOLT
LOCKWASHER
PRESSURE CONVERTER
MOUNTING PLATE
45 FITTING
BRAKE RESERVOIR
NUT
LOCKWASHER
BOLT
9
CROSS-MEMBER PLATE
BLEEDER VALVE
26
16
22
25
24
17
20
1
27
21
28
19
11
18
5
15
14
3
7
6
3
13
12
11
10
15-15
Cause
Correction
1. Adjust linkage (refer to Brake
Actuator Linkage Adjustments in
this section for adjustment procedures).
3. Drain valve(s) of air tank is not fully 3. Ensure that drain valve(s) fully
closed or defective.
closes and is sealing off the air
tank. Replace drain valve(s) if
required.
15-16
Problem
3. Excessive loss of
air pressure with
an air operated
component activated
Cause
1. Defective left or right service brake
valve.
5. Brakes overheat
Correction
15-17
Problem
Cause
Correction
1. Refer to Correction 1. of Problem
4. in this troubleshooting chart.
2. Replace brake shoes.
Cause
Correction
1. Fill brake reservoir to the proper
level with the specified fluid (refer
to the Fuel and Lubricant Specifications in the Appendices).
continued
15-18
Problem
Cause
Correction
7. Refer to the manufacturers axle
manual for repairs.
8. Bleed the brake system (refer to
Wet Disc Brake Bleeding in this
section).
3. Drain valve(s) of air tank is not fully 3. Ensure that drain valve(s) fully
closed or defective.
closes and is sealing off the air
tank. Replace drain valve(s) if
required.
4. Defective check valve in air tank.
continued
15-19
Problem
3. Low air pressure
(no air operated
components activated)
(Continued)
4. Excessive loss of
air pressure with
an air operated
component activated
5. Noisy brakes
15-20
Cause
Correction
AIR
INTAKE
FILTER
GOVERNOR
LEFT
BRAKE
ACTUATOR
AIR
COMPRESSOR
QUICK RELEASE
VALVE
PARKING
BRAKE
VALVE
RIGHT
BRAKE
ACTUATOR
DOUBLE
CHECK
VALVE
TO AIR
PRESSURE
GAUGE
BRAKE
RELAY
VALVE
AIR
INCHING
CYLINDER
RIGHT
BRAKE
VALVE
LEFT BRAKE
VALVE
(INCHING)
TRANSMISSION
CONTROL
VALVE
HYDRAULIC
TANK
DRAIN
VALVES
AIR
TANK
SPRING
BRAKE
CHAMBER
SAFETY
(RELIEF)
VALVE
CUMMINS QSB5.9
ENGINE AIR
COMPRESSOR
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
GOVERNOR
AIR
HORN
BREATHER
BRAKE
RELAY
VALVE
15-2431
15-21
15-22
AIR
INTAKE
FILTER
BRAKE
RESERVOIR
GOVERNOR
PRESSURE
CHECK
AIR
COMPRESSOR
TO AIR
PRESSURE
GAUGE
SPRING
BRAKE
CHAMBER
PARKING
BRAKE
VALVE
QUICK
RELEASE
VALVE
POWER
CLUSTER
BREATHER
HYDRAULIC
TANK
BRAKE
RELAY
VALVE
DOUBLE
CHECK
VALVE
AIR
INCHING
CYLINDER
RIGHT
BRAKE
VALVE
LEFT BRAKE
VALVE
(INCHING)
TRANSMISSION
CONTROL
VALVE
DRAIN
VALVES
AIR
TANK
SPRING
BRAKE
CHAMBER
SAFETY
(RELIEF)
VALVE
CUMMINS QSB5.9
ENGINE AIR
COMPRESSOR
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
GOVERNOR
BREATHER
AIR
HORN
BRAKE
RELAY
VALVE
15-2432
15-23
15-24
Section 15C
cooler. It contains a pressure switch (S23, Illustration 15C-1) and a relief valve set for 325 psi.
Should back pressure in the hydraulic cooler circuit exceed 325 psi, the relief valve will open and
relieve pressure to the hydraulic tank. The brake
manifold valve also contains a 15 psi check; its
function is to ensure that anytime flow is present,
that the 10 psi required to open pressure switch
(S23) can be obtained. Should the hydraulic fluid
pressure drop below 10 psi, pressure switch (S23)
will close, sending ground to the (DS8), illuminating the light.
Hydraulic Fluid Cooler (Illustration 15C-4). The
hydraulic fluid cooler, located on the back of the
radiator, is forced-air cooled. Hydraulic fluid is circulated through the coolers tubes. The fan circulates air across the cooler and through fins to cool
the hydraulic fluid.
PRESSURE
SWITCH (S23)
325 PSI
PRESSURE
RELIEF VALVE
PRESSURE
CHECK (BQ1)
INDICATES BRAKE
COOLING FLUID FLOW
15C-1
15 PSI CHECK
VALVES
PRESSURE
CHECK (PRG2)
PRESSURE
CHECK (BCC)
PRESSURE
CHECK (PRG1)
INDICATES BRAKE
COOLING FLUID FLOW
TEMPERATURE
SWITCH (S24)
15C-2
Cause
Correction
6. The suction line of the pilot pump is 6. Check connections and tighten
taking in air.
connections.
7. Mis-adjusted pressure relief valve
in the pilot pump.
15C-3
POWER
CLUSTER
HYDRAULIC
TANK
SUCTION
STRAINER
HYDRAULIC
TANK
15C-0078 SHT. 01
15C-4
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
04/04)
15C-0078 SHT. 02
TT180S
180S--360L
360L(Rev.
(10/02)
04/04)
15C-5
15C-6
15D-Air Dryer
Section 15D
15D-1
10
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
14 13
9
8
11
30
31
24
17 16
21 22
20
19
22
23
31
32
4
25
28
18
25
29
26
7
5
2
27
3
27
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
15D-2
AIR DRYER
GOVERNOR
DISCHARGE
HOSE
AIR TANK
ELECTRICAL
JUNCTION BOX
15D-0071
15D-3
Cause
Correction
2. Water in vehicle.
3. Defective governor.
4. With the supply port open to atmosphere, apply 120 psi at the control
port. Apply a soap solution to the
supply port and exhaust port
(purge valve seat area). Permissible leakage - 1 bubble in five
seconds.
continued
15D-4
Problem
2. Water in vehicle.
(Continued)
Cause
Correction
2. Air system charged from outside air 2. If system must have outside air fill
source (outside air not passing
provision, outside air should pass
through air dryer).
through air dryer. This practice
should be minimized.
3. Air dryer not purging (see Problem
5.).
4. Purge (air exhaust) time insufficient 4. Check causes and corrections for
due to excessive system leakage
Problem 1.
(see causes for Problem 1.).
5. Air by-passes desiccant cartridge
5. Replace desiccant cartridge / end
assembly.
cover O-ring.
Check to make sure desiccant cartridge assembly is properly
installed.
6. Purge time is significantly less than 6. Replace desiccant cartridge / end
minimum allowable.
cover O-ring.
Check to make sure desiccant cartridge assembly is properly
installed.
Replace desiccant cartridge
assembly.
3. Safety valve on air 1. Desiccant cartridge plugged.
dryer popping off or
exhausting air.
15D-5
Problem
4. Constant exhaust
of air at air dryer
purge valve exhaust
or unable to build
system pressure.
(Charge mode)
Cause
Correction
2. Defective governor.
9. Purge valve stays open - supply air 9. Replace purge valve housing
leaks to control side.
assembly O-rings.
5. Air dryer does not
purge or exhaust air.
15D-6
Problem
Cause
Correction
15D-7
Section 16
Steering System
Introduction. The steering system provides guidance control of the truck. The steering circuits
have priority over hydraulic fluid flow.
Major Components. The steering system consists of a pump, sensing valve, steering valve,
cushion valve (if equipped), hoses, and various
fittings.
Steer Cylinder (Illustration 16-3). The steer cylinder is a double-acting cylinder that turns the steer
tires.
Setting Hydraulic Pressures. Refer to Setting
Hydraulic Pressures in Section 22 for procedures to set the pressures for the steer sensing
valve.
STEER RELIEF
VALVE
STEER SENSING
VALVE
MAIN / STEERING
PUMP
16-1
STEERING
COLUMN
STEERING
VALVE
16-2
Cause
1. Hydraulic fluid is bypassing the
steer cylinder piston packing.
8. Remove restriction.
3. Steering tires do
not track with
steering wheel
Correction
9. Remove restriction.
16-3
Problem
Cause
Correction
4. Wrong response to 1. Hoses to ports in steering valve are 1. Re-connect hoses in the correct
steering wheel
crossed.
hose layout.
5. Continuous steering wheel rotation
6. Limited hydraulic
flow
7. Low steer
pressure
1. Incorrect steer relief valve pressure 1. Adjust steer relief valve for correct
setting.
pressure (refer to Steer Sensing
Valve in the Setting Hydraulic
Pressures in Section 22 for procedures to adjust the steer relief
valve pressure).
2. Defective steer relief valve.
16-4
HYDRAULIC
TANK
STEER
SENSING
VALVE
CUSHION
VALVE
(OPTIONAL)
16-2282
16-5
16-6
Section 17
17-1
WARNINGS:
S Mixing parts of one manufacturers rims with
those of another is potentially dangerous.
Always check manufacturer for approval.
S Do not be careless or take chances. If you
are not sure about the proper mating of rim
and wheel parts, consult a wheel and rim
expert. This may be the tire man who is
servicing your fleet or the rim and wheel
distributor in your area.
1. Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn, damaged, and severely rusted components. Use a
wire brush to remove dirt and rust if necessary.
2. Clean and repaint rims to stop detrimental
effects of corrosion. Be very careful to clean
all dirt and rust from the lock ring gutter. This
is important to secure the lock ring in its proper
position. Using air inflation equipment,
equipped with a filter, helps remove moisture
from the air line, preventing some corrosion.
3. Ensure that the correct parts, that match your
type of wheels, are being used in assembly.
Check with manufacturer if you have any
doubts.
Tire / Wheel Jacking
WARNINGS:
S Never rely solely upon jacks or hoists to
17-2
S
S
S
S
Demounting
WARNINGS:
S Do not let anyone mount or demount tires
without proper training as stated in OSHA
Rules and Regulations 1910.177 Servicing
multi-piece and single piece rim wheels.
S Do not stand in front of the tire during
deflation.
S Demounting tools apply pressure to rim
flanges to unseat tire beads. Keep your
fingers clear. Slant the demounting bead
tool about 10 to keep it firmly in place. If it
slips off, it can fly with enough force to kill.
Always stand to one side when you apply
hydraulic pressure.
S Never force or hammer rim components,
especially rim components under pressure.
S Never attempt to weld on an inflated tire / rim
assembly.
S Do not under any circumstances, attempt to
rework, weld, heat or braze any rim components 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.
S Do not hammer on rims or components with
steel hammers. Use rubber, lead, plastic, or
brass faced mallets, if it is necessary, to tap
components together.
S 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.
S Make sure to remove the valve core to
17-3
WARNINGS:
S Do not locate the compressor in a utility
room used for storing flammable solvents,
paints, thinners, etc. The flammable vapors
will be sucked into the compressor intake
while the compressor is charging.
S Do not clean the compressor air filter with a
flammable solvent. Use a non-flammable
solvent, such as carbon tetrachloride.
S Do not use alcohol, methanol, or other
flammable agents in the compressor to prevent freezing of the condensation inside the
compressor. Drain the compressor tank
frequently or locate the compressor inside to
eliminate the freezing problem.
S Do not locate the compressor near a battery
charger. Batteries emit hydrogen gas, which
is highly flammable, during the charging process, and could be sucked into the compressor intake.
Compressor Precautions
There have been instances of tires exploding violently while on vehicles. The forces involved in
this type explosion are sufficient enough to cause
serious personal injury to anyone in the immediate
vicinity. Some of these explosions are believed to
have been caused by flammable vapors entering
the tire during inflation. When the machine is
operating, the temperature of the air and vapor
mixture inside the tire will increase. The temperature inside the tire will also increase with an
increase in ambient temperature and when subjected to direct sunlight. If the vapor and air mixture inside the tire are within the ratio limits that
will support combustion, and any or all of the
above heat increasing factors cause the temperature to rise, an explosion may occur. The following are some warnings that can prevent flammable vapors from entering the compressor and
subsequently being entrapped in tires.
17-4
1
1.
2.
2
3
3.
4.
5.
6.
7.
DRIVE AXLE
INNER RIM
SPACER
RIM
FLANGE
LOCK RING
NUT
WHEEL NUT
OUTER BASE
5
4
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.
6
7
17-5
Section 18
Chassis
Introduction (Illustrations 18-1 and 18-2). The
chassis is carefully engineered and ruggedly
constructed, although welded steel structures always contain undetectable cracks, especially
welded joints. When these joints are subject to
fluctuating stresses of significant magnitude,
these cracks will grow. This is known as fatigue
crack growth. No matter how low the stress levels
are kept, some fatigue crack growth will occur in
all welded structures.
Structural Inspection and Reporting Procedure
(Refer to SIRR in the Appendices). Follow the
OSHA rules, 29 CFR, 1910.178 (Q)(1), (5), & (7)
which require inspecting industrial trucks daily
before being placed in service, removing trucks
from service if cracks are found, and making
repairs only if authorized by the manufacturer. If
trucks are used on a round-the-clock basis, they
shall be examined after each shift. OSHA 29 CFR
1910.178 (p)(1) requires that trucks in need of
repair be taken out of service. Areas to be
inspected on the truck chassis include mast
Chassis Troubleshooting
Problem
Cause
1. Metal fatigue.
1. Cracks in welds
(Refer to SIRR in the
Appendices)
2. Overloading.
Notify Taylor
Machine Works,
3. Rough terrain.
Inc. for proper
repair procedures.
Correction
1. Have cracks in welds repaired
immediately.
2. Refer to Correction 1. above and
avoid overloading the truck.
3. Refer to Correction 1. above and, if
possible, avoid operating truck on
rough terrain.
2. Engine support
mounts broken
1. Engine vibration.
2. Transmission vibration.
18-1
Problem
3. Transmission
support mounts are
broken
Cause
1. Transmission vibration.
2. Engine vibration.
Correction
1. Refer to Problem 9. in the Transmission Troubleshooting chart in
Section 9.
2. Refer to Problem 19. in the
Engine Troubleshooting chart in
Section 1.
18-2
18-3
18-4
Section 20
Cab
WARNINGS:
S Failure to adhere to any of the above could
lead to personal injury, death, or property
damage.
S Avoid stepping on the top Lexan cover while
servicing the truck.
S Always use approved ladders, stands, or
manlifts to reach high places on the truck.
S The top Lexan cover is a part of the OSHA
mandated FOPS (Falling Object Protective
Structure). Do not remove or replace cover
with glass.
Troubleshooting
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
20-1
20-2
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
20A-Air Conditioning
System
Section 20A
20A-2308
TT180S
180S -- 360L
360L (Rev.
(10/02)
12/03)
pressure gas to the condenser. When the thermostat signals for cooling, an electrical signal is sent
to the compressor clutch, engaging the clutch and
driving the compressor.
NOTE: Any time repairs are made to the air conditioning system which require the recovery of the
refrigerant, it is recommended that the drier be
changed and 3 ounces of AC ester lubricating oil
be added to the dryer.
Condenser. The condenser changes the refrigerant from a hot, high pressure gas (from the compressor) to a warm, high pressure liquid (to the
drier) by cooling the refrigerant.
Drier. The drier stores a volume of refrigerant.
Additionally, it filters and removes moisture from
the refrigerant. The drier receives a warm, high
pressure liquid (from the condenser) and sends a
warm, high pressure liquid (to the expansion
valve). The drier is equipped with a binary switch
which protects the compressor.
20A-1
SCREW
20A-2
FILTER
continued
TT180S
180S -- 360L
360L (Rev.
(10/02)
12/03)
Cause
Correction
5. Replace clutch.
20A-3
Problem
2. Fan blows limited or
no cold air
(Continued)
Cause
8. Evaporator coil is iced up.
5. Air conditioner
operates in one
speed only
20A-4
Correction
1. Remove obstruction.
2. Reset or replace circuit breaker
(CB15). Refer to Circuit Breakers of the Component Troubleshooting in Section 6.
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
12/03)
20H-Heating System
Section 20H
Heating System
HEATER / DEFROSTER
SHUT-OFF VALVE
SHUT-OFF
VALVE
SHUT-OFF VALVE
CUMMINS QSB5.9
GM 8.1L-V8
20H-0074
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
20H-1
20H-2
Cause
1. Defective heater switch (S5).
4. Low coolant.
continued
Correction
5. Defective wire.
20H-3
Problem
4. Heater / defroster
units (if equipped)
fan is not turning
(Continued)
5. Heater / defroster
units (if equipped)
fan is turning, but
no warm air
6. Heater / defroster
unit (if equipped)
operates in one
speed only
20H-4
Cause
Correction
5. Defective wire.
4. Low coolant.
Section 22
Hydraulic System
Introduction. The hydraulic system controls the
lift, tilt, steering, and accessory functions of the
truck.
Major Components (Illustration 22-1). Major
components of the hydraulic system include a
hydraulic tank, main / steering pump, steer sensing valve, lift / tilt valve, pilot pump, pressure
reducing valve, manual lowering valve, hydraulic
control valves, and various actuating cylinders. If
optional equipment, such as side shift or fork positioning is installed, additional valves, controls, and
cylinders will be interconnected with the standard
hydraulic system.
Hydraulic Tank (Illustration 22-3). The hydraulic
tank has a 28 gallon capacity. The tank is
equipped with suction strainers and a full-flow
return line filter. All air entering the tank is filtered
through a 10 micron disposable element.
Main / Steering Pump (Illustration 22-11). The
main / steering pump (located on the right side of
the transmission) is a tandem gear pump that provides hydraulic fluid flow to operate the hydraulic
circuits. When the pump is turned, it creates a
vacuum at the pump inlet which allows atmospheric pressure to force hydraulic fluid through a
suction strainer in the hydraulic tank into the inlet
line of the pump. The pump then mechanically
pushes this fluid to its outlet port for use in the
hydraulic circuits.
The main / steering pump has two sections, each
containing a pumping gear set. The 2 gear set
provides approximately 38 gpm of hydraulic fluid
flow at 2200 governed rpm and 13 gpm at 750
rpm (low idle). It supplies hydraulic fluid to the
steering, lift, and tilt circuits. The 1 1/4 gear set
provides approximately 22 gpm of hydraulic fluid
flow at 2200 governed rpm and 8 gpm at 750 rpm
(low idle). It supplies hydraulic fluid to the accessory valve first (if equipped) and then to the lift / tilt
valve.
Steer Sensing Valve (Illustration 22-11). The
steer sensing valve, located on the end of the
main / steering pump, provides the logic for the
steering circuit. It is linked to the steering valve
and main / steering pump. When the steering
valve is turned, pressure in a load sense line,
between the steering valve and steer sensing
valve, shifts the spool of the steer sensing valve,
directing the flow of fluid from the main hydraulics
to the steering valve. The steer sensing valve
also contains a 2500 psi steer circuit relief.
22-1
HYDRAULIC
CONTROL VALVES
(Illustration 22-11)
HYDRAULIC
TANK
(Illustration 22-3)
MAIN / STEERING
PUMP
(Illustration 22-10)
STEERING
VALVE
(Illustration 16-2)
TILT
CYLINDERS
(Illustration 22-11)
MANUAL LOWERING
VALVE
(Illustration 22-4)
STEER SENSING
VALVE
(Illustration 22-10)
LIFT / TILT
VALVE
(Illustration 22-8)
PRESSURE
REDUCING
VALVE
(Illustration 22-9)
PILOT PUMP
(Illustration 22-10)
ACCESSORY
VALVE
(Illustration 22A-3)
22-2
22-3
CAUTIONS:
S Dispose of drained hydraulic fluid and used
return filters in accordance with federal and
local regulations.
S The lift cylinders should be fully retracted to
keep dilution of the new hydraulic fluid to a
minimum.
S Plug all hoses when they are disconnected
to prevent foreign matter from entering the
hydraulic system.
1. Park the truck on a hard, level surface, block
the wheels in both directions to prevent movement, apply the parking brake and Lock Out &
Tag Out the truck.
2. Provide a suitable container, remove the drain
plug and drain the hydraulic fluid.
3. Remove the filler cap with dipstick and
strainer.
4. Remove the breather filter.
5. Remove the return filter and dispose of
properly.
6. Remove the suction strainers from the hydraulic tank and clean in solvent. Dry with compressed air.
22-4
FILLER CAP
w/DIPSTICK
RETURN FILTER
ASSEMBLY
STRAINER
BREATHER
FILTER
DRAIN PLUG
SUCTION STRAINER
(PILOT PUMP)
SUCTION STRAINER
(MAIN / STEERING PUMP)
22-5
WARNINGS:
S Death or serious injury could result from
being crushed. Do not allow anyone near
the lift truck - certainly not walking, standing
under, or beside the load or lifting
mechanism.
S Death or serious injury could result from a
runaway truck. Apply the parking brake,
block the wheels in both directions to
prevent movement of the truck and Lock Out
& Tag Out the truck.
S Death or serious injury could result from
being crushed. Do not operate the truck
with the manual lowering valve open. Close
valve before attempting to raise the carriage.
Opening The Manual Lowering Valve (Illustration
22-4). Perform the following procedures to open
the manual lowering valve:
STEM
SCREW
COLLAR
LOCK
PLATE
VALVE
STEM
22-6
1/4 turn
FULLY CLOSED
STUD
TT180S
180S--360L
360L(Rev.
(10/02)
11/05)
22-7
RESTRICTOR
OUTLET
SECTION
LIFT
SECTION
INLET
SECTION
RESTRICTOR
TILT
SECTION
22-8
LOCKNUT
PRESSURE
CHECK (PQ2)
HEX WRENCH
PRESSURE REDUCING
VALVE
PILOT PRESSURE RELIEF
(SET TO 400 PSI AT LOW IDLE)
PILOT
PUMP
PRESSURE
CHECK (PQ1)
MAIN / STEERING
PUMP
PRESSURE
CHECK (SQ1)
STEER SENSING VALVE
RELIEF SETSCREW
(SET TO 2500 PSI AT
HIGH IDLE)
Illustration 22-10. Main / Steering Pump and Pilot Pump Pressure Settings
22-9
22-10
TT180S
180S--360L
360L(Rev.
(10/02)
11/05)
3. Outlet Section
a. Install an appropriate pressure gauge into
pressure check (SQ1, Illustration 22-10).
b. Observe the pressure gauge at 2200 rpm.
The pressure reading should be minimal.
c. Install a flowmeter in the 1 1/4 hose connected to outlet section.
22-11
22-12
Problem
Cause
Correction
1. Refer to Problem 5. of this troubleshooting chart.
2. No tilting out or
slow tilting out
22-13
Problem
3. No lifting or slow
lifting
4. No lowering or
slow lowering
Cause
Correction
continued
22-14
Problem
Cause
Correction
22-15
Hoist Circuit
22-16
Hoist Circuit
TT180S
180S--360L
360L(Rev.
(10/02)
01/03)
22-17
Hoist Circuit
22-18
Section 22A
22A-3472
22A-1
22A-2
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
08/03)
22A-3
OUTLET
SECTION
INLET
SECTION
22A-4
T 180S
T 180S
- 360L
- 360L
(Rev.(10/02)
08/03)
Troubleshooting
Follow the troubleshooting chart in Section 22 for
procedures used to troubleshoot all other hydrauProblem
1. Slow or no side
shift (in either
direction)
Cause
Correction
5. Hydraulic fluid is bypassing the cyl- 5. Repack the side shift cylinder.
inder piston packing.
2. Slow or no side
shift (in one direction only)
4. Hydraulic fluid is bypassing the cyl- 4. Repack the side shift cylinder.
inder piston packing.
3. Slow or no fork
1. The accessory valves main relief
positioning (in both
valve is defective.
directions)
2. The accessory valves main relief
valve pressure setting is incorrect.
3. Low pilot pressure.
continued
22A-5
Problem
Cause
Correction
3. Slow or no fork
6. Hydraulic fluid is bypassing the
positioning (in both
cylinder piston packing.
directions)
7. Low hydraulic fluid flow.
(Continued)
4. Slow or no fork
positioning (in one
direction)
22A-6
HYDRAULIC
TANK
(TOP VIEW)
SUCTION
STRAINER
SUCTION
STRAINER
HYDRAULIC
TANK
(SIDE VIEW)
22C-2276
22A-7
22A-8
Hoist Circuit
TT180S
180S--360L
360L(Rev.
(10/02)
01/03)
22A-9
22A-10
22E-Accumulator
Section 22E
Accumulator
Introduction. The accumulator acts as a shock
absorber in the hydraulic system.
When the driven member of the hydraulic system
stops suddenly, it creates a pressure wave that
travels back through the system. This shock wave
can develop peak pressures several times greater
than normal working pressures and can be the
source of system failure. The gas cushion in an
accumulator will minimize this shock, protecting
expensive hydraulic components.
Accumulator. The accumulator, located below
the air tank, is a hydro-pneumatic piston type
accumulator which is precharged to 1250 psi of
dry nitrogen.
Checking Precharge. The precharge check
should be performed monthly or every 250 hours,
whichever comes first. Follow the procedures
listed below to check precharge (a charging kit is
available from Taylor, part number 1000-503).
See Illustration 22E-1 for charging kit.
1. To read and adjust the gas pressure or precharge pressure, all the hydraulic fluid must
be drained from the fluid side of the accumulator to zero hydraulic pressure. To accomplish
this, let the lift cylinder down and hold lever in
DOWN position for approximately one minute.
2. Remove the valve guard and cap from the
accumulator.
3. Ensure that the shaft of the air chuck (4) is fully retracted by turning the bar handle counterclockwise until it stops.
4. Do not have the charging hose (8) connected
to the gauging head assembly (1) unless free
end of charging hose is plugged.
5. Mount the swivel of the air chuck (4) on the
accumulators valve stem and hand tighten to
compress the gasket in the swivel to prevent
gas leakage.
22E-1
2
3
BAR
HANDLE
4
5
8
ACCUMULATOR
6
9
10
11
PSI Setting
2215-121 / 1 qt.
1000 psi
2788-970 / 1 qt.
1000 psi
2215-124 / 1 qt.
1500 psi
2788-955 / 1 qt.
1500 psi
2788-940 / 1 gal.
65 psi
2788-960 / 1 gal.
800 psi
2788-949 / 1 gal.
1250 psi
2788-950 / 1 gal.
1000 psi
2788-951 / 1 gal.
1500 psi
2788-952 / 1 gal.
1500 psi
2788-961 / 1 gal.
1500 psi
800 psi
1500 psi
NITROGEN
BOTTLE
Charging Kit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
22E-2
Section 27
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
27-1
PROCEDURE 2
PROCEDURE 3
PROCEDURE 1
PROCEDURE 4
PROCEDURE 5
27-2
Troubleshooting
Problem
1. Cracks in welds,
especially at the
point where the
mast is pinned to
the chassis.
(Refer to SIRR in the
Appendices)
Notify Taylor
Machine Works,
Inc. for proper
repair procedures.
Cause
1. Metal fatigue.
2. Overloading.
3. Rough terrain.
Correction
27-3
INNER MAST
OUTER MAST
BACK REST
SLIDE BLOCK
27-4
MAST RAIL
SHIM
CRACKED OR
DAMAGED SLIDE
BEARING BLOCK
1-3/4 MINIMUM
27-5
CHAIN
ROLLER
OUTER MAST
SLIDE BEARING
BLOCK
OUTER
MAST
INNER
MAST
SLIDE
BEARING
BLOCK
MAIN
ROLLERS
27-6
TT180S
180S--360L
360L(Rev.
(10/02)
12/03)
27-7
Section 28
Type C Carriage
Introduction. Described in this section is the
maintenance required for the standard Type C
carriage, optional fork positioning, and the side
shift carriage. The standard Type C carriage
permits independent, manual adjustment of the
forks from middle to full width. The Type C carriage with fork positioners permits independent
fork positioning. The side shift carriage allows the
outer carriage to be moved in either direction from
the center.
NOTE: Some trucks may be equipped with both
fork positioning and side shifting capabilities.
Major Components. The carriage consists of two
forks, fork pin, main rollers, slide bearing blocks,
two fork positioner cylinders / side shift cylinder (if
equipped), and the carriage itself.
Structural Inspection and Reporting Procedure
(Refer to SIRR in the Appendices). Follow the
OSHA rules, 29 CFR, 1910.178 (Q)(1), (5), & (7)
which require inspecting industrial trucks daily
MAIN
ROLLER
SLIDE BEARING
BLOCKS
28-1
S If the fatigue crack is allowed to grow, catastrophic failure could occur in the mast
assembly or other welded components causing serious injury to personnel and / or
property.
Maintenance / Inspection. There are several
inspectional requirements which must be performed daily. These inspections must include
checking all welds and structural members for
cracks. Check all carriage mounting hardware for
damage or loose bolts. The hydraulic fork positioner cylinders / side shift cylinder and hydraulic
hoses should be checked for leaks and functional
operation.
Forks. The forks must be inspected daily to
assure proper carriage operation. Forks must be
magnetic particle tested (magnafluxed) annually to
check for cracks (refer to the Fork Inspection,
Repair, and Testing in the Appendices).
Main Rollers (Illustration 28-1). The main rollers
employ greaseable, shielded, tapered roller bearings for increased durability. The main rollers must
be greased monthly or every 250 hours, whichever comes first. The grease fittings for the main
rollers can be found on the inside of the carriage
plate. The main rollers should be inspected for
flat spots or evidence of sliding any time the carriage is taken out of the inner mast.
28-2
Illustration 28-2. Optional Type C Carriage With Side Shift and Fork Positioners
28-3
Troubleshooting
Problem
1. Cracks in welds
(refer to SIRR in the
Appendices)
Notify Taylor
Machine Works,
Inc. for proper
repair procedures.
Cause
Correction
1. Metal fatigue.
2. Overloading.
3. Rough terrain.
28-4
Contents
Appendices
Page
SIRR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Fork Inspection, Repair, and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Leaf Chain Care, Maintenance, and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
Torque Chart - Nuts and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27
Service Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35
Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1
Section Title
SIRR
Structural Inspection, Reporting, And Repair
For Powered Industrial Trucks
A-1
A-2
WARNING:
Dangerous Action. Operating a powered industrial truck without inspecting, identifying, and
repairing fatigue cracks in the mast, carriage,
attachment, steer axle, and frame weldments.
What Can Happen. If the fatigue crack is allowed
to grow, catastrophic failure could occur in the
mast or other welded components causing serious
injury to personnel and / or property.
How To Avoid The Danger. Follow the OSHA
rules, 29 CFR, 1910.178 (q)(1), (5), & (7) which
require inspecting industrial trucks daily before
being placed in service, removing trucks from service if cracks are found, and making repairs only
as authorized by the manufacturer. If trucks are
used on a round-the-clock basis, they shall be
examined after each shift. OSHA 29 CFR
1910.178 (p)(1) requires that trucks in need of
repair be taken out of service.
Structural Inspection and Reporting Procedure. The information enclosed in this procedure
is directed to the structural weldments of the truck
assembly. Areas that should be included for
inspection on the front end of the truck are the
mast and carriage. Areas to be inspected on the
truck chassis include mast hangers, drive axle
mounts, A-frame connections, and steer axle
mounts.
Inspection for Fatigue Cracks. Welded steel
structures always contain undetectable cracks,
especially at welded joints. When these joints are
subject to fluctuating stresses of sufficient magnitude, these cracks will grow. This is known as
fatigue crack growth. No matter how low the
stress levels are kept some fatigue crack growth
will occur in all welded structures.
Eventually, these fatigue cracks will become large
enough to be detectable by nondestructive testing
methods, i.e. VT, MT, DPT, or UT.
Abbreviations. Basic Testing Symbols
Type of Test
Visual
Magnetic Particle
Dye-Penetrant
Ultrasonic
Symbol
VT
MT
DPT
UT
A-3
A-4
List of Illustrations
Illustration. 1.
Illustration. 2.
Illustration. 3.
Illustration. 4.
Illustration. 5.
Illustration. 6.
Illustration. 7.
A-5
Detail 2
Detail 3
Detail 1
Detail 4
A-6
Detail 2
VT (3)
MT (FS)
Detail 1
VT (3)
MT (FS)
A-7
Detail 3
VT (3)
MT (FS)
VT (3)
MT (FS)
Detail 4
VT (3)
MT (FS)
A-8
Carriage Details
VT (3)
MT (FS)
VT (3)
MT (FS)
A-9
Chassis Arrangement
Detail 4
Detail 3
Detail 2
Detail 1
Illustration 5. Chassis Arrangement
A-10
Chassis Details
VT (3)
MT (FS)
Detail 2
Detail 1
VT (3)
MT (FS)
A-11
Chassis Details
VT (3)
MT (FS)
Detail 3
Detail 4
VT (3)
MT (FS)
A-12
(Rev. 3/96)
A-13
A-14
(Rev. 3/96)
A-15
A-16
T 180S
- 360L
(10/02)
T 180S
- 360L
(Rev.
12/03)
Probable Cause
Correction
Normal Wear
Permanent deformation
(stretch) from overload
12.3/FT.
3. Cracked Plates
(Fatigue)
Loading beyond chains capacity (dropping load and catching
it)
A-17
Probable Cause
Correction
6. Tight Joints
Dirt or foreign substance
packed in joints
Replace chain
Replace chain
7. Enlarged Holes
5% of H
9. Worn Surfaces on Outside Links
or Pin Heads
Misalignment, rubbing on roller
flanges
Check alignment of
anchors, chain rollers
and chain roller pin.
WARNING:
I.
A-18
V. Do not weld any chain or component. Welding spatter should never be allowed to come in contact
with chain or components.
A-19
Appendix
Welding Precautions
Introduction. Once a crack is found in the truck
structure, it is advisable that you contact Taylor
Machine Works, Inc. for proper welding procedures. Your truck is comprised of different metals,
each requiring its own unique repair procedure.
Welding Precautions. Occasionally parts have
failed because of electric arc damage that
occurred during welding. This damage (starting
the failure), occurred when the current passed
from the electrode through a pin, bearing, cylinder
piston, or other moving part, seeking the ground.
Illustrated in the illustration below are some of the
parts on lift trucks subject to damage by the
passage of welding current.
LIFT CHAINS
AND MAST
ROLLERS
ENGINE
GEARS AND
BEARINGS
WHEEL
AND
SPINDLE
BEARINGS
CARRIAGE
ROLLERS
AND PINS
AXLE BEARINGS
AND GEARS
UNIVERSAL
JOINT
BEARINGS
TRANSMISSION
GEARS AND
BEARINGS
A-21
Hoist Circuit
A-22
Graphic Illustration
of Torque
Lever Arm or Wrench Handle
SAE Grade 5
SAE Grade 8
Torque
Torque
Torque
NF Threads
1/4 - 28
5/16 - 24
9
17
- 10
- 19
13
23
- 14
- 25
15
31
- 17
- 34
3/8 - 24
7/16 - 20
32
50
- 35
- 55
45
72
- 50
- 80
59
92
- 65
- 102
1/2 - 20
9/16 - 18
81
108
- 90
- 120
108
153
- 120
- 170
135
- 150
NA
5/8 - 18
3/4 - 16
162
270
- 180
- 300
216
378
- 240
- 420
271
482
- 301
- 536
7/8 - 14
1 - 14
423
657
- 470
- 730
594
918
- 660
- 1020
793 - 881
1130 - 1255
1-1/8 - 12
1-1/4 - 12
792 - 880
1116 - 1240
1296 - 1440
1800 - 2000
NA
NA
1-3/8 - 12
1-1/2 - 12
1512 - 1680
1980 - 2200
2448 - 2720
3200 - 3560
NA
NA
1/4 - 20
5/16 - 18
7
15
- 8
- 17
11
23
- 12
- 25
14
28
- 15
- 31
3/8 - 16
7/16 - 14
28
45
- 31
- 50
41
63
- 45
- 70
52
83
- 58
- 92
1/2 - 13
9/16 - 12
68
99
- 75
- 110
99
135
- 110
- 150
120
- 133
NA
5/8 - 11
3/4 - 10
135
234
- 150
- 260
198
342
- 220
- 380
240
432
- 266
- 480
7/8 - 9
1-8
387
576
- 430
- 640
540
810
- 600
- 900
671
940
- 746
- 1044
NC Threads
A- 23
SAE Grade 5
SAE Grade 8
Torque
Torque
Torque
1-1/8 - 7
1-1/4 - 7
720 - 800
1008 - 1120
1152 - 1280
1638 - 1820
NA
NA
1-3/8 - 6
1-1/2 - 6
1314 - 1460
1746 - 1940
2142 - 2380
2844 - 3160
NA
NA
NF Threads
Class 8.8
(Equiv. to Grade 5)
Classs 10.9
(Equiv. to Grade 8)
M6-1.00
- 8
10 - 11
M8-1.25
17 - 19
24 - 27
M10-1.50
33 - 37
48 - 53
M12-1.75
59 - 65
83 - 92
M16-2.00
144 - 160
207 - 230
M20-2.50
279 - 310
405 - 450
M24-3.00
486 - 540
690 - 775
M30-3.50
970 - 1078
1386 - 1540
5/16 - 18
3/8 - 16
14 (168 in-lbs)
16 (192 in-lbs)
7/16 - 14
24 (288 in-lbs)
26 (312 in-lbs)
1/2 - 13
38 (456 in-lbs)
42 (504 in-lbs)
5/8 - 11
74
81
3/4 - 10
135
150
4. Repeat Step 3 until bolts hold at least the minimum torque value indicated in the torque chart
below. Stake head at three places with a center punch.
B lt Si
Bolt
Size
Min.
Max.
A- 24
T 180S
- 360L
(Rev.(10/02)
12/03)
T 180S
- 360L
Min.
Max.
1/4 - 20
10
5/16 - 18
11
16
3/8 - 16
20
28
7/16 - 14
31
43
4. In order to achieve torque values of this magnitude, a high quality hex bit driver tool should
be used.
1/2 - 13
45
62
9/16 - 12
70
95
5/8 - 11
90
122
3/4 - 10
155
210
7/8 - 9
225
312
1-8
360
402
H Bit
Hex
Bi Size
Si
5/16 - 18
Min.
Max.
3/16
13
15
3/8 - 16
7/32
20
22
7/16 - 14
1/4
30
32
1/2 - 13
5/16
65
70
5/8 - 11
3/8
110
115
3/4 - 10
1/2
265
270
TT 180S
11/05)
180S -- 360L
360L (Rev.
(10/02)
Torque (ft-lbs)
Bolt Size /
Threads Per
Inch (NF)
Torque (ft-lbs)
Min.
Max.
1/4 - 28
10
5/16 - 24
12
17
3/8 - 24
21
29
7/16 - 20
31
43
1/2 - 20
50
70
9/16 - 18
70
95
5/8 - 18
90
125
3/4 - 16
155
210
7/8 - 14
225
312
1 - 14
362
500
A- 25
Hoist Circuit
A- 26
Lubrication
Introduction. The fork lift truck has a large number of moving parts which operate under extreme
conditions. Frequent periodic lubrication is absolutely essential to keeping the truck performing
satisfactorily with a minimum of downtime. The
illustrations in this section indicate the lubrication
locations, intervals and type of lubrication service
to be performed. The Lube Chart Legend, located
below, contains the type of lubricant to be used for
each symbol and the abbreviation representation
for each type of lubrication service. Refer, also, to
the Preventive Maintenance chart in the Appendices for lubrication intervals and to the Fuel and
Lubricant Specifications in the Appendices for
the types and weights of lubricants to be used in
different temperature ranges.
WARNINGS:
S Always park the truck on level ground, apply
the parking brake, shut down engine and
Lock Out & Tag Out truck before performing
lubrication.
S Do not climb on the mast assembly or on
other high places of the truck while performing lubrication.
S Always use OSHA approved ladders, stands,
or manlifts to reach high places on the truck.
SYMBOL
LUBRICANT
ABBREVIATIONS
A-27
500 GR
LIFT CHAINS
250 GR
TILT CYLINDERS
10 X
3000 CG
HYDRAULIC
RESERVOIR
10 X
250 DR / CG
ENGINE
250 X
BRAKE
RESERVOIR
10 X
1000 DR
TRANSMISSION
250 X
3000 DR
PLANETARY
HUBS
250 X
3000 DR
DRIVE AXLE
250 GR
DRIVE SHAFT
NOTE: Refer to the Lube Chart Legend for the type of lubricant to be
used. In addition, refer to the Fuel and Lubricant Specifications for
the types and weights of lubricants to be used in different temperature
ranges.
Illustration 1. Chassis Lubrication Points (See Lube Chart Legend for Lubrication Symbol Designation)
A-28
250 GR
FORK
250 GR
FORK PIN
250 GR
CARRIAGE
MAIN ROLLERS
NOTE: Refer to the Lube Chart Legend for the type of lubricant to be
used. In addition, refer to the Fuel and Lubricant Specifications for
the types and weights of lubricants to be used in different temperature
ranges.
Illustration 2. Carriage Lubrication Points (See Lube Chart Legend for Lubrication Symbol Designation)
A-29
CHAIN
ROLLER
OUTER MAST
SLIDE BEARING
BLOCK
OUTER
MAST
INNER
MAST
250 GR
MAIN
ROLLERS
250 GR
TILT CYLINDER
EAR
250 GR
MAST HANGER
PIN (LOCATED
ON CHASSIS)
Illustration 3. Mast Lubrication Points (See Lube Chart Legend for Lubrication Symbol Designation)
A-30
250 GR
UPPER SPINDLE PIVOT
250 GR
PIVOT BLOCK
3000 GR
WHEEL BEARING
250 GR
STEER LINK
250 GR
STEER LINK
250 GR
LOWER SPINDLE
PIVOT
NOTE: Refer to the Lube Chart Legend for the type of lubricant to be used. In addition, refer to the Fuel and Lubricant
Specifications for the types and weights of lubricants to be
used in different temperature ranges.
Illustration 4. Steer Axle Lubrication Points (See Lube Chart Legend for Lubrication Symbol Designation)
A-31
SERVICE CAPACITIES
Engine Lubrication
Cummins QSB5.9-C155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Quarts
General Motors 8.1L-V8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Quarts
General Motors 7.4L-V8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Quarts
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gallons
Fuel Tank
T 180S - 220S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Gallons
T 250M - 360L, TH 300L, TH 350L, TB 180S - 300L . . . . . . . . . . . . . . . . . 50 Gallons
Transmission
TC-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Quarts
Drive Axle
PRC-425Q
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Each Planetary Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRC-775P
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Each Planetary Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Quarts
Quarts
Quarts
Quarts
Hydraulic Tank
T 180S - 360L, TH 300L, TH 350L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Gallons
TB 180S - 300L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Gallons
Lift
Tilt Out
Steering
T 180S - 330M
2650 psi
1250 psi
T 360L
2750 psi
TH 300L
Side Shift
Fork Positioner
2500 psi
2500 psi
1500 psi
1250 psi
2500 psi
2500 psi
1500 psi
2650 psi
1250 psi
2500 psi
2500 psi
1500 psi
TH 350L
2750 psi
1250 psi
2500 psi
2500 psi
1500 psi
TB 180S, TB 220S
2650 psi
1250 psi
2500 psi
2500 psi
1500 psi
TB 250M, TB 300L
2750 psi
1250 psi
2500 psi
2500 psi
1500 psi
A-33
Hoist Circuit
A-34
Preventive Maintenance
A-Adjust
C-Clean
D-Drain
GR-Grease
POWER UNIT
Service Symbols
CG-Change
X-Check
Service Intervals
Daily Or
10 Hours
Six Months Or
1500 Hrs.
Yearly Or
3000 Hrs.
X
X
D / CG
X
C
X
X
D
CG
CG
CG
X
X
X
CG
CG
X
X
X
X
X
X
C
DRIVE SHAFT:
Lubricate drive shaft, universal joints, slip joints, and all other bearings.
AXLES
STEER AXLE - Visually inspect daily
Lubricate all grease fittings on steer axle (refer to the Lubrication section in the
Appendices)
Repack wheel bearings
Check mounting bolts
Monthly Or
250 Hours
GR
X
GR
GR
X
X
X
D
X
X
D
X
A-35
Service Symbols
A-Adjust
C-Clean
CG-Change
D-Drain
GR-Grease
X-Check
BRAKE CONTROL SYSTEM (Continued)
Fluid level in wet disc brake reservoir
PARKING BRAKE:
Actuation
Brake pads (replace as conditions warrant; refer to Section 15)
Actuator adjustment (or whenever the parking brake pads are replaced)
CHASSIS
Visually inspect chassis structure
Lubricate all grease fittings on machine not listed elsewhere. Use engine oil on
linkage not having grease fittings.
Mirrors and windows
Access and anti-slip surfaces (clean)
Audio-visual warning devices
Handrails
WHEEL EQUIPMENT:
Check tires, valve caps, wheels, lugs, and tire pressure (refer to data plate on
vehicle for torque information)
HYDRAULIC SYSTEM
HYDRAULIC PIPING AND RESERVOIR:
Maintain fluid level in hydraulic tank to full mark.
Check piping for chafing, cracked hoses, loose fittings, and leaks.
Drain hydraulic fluid, clean inside hydraulic tank and refill entire hydraulic
system.
Service Intervals
Daily Or
10 Hours
Monthly Or
250 Hours
X
X
A
X
GR
X
C
X
X
X
X
CG / C
CG
CG
C
HYDRAULIC VALVES:
Check for free operation
HYDRAULIC CYLINDERS:
Observe speed of movement - check for leaks
ACCUMULATOR:
Check precharge
Yearly Or
3000 Hrs.
HYDRAULIC FILTERS:
Replace hydraulic tank breather (as conditions warrant)
Hydraulic tank return filter
Hydraulic filter screens (suction strainers)
ATTACHMENT
MAST - Visually inspect daily
Lubricate inner and outer mast channels (or as required)
Lubricate mast hinge
Lubricate tilt cylinder bushings and other grease fittings on mast, including
special equipment.
Refer to Leaf Chain Care, Maintenance, and Replacement for additional
inspection requirements.
Check all mast mounting hardware (mast hanger)
Six Months Or
1500 Hrs.
X
X
GR
GR
GR
X
X
X
GR
GR
X
The service intervals for Preventive Maintenance are calculated based on normal operating conditions including ten hours
per day, fifty hours per week. If your operating conditions or duty cycles are more severe, the service should be conducted
more frequently, i.e. extremely dusty conditions may require more frequent servicing of the filters.
A-36
RTGP-9040
(12/95)
T 180S
- 360L (10/02)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
Hoist Circuit
Section 6
Electrical System
6-1
Hoist Circuit
6-2