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Group 05
Operational Checkout
WARNING
Be sure to read the warnings prior to performing the
checkout procedures.
WARNING
Before operating the lift truck, FASTEN YOUR SEAT
BELT.
At the end of each check, a question is asked: When a problem is found, stop operational checkout
and correct it before going to the next check. Repeat
• If the answer indicates the check is OK, you will be check after repair to confirm repair was successful be-
instructed to go to next check. fore proceeding with the remaining checks.
• If the answer indicates that the check is not OK, you
will be given a required SRM repair or be linked to the
test to perform.
DTC Check 1. Turn key switch to ON position or press power YES: Refer to Diagnostic Trou-
ON/OFF button. ble Codes, Page 9030-20-1.
2. Check display for any DTCs. See General Main- NO: DTCs are OK. Go to next
tenance and Diagnostic Data, Diagnostic Trouble check.
Codes, Page 9030-03-6.
Are any DTCs displayed?
Horn Circuit Check Press horn button. YES: Horn is OK. Go to next
Does horn sound? check.
NO: Refer to Observed
Symptoms, Observed Symp-
toms, Horn Failure, Page
9030-30-41.
Light Circuit Check 1. Turn key switch to ON position or press power YES: Lights are OK. Go to next
ON/OFF button. check.
2. Turn front and rear work light switches ON. NO: Check fuse. If OK, check
Do lights turn on? DSC to see if light switch is
turned ON. Check bulbs, see
Electrical Functions Do Not
Operate.
Windshield Washer NOTE: Do not operate windshield wipers on a dry YES: Washer function is OK.
Wiper Check (If windshield. Dirt and debris on windshield can cause Continue with this procedure.
equipped) scratches. If windshield is dry, use washer function to NO: Check windshield washer
start wiper checks or lift wiper arms from windshield fluid level. Refer to Trou-
and place in the cam-lock position. bleshooting Procedure SPN
1. Turn key switch to ON position or press power 524240. See General Mainte-
ON/OFF button. nance and Diagnostic Data,
2. Press windshield washer switch. Diagnostic Trouble Codes,
Does washer fluid spray on front and rear wind- Page 9030-03-6.
shields?
3. After wipers time out from washer cycle, lift front YES: Normal wiper operation
and rear wipers off windshield and place in cam- is OK. Continue with this pro-
lock position. Turn front and rear wipers on using cedure.
DSC switches. NO: Refer to Troubleshooting
Do front and rear wipers operate properly? Procedure for SPN 524237 or
524238. See General Mainte-
nance and Diagnostic Data,
Diagnostic Trouble Codes,
Page 9030-03-6.
Heater Check (If 1. Turn key switch to ON position or press power YES: Heater fan function is
equipped) ON/OFF button. OK. Set heater fan switch to
2. Verify that air ducts in right hand cab door are desired position. Continue
open. with this procedure.
3. Turn heater fan switch to each of the three speed NO: Refer to Observed Symp-
select positions. toms, Heater Fan Does Not
Does fan speed increase at each switch position Operate Properly.
and does airflow increase accordingly?
NOTE: If engine is at normal operating temperature, YES: Heater operation is OK.
proceed to step 4. If engine is cold, wait until engine Adjust heater temperature to
has reached normal operating temperature, then pro- desired position. Go to next
ceed to step 4. check.
Continue: NO: Refer to Observed Symp-
4. Turn heater temperature control fully counter- toms, Heater Airflow Does Not
clockwise to the maximum heat position. Reach Desired Temperature.
Does hot air flow from the heater air ducts?
Dome Light Check (If 1. Turn interior cab dome light switch ON. YES: Dome light operation is
equipped) Does dome light operate? OK. Go to next check.
NO: Refer to Observed Symp-
tom, Dome Light Inoperative.
Circulating 1. Turn circulating fan switch ON. YES: Circulation fan function is
(Accessory) Fan Check Does circulating fan operate? OK. Go to next check.
(If equipped) NO: Refer to Observed Symp-
tom, Circulating (Accessory)
Fan Inoperative.
A. LCD SCREEN
B. WARNING AND INDICATOR LIGHTS
1. LEFT TURN SIGNAL
2. ENGINE MALFUNCTION
3. SYSTEM MALFUNCTION
4. AIR FILTER RESTRICTION
5. DIRECTION INDICATORS
6. BRAKE FLUID LEVEL
7. FASTEN SEAT BELT
8. PARK BRAKE
9. ALTERNATOR
10. RIGHT TURN SIGNAL
11. TRANSMISSION OIL TEMP
12. ENGINE OIL PRESSURE
13. ENGINE COOLANT TEMP
14. COOLANT LEVEL
15. FUEL LEVEL
16. 1ST GEAR LOCKING (If equipped)
17. WATER SEPARATOR (If equipped)
18. COLD START (If equipped)
Turn key switch to ON position or press power
ON/OFF button with park brake applied.
Do the following lights turn ON?
• Fasten Seat Belt (7); Park Brake (8), Alternator
(9), Direction Indicator (5) Engine Oil Pressure
(12).
NOTE: Fasten seat belt light will turn off after 10 sec-
onds.
Continue:
Are the following items in display window (A)? YES: Display is OK. Go to next
• Clock and Hourmeter. check.
NO: Replace DSC.
Engine Malfunction 1. Start engine and increase to governed speed for YES: Repair engine malfunc-
Indicator Check 5 seconds. tion. Go to General Mainte-
2. Decrease engine to low idle. nance and Diagnostic Data,
3. Check DSC for engine warning indicator lights. Diagnostic Trouble Codes,
Are any engine warning lights ON? Page 9030-03-6.
NO: Engine indicators are OK.
Resume operation.
Cold Start Check NOTE: Engine must be cold to properly check the YES: Go to next check.
(Cummins and cold start circuit. NO: Continue with this proce-
Yanmar) • Turn key switch to ON position or press power dure.
ON/OFF button.
Does cold start indicator illuminate?
Continue: YES: Engine temperature suf-
Turn key switch to Start position or press engine start ficient not to require cold start
button. aid.
Does engine start normally? NO: Check DSC for SPN
524195 and troubleshoot per
procedure. If DTC is not dis-
played, contact your autho-
rized service technician to
check cold start circuit.
Backup Alarm Check 1. With engine running, apply service brake. YES: Back up alarm is OK. Go
(If equipped) 2. Release park brake. to next check.
3. Shift transmission to reverse. NO: Check wiring connections
Does backup alarm sound? first. If connections are OK,
check DSC for SPN 522755
and troubleshoot per proce-
dure. See General Mainte-
nance and Diagnostic Data,
Diagnostic Trouble Codes,
Page 9030-03-6.
Operator Presence NOTE: This procedure requires Service Password. YES: Continue with this proce-
System Check NOTE: Operator presence sensor requires a mini- dure.
mum of 45.4 kg (100 lb) to actuate. NO: Check DSC for SPN
NOTE: Hydraulic Interlock message will result if op- 524245 and troubleshoot per
erator is not detected in seat or mini-levers not me- procedure. See General Main-
chanically or electronically in neutral position when tenance and Diagnostic Data,
power ON. Diagnostic Trouble Codes,
Page 9030-03-6.
1. While operator in seat, power truck ON.
2. At the DSC, Enter Main Menu, scroll to Diagnos-
tics, Enter, scroll to General Data Display.
3. Scroll display until seat sensor appears. Read
display.
Does display show 1.4 volts or greater?
Continue: YES: Operator presence sen-
While operator out of seat, power truck ON. sor is OK. Go to next check.
Does display show less than 0.8 volts? NO: Operator presence sen-
sor has failed. Replace seat
NOTE: BEFORE PROCEEDING TO NEXT CHECK,
sensor. See Electrical Sys-
RETURN TO SEAT AND FASTEN SEAT BELT.
tem 2200 SRM 1142.
Hydraulic Interlock NOTE: Hydraulic Interlock message will result if Op- YES: Be sure Operator Pres-
Check erator not detected in seat or mini-levers not mechan- ence System Check has been
ically or electronically in the neutral position when performed and passed, then
power ON. continue.
While operator in seat, power truck ON. NO: Hydraulic Interlock is OK.
Does display show "Hydraulic Interlock?"
Continue: YES: Go to Electrical System
While operator in seat and not touching MLM, power 2200 SRM 1142 and perform
truck ON. TEST, Mini-Levers.
Does display show "Hydraulic Interlock?" NO: Hydraulic Interlock is OK.
Armrest Hydraulic 1. With engine running and seated in seat, move YES: Inspect switch and
Interlock Check (If armrest upward. wiring. Go to Observed Symp-
equipped and with 2. Attempt to operate hydraulics (with armrest up). toms, Electro-Hydraulics Can
original Configuration Does hydraulic control function with armrest up? Still Function With Armrest
Data File (CDF)) Raised, Page 9030-30-18.
NO: Armrest switch is OK. Go
to next check.
Engine Cover Latch 1. Apply park brake. YES: Sensor is OK. Go to next
Sensor Check (If 2. With engine running, open engine cover latch check.
equipped) and raise cover. NO: Check DSC to see if en-
Does engine stop? gine cover latch sensor is ON
in the VSM. If engine cover
latch is ON, go to Observed
Symptoms, Engine Continues
to Run When Engine Cover is
Raised, Page 9030-30-1.
Brake and Inching 1. With engine running, fully depress inching pedal. YES: Inching function is OK.
Pedal Check 2. Release park brake. Go to next check.
3. Shift to forward and increase engine to governed NO: Operate truck to 10 full
speed. stops in each direction while
NOTE: There is not an exact operating procedure for fully pressing inch/brake pedal
the inching function, except it must disengage the each time. The VSM will
transmission. Inching can be set to operator’s pref- re-learn the brake characteris-
erence to fit the lift truck application in the DSC. tics.
Does engine increase smoothly to governed
speed?
Park Brake Sensor 1. With engine running, release park brake. YES: Park brake sensor is OK.
Check 2. Slowly apply park brake and note when park Go to next check.
brake light comes ON. NO: Adjust park brake sen-
Does light come on before park brake reaches sor. For 1.0-3.5 Ton Cush-
first click of engagement? ion and Pneumatic Trucks,
see Brake System 1800 SRM
1135. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks,
see Brake System 1800 SRM
1247.
WARNING
Ensure load is secured so it will not move when
mast is tilted fully forward.
Engine Speed Check Lift Trucks with Duramatch™ Transmissions YES: Engine speed is OK. Go
(All Cummins, Yanmar, Only to next check.
and Mazda Engines 1. Scroll DSC to display engine rpm. NO: Adjust throttle cable or
Except 2007 Mazda 2. Run engine at low idle. Record engine rpm. accelerator pedal. For 1.0-2.0
Emission Compliant 3. Run engine at governed speed. Record engine Ton Cushion and Pneumatic
Engines) rpm. Trucks and 2.0-3.5 Ton Cush-
Does engine rpm match below specifications? ion and Pneumatic Trucks,
see Frame 100 SRM 1120.
• Low Idle - refer to Operating Manual for your lift
For 4.0-5.5 Ton Cushion and
truck.
Pneumatic Trucks, see Frame
• Governed Speed - refer to Operating Manual for
100 SRM 1243. For 6.0-7.0
your lift truck.
Ton Cushion Trucks, see
Frame 100 SRM 1316. For
6.0-7.0 Ton Pneumatic Trucks,
see Frame 100 SRM 1321.
Engine Power Check 1. Ensure lift truck transmission and engine are at YES: Engine power is OK. Go
operating temperature, fully warmed transmis- to next check.
sion temperature 66 C (150 F). NO: To diagnose this problem,
go to Tests and Adjustments,
WARNING Torque Converter Stall Test,
Ensure load is secured so it will not move Page 9040-40-5.
when mast is tilted fully forward.
Transmission Check NOTE: Make sure you have clear driving area for this YES: Transmission shift pro-
check. gram is OK. Go to next check.
1. Drive lift truck at governed speed for a short dis- NO: Install Service Tool and
tance. check program. See Calibra-
2. Decelerate and shift to opposite direction. Ob- tion Procedures 8000 SRM
serve lift truck direction changes. 1134.
3. Repeat above steps three times and observe en-
gine rpm and tire engagement during direction
changes.
Does truck make smooth direction changes with-
out excessive delay or engine surges?
Transmission Speed NOTE: Make sure you have clear driving area for this YES: Transmission Output
Selection Check (If check. Speed Sensor (TOSS) speed
equipped) 1. Check DSC to see if 1st gear locking light is OFF. is OK. Go to next check.
2. Go to Diagnostic menu in DSC and display speed NO: Check 1st gear lockup
in kph or mph. switch. Go to Observed Symp-
3. Drive truck in forward and increase speed until toms, Transmission Will Not
transmission shifts to high speed. Shift To Forward High Range,
Does lift truck make shift to high range above Page 9040-30-39.
8 km/h (5 mph)?
Brake and Axle Drag NOTE: Move truck to level surface before performing YES: Repair brakes. For 1.0-
Check the following steps. 3.5 Ton Cushion and Pneu-
1. Raise lift truck until drive tires are off ground. matic Trucks, see Brake Sys-
Support lift truck using suitable shop standard. tem 1800 SRM 1135. For 4.0-
(See "How to Raise Drive Tire" procedure in 7.0 Ton Cushion and Pneu-
Operating Manual.) matic Trucks, see Brake Sys-
2. Stop engine and release park brake. tem 1800 SRM 1247.
3. Back off park brake adjustment on handle. NO: Brakes are OK. Continue
4. Check brakes for dragging. with this procedure.
Are the brakes dragging?
Priority Flow Divider NOTE: Observe the movement of lift carriage frame YES: Continue with this proce-
Valve Check (1) during the following two operations: dure.
NO: If no steering, flow divider
spool is stuck. Remove, clean,
and inspect spool. See Main
Control Valve 2000 SRM
1137.
Steering Relief Valve 1. With engine running at slow idle. YES: Relief pressure is OK.
Low Pressure Check 2. Position steer axle wheels straight to start check. Go to next check.
3. Turn steering wheel stop-to-stop in both direc- NO: If steer axle wheels do
tions. not turn stop-to-stop, pressure
Does steer axle wheels turn stop-to-stop without is too low. Adjust steering
stopping? relief pressure. Go to Tests
and Adjustments, Steering Re-
lief Pressure Test and Adjust-
ment, Page 9050-40-14.
Steering Relief Valve 1. With engine running, turn steering wheel to stop, YES: Steering relief valve high
High Pressure Check then jerk wheel against the stop and continue to pressure setting is OK. Con-
turn with moderate force. tinue with this procedure.
2. Observe reaction of steering wheel as tilt func- NO: If steering wheel does not
tion is held over relief. Repeat several times. jerk and moves faster when tilt
Does steering wheel jerk each time tilt function is is held over relief, relief pres-
held over relief? sure is set too high. Adjust
NOTE: Continue: steering relief pressure. Go to
Tests and Adjustments, Steer-
It is normal for steering wheel to jerk when tilt function ing Relief Pressure Test and
is held over relief because the secondary relief valve Adjustment, Page 9050-40-14.
is set higher than the steering relief.
Does engine rpm drop when tilt function goes YES: Secondary relief is work-
over relief? ing. Go to next check.
NO: Do Tests and Adjust-
ments, Secondary Relief Valve
Test and Adjustment, Page
9050-40-3.
Lift Drift Check Ensure the following before starting procedure: YES: Go to Tests and Adjust-
• Truck operating on flat surface. ments, Lift Cylinder Leakage
• Hydraulic oil at operating temperature. Test, Page 9050-40-16 to iso-
late if problem is in cylinder or
control valve.
WARNING
NO: Main cylinder drift is OK.
Ensure load is secured so it will not move when Continue with this procedure.
mast is tilted fully forward.
Tilt Function Drift Ensure the following before starting procedure: YES: Go to Tests and Adjust-
Check • Truck operating on flat surface. ments, Tilt Cylinder Leakage
• Hydraulic oil at operating temperature. Test, Page 9050-40-18 to con-
firm if cylinder or control valve
is leaking.
WARNING
NO: Tilt drift is OK. Go to next
Ensure load is secured so it will not move when check.
mast is tilted fully forward.
Mast Cushion Check Ensure the following before starting procedure: YES: Cushion valve is OK. Go
(All Except 2-Stage • Truck operating on flat surface. to next check.
Mast) • Adequate overhead clearance to raise forks to NO: Inspect and clean cushion
maximum height. valve. For 1.0-5.5 Ton Cushion
and Pneumatic Trucks, See
Cylinder Repair 2100 SRM
WARNING
1139. For 6.0-7.0 Ton Cush-
Ensure load is secured so it will not move when ion and Pneumatic Trucks,
mast is tilted fully forward. See Cylinder Repair 2100
• Secured capacity load on forks. SRM 1328.
1. Operate engine at low idle and raise forks to max-
imum height of main lift cylinders.
2. Lower forks as fast as possible and observe
cylinder rod as main lift cylinders reach bottom
of stroke.
Does fork speed slow and does a hissing sound
come from cylinder at bottom of stroke?
Lift/Tilt Mast Ensure the following before starting procedure: YES: Shim lift cylinders. For
Adjustment Check • Truck operating on flat surface. 1.0-3.5 Ton Cushion and
• Adequate overhead clearance to raise forks to Pneumatic Trucks, see Mast
maximum height. Repairs, 2, 3, and 4-Stage
• No load on forks. Masts 4000 SRM 1148. For
4.0-7.0 Ton Cushion and
1. Operate engine at governed speed and raise
Pneumatic Trucks, see Mast
forks to maximum height
Repairs, 2 and 3-Stage
Does the top sections of mast kick to one side at Masts 4000 SRM 1250.
maximum height?
NO: Mast cylinder is adjusted
OK. Continue with this proce-
dure.
Tilt Racking Check Actuate mast back tilt function until hydraulic valve YES: Tilt stops are adjusted
goes over relief. OK. Go to next check.
Do both sides of mast stop evenly? NO: Adjust tilt stops. See
Mast Adjustment, For 1.0-3.5
Ton Cushion and Pneumatic
Trucks, see Mast Repairs,
2, 3, and 4-Stage Masts
4000 SRM 1148. For 4.0-7.0
Ton Cushion and Pneumatic
Trucks, see Mast Repairs,
2 and 3-Stage Masts 4000
SRM 1250.
Chain and Header Ensure the following before starting procedure: YES: Adjust lift chains. See
Hose Adjustment • Truck operating on flat surface. Lift Chains Adjustment, For
Check • Hydraulic oil at operating temperature. 1.0-3.5 Ton Cushion and
• No load on forks. Pneumatic Trucks, see Mast
1. Install angle meter on mast and position mast at Repairs, 2, 3, and 4-Stage
approximately 90 angle to ground. Masts 4000 SRM 1148. For
2. Raise and lower forks through two complete lift 4.0-7.0 Ton Cushion and
cycles. Pneumatic Trucks, see Mast
3. Lower forks to lowest position. Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NOTE: The correct fork height adjustment is approx-
imately 6 mm (0.25 in.) off floor. NO: Chains are adjusted OK.
Continue with this procedure.
Does the heel of forks touch the floor?
Continue: YES: Adjust header hoses.
4. Look at condition of hoses as they go over See Header Hose Arrange-
sheaves. ment, For 1.0-3.5 Ton Cush-
ion and Pneumatic Trucks,
Are the hoses compressed?
see Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NO: Hose tension is OK. Con-
tinue with this procedure.
Mast Mounting Check 1. Move mast to lowered position and stop engine. YES: Inspect and repair
2. Inspect the mounting hardware at axle. mast mounting. For 1.0-3.5
3. Push the top of mast by hand while off the lift Ton Cushion and Pneumatic
truck and note any movement of lift truck. Trucks, see Mast Repairs,
NOTE: If the mast mounting is loose, mast will 2, 3, and 4-Stage Masts
move without moving truck frame. 4000 SRM 1148. For 4.0-7.0
Ton Cushion and Pneumatic
Is the mast mounting loose?
Trucks, see Mast Repairs,
2 and 3-Stage Masts 4000
SRM 1250.
NO: Mast mounting is OK. Go
to next check.
Mast Channel Check NOTE: This is a visual check of the mast to deter- YES: Repair mast chan-
mine if parts are worn or out of adjustment. nels. For 1.0-3.5 Ton Cush-
1. Raise mast to full height without load and stop ion and Pneumatic Trucks,
engine. see Mast Repairs, 2, 3, and
2. Inspect outer and inner channels for wear pattern 4-Stage Masts 4000 SRM
and gouging. 1148. For 4.0-7.0 Ton Cush-
3. Move forks to lowered position. ion and Pneumatic Trucks, see
4. Inspect the inner channel wear pattern for wear Mast Repairs, 2 and 3-Stage
or gouging. Masts 4000 SRM 1250.
Do channels show signs of excess wear? NO: Mast wear is OK. Con-
tinue with this procedure.
Continue: YES: Channel spacing is OK.
5. Inspect spacing between channels. Go to next check.
Is the channel spacing even on each side? NO: Adjust or repair mast.
For 1.0-3.5 Ton Cushion
and Pneumatic Trucks, see
Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
Carriage Adjustment 1. Stop engine and lower forks to approximately YES: Adjust or repair car-
Check 50 mm (2 in.) off ground. riage bearings. For 1.0-3.5
2. Rock the carriage frame side to side. Ton Cushion and Pneumatic
Does carriage move more than 0.5 mm (0.020 in.) Trucks, see Mast Repairs,
at tightest point? 2, 3, and 4-Stage Masts
4000 SRM 1148. For 4.0-7.0
Ton Cushion and Pneumatic
Trucks, see Mast Repairs,
2 and 3-Stage Masts 4000
SRM 1250.
NO: Carriage adjustment is
OK. Go to next check.
Chain Sheave Check 1. Stop engine and lower forks. YES: Chain sheaves are OK.
2. Inspect wear pattern on chain sheaves. Go to next check.
Does sheave show a wear pattern without side NO: Replace chain sheaves.
wear? For 1.0-3.5 Ton Cushion
and Pneumatic Trucks, see
Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
Carriage Adjustment 1. Lower forks and stop engine. YES: Chains are out of adjust-
Check (Standard and 2. Inspect wear on carriage stop. ment. For 1.0-3.5 Ton Cush-
Integral Side Shift) Does carriage stop show a wear pattern on it? ion and Pneumatic Trucks,
see Mast Repairs, 2, 3, and
4-Stage Masts 4000 SRM
1148. For 4.0-7.0 Ton Cush-
ion and Pneumatic Trucks, see
Mast Repairs, 2 and 3-Stage
Masts 4000 SRM 1250.
NO: Checks complete.