Taylor THDC THDCP 954 955 974 Forklift Trucks Maintenance Manual PDF

Maintenance Manual
THDC / THDCP - 954 / 955 / 974
https://www.forkliftpdfmanuals.com/
DEATH OR SERIOUS INJURY MAY RESULT FROM IMPROPER
OPERATION OF THIS MACHINE
D OPERATOR MUST BE TRAINED AND KNOWLEDGEABLE OF

THE OPERATOR’S GUIDE, SAFETY MANUAL, AND OSHA
STANDARD SECTION 29 CFR 1910.178 FOR POWERED
INDUSTRIAL TRUCKS.
D CAPACITY
CAPACITY IS WITH MAST IN VERTICAL POSITION AND
LOAD RETRACTED.
D CAPACITY GREATLY DECREASES WITH TILTING, HIGH

LOAD LIFTING, ACCELERATION, BRAKING, SHARP
TURNING, HIGH WIND VELOCITY, AND POOR YARD
CONDITIONS.
D TILT
TILT (MAST AND LOAD OUT) ONLY WHEN LOAD IS OVER
A ST
STACK.
ACK.
D VISIBILITY MAY
MAY BE IMPAIRED
IMPAIRED BY STRUCTURAL
STRUCTURAL
DESIGN. (ALWAYS LOOK IN DIRECTION OF TRAVEL;
DO NOT RELY ON MIRRORS.)
D DO NOT OPERATE WITH BYSTANDERS PRESENT.
D ALWAYS TRAVEL WITH LOAD IN LOWEST POSSIBLE
POSITION THAT ALLOWS GOOD VISIBILITY.
D ALWAYS WEAR SEAT BELT WHILE MACHINE IS IN
OPERATION.
D DO NOT ATTEMPT TO JUMP FROM MACHINE IN EVENT OF
TIP OVER. REMAIN SEATED WITH SEAT BELT FASTENED.
TAYLOR MACHINE
MACHINE WORKS,
WORKS, INC.
650NORTHCHURCHAVENUE
650NORTHCHURCHAVE NUE
LOUISVILLE,MISSISSIPPI39339-2017
LOUISVILLE,MISSISSIPPI39339-2017 3374 715
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)

CAUTION
Observe The Following Precautions For Maximum Safety Of Machine Operation
1. Only trained
trained and responsible operators
operators shall be permitted to handle loads
loads with thi
this
s truck.
2. Operate
Operate the truck
truck from the
the operator’s
operator’s seat
seat only.
only. Do not allow
allow riders.
riders.
3. Test hydraulic
hydraulic controls for
for proper response
response before using the machine.
machine.
4. Know your load.
load. Do not attempt
attempt to lift or transport
transport loads in
in excess of rated capacity
capacity..
5. When the load obstructs
obstructs the view,
view, operate the truck in
in the reverse range.
6. Do not stand
stand or work
work under
under an elevate
elevated
d load.
7. Transport
ransport the
the load low and
and tilted
tilted back.
back.
8. Avoid
Avoid sudden
sudden stops
stops with
with a load.
load.
9. Center
Center the load to evenly
evenly distri
distribute
bute the weight.
weight.
10. Back down
down a ramp
ramp in excess
excess of 10 percent
percent when loaded.
11. Do not move the truck until the air system reaches recommended
recommended pressure.
pressure. Air pressure is
required for the service brakes.
12. Have defects repaired
repaired immedi
immediately
ately.. Do not operate a truck with damaged or defecti
defective
ve sys-
tems.
13. When leaving truck, lifting
lifting mechanism shall be fully lowered, controls shall be neutralized, pow-
er shut off, parking
parking brake set, and key removed. Block wheels ifif 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 the earlier of
twelve (12)provide
Taylor will monthsgenuine
months or two thousand (2000
(2000)
Taylor parts, ) hours.
labor, During
and travel theto
time first six (6)ormonths
replace or one
repair any partthousand
furnished(1000) hours,
by Taylor and
found to be defective in material and workmanship. If a defect in material and workmanship is found during during the
first six (6) months and/or one thousand (1000) hours whichever occurs first of the warranty period, Taylor will
replace lubricating oil, filters, antifreeze, and other service
service items made unusable by the defect. In the second six
(6) months and/or second one thousand (1000) hours after the delivery date of the truck, Taylor will approve parts
only.. Only genuine Tayl
only Tayloror parts provided by Taylor’s Sudden Service, Inc. will be used during the warranty period.
THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY:

1. Normal mai
maintenan
ntenance
ce services
services and parts or supplies used
used therein including,
including, witho
without
ut limitation
limitation,, en-
gine tune-up, wheel alignment, brake and linkage adjustment, lubrication services, tightening and
adjusting such as bolts, screws, hoses, fittings, etc., replacement of fuses, bulbs, filters, tune-up
parts, fluids and brake and clutch linings, glass; shop supplies such as rags, oil dry, hand soaps,
degreasers, cleaning solutions including brake clean, etc.; and adjustments which are a part of
the required or recommended predelivery inspection and periodic inspections in accordance with
Operator’s Manual.
Manual. Electrica
Electricall components
components including
including wiring will be excluded after the first six (6)
months or one thousand (1000) hours whichever occurs first.
2. Normal de
deteriorati
terioration
on of appearance
appearance due
due to use and exposure;
exposure; or conditions
conditions resu
resulting
lting from mis
mis--
use, negligence, or accident.
3. Any produ
product
ct on which any of the required
required or recommende
recommended
d period
periodic
ic inspec
inspections
tions or servi
services
ces have
not been made.
4. Any parts or acces
accessories
sories,, installed on
on the product which
which were not manufacture
manufactured d or installe
installed
d by
Taylor whether or not such parts or accessories were selected, recommended or installed by Tay-
lor (including
(including without limitation
limitation,, engines,
engines, tires, batteries,
batteries, air condi
conditioners
tioners,, air dryers, etc.). Such
parts or accessories shall be covered by the warranties given by the manufacturers thereof and
any claim thereof shall be made to such manufacturers.
5. Loss of time, inco
inconveni
nvenience,
ence, loss
loss of equipment
equipment use, other consequen
consequential
tial dama
damages
ges or other mat-
ters not specifically included.
Taylor parts and assemblies which are furnished and installed under this warranty are themselves within
the coverage of the machine warranty and are covered only for the duration of the original machine
warranty period.
NOTE: All International warranty
warranty parts shipments are F.O.B.
F.O.B. point of debar
debarkation,
kation, duties, tarif
tariffs,
fs, 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 defect
Replacement defects
s in mater
material
ial or workmanship
workmanship.. Parts
only,, no labor.
only
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 mac
machine
hine rated capacity at any stipulated load center is the rated lift capacity at less than
load center.
center. That is, a machin
machine
e rated at 20,000 pounds at 24-inch
24-inch load center connotes 20,000 pounds
is the maximum lift capacity even though the load center may be less than 24-inches.
24-inches. Subjecting T Taylor
aylor
products to conditions or loads exceeding those stipulated is justification for immediate cancellation of
warranty for products involved.
TAYLOR MACHINE WORKS, INC.

650 North Church Avenue
Louisville, Mississippi 39339
(662) 773-3421 / Fax 662-773-9146
https://www.forkliftpdfmanuals.com/ TMW-057-3 (7/99)
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
componen t 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
exclusion of others. Each rule must be considered
considered in
light of the other rules, the knowledge and training of the man (operator), the limitations of the machine,
and the workplace environment.
Warnings and cautions are included to reduce the probability of personal injury, when performing mainte-
nance procedures which if improperly
improperly performed
performed could be potentially
potentially hazardous. Failure to comply with
with
these warnings and cautions can result in serious injury and possible death.
All circumstances and conditions under which service will be
b e performed cannot be anticipated. Do not
perform any service if you are unsure that it can be done safely.
safely. Contact your Taylor
Taylor Dealer or Taylor
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
before the machine
machine is placed
placed in servi
service,
ce,
2. by qualified,
qualified, trained, and skilled
skilled personnel who
who have proper tools
tools and knowl
knowledge,
edge, and
3. in accordance
accordance with the
the Operator’s Guide,
Guide, Maintenance
Maintenance Manual and Safety
Safety Check booklet.
booklet.
Maintenance
Maintenance Manual
Operators Guide
! .
! .
Regularly Scheduled maintenance, lubrication, and safety inspections will help ensure a safe and
productive work life for the machine and the operator(s).
WARNING: Do not operate

operate the truck if it is in need of repair.
repair. Remove the igni
ignition
tion 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.
THDC/ -THDCP
THDC 954 - 95-5954
(6/9/9955
) / 974 (Rev. 06/03) Intro
WARNING: Use only genuine Taylor
Taylor replacemen
replacementt parts. Lesser quality parts
parts may fail,
resulting in property
resulting property damage, personal injury
injury or death.
Maintenance and / or service personnel who find it necessary to operate this machine, even for a short
period of time, must fully understand all operational literature including:
• OSHA operating rules
rules found in 29 CFR 1910.178;
1910.178; Appendix A in Safety Chec
Check
k
• ANSI B56.1 rules for operating

operating a powered industrial truck;
truck; Appendix B in Safety Check
• The Operator’s Guide for the machine

machine
• The manufacturer’s
manufacturer’s Safety
Safety Booklet
manufacturer’s Safety
Safety Video
manufacturer’s Service
Service Bulletins
Bulletins
• The content and meaning of all

all machine decals
decals
WARNING:
Fall Accidents Know of
Section how to avoid
Safety slip and fall accidents such as those described in the Slip and
Check.
Intro THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)

Safety
Safety First
Important Safety Instructions 1. Use of hois

hoisting
ting devic
devices
es not capabl
capable
e of
Observe these rules. They are recognized as supporting the weight of the component being
practices that reduce the risk of injury to yourself lifted.
and
truckothers,
or load.or damage to the container handling 2. Improper
Improper attac
attachmen
hmentt of slings
slings to heavy
heavy
components being hoisted.
This manual contains maintenance and service 3. Use of inadequ
inadequate
ate or rotten
rotten timbers
timbers for
for sup-
procedures for filling,
filling, lubricating,
lubricating, removing, repair- port or improper alignment of supporting
ing, and installing various components comprising material.
a container handling
handling truc
truck.
k. Because of the size
size 4. Failure
Failure to securely
securely block
block the wheels,
wheels, when
when dis-
and weight of the container handling truck, and connecting or removing components that hold
high pressures in some of the components and the container handling truck stationary under
systems,
system s, improperly performing service on the normal conditions.
conditions.
truck can be dangerous. 5. Failur
Failure
e to read and understan
understand d the safety
safety pre-
Warnings and cautions are included to reduce the cautions in this manual.
probability
probabilit y of personal injury,
injury, when perform
performing
ing
maintenance procedures which if improperly
WARNING: Know how to avoid accidents
performed could
could be potentially hazardous.
hazardous. Failure
such as those described in the Maintenance /
to comply with these warnings and cautions can
result in serious injury and possible death. Service Accidents Section of Safety Check:
No single rule in the booklet can be followed to Some Maintenance / Servicing
Servicing Accidents
Accidents
the exclusion
exclusion of others.
others. Each rule mustmust be con- Listed below:
sidered in light of the other rules, the knowledge 1. Improperly
Improperly refueling the truck.
and training of the man (operator / maintenance), 2. Improperly
Improperly checking
checking for hydraulic
hydraulic leaks or
the limitations of the machine, and the workplace diesel fuel leaks.
environment. 3. Improperly
Improperly checking
checking the engine cooling
Report all mechanical problems to mechanics and system.
supervisors. 4. Improperly
Improperly checking
checking battery fluid levels
levels or
Proper Training: “jump” starting engines.
5. Putting
Putting air in a mult
multi-p
i-piece
iece ti
tire
re and rim assem-
assem-
Taylor Machine Works,
Works, Inc. publishes Safety bly without proper tools and training.
Check, TMW-072 a booklet citing some safety
precautions to observe during lift truck operation. 6. Attempting
Attempting to ser
service
vice a multi-piece
multi-piece tire
tire and rim
rim
One copy is shipped with each lift truck; additional 7. assembly without
Using an improperly
im proper
properly suitedtools
chainandwhile
wtraining.
hile
copies are available at a nominal fee from the
authorized Taylor dealer from which the equip- performing
perform ing maintenance.
maintenance.
ment was initially
initially purchased. 8. Using the container
container handling
handling truck
truck hydraulic
hydraulic
Minimum Required Personnel Safety Equipment system as a substitute for a fixed stand.
1. HaHard
rd Hat
Hat 9. Relyin
Relyingg on jacks or hoist
hoistss to support
support heavy
heavy
loads.
2. Safety
Safety Shoes
Shoes
10. Oper
Operatin
atingg a truck
truck that is damaged
damaged or in need
3. Safety
Safety Glasses
Glasses of repair.
4. Heavy
Heavy Glove
Glovess 11. Climbing on the mast of a forklift, on the top of
5. Hearing
Hearing Protecti
Protection
on the cab, or other high places on the container
6. Reflecti
Reflective
ve Clothin
Clothing
g handling truck.
Failure to follow the safety precautions outlined in 12. Operating a contain
container
er handling truck
truck which
this manual can create a dangerous situation. has been modified without the manufacturer’s
Some of the common ways this can occur are as approval.
terwei
terweight, This includes
ght, tires, incl
etc.udes the attachment,
attachment, coun-
follows:
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) Safety-1

13. Lifting people with a forklift
forklift not properly equipment. Under no circumstances
equipment. circumstances should
should
equipped for elevating personnel. any attempt be made to disconnect or in any
14. Improperly
Improperly using chains.
chains. way render any of
of these devices inoperab
inoperable.
le. If
you discover that any safety device is mal-
15. Improperly blocking and supporting mast, car-
functioning, Do Not operate the truck; notify
riage, or attachment before repairing truck.
appropriate maintenance personnel immedi-
Maintenance / Service Personnel:
Maintenance ately.
1. Keep the truck
truck clean,
clean, free
free of oil, grease
grease and
fuel.
WARNING: Use only genuine Taylor
2. Steam clean
clean / wash
wash the truck
truck prior
prior to perf
perform
orm-- replacement parts. Lesser quality
replacement quality parts may
ing maintenance.
maintenance. Wear anti anti-sli
-slip
p footwear fail, resulting in property damage, personal
when performing
performing maintenance
maintenance procedures.
procedures. injury
injur y or death.
3. Use OSHA
OSHA approved
approved ladders
ladders and otherother proper
proper
cleaning accessories to access hard to reach
maintenance places. WARNING: Keep all hydraulic com-
ponents in good repair.
4. Keep gratings
gratings free
free of ice,
ice, dirt
dirt and gravel.
gravel.
5. Regularly
Regularly inspect
inspect and replace
replace anti-slip
anti-slip mastic
mastic
on the vehicle as needed. WARNING: Relieve pressure on the
6. Ensure
Ensure all safety
safety decal
decals s are in place
place on the
the hydraulic
hydrau lic system before repairing
repairing or adjusting
or disconnecting.
vehicle.
WARNING: Remove all rings, watches, WARNING: Wear proper hand and eye
chains, other jewelry,
jewelry, and all loose clothing protection when searching for leaks. Use wood
before working around moving parts! or cardboard instead of hands.
WARNING: Do not operate the vehicle or WARNING: Under no circumstances,

attemptt to perform maintenance
attemp maintenance on the vehicle without prior written approval from Taylor
while under the influence of alcohol, drugs, or Machine Works, Inc. Engineering Department,
any other medications or substances that slow should
shoul d the container handling truck be modi-
reflexes, alter safe judgement, or cause drows- fied, i.e. adding of additional counterweights.
iness. As per OSHA 29 CFR1910.178 (a) (4).
Container Handling Truck Lock-out / Tag-out:
WARNING: Never park the container The engine should be locked-out / tagged-out to
handling
handl ing truck on an incline.
incline. Always park the
container handling truck on a level surface; prevent ing
perform it from
performing being inadvertently
maintenance
maintenanc e or repairs.started before
The battery
otherwise, the lift truck could possibly roll should be locked-out / tagged-out to prevent acci-
resulting
resulting in possible
possible injury
injury to personnel or dental activation of the starter and possible start-
damage to the truck or other property. ing the
the engine. Refer to Lock-Out / Tag-Out Pro-
engine. Refer
cedure in the back of this section for the
procedures to be followed to perform lock-out /
WARNING: Maintenance and service
tag-out.
personnel
person nel should never operate this lift truck
unless they are thoroughly familiar with Safety
Check, TMW-072 and the Operator’s Guide for WARNING: Turn the engine off and
this lift truck. remove the ignition key before entering the tire
pivot area to prevent death or serious injury
from pivoting tires.
WARNING: Electrical, mechanical, and
hydraulic safety devices have been installed
on this container handling truck to help protect WARNING: Deflate
Deflate tires before removing
against personal injury and / or damage to (the tires).
tires). Always remove
remove the valve core and
Safety-2 THDC / THDCP - 954 / 955 / 974 (Rev

(Rev.. 06/03)
exhaust all air from a single tire and both tires Traveling:
of a dual assembly prior to removing any rim Start, stop, change direction and travel smoothly.
components or wheel components such as Slow down while turning.
nuts and rim
rim clamps.
clamps. Run a piece of wire
through the valve stem to make sure the valve Obstructions And Clearances:
stem is not damaged or plugged and all air is Watch end clearances and overhead obstructions.
exhausted.
WARNING: Do not release the parking
WARNING: Serious falls and injuries can brake or attempt to move the container han-
result from improper mounting or dismounting dling truck if the air pressure gauge indicates
of the container
container handling
handling truck. that the air pressure is below 100 psi.
Mounting and Dismounting:

1. Face
Face the container
container handli
handling
ng truck
truck when get-
get- WARNING: Make sure all ground person-
ting on or off the truck. nel know the rules and responsibilities set by
your employer
employer.. Make sure they know what you
2. One hand andand two
two feet or
or two
two hands and one are going to do and be sure they are clear of
foot must be in contact with the truck at all the area before you move the container han-
times (3 point contact). dling truck.
3. Use handra
handrails
ils and
and other grab
grab points.
points.
WARNING: Do not start the engine if the WARNING:

for looking in the Cameras
direction are notkeeping
of and substitutes
a
ignition
ignition switch, or engine control panel has clear view
view of the path of travel.
travel. Never
Never use
been locked-out / tagged-
tagged-out
out by maintenance
maintenance them as substitutes,
substitutes, Always look in the path of
personnel.
personn el. Doing so can result
result in person
personal
al travel.
injury
injury and / or damage to the equipment
equipment.. If in
doubt, contact the maintenance supervisor.
WARNING: Total reliance on electrical
aids can be dangerous.
dangerous. The responsibili
responsibility
ty for
WARNING: If maintenance requires run- safe operation
operation of the container handling truck
ning the engine indoors, ensure the room has shall remain with the operator who shall
adequate flow-through ventilation! ensure that all warning and instructions pro-
vided are fully understood and observed.
WARNING: Never operate the container
handling truck without proper instruction. WARNING: Do not operate the container
container
Ignorance
Ignor ance of operational characteristics
characteristics and
limitations
limitations can lead to equipment
equipment damage, handli
handling
travel ng truck
path
pathss areuntil both
clear. Doforward and reverse
not operate
operate the truck
truck
personal injury, or death. with bystanders
bystanders present.
present.
WARNING: Do not operate the container

container WARNING: Do not move the container
handling truck without
handling without the seat belt properly
properly handling truck until the surrounding
handling surrounding area has
and securely fastened. been checked and is clear of personnel and
obstructions.
WARNING: Operating instructions, warn-
ings, and caution labels are placed on the con- WARNING: Always look in the direction
tainer handling truck to alert personnel to dan- of travel and keep a clear view of the path of
gers and to advise personnel of proper travel; slow down and sound
sound the horn
horn at cross
operating
operati ng procedures
procedures (of the lift truck).
truck). Do not aisles and other locations where vision may be
remove or obscure any warning, caution, dan- obscured.
ger, or instructional sign or label.

WARNING: This equipment is not electri- WARNING: Stacks of containers or mate-
cally insulated.
insulated. Contact
Contact with electricity
electricity can rials can cause “blind spots” for the operator.
cause severe injury
injury or death
death.. Electrocution
Electrocution It is essential, for safe operation, that the
can occur without
without direct
direct contact. Do not oper-
oper- ground crew stay clear of “blind spots” and
ate this container handling truck in areas with stay within sight of the operator at all times.
energized
Check local,power
statelines
and or a power
federal supply.
safety codes for Do not allow anyone to walk in the travel aisle-
ways.
proper
prop er clearance. Use a groundman
groundman to ensure
ensure
that there is proper clearance.
WARNING: Do not move or lift container
until all four twistlocks are fully locked (green
WARNING: Do not allow anyone on the container
contai ner light illuminated
illuminated).
). The container
container
container handling truck during operation. could fall from the attachment causing death
or serious injury to ground personnel or physi-
cal damage to the container, container han-
WARNING: Do not move the container dling truck or other yard equipment.
equipment.
handling truck onto a surface or area that has
not been approved
approved for container handling
handling
truck operation.
operation. The container handling
handling truck
truck WARNING: Do not lift a loaded container
is heavy and could possibly break through an that exceeds the rated capacity of the contain-
insufficient surface and cause damage to the er handling
handling truck. Failure
Failure to do so, may result
truck or injury to personnel. in death, personal injury or damage to the con-
tainer handling truck.
WARNING: Do not operate the container
handling truck over potholes
handling potholes and debris. Clear WARNING: Do not handle unstable
the yard of obstructions.
obstructions. loaded containers.
If the load shifts in the container, stop the truck
WARNING: Avoid
Avoid sudden starts
starts and immediately, lower the container and adjust the
stops. side shift until load weight is centered and proper-
ly held. If the load shift is
is too great for adjustment
adjustment
with side shift, lower the container and rearrange
WARNING: Serious falls or injuries can the load before attempting to move the container.
result from riding on the container handling
truck! Do not ride on the container
container handling
handling
truck. WARNING: Never move containers over
personnel or vehicles.
personnel
Handling Loads:
WARNING: Do not back away from a
WARNING: If any abnormal operating rack or stack without complete release of the
condition occurs while operating the container container
contai ner.. Failure to do so, may result in death
handling truck, move the truck to a safe park- or serious bodily injury and property damage
ing area, if possible; when safe to do so, shut caused by dropping a container on the truck, a
down the truck and notify the appropriate bystander
bystand er or on the ground.
maintenance personnel.
WARNING: Position the container before
WARNING: Do not allow anyone near the traveling
traveli ng to eliminate
eliminate interference
interference with visibili-
visibili-
container handling truck - certainly
container certainly not walk- ty in the direction of travel.
ing or standing under or beside the container
or lifting mechanism.
WARNING: Use care when traveling with
or without a container.

(Rev.. 06/03)
Lock-Out / Tag-Out Procedure
WARNING: Never leave the container Purpose. This procedure establishes the mini-
handling truck with a container
handling container suspended.
suspended. mum requirements for lock-out / tag-out of energy
The load could inadvertently lower and cause sources that could
could cause injury
injury to personnel. All
serious injury or death. employees shall comply with the procedure.
Responsibility. The responsibility for seeing that
WARNING: Be exact in load placement. this procedure is followed is binding upon all
Make sure the load will not tilt, fall or slide out employees.. All employees
employees employees shall be instructed
instructed in
of position
position when released.
released. Personal in injury
jury or the safety significance of the lock-out / tag-out
equipment
equipm ent damage can result from unstable procedure by (designated
(designated individual)
individual).. Each new
placement of loads. or transferred affected employee shall be
instructed by (designated individuals) in the pur-
pose and use of the lock-out / tag-out procedure.
WARNING: Do not unlatch a container
until you, the operator
operator,, have determined
determined that it Preparation for Lock-Out / Tag-Out. Employees
is safe to do so. Never unlatch
unlatch a container
container authorized to perform lockout / tagout shall be cer-
that is not positioned securely; the container tain as to which switch, valve, or other energy iso-
could shift or fall. lating devices apply to the equipment being
locked
lock ed out / tagged out. Mor
More e than one energy
source (electrical, mechanical, or others) may be
WARNING: Do not back away from a involved. Any questionable
questionable identification
identification of
rackcontainer
the or stack
contain er with
belowa container
Failureuntil
it. Failure to doit so,
is clear
may of sources
their shall
superv be cleared
supervisors.
isors. Beforeby theout
employees
lock-out
lock- / tag-out with
com-
result in death or serious bodily injury and mences, job authorization should be obtained.
property damage caused by dropping a con-
Sequence of Lock-Out
Lock-Out / Tag-Out Procedure
Procedure
tainer on the truck, a bystander or on the
ground. 1. Notify
Notify all affec
affected
ted empl
employee
oyees s that a lock-out
lock-out /
tag-out is required and the reason therefor.
Battery Safety: 2. If the equipmen
equipmentt is operati
operating,
ng, shut itit down by
the normal stopping procedure.
WARNING: Lighted smoking materials, 3. Operate
Operate the switch,
switch, valve
valve,, or other energy
energy iso-
flames, arcs, or sparks may result in battery lating device so that the energy source(s)
explosion. (electrical,
(electrical, mechanical, hydraulic, etc.) is dis-
connected or isolated from the equipment.
1. Keep all metal
metal tools
tools away from
from battery
battery termi-
termi-
Stored energy, such as that in capacitors,
nals.
springs, elevated crane members, rotating fly-
2. Batteries contain sulfuric
sulfuric acid which
which will
will burn
burn
skin on contact; wear rubber gloves and eye wheels,
steam, orhydraulic systems,etc.
systems,
water pressure, andmust
air,
air, gas,
also be
protection when working with batteries. dissipated or restrained by methods such as
3. Flush
Flush eyes or wash
wash skin
skin with
with water andand seek grounding, repositioning, blocking, bleeding-
medical attention immediately in case of down, etc.
contact. 4. Lock-out / tag-out
tag-out the energy isolating
isolating devices
4. When jump
jump start
starting:
ing: with an assigned individual lock / tag.
a. Do not lean
lean over the batter
batteryy while
while making
making 5. After ensur
ensuring
ing that no personne
personnell are exposed
exposed
connection. and as a check on having disconnected the
b. First,
First, connect
connect the positive
positive (+)
(+) terminal
terminal of energy sources, operate the push button or
the booster battery to the positive (+) other normal operating controls to make cer-
terminal
termi nal of the discharged
discharged battery.
battery. tain the equipment will not operate.
c. Then,
Then, connect
connect the negative
negative (-)
(-) terminal
terminal of
the booster battery to the engine or body
CAUTION: Return operating controls to
ground (-). Never CrossCross Polarity
Polarity of
Terminals. neutral after the test.
d. Disconnect
Disconnect cables
cables in exact
exact reverse
reverse order
order..

6. The equipment
equipment is is now locke
locked
d out / tagged
tagged out.
Restoring
Restoring Equipment to Service
1. When the
the job is compl
complete
ete and equipm
equipment
ent is
ready for testing or normal service, check the
equipment area to see that no one is exposed.
2. tags.
When The
equipment
energyisisolating
all clear
clear,devices
isolating , remove
dev mal
all
ayl locks
ices may be /
operated to restore energy to equipment.
Procedure
Procedu re Involving
Involving More Than One Person.
In the preceding steps, if more than one individual
is required to lock-out / tag-out equipment, each
shall place his own personal lock / tag on the
energy isolating
isolating device(s).
device(s). One designated indi-
vidual of a work crew or a supervisor, with the
knowledge of the crew, may lock-out / tag-out
equipment for the whole crew crew.. In such cases, it
shall be the responsibility of the individual to carry
out all steps of the lock-out / tag-out procedure
and inform the crew when it is safe to work on the
equipment. Additionally
Additionally,, the designated individual
shall notthat
verified remove a crew lock
all individuals are/ clear.
tag until it has been
Rules for Using Lock-Out / Tag-Out Procedure.
All equipment shall be locked out / tagged out to
protect against accidental or inadvertent operation
when such operation could cause injury to person-
nel. Do not attempt to operate
operate any switch,
switch, valve,
or other energy isolating device bearing a lock /
tag.

(Rev.. 06/03)
Major Components Locations
ATTACHMENT
ATTACHMENT MAST
(Section 29) (Section 27)
LIFT CYLINDER
(Section 22)
TILT CYLINDER
(Section 22)
CAB
(Section 20)
STEER AXLE
(Section 13)
FUEL TANK
(Section 2)
HYDRAULIC TANK
(Section 22) RADIATOR
(Section 5)
ENGINE
(Section 1)
TRANSMISSION
(Section 9)
DRIVE AXLE
(Section 14) DRIVE SHAFT
(Section 11)
NOTE: All circuit draw

drawings
ings illustrate
illustrate the components in de-energized
de-energized states. Circuit
Circuit drawings and
illustrations are drawn in the position of the operator facing forward, looking toward the mast
assembly.
https://www.forkliftpdfmanuals.com/THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)

1-2 https://www.forkliftpdfmanuals.com/ (Rev. 11/94)
Contents
Maintenance Manual
Section
Introduction
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A
Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Cab Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22E
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Container Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendices
Section 1
Engine
OIL
DIPSTICK
OIL
FILLER
CAP
OIL
FILTER
ELEMENT
WASHER
DRAIN PLUG
Illustration 1-1. Cummins

Illustration Cummins QSM11-C330
QSM11-C330 Engine Service Points
Introduction. This engine is pressure lubricated, on the oil dipstick to ensure the engine has the
generating 330 horsepower at 2100 governed rpm proper amount of oil for operation.
and delivering 1170 ft-lbs of peak torque at 1400
Changing the Oil and Filter Element (Illustration
rpm. Oil pressure
pressure is supplied
supplied by a gear-type lubri-lubri-
1-1).. The engine lubricating oil should be
1-1)
cating oil pump and controlled by a pressure regu-
changed monthly or every 250 hours, whichever
lator.. The filter bypass
lator bypass valve ensures that a sup-
comes first.
first. The oil filter
filter should be replaced
replaced each
ply of oil, in the event the filter becomes plugged,
time
tim e the engine oil is cchanged Refer to the Fuel
hanged.. Refer
is present. One full flow oil filter
filter is incorporated
incorporated in
and Lubricant Specifications chart in the back
the lubricating system to provide maximum
of this manual for the proper grade of oil to use.
cleansing and filtration of the engine lubricating
oil. If additional
additional engine information
information is needed,
refer to the engine operation and maintenance WARNINGS:
manual supplied with the truck. S Park machine on a level surface, apply
Checking
The enginethe Lubricating
Lubricating
lubricating Oil (Illustration
oil should be checked 1-1).
1-1).
daily parking
Tag Out brake, block wheels
while servicing and Lock Out &
machine.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-1
S Avoid touching exhaust components while 8. Remove
Remove the oil fillfill cap and fill
fill crankcas
crankcase
e with
changing the oil for severe burns could oil to the FULL mark on the oil dipstick (see
occur. Illustration 1-1).
S Some state and federal agencies in the 9. Start
Start the engine
engine and allow
allow to idle.
idle. Visuall
Visually
y
United States have determined that used check the drain plug and oil filter for leaks.
engine oil can be carcinogenic and can
cause reproductive
reproductive toxicity.
toxicity. Avoid
Avoid inhala- 10. Shut down the engine and wait approximatel
approximately y
tion of vapors, ingestion and prolonged 5 minutes for the oil to drain back into the oil
contact with used engine oil. pan. When the engine
engine has cooled, recheck
recheck
the oil level and add oil as necessary to bring
the oil level to the FULL mark on the oil dip-
CAUTIONS: stick.
S Dispose of oil and filter in accordance with
federal and local regulations.
regulations.
S Do not use a strap wrench to tighten the oil
filter.. Mechanical
filter Mechanical over-tightening
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.
S Do not use excessive amounts of starting
fluid when
when starting
starting the engine.
engine. The use of
too much starting fluid will cause engine
damage.
1. Operate
Operate the engine
engine until the
the water
water tempera-
tempera-
ture reaches 140˚F and then shut off the
engine.
2. Place
Place a suitable
suitable container
container under
under the drain
drain plug Illustration
Illustration 1-2. Drive
Drive Belt Inspection
Inspection
of the oil pan. Remove
Remove the drain
drain plug and
washer to drain
drain the oil.
oil. Replace washer
washer if Drive Belts (Illustration 1-2).
1-2). Visually inspect the
damaged. drive belts daily.
daily. Check the belt for intersecting
intersecting
3. When the oil has completely
completely drained,
drained, reinstall
reinstall cracks.
crack s. Tr
Transverse
ansverse cracks
cracks (across
(across the belt width)
the washer
washer and drain
drain plug. Apply a torque
torque of are acceptable.
acceptable. Longitudinal c cracks
racks (directi
(direction
on of
65 ft-lbs of torque to tighten the drain plug. belt length) that intersect with transverse cracks
are not acceptable.
acceptable. Replace the beltbelt if belt is
is
4. Unscrew the spin-off
spin-off type
type oil filter (see frayed or has pieces
pieces of material
material missing.
missing. Adjust
Illustration
Illustration 1-1). It should be possible
possible to drive belts that have a glazed or shiny surface
unscrew the oil filter by hand; however, a band which indicates
indicates belt slippage. Correc
Correctly
tly installed
installed
type filter wrench may be used if necessary. and tensioned belts will show even pulley and belt
Discard the used oil filter. wear.. After installation
wear installation of a new belt, check the
5. Clean
Clean the area on the filte
filterr base that
that will
will con- tension and adjust if necessary.
tact the gasket on the new oil filter. Belt damage can be caused by:
6. Fill
Fill the new filter
filter with
with clean
clean engine
engine oil S Incorrect tension
before installation.
installation. S Incorrect size or length
7. Apply a light
light film
film of engine
engine oil on the gasket
gasket of S Pulley misalignment
the new filter.
filter. Screw the new filter
filter onto the S Incorrect installation
filter base until the gasket comes in contact
S
with the filter base and then tighten filter 1/2 to Severe operating environment
3/4 turn by hand only. S Oil or grease on the belts
1-2 https://www.forkliftpdfmanuals.com/
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
ered used if it has been in operation for 10 min-
utes or longer.
longer. If the used belt tension
tension is less than
the minimum tension value, tighten the belt to the
maximum
maxim um tension value. To obtain the proper belt
tension value, use an appropriate belt tension
gauge. Perform the following
following procedures
procedures to
adjust the tension of the belt.
CAUTION: Do not adjust belt tension to

the maximum value with the adjusting screw.
Belt tension can increase when the locknut is
tightened and cause reduced belt and bearing
life.
1. Loosen
Loosen the idler
idler pulley
pulley shaft
shaft locknut.
locknut.
2. Adjust
Adjust the bel
beltt to the correc
correctt tension
tension by turning
turning
the adjusting screw clockwise until the proper
belt tension is obtained (see Caution above).
3. Tighten
ighten the idl
idler
er pulley
pulley shaft
shaft locknut
locknut to a
⋅
torque value of 140 ft-lbs (190 N m).
4. Check
Check the belt tensi
tension
on again to make
make sure
sure the
belt is adjusted to the correct value.
Alternator Drive Belt Tension (Illustration 1-4).
1-4).
The tension of the alternator drive belt should be
60 - 120 ft-lbs (270 - 530 N ⋅m) for a used belt and
Illustration
Illustration 1-3.
1-3. Fan Drive
Drive Belt
150 ft-lbs (670 N⋅m) for a new belt.
belt. A belt is con-
con-
sidered used if it has been in operation for 10 min-
ADJUSTMENT utes or longer.
longer. If the used belt tension
tension is less than
LINK LOCKING the minimum tension value, tighten the belt to the
CAPSCREW maximum
maxim um tension value. To obtain the proper belt
ADJUSTING
SCREW LOCKNUT tension value, use an appropriate belt tension
gauge. Perform the following
following procedures
procedures to
adjust the tension of the belt:
1. Loosen
Loosen the adjusti
adjusting
ng screw
screw locknut
locknut..
2. Loosen the adjustment
adjustment link locking
locking capscrew
capscrew..
3. Loosen
Loosen the pivot
pivot capsc
capscrew
rew and nut.
nut.
4. Adjust
Adjust the belt to the
the correct
correct tensio
tension
n by turning
turning
the adjusting screw clockwise until the proper
belt tension is obtained.
5. Tighten
Tighten the adjusting screw locknut against
PIVOT CAPSCREW the retainer.
AND NUT
6. Tighten
Tighten the adjustment
adjustment link locking
locking capscrew
capscrew
Illustration
Illustration 1-4. Alternator Drive
Drive Belt to a torque
torque value of 60 ft-lbs
ft-lbs (80 N⋅m).
7. Tighten
ighten the piv
pivot
ot capscrew
capscrew and
and nut to a torque
torque
Fan Drive Belt Tension (Illustration 1-3).
1-3). The
value of 35 ft-lbs (47 N ⋅m).
tension of the fan drive belt should be 200 - 240
ft-lbs (890 - 1070 N ⋅m) for a used belt and 300 Engine Cleaning. The engine must be steam
ft-lbs (1330 N⋅m) for a new belt. A belt is consid- cleaned every 6 months or 1500 hours, whichever
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-3
comes first.
first. If steam is not available,
available, use a sol-
sol- tion position (first click).
vent to wash
wash the engine. When cleanin
cleaning
g the
2. Cycle
Cycle the acceler
accelerator
ator pedal
pedal through
through its full
full
engine, protect all electrical components, open-
range of travel three times.
ings and wiring from the full force of the cleaner
spray nozzle. 3. Turn
Turn the igniti
ignition
on switch
switch to the Off
Off position
position for
30 seconds.
WARNING: When using a steam cleaner, Diagnostic Lights (Illustration 1-5). 1-5). The diagnos-
wear protective clothing and safety glasses or tic lights, located on the right side of the dash, are
a face shield. Hot steam will cause serious
serious used to alert the operator of engine related prob-
personal injury. lems. At initial power up, all 3 lights
lights will be illumi-
illumi-
nated for 2 seconds.
seconds. After
After 2 seconds,
seconds, thethe red
Checking Engine Mounting Bolts. The engine light will
will turn off. After 2.5 seconds,
seconds, the yellow
mounting bolts should be checked for the light will
will turn off.
off. After 3 seconds from power up,
appropriate torque every 6 months or 1500 hours, the blue light will turn
turn off. Each light’s
light’s function is
whichever
whichev er comes first.
first. The torque value of the listed as follows:
follows:
engine mounting bolts
bolts is 380 ft-lbs.
ft-lbs. Inspect the 1. Blue Light. This light will begin to flash at
rubber mounts for deterioration and age harden- approximately 230 hours, indicating routine
ing. Replace
Replace any broken
broken or lost
lost bolts and dam- maintenance is forthcomi
forthcoming.
ng. This light illumi-
illumi-
aged rubber mounts. nates at approximately 250 hours when rou-
tine maintenance is required.
required. To reset this
Cummins
mation QSM11-C330 Engine General Infor- light, perform
the blue light: the following procedures to reset
Oil Pressure (normal) 2 8 - 3 5 p si a. Toggle the diagnostic
diagnostic switch
switch (located
(located
inside the dash on the right side) to the ON
Oil Capacity position.
39.2 quarts
(includes
(includes filter change)
b. Turn
Turn the ignition
ignition key to its accessory
accessory posi-
High RPMs (no load) 2250 rpm tion (first click).
Low RPMs 750 rpm c. Allow
Allow all the
the diagnosti
diagnostic
c lights
lights to complet
complete
e
the flash sequences prior to starting proce-
NOTES: dure 4.
S Setting high rpms under no load conditions
conditions to d. Fully
Fully depress
depress the
the accelerat
accelerator
or pedal an
and
d
2250 rpm ensures that the engine will have hold for more than 3 seconds.
2100 rpms under a loaded condition.
e. Fully depress the accelerator
accelerator pedal twice
twice
S Some
speed special
spec ial applications
settings appl
thatications may use
are different us e engine
from the stan- (each time less than 1 second).
dards shown.
shown. The proper settings
settings are perma- f. Fully
Fully dep
depres
ress
s the
the accel
accelerat
erator
or p
pedal
edal and
nently stamped on a metal tag affixed to the hold for more than 3 seconds.
engine.
NOTE: Procedures d. through f. must be com-
Calibration Of Electronic Accelerator Pedal To pleted within 30 seconds.
ECM Of Engine. The Cummins QSM11 engine
uses an electronic accelerator to control engine g. The blue light
light will
will flash
flash three quick
quick flashes
flashes
speed. Each time the
the accelerator
accelerator pedal is signifying that the ECM has responded to
changed, disconnected and the ignition switch is the reset command.
turned on, or ECM (Electronic Control Module) is
h. Toggle the diagnostic
diagnostic switch
switch to the OFF
OFF
changed out, the accelerator pedal must be cali-
position.
brated to the ECM. Calibr
Calibration
ation procedures
procedures are as
follows: i. Turn the
the ignit
ignition
ion swit
switch
ch to the OFF
OFF posi-
posi-
tion. Allow the ignition
ignition switch
switch to remain off
off
1. neutral,
Apply the
the parking
park
and ingthe
turn brake,
braignition
ke, place
place the shift
switchsh
toifter
er in
the Igni- for a minimum of 30 seconds before turn-
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
ing the ignition switch back on to confirm that will come
come on. Only active
active fault codes can
can be
that the blue light has been reset. viewed by use of the diagnostic lights.
lights. To view
inactive fault codes, a laptop computer equipped
2. Yellow Light (System Fault).
Fault). This light illumi-
with Cummins Insite software is required.
nates during a non-fatal
non-fatal system error
error.. The
engine can still be run, but the fault should be To view active fault codes, perform the following:
corrected as soon as possible. 1. Turn off the engine.

engine.
NOTE: In the diagnostic mode, the yellow light 2. Toggle the diagnostic
diagnostic switch
switch (located
(located inside
inside
will flash after the red light completes the three- the dash on the right side) to the ON position.
digit fault code.
3. Turn
Turn the ignition
ignition key to its accessory
accessory position
position
3. Red Light (Engine Shutting Down).
Down). This light (firstt click).
(firs click). If no active fault codes are record-
record-
illuminates when the engine needs to be shut ed, the yellow light (System Fault) and red
off before permanent damage occurs to the light (Engine Shutting Down) will illuminate
engine. Should the red light
light illuminate
illuminate while
while and stay on. If active
active fault codes are record-
record-
operating, the fault can be engine disabling ed, the yellow light and red light will illuminate
after approximately
approximately 32 seconds. Should the momentarily, and then the red light will begin
engine shut down due to the severity of the to flash the three-digit code of the recorded
fault, it can be restarted and will run for fault(s).
approximately
approxim ately 32 seconds.
seconds. The engine willwill 4. The fault
fault code will
will flas
flash
h in the followi
following
ng
run for approximately 32 seconds each time it sequence:
is restarted.
restarted. There are no limits
limits on the num- a. First,
First, the yellow
yellow light
light will
will flash
flash beginning
ber of times the engine may be restarted.
the sequence.
sequence. There
There will be a short 1 or 2
NOTES: second pause after which the red light will
S The engine
engine should
should be shut
shut off as soon
soon as it flash the first, second, and third digits of
can be shut off safely. should not
safely. The engine should the recorde
recordedd fault code.
code. There
There will be a 1
be run until the fault is corrected. or 2 second pause between each number
of the code. When all threethree digits
digits of the
S This light
light is also used to flash out the fault
fault fault code have flashed, the yellow light will
code number in the diagnostic mode. illuminate again and repeat the sequence
until the fault is cleared or the Diagnostic
switch is toggled to the OFF position.
BLUE YELLOW RED
LIGHT LIGHT LIGHT Example:
Fault Code 432
4 flashes, pause
3
2 flashes,
flashes pause
b. If multip
multiple
le fault
fault codes have
have been stored
stored,,
the first fault code must be cleared before
the second fault code can be displayed.
Fault Code Information. All fault codes identified
in bold print on the preceding fault code informa-
tion chart deal with engine and transmission
Illustration
Illustration 1-5. Diagnostic
Diagnostic Lights protection systems external to the Cummins
QSM11
QSM1 1 engine. Fault code
code #151 can be caused
Diagnostic Fault Codes (Illustration 1-5).
1-5). If the by both engine and external components.
red light (Engine Shutting Down) or yellow light Contact Taylor Machine Works Sudden Service
(System Fault) light comes on when the engine is Department for additional assistance if needed.
running, it means a fault code has been recorded.
The light will of
The severity remain on as
the fault willlong as the fault
determine exists.
the light
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-5
QSM11 Fault Code Information
Fault Code - Light Failure Description Failure Results
111 - Red Error internal to the ECM related to memory The engine will not start.
hardware failures or internal ECM voltage sup-
ply circuits.
115 - Red No engine speed signal detected at both The engine will die and will not start.
engine position sensor circuits.
121 - Yello w No engine sp
spe
eed signal detected from one of None on performance.
the engine position sensor circuits.
122 - Yello w Hi
Hig
gh vo
vollta g
ge
e dete c
ctted on the intake man iiffo ld
ld Derate in power output of the engine.
pressure circuit.
123 - Yello w Low voltag e de te
te c
ctted on the in ta
take ma n
niifold Derate in power output of the engine.
pressure circuit.
131 - Red High voltage detected at the throttle position Severe derate
derate (power and speed)
speed).. Limp home
signal circuit. power only
only..
132 - Red Low voltage detected at the throttle position Severe derate
derate (power and speed)
speed).. Limp home
signal circuit. power only
only..
133 - Red High voltage detected at the remote throttle None on performance if remote throttle is not
position signal circuit. used.
134 - Red Low voltage detected at the remote throttle None on performance if remote throttle is not
position signal circuit. used.
135 - Yello w Hi
Hig
gh vo
volltage detected at the oil pressu
surre cir- No engine protection for oil pressure.
cuit.
141 - Yello w Low voltag e d e
ette c
ctted at the oil pre s
ssu
surre cir- No engine protection for oil pressure.
cuit.
143 - Yello w Oil pressu
surre signal indicates o iill p rre
ess
ssu
ure is Progressive power and speed derate with
below the low oil pressure engine protection increasing time after
after alert. Engine will shut
limit. down 30 seconds after red light starts flashing.
144 - Yello w Hi
Hig
gh vo
vollta g
ge
e detected at the co o
ollant tempera- Possible
Possib le white smoke
smoke.. Fan will stay on if con-
ture circuit. trolled by the electronic control module (ECM).
No engine protection for coolant temperature.
145 - Yello w Low voltage de te
tecte
cted at the coolant tempera - Possible
ture circuit. trolled by the electronic control module (ECM).
147 - Red A frequency of less than 100 Hz was detected Calibration dependent power and speed
at the frequency throttle signal pin of the derate.
actuator
actuat or harness connector at the ECM.
148 - Red A frequency of more than 100 Hz was Calibration dependent power and speed
detected at the frequency throttle signal pin of derate.
the actuator harness connector at the ECM.
151 - Red Coolant temperature signal indicates coolant Progressive power derate with increasing time
temperature is above 104 _C (220_F). after alert.
alert. Engine wil
willl shut down 30 seconds
after red light starts flashing.
153 - Yello w Hi
Hig
gh vo
vollta g
ge
e detected at the intake manifold Possible
temperature circuit. trolled by the electronic control module (ECM).
154 - Yello w Low voltag e de te
te c
ctted at the intake manifold Possible
temperature circuit. trolled by the electronic control module (ECM).
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
155 - Red Intake manifold temperature signal indicates Progressive power derate with increasing time
temperature is above 87.8_C (190_F). after alert.
alert. If Engine Protect
Protection
ion Shutdown fea-
ture is enabled, engine
engine will shut down 30 sec-
onds after red light starts flashing.
187 - Yellow Low vo
volltage detected on the ECM voltage The engine will
will run derate
derated.
d. No engine
supply line to some sensors (VSEN2 supply). protection for oil pressure and coolant level.
211 - No
Non
ne Addition a
all OEM or Veh iic
cle dia g
gn
nostic code s None on engine performance.
have been logged.
logged. Check other ECM’ECM’ss for
diagnostic codes.
212 - Yellow Hi
Higgh voltage detecte
cte d at the oil temperature No engine protection for oil temperature.
circuit.
213 - Yellow Low vo
volltage detecte
cted at th e oil temperatu re
re No engine protection for oil temperature.
circuit.
214 - Red Oil temperature signal indicates oil tempera- Progressive power derate with increasing time
ture is above 123.9 _C (255_F). after alert.
alert. If Engine Protect
Protection
ion Shutdown fea-
ture is enabled, engine
engine will shut down 30 sec-
onds after red light starts flashing.
219 - Blue Low oil level was detected in the Centinelt None on performance.
performance. Centin
Centinel
elt is deacti-
makeup oil tank. vated.
221 - Yellow Hi
Hig
gh circuit.
sure voltage detecte
cte d a t the ambient a irir pres- Derate in power output of the engine.
222 - Yellow Low vo
volltage detecte
cted at th e a m
mb
b iie
ent air pres- Derate in power output of the engine.
sure circuit.
223 - Yellow Inco
corrrect voltage detecte
cte d a t the Ce
Cen
ntinelt None on performance.
performance. Centin
Centinel
elt is deactiva-
actuator circuit by the ECM. ted.
227 - Yellow Hi
Hig
gh voltage detecte
cted on the ECM voltage The engine will
will run derate
derated.
d. No engine
supply line to some sensors (VSEN2 supply). protection for oil pressure and coolant level.
234 - Red Engine speed signal indicates engine speed is Fuel shutoff valve closes until engine speed
greater than 2730 rpm. falls to 2184 rpm.
235 - Red Coolant level signal indicates coolant level is Engine will shut down 30 seconds after red
below the normal range. light starts
starts flashin
flashing.
g. Add coolant as require
required.
d.
237
237 - Yell
ellow Duty
Duty cy
cycl
cle
e of the thro
throtttl
tle
e input
nput si
sign
gnal
al to the
the pr
pri-
i- All engines (primary and secondary) are shut
mary or secondary engine for multiple unit down with increasing time after alert if hard-
synchronization is less than 3% or more than coupled.
couple d. Only second
secondary
ary engin
engines
es are shut
97%. down with increasing time after alert if soft-
coupled.
241 - Yellow Th e ECM
ECM lost the ve h
hiicle sp
spe
eed si
sig
gnal. En
Enggine sp ee
eed limited to Maximum Eng in
ine
Speed without Vehicle Speed Sensor parame-
ter value Cruise Control, Gear-Down Protec-
tion and Road Speed Governor will not work
(automotive only).
242
242 - Yell
ellow Inv
nval
aliid or inapp
napprrop
oprriate
ate ve
vehi
hicl
cle
e spee
speed
d si
sign
gnal
al Engine speed limited to Maximum Engine
detected. Signal indicates an intermittent con- Speed without Vehicle Speed Sensor parame-
nection or VSS tampering. ter value Cruise Control, Gear-Down Protec-
tion and Road Speed Governor will not work
(automotive only).
245 - Yellow Less th a
an
n 6 VD
VDCC detecte
cte d at fan clutch ci
cirrcui
cuit Then fan may stay on at all times.
when on. Indica
Indicates
tes an excessive curre
current
nt draw
from the ECM or faulty ECM output circuit.
254 - Red Less than 6 VDC detected at FSO circuit when The ECM turns off the FSO supply voltage.
on. Indica
Indicates
the ECM ortes an excessive
a faulty curre
current
ECM output nt draw from
circuit. The engine will shut down.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-7
25
255
5 - Yel
elllow Ex
Exte
terrnal
nally supp
suppllied vol
voltage
age de
dete
tect
cted
ed go
goiing to None on performance.
performance. Fuel shutof
shutofff valve
the fuel shutoff solenoid supply circuit. stays open.
285 - Yello w Th
Thee ECM exp
xpe
ecte
cted in fo
formation from a mu lltti- At least one multiplexed device w
will
ill not oper-
plexed device
device but did not receive it soon ate properly
properly..
enough or did not receive it at all.
286 - Yello w Th
Thee ECM exp
xpe
ecte
cted in fo
formation from a mu lltti- At least one multiplexed device will not oper-
plexed device but only received a portion of ate properly
properly..
the necessary information.
287 - Red The OEM vehicle electronic control unit The engine will only idle.
(VECU) detected a fault with its throttle pedal.
288 - Red The OEM vehicle electronic control unit The engine will not respond to the remote
(VECU) detected a fault with its remote throttle.
throttle.
293 - Yello w Hi
Hig
gh vo
volltage detected at the OEM temperature No engine protection for OEM temperature.
sensor signal pin of the 31-pi
31-pin
n OEM connec-
tor.
tecte
cted at the OEM te m
mp
peerrature No engine protection for OEM temperature.
31-pin
n OEM connec-
tor.
295 - Yello w An error in th e ambient air pressu
surre se n
ns
so r The engine is derated to no air setting.
signal was detected
detected by the ECM.
297 - Yello w Hi
Hig
gh vo
vollta g
ge
e detected at the OEM press
ssu
u rre
e No engine protection for OEM pressure.
31-pinn OEM connec-
tor.
298 - Yellow Transmission’s temperature exceeds 245_F. Engin
Engine e wi
willll shut down 30 seconds after the red
light begins flashing.
299 - Yello w En g
giine shutdown by device other than key- No action taken by the ECM.
switch before proper engine cool down result-
ing in filtered load factor above maximum shut-
down threshold.
311 - Yellow Cu
Currrent detect
cte
e d a t No
No.. 1 inje c
cttor wh e
en
n the Current to the injector is shut off.
voltage is turned off.
312 - Yello w Cu
Currrent detecte
cted at No
No.. 5 injecto
ctor whe n the Current to the injector is shut off.
313 - Yello w Cu
Currrent detecte
cted at No
No.. 3 injecto
314 - Yello w Cu
Currrent detecte
cted at No
No.. 6 injecto
315 - Yello w Cu
Currrent detecte
cted at No
No.. 2 injecto
319 - Blue Real time clock lost power. None on performance. Data in the ECM will
not have accurate time and date information.
321 - Yello w Cu
Currrent detecte
cte d a t No
No.. 4 inje c
cttor wh e
en
n the Current to the injector is shut off.
voltage is turned on.
322 - Yello w No current d eette c
ctted at No
No.. 1 injector wh
whe
en th e Current to the injector is shut off.
ctted at No
No.. 5 injector wh
whe
ctted at No
No.. 3 injector wh
whe
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
325 - Yellow No cu
currrent detecte
cte d a t No
No.. 6 inje c
cttor wh
whe
en the Current to the injector is shut off.
331 - Yellow No cu
currre n
ntt detecte
cted at No
No.. 2 injecto
332 - Yellow No cu
currre n
ntt detecte
cted at No
No.. 4 injecto
341 - Yellow Severe loss of data from the ECM. Possible no noticeable performance effects
OR engine dying OR hard starting.
starting. Fault info
infor-
r-
mation, trip information, and maintenance
monitor data may be inaccurate.
343 - Yellow Internal ECM error. Possible none on performance or severe
derate.
349
349 - Yell
ellow A freque
equenc
ncy
y gr
grea
eatter than
than cal
calibrat
brated
ed thr
thres
esho
holld Calibration dependent power and speed
was detected at the tailshaft governor signal of derate.
the 31-pin OEM connector.
352 - Yellow Low vo
volltage detected on the ECM voltage The engine is derated to no air setting.
supply line to some sensors (VSEN1 supply).
386 - Yellow Hi
Hig
gh voltage detecte
cted on the ECM voltage The engine is derated to no air setting.
supply line to some sensors (VSEN1 supply).
387 - Yellow Hi
Hig
gh voltage detecte
cted on the ECM voltage The engine will only idle.
supply line to the throttle(s) (VTP supply).
415 - Red Oil pressure signal indicates oil pressure is Progressive power derate with increasing time
below the very low oil pressure engine protec- from alert.
alert. Engine wil
willl shut down 30 seconds
tion limit. after red light starts flashing.
418 - Blue Water has bee n de te
tecte
cted in the fuel filter. Po
Posssi
sibble wh
whiite smoke,
ke, loss of powe
werr, or ha rd
rd
starting.
419 - Yellow An erro r in the intake man iiffo lld
d press
ssu
ure sen
sen- The engine is derated to no air setting.
sor signal was detected by the ECM.
422 - Yellow Voltage detected simultaneously on both the Engine will shut down 30 seconds after red
coolant level high and low signal circuits OR light starts
starts flashing
flashing.. Disconn
Disconnected
ected or loose
no voltage detected on both circuits. plug at coolant sensor, defective coolant sen-
sor, or loose or broken wire between sensor
and ECM.
426 - None Communication between the ECM and the None on performance.
performance. J1939 devi
devices
ces may
J1939 data link has been lost. not operate.
428
428 - Yell
ellow High
High vo
volltage
tage de
dettecte
ected
d at wate
waterr-in-
n-ffuel
uel sens
sensor
or.. None
None on perf
perfor
orma
manc
nce.
e.
429
429 - Yell
ellow Low
Low vol
voltage
tage de
dete
tect
cted
ed at wat
water-
er-in-fu
n-fuel
el sens
sensor
or.. None
None on perf
perfor
orma
manc
nce.
e.
431 - Yellow Voltage detected simultaneously on both the None on performance.
idle validation off-idle and on-idle circuits.
432 - Red Voltage detected at idle validation on-idle cir- The engine will only idle.
cuit when voltage at throttle position circuit
indicates the pedal is not at idle OR voltage
detected at idle validation off-idle circuit when
voltage at throttle position circuit indicates the
pedal is at idle.
433
433 - Yell
ellow Vol
olttage
age si
sign
gnal
al at intak
ntake
e ma
mani
niffol
old
d pres
pressu
sure
re ci
cirr- Derate to no air setting.
cuit indicates high intake manifold pressure
but other engine characteristics indicate intake
manifold pressure must be low.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-9
434 - Yello w Supp lly
y vo
vollta g
ge
e to the ECM fell below 6.2 VD
VDC
C Possible no noticeable performance effects
for a fraction of a second OR the ECM was not OR possibility
possibility of engine dying OR hard star-
allowed to power down correctly (retain battery ing. Fault information, trip informati
information,
on, and
voltage for 30 seconds after key off). maintenance monitor data may be inaccurate.
435 - Yello w An error in th e oil p rre
essu
surre se n
ns
sor si
sig
gnal wa
was
s None on performance.
performance. No engine prote
protection
ction
detected
detected by the ECM. for oil pressure.
441 - Yellow Battery voltage is below the normal operating Possible no noticeable performance effects
level. OR possibility of rough idle.
442 - Yellow Battery voltage is above the normal operating None on performance.
level.
443 - Yellow Low voltage detected on the ECM voltage The engine will only idle.
supply line to the throttle(s) (VTP supply).
489 - Yello w Auxi
xilliary sp
spe
eed frequency on inp u
utt pin ind ii-- The engine will only idle.
cated that the frequency is below a calibration
dependent threshold.
527 - Yello w Less than 17.0 VDC de te tecte
cted a t the dual out- No action taken by the ECM.
put A signal pin of the 31-pin OEM connector.
put B signal pin of the 31-pin OEM connector.
put B signal pin at the ECM.
551 - Yellow No voltage detected simultaneously on both The engine will only idle.
the idle validation off-idle and on-idle circuits.
58
581
1 - Yel
elllow High
High vol
voltage
tage de
dete
tect
cted
ed at the
the fuel
fuel inl
nlet
et res
esttri
ric-
c- Fuel inlet restriction monitor deactivated.
tion sensor signal pin.
tecte
cted at the fu e
ell inlet restric- Fuel inlet restriction monitor deactivated.
tion sensor signal pin.
583 - Yello w Re
Rest
strriction has been detected at the fuel pump Fuel inlet restriction monitor warning is set.
inlet.
596 - Yello w Hi
Hig
gh battery vo
volltage detected by the battery Y
Yellow
ellow light will be illuminated until high battery
voltage monitor feature. voltage condition is corrected.
597 - Yellow ICONt has restarted the engine 3 times within Y
Yellow
ellow light will be illuminated until low battery
3 hours due to low battery voltage (automotive voltage
voltage conditi
condition
on is corrected
corrected.. The ECM may
only) OR
battery low battery
voltage voltage
monitor detected by the
feature. increase
switidle
ment switchch ifspeed and deactivate
idle speed
speedup idle decre-
up is enabled. The
engine will run continuously if ICONt is active
(automotive only).
598 - Red Very low battery voltage detected by the bat- Red light will be illuminated until very low bat-
tery voltage monitor feature. tery voltage condition is corrected.
611 - None Engine shutdown by operator before proper No action taken by the ECM.
engine cool down resulting in filtered load fac-
tor above maximum shutdown threshold.
951 - None A power imbalance between cylinders was The engine may have rough idle or misfire.
detected
detected by the ECM.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Engine Troubleshooting (Cummins QSM11-C330)
(Illustration
(Illustration 1-6)
The following chart includes some of the problems 3. Has a simil
similar
ar trouble
trouble occur
occurred red before?
before?
that an operator may encounter during the service 4. If the engine
engine still
still runs,
runs, is itit safe to contin
continue
ue
life of a Cummins
Cummins diesel engine.
engine. Always check
check operation of the engine in an effort to diag-
the easiest and obvious things first, such as the
master disconnect switch, the neutral start switch, nose
Check thethe trouble?
items most easily and inexpensively
an empty fuel tank, closed fuel shut off, dead bat-
corrected before proceeding to the more difficult,
tery or corroded
corroded terminals.
terminals. Study the problem
time consuming
consuming and expensive
expensive items. After a
thoroughly before starting to work on the engine.
malfunction has been corrected, locate and cor-
Ask yourself the following questions.
rect the cause of the trouble to prevent recurrence
1. What were
were the warnin
warning
g signs preced
preceding
ing the of the same trouble.
trouble?
2. Has the
the engine
engine been subjec
subjected
ted to recent
recent
repair or maintenance?
Problem Cause Correction
1. Air compres
compressor
sor air 1. Intake air
air restric
restriction
tion to air compres-
compres- 1. Remove
Remove restri
restricti
ction.
on.
pressure rises sor is excessive.
excessive.
slowly 2. Air system
system leaks.
leaks. 2. Check
Check for air
air compres
compressorsor gasket,
gasket,
hoses, and fitting
fitting leaks.
leaks. Check for
safety pressure
pressure valve
valve leaks.
leaks. Rat-
ing must be 135 psi.
3. Carbon
Carbon buildup
buildup excessi
excessive
ve in the air
air 3. Check
Check valve
valve or cyli
cylinder
nder head
head for
discharge line. carbon buildup and remove.
4. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
Repair Facility.
2. Air compres
compressor
sor 1. Air system
system leaks.
leaks. 1. Block
Block the
the truck’
truck’s
s wheels
wheels.. Inspect
Inspect
cycles frequently the air system for leaks with the
parking brakes applied and re-
leased. Check for leaks from
from the
air compressor
system gasketsand
hoses, fittings, andvalves.
the air
2. Carbon
Carbon buildup
buildup is exces
excessiv
sive
e in the 2. Check
Check for air disc
discharge
harge line,
line, check
check
air discharge line, check valve, or valve, and cylinder head for carbon
cylinder head. buildup. Replace the the air compres-
compres-
sor discharge line if required.
3. Air compr
compress
essor
or pumping
pumping ti
time
me is 3. Replace
Replace the desicc
desiccant
ant cartri
cartridge
dge in
excessive. the air dryer
dryer (if equipped).
equipped). Check
the air compressor duty cycle.
4. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
Repair Facility.
3. Air compres
compressor
sor 1. Carbon
Carbon buildup
buildup excessi
excessive
ve in the air
air 1. Refer
Refer to Corre
Correcti
ction
on 3. of Proble
Problem
m
noise is excessive
excessive discharge line. 1. of this troubleshooting chart.
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-11
3. Air compres
compressor
sor 2. Ice buildu
buildup
p in the air
air system
system com-
com- 2. Insp
Inspect
ect air
air dischar
dischargege line
line and
noise is excessive ponents. elbow fittings
fittings for ice.
ice. Remove ice. ice.
(Continued) 3. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
4. Air compres
compressor
sor 1. Air compr
compress
essor
or pumping
pumping time
time 1. Check air compressor
compressor duty cycle.
cycle.
pumping excess excessive.
lubricating
lubricating oil into 2. Carbon
Carbon buildup
buildup excess
excessive
ive in
in the air 2. Refe
Referr to Correc
Correction
tion 3. of
of Problem
Problem
the air system discharge
discharge line. 1. of this troubleshooting chart.
3. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
5. Air compres
compressor
sor will
will 1. Ai
Air system leaks. 1. Re
Refer to Correction 2. of Problem
not maintain ade- 1. of this troubleshooting chart.
quate air pressure 2. Cont
Contact
act a Cumm
Cummins
ins Au
Author
thorize
ized
d
(not pumping con-
tinuously) Repair Facility.
6. Air compres
compressor
sor will
will 1. Air system
system leaks.
leaks. 1. Refe
Referr to Correc
Correction
tion 2. of
of Problem
Problem
not stop pumping 1. of this troubleshooting chart.
2. Defective
Defective air governor.
governor. 2. Repl
Replace
ace air
air governo
governorr.
3. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
7. Alternat
Alternator
or not 1. Alternat
Alternator
or belt
belt iis
s loose.
loose. 1. Chec
Check k belt
belt tension.
tension.
charging or insuffi-
insuffi- 2. Battery
Battery cable
cable or
or connect
connection
ion is
is 2. Chec
Check k battery
battery cables
cables and connec-
connec-
ciently charging loose, broken or corroded (exces- tions.
sive resistance).
3. Batterie
Batteries
s failed.
failed. 3. Chec
Checkk batter
batteryy condit
conditions
ions..
4. Alternat
Alternator
or pul
pulley
ley is
is loose
loose on shaft.
shaft. 4. Tighten
ighten ppull
ulley
ey..
5. Cont
Contact
act a Cumm
Cummins ins Au
Author
thorize
ized
d
Repair Facility.
8. Coola
Coolant
nt lo
loss
ss - 1. Coolant
Coolant level
level is high.
high. 1. Chec
Check k coolan
coolantt llevel
evel..
External 2. Radiator
Radiator cap
cap is incor
incorrec
rectt or 2. Replace with correct
correct radiator
radiator cap
defective. (15 psi).
3. External
External engine
engine lleak.
eak. 3. Vis
Visuall
ually
y inspect
inspect the engine
engine and
components for seal or gasket
leaks and repair.
repair.
4. Radiator
Radiator or cab
cab heater
heater is leaki
leaking.
ng. 4. Visually
Visually inspect
inspect the radiator
radiator,, heat-
er, hoses and connections for leaks
continued and repair.
1-12
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
8. Coo
Coola
lant
nt loss
loss - 5. Engine is overheating. 5. Refer to Problems 9. and 10. of
External this troubleshooting chart.
(Continued) 6. Contact
Contact a Cumm
Cummins
ins Author
Authorized
ized
Repair Facility.
9. Coolant
Coolant tempera-
tempera- 1. Coolant
Coolant level
level is low
low.. 1. Inspect
Inspect the
the engine
engine and coolin
cooling g sys-
sys-
ture above normal tem for external
external leaks.
leaks. Repair as
(gradual overheat) required. Add coolant as required.
required.
2. Charge
Charge air cooler
cooler fins,
fins, radiator fins, 2. Inspect
radiator fins, Inspect the
the charge airair cooler
cooler,, air
or air conditioner condenser fins conditioner condenser,
condenser, and radiator
are damaged or obstructed with fins. Clean or repair
repair as required.
required.
debris, insects, dirt, etc.
3. Radiator
Radiator hoses
hoses are colla
collapsed
psed,, 3. Inspect
Inspect and
and repair
repair radiator
radiator hoses
hoses..
restricted
restricted or leaking.
4. Fan drive
drive belt
belt or water
water pump belt is 4. Check
pump belt Check belt
belt tension
tension and tight
tighten
en if
loose. necessary.
5. Incorre
Incorrect
ct oil level.
level. 5. Add or drai
drain
n engine
engine oil asas requir
required.
ed.
6. Cooling
Cooling fan
fan shroud
shroud is damaged.
damaged. 6. Inspect
Inspect shroud
shroud;; repair
repair or replac
replace.
e.
7. Radiator
Radiator cap
cap is incor
incorrec
rectt or 7. Replace
Replace with
with correct
correct radiat
radiator
or cap
defective. (15 psi).
8. Overconcentration
Overconcentration of antifreeze
antifreeze 8. Use the
the correc
correctt antifre
antifreeze
eze con-
con-
and / or supplemental coolant addi- centration (refer to the engine op-
tives. eration and maintenance manual).
9. Defecti
Defective
ve water
water pump
pump.. 9. Replace
Replace water
water pump.
pump.
10. Defective
Defective thermostat.
thermostat. 10. Replace thermostat.
thermostat.
11. Contact a Cummins Authorized
Repair Facility.
10. Coolant
Coolant tempera-
tempera- 1. Electronic
Electronic ffault
ault codes
codes are
are active.
active. 1. Re fer to the QSM11 Fault Code
Refer
ture above normal Information chart in this section.
(sudden overheat) 2. Coolant
Coolant temperature
temperature sensor mal- 2. Check / clean sensor and cool-
function. ant passage.
3. Coolant
Coolant level
level is low
low.. 3. Inspect
Inspect for
for extern
external
al le
leaks
aks on
engine and radiator, and make
repairs.
4. Radiator
Radiator hoses
hoses are collacollapsed
psed,, 4. Inspect
Inspect and
and repair
repair radiator
radiator hoses
hoses..
restricted,
restricted, or leaking.
5. Fan drive
drive belt
belt is bbroke
roken.n. 5. Replace
Replace drive
drive belt.
belt.
6. Charge
Charge air cooler
cooler fins,
fins, radiator
radiator fins,
fins, 6. Inspect
Inspect the
the charge
charge air cooler
cooler,, air
or air conditioner condenser fins conditioner condenser,
condenser, and radiator
are damaged or obstructed with fins. Clean or repair
repair as required.
required.
debris, insects, dirt, etc.
7. Radiator
Radiator cap
cap is incorr
incorrect
ect or def
defec-
ec- 7. Replace
Replace with
with correct
correct radiat
radiator
or cap
tive. (15 psi).
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-13
10. Coolant
Coolant tempera-
tempera- 8. Defecti
Defective
ve water
water pump
pump.. 8. Repl
Replace
ace water
water pump.
pump.
ture above normal 9. Defecti
Defective
ve therm
thermosta
ostat.
t. 9. Repl
Replace
ace thermos
thermostat.
tat.
(sudden overheat)
(Continued) 10. Contact a Cum
Cummins
Repair Facility. mins Authorized
Authorized
11. Coolant tempera- 1. Electron

Electronic
ic fau
fault
lt codes
codes are active
active.. 1. Re fer to the QSM11 Fault Code
Refer
ture below normal Information chart in this section.
2. Coolant
Coolant temperature
temperature sensor mal- 2. Check / clean sensor and and cool-
function. ant passage.
3. Engine
Engine operating
operating at low ambient 3.
temperature.
4. Temperature
emperature gauge malfunction.
malfunction. 4. Test the
the gauge and replac
replace
e if nec-
nec-
essary.
5. Thermostat
Thermostat is incorrect
incorrect or malfunc- 5. Chec
Check k thermos
thermostat
tat and repla
replace
ce if
tioning. necessary.
6. Cont
Contact
actFacility.
Repair a Cumm
Cumminsins Au
Author
thorize
ized
d
12. Engine
Engine accelera-
accelera- 1. Electron
Electronic
ic fault
fault codes are
are active.
Refer
tion or response is Information chart in this section.
poor 2. Engine
Engine operating
temperature.
3. Air intak
intake
e system
system or exhaust
exhaust sys-
sys- 3. Chec
Check k for loose
loose or damaged
damaged piping
piping
tem leaks. connections, and missing pipe
plugs. Check thethe turbocharger
turbocharger and
exhaust manifold mounting (Refer
to the Cummins Engine Operation
and Maintenance Manual.
4. Oper
Operate
ate the engine
engine from
from a tank
tank of
4. Fuel grade
grade is no
nott correc
correctt or fuel
fuel high-quality fuel (refer to the Fuel
quality is poor. and Lubricant Specifications in
the Appendices
Appendices)).
5. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
izedd
Repair Facility.
13. Engine
Engine deceler-
deceler- 1. Electron
Electronic
ic fault
fault codes are
are active.
Refer
ates slowly Information chart in this section.
2. Acceler
Accelerator
ator pedal
pedal is sti
sticki
cking.
ng. 2. Check for a sticking
sticking accelerator
accelerator
pedal.
3. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
1-14 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
14. Engine
Engine diffic
difficult
ult to 1. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
start or will not Information chart in this section.
start (no smoke
from exhaust) 2.
3. Low
Exhafuel
Exhaust
ust s tank
syst
ystemlevel.
levis
em el.leaki
leaking
ng hot air 2. Add
3. Add fuel
Check
Chec fu
k el.
. exhaus
the exhaustt plumbi
plumbingng for
into engine compartment. leaks or broken components.
4. Fuel shutoff
shutoff valve
valve closed.
closed. 4. Repair
Repair ffuel
uel shutdow
shutdown n solenoid
solenoid..
5. Battery
Battery volta
voltage
ge supply
supply to the elec-
elec- 5. Check
Check the battery
battery connec
connection
tions.
s.
tronic control system is low low,, inter- Check the fuses and the un-
rupted, or open. switched
switc hed battery supply circuit. circuit.
6. Fuel fil
filter
ter(s)
(s) are plugged.
plugged. 6. Replace
Replace fuel fuel filt
filter(
er(s).
s).
7. Fuel connec
connectiontion is
is loose
loose on suction
suction 7. Tighten
ighten all fue
fuell fittings
fittings and
and connec-
connec-
side of fuel pump. tions from fuel tank to fuel pump.
8. Starting motor rotation is incorrect
incorrect.. 8. Check direction
direction of crankshaft
crankshaft rota-
rota-
tion. Replace starting
starting motor
motor if nec-
nec-
essary.
9. Engine
Engine crankin
cranking
g speed too
too slow.
slow. 9. Check
Check engine
engine crank
cranking ing rpm.
rpm. Refer
Refer
to Problem 26. of this troubleshoot-
ing chart.
10. Loose wire on master
master disconnect
disconnect 10. Iso
Isolate
late and tighten wire. wire.
switch.
11. Contact a Cummins Authorized
Repair Facility.
15. Engine
Engine diffic
difficult
ult to 1. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
start or will not Information chart in this section.
start (exhaust 2. Batterie
Batteries
s have
have drained
drained oorr are
are 2. Recharg
Recharge e or replac
replace
e batterie
batteries.
s.
smoke present) defective.
3. Fuel shutof
shutofff valve(s)
valve(s) is
is closed
closed 3. Check
Check the fuel
fuel shutof
shutofff valve
valve and
(electronically controlled injection). circuit.
4. Fuse(s)
Fuse(s) malfunct
malfunctioning.
ioning. 4. Replace
Replace the the fuse(s
fuse(s)) in the
the OEM
interface
interfac e harness.
5. Fuel fil
filter
ter(s)
(s) are plugged.
plugged. 5. Replace
Replace fuelfuel filt
filter(
er(s).
s).
6. Intake
Intake air oror exhaust
exhaust syste
system
m is 6. Check
Check intake
intake air
air and exhaust
exhaust sys-
sys-
restricted. tems for restric
restrictions.
tions. Remove
restrictions.
7. Fuel grade isis not corr
correct
ect o
orr fuel 7. Operate
Operate thethe engine
engine fromfrom a tank
tank of
quality is poor. high-quality fuel (refer to the Fuel
and Lubricant Specifications in
the Appendices
Appendices). ).
8. Engine
Engine crankin
cranking
g speed too
too slow.
slow. 8. Check
Check engine
engine crank
crankinging rpm.
rpm. Refer
Refer
to Problem 26. of this troubleshoot-
ing chart.
9. Hydraul
Hydraulic
ic pump
pump is dead-he
dead-headed.
aded. 9. De-energize
De-energize hydraulic
hydraulic circuit.
circuit.
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-15
15. Engine
Engine diffic
difficult
ult to 10. Starting
Starting aid needed for cold weath-
weath- 10. Check / repair or repl
replace
ace cold start-
start or will not er or not working properly. ing aid if necessary.
start (exhaust
smoke present) 11. Repair
ContactFacility.
a Cummins
Cummins Authorized
(Continued)
16. Engine
Engine noise
noise 1. Oil supply
supply insuf
insuffic
ficient
ient or oil
oil pres-
pres- 1. Chec
Check k oil
oil llevel
evel.. Refer
Refer tto
o Proble
Problem m
excessive sure is low. 36. of this troubleshooting chart.
2. Lubrica
Lubricating
ting oil
oil is thin
thin or dilute
diluted.
d. 2. Re fer to the Fuel and Lubricant
Refer
Specifications in the Appendices
for the proper type of oil to use.
Refer to Problem 34. of this trou-
bleshooting chart.
3. Coolant
Coolant tempera
temperature
ture is
is above
above 3. Refe
Referr to Problem
Problem 10. of this this trou-
trou-
normal. bleshooting chart.
4. Loose
Loose motor
motor moun
mount.
t. 4. Insp
Inspect
ect and
and tighten
tighten motor
motor mounts.
mounts.
5. Fan belt
belt is
is malfunc
malfunction
tioning.
ing. 5.
a. Fan belt
belt iis
s too loose
loose or too
too a. Check
Check the tensi
tension
on and adjust
adjust ifif
tight. needed.
b. Fan belt
belt iis
s not in alignm
alignment.
ent. b. Check
Check pulley
pulley alignmen
alignmentt and
adjust is necessary.
6. Damaged vibration
vibration damper.
damper. 6. Chec
Checkk vibrat
vibration
ion ddampe
amperr and
replace if required.
7. Dr
Drive
ive shaft
shaft is
is not in phase.
phase. 7. Repo
Reposit
sition
ion driv
drive
e shaft.
shaft.
8. Cont
Contact
act a Cumm
Cummins ins Au
Author
thorize
ized
d
Repair Facility.
17. Engine
Engine noise
noise 1. Poor fuel quality
quality.. 1. Verify
erify by operatin
operating
g from a tem
tempo-
po-
excessive (com- rary tank
tank with
with good fuel. Clean
bustion knocks) and flush the fuel supply tanks,
and use the proper fuel (refer to
the Fuel and Lubricant Specifica-
tions in the Appendices
Appendices). ).
2. Engine
Engine operating
temperature.
3. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
18. Engine
Engine power out-
out- 1. Electron
Electronic
ic fault
fault codes are
are active.
Refer
put low Information chart in this section.
2. Fuel sucti
suction
on line
line or fuel filt
filter
er is 2. Repl
Replace
ace fuel filt
filter
er or check
check fuel line
line
restricted. for restriction and replace if neces-
sary.
continued
1-16 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
18. Engine
Engine power out-
out- 3. Oil level
level iis
s too
too high.
high. 3. Check
Check oil dipstic
dipstick k and oil
oil pan
put low capacity.. Adjust to the
capacity the proper oil
(Continued) level.
4. Intake
Intake or exhau
exhaust
st sy
system
stem is 4. Check
Check intake
intake and exhaust
exhaust syst
systems
ems
restricted. for restrictions
restrictions.. Remove restric-
restric-
tions.
5. Air intake
intake or exhaust
exhaust leak.
leak. 5. Check
Check for loose
loose or damaged
damaged piping
piping
connections or missing pipe plugs.
Check turbocharger and exhaust
manifold
manifol d mounting.
6. Air in fuel.
fuel. 6. Check
Check for airair in the fuel,
fuel, and
and tight-
tight-
en fuel connections and filter.
7. Fuel drai
drain
n line restr
restrict
iction.
ion. 7. Check the fuel lines for restric
restriction.
tion.
Clear or replace the fuel lines.
correct
ect o
orr fuel 8. Refer
Refer to Corre
Correctiction
on 1. of Proble
Problem m
quality is poor. 17. of this troubleshooting chart.
9. Engine
Engine operatin
mended oper ating
altitude.g above
above recom-
recom- 9. feet
Engine
Engiabove
ne powe
power
sear decreas
dec reases
level. es at 10,000
10,000
10. Contact a Cum
Cumminsmins Authorized
Authorized
Repair Facility.
19. Engine
Engine runs rough
rough 1. Engine operating
operating at low
low ambient 1. Refer
Refer to the Cumm
Cummins
ins E
Engin
ngine
e
at idle temperatures. Operation and Maintenance
Manual.
2. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
Information chart in this section.
3. Engine
Engine mounts
mounts are
are worn
worn or dam- 3. Visuall
Visuallyy check
check engine
engine mounts
mounts and
aged. replace if necessary.
4. Engine
Engine idle
idle speed is
is set ttoo
oo low 4. Verify the correct
correct idle speed set-
(electronically
(electr onically controlled fuel sys- ting.
tems).
5. Air in the fuel.
fuel. 5. Check
Check for air
air in the fuel,
fuel, and
and tight-
tight-
en fuel connections and filter.
correct
ect o
orr fuel 6. Refer
Refer to Corre
Correcti
ction
on 1. of Proble
Problemm
7. Overhead
Overhead adjustm
adjustments
ents are
are incor-
incor- 7. Measure
Measure andand adjust
adjust the overhe
overhead
ad
rect. settings.. Refer to the
settings the Cummins
Cummins
Engine Operation and Mainte-
nance Manual.
8. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
Repair Facility.
20. Engine
Engine runs rough
rough 1. Co
Cond
ndit
itio
ion
n occu
occurs
rs only
only at id
idle
le.. 1. Refe
Referr to Pr
Prob
oble
lem
m 19.
19. of this
this tr
trou
ou--
or misfires bleshooting chart.
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-17
20. Engine
Engine runs rough
rough 2. Engine
Engine oper
operatin
ating
g in low ambient
ambient 2. Refe
Referr to the Cumm
Cummins ins Engine
Engine
or misfires temperatures. Operation and Maintenance
(Continued) Manual.
3. Electron
Electronic
ic fault
fault codes are active..
are active 3. Re fer to the QSM11 Fault Code
Refer
Information chart in this section.
4. Fuel
Fuel leak.
leak. 4. Chec
Check k the fuel
fuel lines,
lines, fuel
fuel connec-
connec-
tions, and the fuel filters for leaks.
5. Fuel grade
grade is nonott correc
correctt or fuel
fuel 5. Refe
Referr to Correc
Correction tion 1. ofof Problem
Problem
6. Ai
Airr in
in the
the fuel
fuel.. 6. Chec
Check k for air
air in the fuel
fuel and tighten
tighten
fuel connections and filter. filter.
7. Fuel fil
filter(
ter(s)
s) are
are plugged.
plugged. 7. Repl
Replace
ace fuel
fuel filt
filter(
er(s).
s).
8. Overhead
Overhead adjust
adjustment
mentss are incor
incor-- 8. Meas
Measure
ure and
and adjust
adjust the overhea
overhead d
Cummins
nance Manual.
9. aged.
Engine
Engine mo
mounts
unts are worn
worn or
or dam
dam-- 9. Vis
Visuall
ually
replacey ifcheck
chec k engine
engine mounts
necessary. mounts and
10. Contact a CumCummins
mins Authorized
Authorized
Repair Facility.
21. Engine
Engine shuts off
off 1. Electron
Electronic
ic fault
fault codes are
are active.
Refer
unexpectedly or Information chart in this section.
dies during decel- 2. Battery
Battery volt
voltage
age supply
supply to the
the elec-
elec- 2. Chec
Check k the batter
battery
y connecti
connections.
ons.
eration tronic control module (ECM) has Check the fuses and the un-
been lost. switched
switc hed battery supply circuit.
circuit.
3. Engine
Engine wi
willll not
not restar
restart.
t. 3. Refe
Referr to Proble
Problems
ms 14
14.. and 15. of
this troubleshooting chart.
4. Fuel inlet
inlet restr
restrict
iction
ion or air in
in the 4. Check fuel tank,
tank, fuel filter,
filter, fuel
fuel. lines,
plate. connections and fuel cooling
5. Low battery
battery voltage.
voltage. 5. Chec
Check k battery
battery power
power suppl
supply
y cir
cir--
cuits.
6. Loose
Loose wire
wire on master
master disco
disconnect
nnect 6. Isol
Isolate
ate and tighten
tighten wire
wire connecti
connection.
on.
switch.
7. Fuel cutoff
cutoff valve
valve is
is closed.
closed. 7. Chec
Check k for loose
loose wire
wires
s and power
power to
the fuel cutoff valve solenoid.
8. Fuel grade
grade is no
nott correc
correctt or fuel
fuel 8. Refe
Referr to Correc
Correction
tion 1. of
of Problem
Problem
9. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
1-18 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
22. Engine
Engine speed
speed 1. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
surges at low idle Information chart in this section.
or high idle
2. Low fuel
fuel level
level in the
the tank.
tank. 2. Contact
3. Fill fuel
Fill
Cont fuel tank
act tankummins
with
with ins
a Cumm
C fuel.
fuel.
Author
Authorized
ized
Repair Facility.
23. Engine
Engine speed
speed 1. Electronic
Electronic ffault
ault codes
codes are
are active.
active. 1. Re
Referfer to the QSM11 Fault Code
surges under load Information chart in this section.
or in operating 2. Low fuel
fuel level
level in the
the tank.
tank. 2. Fil
Filll fuel
fuel tank
tank with
with fuel.
fuel.
range
3. Contact
Contact a CummCumminsins Author
Authorized
ized
Repair Facility.
24. Engine
Engine starts,
starts, but 1. Electronic
Electronic ffault
ault codes
codes are
are active.
active. 1. Re
will not keep run- Information chart in this section.
ning 2. Low fuel level
level iin
n tank.
tank. 2. Fil
Filll fuel
fuel tank
tank with
with fuel.
fuel.
3. Load on hydrau
hydraulic
lic pump.
pump. 3. Isolate and remove
remove restric
restriction
tion from
from
hydraulic circuit.
4. Air in the
the fuel
fuel syst
system.
em. 4. Check
Check for airair in fuel,
fuel, tighten
tighten fuel
fuel
connections and tighten fuel filter.
5. Fuel filt
filter
er plugged
plugged or fuel
fuel waxing
waxing 5. Replace
Replace fuel
fuel filt
filter
er.. Weather
Weather condi-
condi-
due to cold weather. tions can require fuel heater.
6. Fuel inlet
inlet restr
restrict
iction.
ion. 6. Inspect
Inspect fuel
fuel line
line for restri
restricti
ction
on and
replace if necessary.
correct
ect o
orr fuel 7. Refer
Refer to Corre
Correctiction
on 1. of Proble
Problem m
8. Intake
Intake or exhau
exhaust
st sy
system
stem is 8. Check
Check intake
intake and exhaus
exhaustt for
restricted. restriction
restriction and remove restriction.
restriction.
9. Loose wire
wire on maste
masterr disconne
disconnect ct 9. Isolate
Isolate and tighten
tighten wirewire connect
connection.
ion.
10. switch.
Engine protection circuit
circuit is active.
active. 10. Re fer to the Engine Protection
Refer
System Troubleshooting chart.
11. Fuel cutoff valve is closed. 11. Check for loose wires and power to
the fuel cutoff valve solenoid.
12. Contact a Cum
Cummins
mins Authorized
Authorized
Repair Facility.
25. Engine
Engine vibrati
vibration
on 1. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
excessive Information chart in this section.
2. Engine
Engine is
is misf
misfiri
iring.
ng. 2. Refer
Refer to Problem
Problem 20. of this
this trou-
trou-
bleshooting chart.
3. Engine
Engine idle
idle speed
speed is too
too low.
low. 3. Adjust
Adjust idle
idle speed.
speed.
4. anced.
Fan is
is loose,
loose, damaged
damaged or unbal
unbal-- 4. adjust.
Check
Check fan. Tighten,
ighten, replace
replace or
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-19
25. Engine
Engine vibrati
vibration
on 5. Engine
Engine belt dr
drive
iven
n accessori
accessories
es 5. Chec
Check k for interfer
interference.
ence. Loosen
Loosen
excessive malfunctioning:
malfunctioning: fan hub, alternator,
alternator, belt, if applicable, to isolate compo-
(Continued) Freon compressor or air compres- nent from vibration.
sor.
6. Engine
Engine mo
mounts
unts are worn
worn or
or dam
dam-- 6. Vis
Visuall
ually y check
check engine
engine mounts
mounts and
aged. replace if necessary.
7. Damaged vibration
vibration damper.
damper. 7. Chec
Check k vibrat
vibration
ion d
dampe
amperr and
replace if required.
8. Cont
Contact
act a Cumm
Cummins ins Au
Author
thorize
ized
d
Repair Facility.
26. Engine
Engine will
will not 1. Master disconnect
disconnect switch
switch is turned 1. Turn
Turn mas
master
ter disconnect
disconnect switch
switch on.
crank or cranks off.
slowly
slowly (OEM 2. Load on hydraul
hydraulic
ic pump.
pump. 2. Isolate and remove
remove restric
restriction
tion from
electrical) hydraulic circuit.
3. Battery
Battery connec
connection
tions
s are broken,
broken, 3. Chec
Check k for
for damage.
damage. Replace,
Replace, tight-
tight-
loose or corroded. en or clean.
4. Low battery
battery charge.
charge. 4. Check electrolyte
electrolyte level and specific
specific
gravity.. Recharge or replace
gravity replace bat-
teries.
5. Battery
Battery ratin
rating
g is too low
low or batter
batteryy 5. Replace with correct rated battery
battery..
is defective.
defective.
6. Shifter
Shifter is not in the
the neutral position.. 6. Plac
neutral position Place
e shifter
shifter in the neutral
neutral positi
position.
on.
7. Circui
Circuitt breaker
breaker (CB2,
(CB2, CB7
CB7 or 7. Res
Reset
et or replac
replacee circuit
circuit break
breaker
er
CB10; Illustration 6-16
6-16)) is tripped or (CB2, CB7 or CB10).
defective.
8. Circuit
Circuit breaker
breaker (CB1)
(CB1) iis
s defective.
defective. 8. Replace circuit
circuit breaker (CB1).
9. Defecti
Defective
ve truck
truck power
power soleno
solenoid
id 9. Repl
Replace
ace truck
truck power
power solenoi
solenoid
d (L1).
(L1).
10. Defective
Defective neutral start relay
relay (K1). 10. Replace neutr
neutral
al start relay
relay (K1).
11. Defective
Defective starter solenoid (L2). 11. Replace starter solenoid (L2).
12. Defective starter. 12. Replace or repair s
starter
tarter..
13. Defective
Defective ignition switch
switch (S1). 13. Refe
Referr to Component
Component 4. of the
Component Troubleshooting
chart in Section 6.
14. Defective
Defective fuel cutoff valve
valve (L4). 14. Re fer to Fuel Solenoid Valve
Refer
found in Section 2 for proper fuel
cutoff valve operation.
15. Loose
Loose or brok
broken
en wires,
wires, pins, or 15. Isolate an
and
d repair.
repair.
plugs between any of the compo-
nents in Causes 1. thru 14.
1-20 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
27. Engine
Engine will
will not 1. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
reach rated speed Information chart in this section.
(rpm)
2. Engine
Engine power
power outp
output
ut is low.
low. 2. Refer
Ref er to Problem
Problem
bleshooting chart.18. of this
this trou-
trou-
correct
ect oorr fuel 3. Refer
Refer to Corre
Correctiction
on 1. of Proble
Problem m
4. Fuel suction line is restric
restricted.
ted. 4. Check
Check fuel inlet
inlet for
for restric
restriction
tion..
5. Overhead
Overhead adjustm
adjustments
ents are
are incor-
incor- 5. Measure
adjust the overhe
overheadad
Cummins
nance Manual.
6. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
repair facility.
28. Engine
Engine will
will not 1. Ignition switch
switch circuit
circuit is malfunc-
malfunc- 1. Check ignition key switch
switch circuit.
circuit.
shut off tioning.
NOTE: Should
function preventan electrical
engine mal-
shutdown,
turn the master disconnect switch
off.
2. Engine
Engine is runni
running
ng on fumes
fumes drawn
drawn 2. Locate
Locate and isol
isolate
ate the sourc
source
e of
into air intake. fumes.
29. Fuel consumptio

consumption
n 1. Oil level
level iis
s too
too high.
high. 1. Check
Check oil dipstic
dipstick
k and oil
oil pan
excessive capacity.. Adjust to the
capacity the proper oil
level.
2. Intake air restric
restriction
tion is excessive.
excessive. 2. Visually
Visually inspect
inspect air filter and restric-
restric-
tion indicator.
indicator. Replace air filter
filter if
necessary.
3. Fue
Fuell leaks
leaks.. 3. Visuall
Visually
y check
check fuel syst
system
em and
supply for leaks.
4. Contact
Contact a Cumm
Cumminsins Author
Authorized
ized
Repair Facility.
30. Fuel in
in coolant
coolant 1. Bulk coolant
coolant supply
supply contami
contaminated
nated.. 1. Check
Check coolant
coolant supply
supply.. Drain
Drain cool-
cool-
ant and replace with non-contami-
nated coolant.
coolant. Replace coolant
filter.
2. Contact
Contact a Cumm
Cumminsins Author
Authorized
ized
Repair Facility.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-21
31. Fuel in
in the lubri-
lubri- 1. Bulk oil
oil supply
supply is
is contami
contaminated
nated.. 1. Chec
Check k oil
oil supply
supply.. Drain
Drain oil
oil and
and
cating oil replace with non-contaminated oil
and replace filters.
2. Engine
Engine idle ttime
ime is
is excess
excessive
ive.. 2. Low oioill and coolan
coolantt temperat
temperatures
ures
can be caused by long periods of
engine idling (time greater than
10 minutes)
minutes).. Shut off off the engine
rather than idle for long periods of
time.
3. Cont
Contact
act a Cumm
Cummins ins Au
Author
thorize
ized
d
Repair Facility.
32. Intake
Intake manifold
manifold air 1. Truck
ruck speed
speed too lowlow for
for adequate
adequate 1. Redu
Reduce
ce engine
engine load.
load.
temperature
temperatur e above cooling at high engine load.
specification 2. Cooling
Cooling fan
fan shroud
shroud is dama
damaged.
ged. 2. Repa
Repair
ir or replace
replace shrou
shroud.
d.
3. Fan driv
drive
e belt is brok
broken.
en. 3. Chec
Check
k the fan drive
drive belt
belt and
replace belt if necessary.
necessary.
4. Charge
Charge air cooler
cooler fins,
fins, radiat
radiator fins, 4. Inspect charge
or fins, charge air cooler,
cooler, radiator,
radiator,
and Freon condenser fins are dam- and Freon condenser
condenser.. Clean fins if
aged or obstructed with debris, necessary.
insects,, dirt, etc. (external)
insects (external)
5. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
33. Lubrica
Lubricating
ting oil con- 1. Verify oil consumption
consumption rate.
rate. 1. Chec
Check k oil added vers
versus
us hours.
hours.
sumption
sumption exces- 2. External
External oil leaks.
leaks. 2. Tighten
ighten caps
capscre
crews,
ws, pipe
pipe plugs and
and
sive fittings as needed. Replace gas-
kets if necessary.
3. Oil does
does not meet
meet specif
specifica
ication
tions.
s. 3. Chan
Change ge oil and
and replac
replace
e with
with the
proper oil (refer to Fuel

cant Specifications andAppen-
in the Lubri-
dices).
dices).
4. Crankcase
Crankcase ventilation
ventilation system
system is 4. Chec
Checkk and clean
clean crank
crankcas
casee
plugged. breather and vent tube.
5. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
34. Lubrica
Lubricating
ting oil con- 1. Identif
Identify
y contam
contaminat
ination.
ion. 1. Perf
Perform
orm anan oil analys
analysis
is to deter-
deter-
taminated mine the contaminants.
2. Bulk oil
oil supply
supply is
is contami
contaminated
nated.. 2. Chec
Check k oil
oil supply
supply.. Drain
Drain oil
oil and
and
replace with non-contaminated oil
and replace filters.
3. Oil sludge
sludge is
is excessi
excessive.
ve. 3. Refe
Referr to Problem
Problem 37. of this
this trou-
trou-
bleshooting chart.
continued
1-22 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
34. Lubricati
Lubricating
ng oil con- 4. Fuel in the oil. 4. Re
Refer to Problem 31. of this trou-
taminated bleshooting chart.
(Continued)
5. Repair
Contact
ContactFacility.
a Cumm
Cumminsins Author
Authorized
ized
35. Lubricati
Lubricating
ng oil 1. Oil press
pressure
ure switc
switch,
h, gauge or sen- 1. Verify that the oil
oil pressure
pressure switch,
switch,
pressure (high) sor is malfunctioning.
malfunctioning. gauge and sensor is functioning
properly.
2. Engine
Engine coolant
coolant temperat
temperature
ure is too
too 2. Refer
Refer to Problem
Problem 11. of this
this trou-
trou-
low. bleshooting chart.
3. Oil does
does not meet
meet specif
specifica
ication
tions.
s. 3. Change
Change the oil oil with
with the prope
properr type
type
of oil (refer to the Fuel and Lubri-
cant Specifications in the Appen-
dices).
dices ).
4. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
Repair Facility.
36. Lubricati
Lubricating
ng oil 1. Electronic
Electronic ffault
ault codes
codes are
are active.
active. 1. Re
pressure (low) Information chart in this section.
2. Incorre
Incorrect
ct oil level.
level. 2. Add or or drai
drainn engine
engine oil.
oil.
3. External
External oil leaks.
leaks. 3. Visuall
Visually y inspect
inspect for oil
oil leaks.
leaks. Tight-
ight-
en the capscrews, pipe plugs, and
fittings.. Replace gaskets
fittings gaskets if neces-
sary.
4. Oil press
pressure
ure switc
switch,
h, gauge or sen- 4. Refer
Refer to Corre
Correcti
ction
on 1. of Proble
Problem m
sor is malfunctioning.
malfunctioning. 35. of this troubleshooting chart.
5. Oil does
does not meet
meet specif
specifica
ication
tions.
s. 5. Change
Change oil oil and
and filter
filters.
s. Refer
Refer to
to
Fuel and Lubricant
Lubricant Specifica-
tions in the Appendices for the
6. Oil contam
contaminatinated
ed with
with coolant
coolant or 6. proper
Refer totype
Refer of oil to
Problem
Problem 34.beofused.
this trou-
trou-
fuel. bleshooting chart.
7. Oil filt
filter(
er(s)
s) ar
are
e plugged.
plugged. 7. Change
Change oil and replac
replace e oil filter
filter(s)
(s)..
8. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
Repair Facility.
37. Lubricati
Lubricating
ng oil 1. Bulk oil
oil supply
supply is
is contami
contaminated
nated.. 1. Refer
Refer to Corre
Correcti
ction
on 2. of Proble
Problemm
sludge in the 34. of this troubleshooting chart.
engine crankcase
crankcase 2. Oil does
does not meet
meet specif
specifica
ication
tions.
s. 2. Change
Change the oil oil with
with the prope
properr type
type
excessive of oil (refer to the Fuel and Lubri-
cant Specifications in the Appen-
dices).
dices ).
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-23
37. Lubrica
Lubricating
ting oil 3. Oil drain interval
interval is excessiv
excessive.
e. 3. Chan
Changege oil and
and filter(
filter(s)
s) at the
sludge in the appropriate intervals (refer to the
engine crankcase
crankcase Preventive
Preventiv e Maintenance
Maintenance chart in
excessive the Appendices
Appendices). ).
(Continued) 4. Fuel grade
grade is no
nott correc
correctt or fuel
fuel 4. Refe
Referr to Correc
Correction
tion 1. of
of Problem
Problem
5. Crankcase
Crankcase ventilation
ventilation system
system is 5. Chec
Check k and clean
clean crank
crankcas
casee
plugged. breather and vent tube.
6. Cont
Contact
act a Cumm
Cummins ins Au
Author
thorize
ized
d
Repair Facility.
38. Lubrica
Lubricating
ting oil tem- 1. Incorrec
Incorrectt oi
oill llevel
evel.. 1. Add or drain
drain engine
engine oil.
oil.
perature above 2. Engine
Engine cool
coolantant te
temper
mperatur
ature
e is 2. Refe
Referr to Problem
Problem 10. of this
this trou-
trou-
specification above normal. bleshooting chart.
3. Oil pressu
pressure
re switc
switch,h, gauge
gauge or sen- 3. Refe
Referr to Correc
Correction
tion 1. of
of Problem
Problem
sor is malfunctioning.
malfunctioning. 35. of this troubleshooting chart.
4. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
ized
d
Repair Facility.
39. Lubrica
Lubricating
ting or 1. Bulk coolant
coolant supply
supply contami
contaminated
nated.. 1. Check
Check coolant
coolant supply
supply. Drain
Drain cool-
cool-
transmission
transm ission oil in ant, flush cooling system and
the coolant replace with non-contaminated
non-contaminated
coolant. Replace coolant
coolant filter.
filter.
2. Cont
Contact
act a Cumm
Cumminsins Au
Author
thorize
izedd
Repair Facility.
40. Excess
Excessive
ive black 1. Turbocharger
Turbocharger wheel clearance
clearance is 1. Chec
Check
k the radial
radial bearin
bearing
g clearanc
clearance
e
smoke
out of specification. and axial clearance.
clearanc
turbocharger.
turbocharger e. Inspect
. Repair the
the
or replace
the turbocharger if necessary.
necessary.
2. Air intak
intake
e or exhaust
exhaust leaks.
leaks. 2. Chec
Check k for loose
loose or damaged
damaged piping
piping
connections or missing pipe plugs.
Check turbocharger and exhaust
manifold mounting.
3. Fuel grade
grade is no
nott correc
correctt or fuel
fuel 3. Refe
Referr to Correc
Correction
tion 1. of
of Problem
Problem
4. Fuel drain
drain line restr
restrict
iction.
ion. 4. Check the fuel lines for restric
restriction.
tion.
Clear or replace the fuel lines.
5. Cont
Contact
act a Cumm
Cummins ins Au
Author
thorize
izedd
Repair Facility.
1-24 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
41. Excessive
Excessive white
white 1. Electronic
Electronic ffault
ault codes
codes are
are active.
Refer
smoke Information chart in this section.
2. (if
Engine
Engin e block heater
equipped). heater malfu
malfuncti
nctioning
oning 2. Check electrical
electri
to cylinder cal source
block heater. and
heater. wiring
wiring
Replace
block heater if necessary.
necessary.
3. Coolant temperature
temperature is too lowlow.. 3. Refer
Refer to Problem
Problem 11. of this
this trou-
trou-
bleshooting chart.
4. Eng
Engine
ine is cold.
cold. 4. Allow
Allow eng
engine
ine to warm
warm toto operatin
operating g
temperature.
5. Fuel grade is is incorr
incorrect
ect or fuel 5. Refer
Refer to Corre
Correcti
ction
on 1. of Proble
Problem m
quality poor. 17. of this troubleshooting chart.
6. Overhead
Overhead adjustm
adjustments
ents are
are incor-
incor- 6. Measure
adjust the overhe
overheadad
Cummins
nance Manual.
7. Contact
Contact a Cumm
Cummins ins Author
Authorized
ized
Repair Facility.
42. Intake
Intake manifold
manifold 1. Air intak
intake
e or exhaus
exhaustt leaks.
leaks. 1. Check
Check for loose
loose or damaged
damaged piping
piping
pressure (Boost) is connections or missing pipe plugs.
below normal Check turbocharger and exhaust
manifold
manifold mounting.
2. Air compressor loose 2. Check
compressor connection is loose Check the connec
connection
tion betwe
between
en the
or damaged. manifold and the air compressor.
Repair or replace if necessary.
necessary.
3. Contact
Contact a Cumm
Cummins
ins Author
Authorized
ized
Repair Facility.
43. Turbocharg
urbocharger
er 1. Operatin
Operatingg for extende
extendedd periods
periods 1. Refer
Refer to the Cumm
Cummins ins E
Engin
ngine e
leaks engine oil or under light or no load conditions. Operation and Maintenance
fuel Manual.
2. Engine
Engine oil or
or fuel
fuel ente
enterin
ring
g turbo-
turbo- 2. Remove
Remove intake
intake and
and exhaust
exhaust piping,
piping,
charger. and check for oil or fuel.
3. Turbocharge
urbochargerr dra
drain
in line
line is 3. Remove
Remove the turboc
turbocharge
hargerr drain
drain line
restricted. and check for restriction.
restriction. Clean or
replace the drain line.
4. Contact
Contact a Cumm
Cumminsins Author
Authorized
ized
Repair Facility.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-25
Cummins QSM11-C330 Diesel Engine
Engine Operating Conditions 2100 rpm
Lubrication System English Metric
Lubri
ric
catin
ting oil pressure (min. / max. at ra
rate
ted
d sp
spe
eed) . . . . . . . . . . . . . . psi (kPa
(kPa)) 15 - 35 103 - 241
Minimum for safe operation (at idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (kPa) 10 69
*Lubrication
*Lubrication oil tempe
t emperature
rature maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . ˚F (˚C) 275 135
Oil pan capacity High / Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . qt (L) 36 / 28 34 / 26.5
Total engine oil capacity with filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . qt (L) 39.2 37
Air System
Air inlet restriction,
restriction, Dirty air cleaner
cleaner . . . . . in H 2O (mm H2O) 25 635
full load maximum
Clean air cleaner . . . . in H2O (mm H2O) 15 381
Exhaust back pressure maximum full load . . . . . . . . . . . . . . . . . . in Hg (mm Hg) 3.0 76
Max. allowable air temp. rise over ambient at turbo compressor inlet . ˚F (˚C) 30 16
Fuel System
Maximum fue
fuel inlet res
restri
trictio
tion Dirt
rty
y fu
fue
el fi
fillte
terr . . . . . . . . . in Hg (mm
(mm Hg) 8 203
Clean fuel filter . . . . . . . . in Hg (mm Hg) 4 102
Maxi
Maximu
mum
m fuel
fuel dra
drain rest
restri
rict
ctio
ion
n le
less
ss ch
chec
eck
k va
valv
lves
es . . . . . . . . . . . . in Hg (mm
(mm Hg
Hg)) 2.5 63
Maximum fue
fuel flow (on supply side of fuel pump) . . . . . . . . . . . . . . lb/h
/hrr (kg/hr) 540 245
Cooling System
Coolant flow Normal temp. . . . . . . . . . . . . . . . . ˚F (˚C) 190 88
Full load speed . . . . . . . . gal/mi
/min (L/sec) 62 3.9
Engine coolant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . qt (L) 13.6 12.9
Min. pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (kPa) 7 48
Max. pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (kPa) 15 103
Max. top tank temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˚F (˚C) 212 100
˚ ˚
Min. top tank temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F ( C) 160 71
Thermostats Start to open . . . . . . . . . . . . . . . . ˚F (˚C) 180 82
Fully open . . . . . . . . . . . . . . . . . . ˚F (˚C) 200 93
*The lubricating
lubricating oil temperature range is based on the temperature measurement
measurement in the oil galle
gallery
ry.. When measur-
ing the oil temperature in the pan, it will normally be approximately 10 ˚F higher than the oil gallery temperature.
1-26 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Illustration
Illustration 1-6. Cummins
Cummins QSM11-C330
QSM11-C330 Engine Electrical
Electrical Wiring ANSI Circuit
THDC / THDCP 954 / 955 / 974 (Rev. 06/03) 1 27
1 28 THDC / THDCP 954 / 955 / 974 (Rev. 06/03)
06B-2106 SHT. 02
THDC / THDCP 954 / 955 / 974 (Rev. 06/03) 1 29
Hoist Circuit
1 30 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Hoist Circuit
PLACE THE FOLLOWING ILLUSTRATIONS IN

FOLDER ENVELOPES:
Illustration 1-7 - CUMMINS QSM11 ECM CIRCUIT
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 1-31
Hoist Circuit
1-32 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Section 2
Fuel System
ENGINE
CYLINDER
HEAD
FUEL
COOLER
FUEL
SOLENOID RETURN LH RH
LINE
SUPPLY
LINE
FUEL
TANK
FUEL / WATER
SEPARATOR
FILTERS FUEL
PUMP
FUEL FLOW
INDICATES FUEL SUPPLY
INDICATES
INDICATES FUEL RECOVER
RECOVERY
Y
Illustration
Illustration 2-1.
2-1. Fuel System
System
Introduction. Fuel is drawn from the tank through tors. The fuel solenoid
solenoid valve is normally
normally closed
closed
the fuel / water separator filters by the fuel pump. and requires a 12 VDC signal to energize the coil,
From here, the fuel is sent to the fuel injectors. shifting the spool
spool to the open state. This allows
allows
Unused fuel is returned through the fuel cooler the fuel to flow to the injector pump.
and into the fuel tank.
Adding Fuel (Illustration 2-3).
2-3). When adding die-
Major Components (Illustration 2-1).
2-1). The fuel sel fuel to the fuel tank, make sure the fuel strain-
system consists of a fuel tank, two fuel / water er is in the filler neck
neck and free of debris. Addi
Adding
ng
separator filters, fuel pump, fuel solenoid valve, fuel with the strainer removed could lead to debris
fuel cooler, fuel injectors and fuel lines. entering the fuel tank, resulting in poor engine
performance.
Fuel Solenoid
solenoid valve, Valve
located (Illustration
on the fuel2-1).
2-1). The
pump fuel
itself, Fuel Cooler (Illustration 2-1).
2-1). The fuel cooler,
controls the on / off flow of fuel to the fuel injec- located inside the radiator shroud, is forced-air
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 2-1
cooled. Fuel is circulated

circulated through
through its tubes and S Do not overtigh
overtighten
ten the drain
drain valve. Overtigh-
Overtigh-
the engine fan circulates air across the cooler and tening may cause thread damage.
through the fins, cooling the fuel before it returns
to the fuel tank. 1. Provide a suitable
suitable container
container to catch drained
water and open the drain valve approximately
Changing
Changing the Fuel / Water
Water Separator
Separator Filters
Filters 1-1/2 to 2 turns until draining
draining occur
occurs.
s. Drain
(Illustration 2-2). With
2-2).
form the following the engine
procedures shut down,
to replace per-/
the fuel each fuel / water separator filter of water until
clear fuel is visible.
water separator
separator filters.
filters. They should be changed
every 250 hours or more often if conditions war- 2. Once the
the water
water has draine
drained,
d, tur
turn
n the valve
valve
rant. clockwise to close the drain valve.
CAUTIONS:
S Dispose of used fuel / water separator filters
and drained fuel in accordance to federal ADAPTER
and local regulations.
regulations.
S Mechanical tighteni
tightening
ng of the fuel / water ADAPTER
SEALING
separator filter may result in seal and / or
RINGS
cartridge
cartridge damage. Tighten
Tighten the fu
fuel
el / water
separator filter by hand only.
1. Provide
Provide a suitable
suitable containe
containerr to catch drained
drained
fuel and use a strap wrench to remove the fuel
/ water separator filters from the filter base.
2. Clean
Clean the area
area around
around the filter
filter heads.
heads. FUEL / WATER
SEPARATORS
3. Remove
Remove the fuel filter
filter thread
thread adapter
adapter sealin
sealing
g
rings.
4. Clean
Clean the gasket
gasket surface
surface of the
the fuel filter
filter head
head
with a lint free cloth.
5. Install
Install the new
new thread
thread adapter seali
sealing
ng rings
rings on
the fuel filter head.
6. Fill new filters
filters with clean
clean fuel and lubricate
lubricate the
the Illustration
Illustration 2-2. Fuel / Water
Water Separator Filters
Filters
filter seals with clean oil.
7. Install
Install filter
filters
s and tighten
tighten them 1/2 turn after
after the
seals contact the filter head surface.
General Information
Fuel Capacity 240 Gallons
Draining The Fuel / Water Separator Filters
2-2). The fuel / water separator filters
(Illustration 2-2).
should be drained daily to remove water and sedi-
ments from
from the fuel. Perform the
the following
following proce-
dures to drain the water from the fuel / water sep-
arator filters.
S CAUTIONS:
Dispose of drained fuel
fuel in accordance to
federal and local regulations.
regulations.
2-2 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
COVER PLATE
FILLER CAP FUEL LEVEL

SENDING UNIT
FUEL STRAINER
FILLER NECK
DRAIN PLUG
FUEL TANK
Illustration
Illustration 2-3. Fuel Tank
Tank
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 2-3
Section 3
Air Intake System
COTTER PIN INTERNAL PRECLEANER

FILTER CAP
INDICATOR AIR RESTRICTION
SAFETY INDICATOR
FILTER
IF EQUIPPED
SIGNAL
LINE
SAFETY
FITTING
WING
NUT
PRIMARY VACUATOR
FILTER
AIR
ASSEMBLY
ASSEMBL Y
CLEANER
HOUSING
INDICATES AIR FLOW
Illustration
Illustration 3-1. Air Intake System
System Components
Introduction. The air cleaner is designed to be Major Components (Illustration 3-1).3-1). The air
serviced
serviced efficiently
efficiently and quickly.
quickly. Intake air enters cleaner consists of the primary filter element, inter-
the air cleaner through the cap or optional pre- nal filter indicator, safety element, air cleaner
cleaner.. When the air reaches the filter
cleaner filter body,
body, a housing, cap (or optional precleaner), vacuator
helical ramp imparts a high-speed circular motion and an air restriction
restriction indicator.
indicator.
to the intake air.
air. This action
action separates up to 85%
Servicing (Illustration 3-1).
3-1). If the equipment is
of the dust from the air
air by centri
centrifugal
fugal action. The
being operated under extremely dusty conditions,
dust is then forced
forced out the vacuator.
vacuator. The air then
the vacuator should be checked every day to be
passes through the primary and safety elements,
certain it is
is not clogged. Perform the
the following
where it is cleaned, before entering the engine. procedures to service the filter element and air
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 3-1
cleaner components.
components. Overservicing
Overservicing of the filter
filter 8. Re-ins
Re-install
tall wing
wing nut, washe
washerr and clip
clip on
elements is not recommended.
recommended. Filter element
element effi-
effi- replacement
replacem ent primary filter
filter element. Re-install
Re-install
ciency increases with initial operation. and secure the primary filter assembly in the
air cleaner housing.
CAUTIONS: 9. Push the

the reset
reset button
button on the
the top of the air
air
S Normally
Normally the primary
primary filter element should restriction indicator.
be changed after 1500 hours of operation or 10. Inspect air intake
intake system for leaks.
leaks.
when the air restriction indicator shows red.
In dusty conditions, the primary filter 11. Inspect rubber elbow, joints and clamps for
element may have to be changed more often. wear, damage and looseness.
S Replace the safety element when the internal 12. Inspect the vacuator
vacuator cup joint for sealing.
filter indicator turns red, yearly or every
3000 hours, whichever comes first.
S Do Not use ether type fuels to help start the
engine for this may damage the engine.
1. When the air air restricti
restriction
on indicator
indicator indicates
indicates ele-
ment servicing is required, remove the wing
nut and cover assembly, then remove the pri-
mary filter assembly
assembly.. In high humidity situa-
tions, the air restriction indicator may indicate
a restricted condition due to moisture in the
filter element.
element. When the element
element dries out,
out, GREEN DOT
restriction
restri ction levels
levels drop back to normal.
normal. The
indicator will now have to be reset (refer to
procedure 9. to reset the indicator).
Illustration
Illustration 3-2. Internal Filter
Filter Indicator
Indicator
2. Check the
the internal filter indicator to determine
determine
if the safety element also requires servicing.
3. If the internal
internal filter
filter indicator
indicator indicates a green
dot in its center (Illustration 3-2), the safety
element is good, continue to procedure 6.
4. If the internal
internal filter
filter indicator
indicator indicates red, the
safety filter element must be replaced.
Remove internal
and replace with filter
a new indicator
indicator,
, old safety
safety filter filter
element.
5. Reset the
the internal filter indicator by applying
applying
suction to window and re-install
re-install indicator.
indicator.
6. Remove
Remove all dust
dust and foreign
foreign particle
particles
s from the
the
air cleaner components, and clean the inside
of the air cleaner housing with a damp cloth.
CAUTION: Do not use flammable liquids

to clean the inside of the air cleaner housing.
Only use a cloth dampened with water.
7. Replace
Replace the primar
primary
y filter
filter element
element with
with a new
filter element.
element. Remove clipclip from the used pri-
pri-
mary filter element to release the wing nut and
washer.
3-2 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Air Intake System Troubleshooting

1. Short element
element liflife
e 1. Improper
Improper assem
assembly
bly when
when prior
prior ele- 1. Properl
Properly
y install
install..
(primary filter element was replaced.
ment)
2. Damaged or missing
missing vacuator
vacuator.. 2. Replace
Replace vacuator
vacuator..
3. Damaged
Damaged seal
seal on the
the cover
cover.. 3. Replace
Replace seal
seal on the
the cover
cover..
4. Damaged
Damaged air
air cleaner
cleaner b
body
ody.. 4. Replace
Replace air
air cleaner
cleaner body.
body.
5. Loose
Loose system
system connecti
connections.
ons. 5. Ti
Tighten
ghten system connections.
connections.
6. Loose wing
wing nut on
on cover
cover.. 6. Tighten
ighten wing
wing nut.
nut.
7. Excessively
Excessively dusty environment.
environment. 7. Replace
Replace element
element a
as
s needed.
needed.
8. Incorre
Incorrect
ct e
elem
lement
ent used.
used. 8. Replace
Replace with
with proper
proper element.
element.
9. Seal on dust
dust cover
cover is not
not sealing.
sealing. 9. Ensure
Ensure tha
thatt no foreign
foreign objec
objectt is
between seal and metal mating
surface.
2. Short element
element lif
life
e 1. Bypassing primary
primary ffilter
ilter element. 1.
(safety element)
a. Seal of prim
primary
ary filt
filter
er element
element is
is a. Repl
Replace
ace element.
element.
not sealing.
b. Damaged
Damaged prima
primary
ry elem
element.
ent. b. Replace primary
primary ffilter
ilter element.
c. Loos
Loose
e primar
primary
y filter
filter element
element c. Tighten
ighten wing
wing nut.
wing nut.
3. Airborne
Airborne contami
contami-- 1. Damaged
Damaged element(
element(s).
s). 1. Replace
Replace element(
element(s).
s).
nants entering the
engine 2. Damaged
Damaged seals
seals or
or sea
sealin
ling
g sur-
sur- 2. Replace
Replace damag
damaged
ed component
components.
s.
faces.
3. Damaged
Damaged or
or loose
loose connec
connection
tions
s 3. Replace
Replace or repair
repair connecti
connections.
ons.
between air cleaner body and
engine.
4. Incorre
Incorrect
ct e
elem
lement
ent used.
used. 4. Replace
Replace with
with proper
proper element.
element.
4. Air restri
restricti
ction
on indi-
indi- 1. Restri
Restricti
ction
on in air hose between
between the
the 1. Remove
Remove restri
restricti
ction.
on.
cator indicates
indicates air restriction indicator and the
green condition safety fitting.
and primary filter
element is clogged 2. Air leakleak in
in air hose
hose between
between the
the air 2. Repair
Repair or
or replac
replace
e air hose.
hose.
restriction indicator and the safety
fitting.
3. Damaged air restric
restriction
tion indicator
indicator.. 3. Replace air restric
restriction
tion indicator
indicator..
4. Damaged
Damaged safety
safety fitt
fitting.
ing. 4. Replace
Replace safet
safety
y fitti
fitting.
ng.
5. Loose
Loose system
system connecti
connections.
ons. 5. Tighten
ighten connecti
connections.
ons.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 3-3
Section 4
Exhaust System
Introduction. The exhaust system is responsible
for venting exhaust gases, generated by the
engine, to the atmosphere.
atmosphere. It also provides
provides noise
suppression.
WARNINGS:
S Do not service exhaust system until exhaust
system is cool.
cool. Failure
Failure to do so may result
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 con-
centrated
centrat ed in enclosed areas. Exposure
Exposure to
carbon monoxide can result in serious inju-
ries or health hazards, including
including death.
Properly ventilate work areas, vent exhaust
fumes, and keep shop clean and dry.
(A) Initial
Initial symptoms
symptoms of carbon monoxide
monoxide
poisoning include headaches, dizzi-
ness, and nausea.
nausea. The smell of
of lift truck
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 car-
bon monoxide
monoxide output.
output. Carbon
Carbon monoxide
monoxide
levels can change depending on mainte-
nance. Make sure carbon
carbon mono
monoxide
xide level
testing is included
included in regular maintenance
maintenance
procedures and that ventilation is used as
the primary control for emission
emissions.
s.
Maintenance. There is minimal maintenance re-
quired on the standard exhaust system.
1. Check
Check for leaks
leaks at all pipe
pipe connect
connections
ions..
2. Check
Check for holes
holes in the muffl
muffler
er and exhaust
exhaust
piping.
3. Keep guard
guard clean
clean and
and in plac
place.
e.
4. Keep exhaust
exhaust syst
system
em free
free of debris.
debris.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 4-1
Section 5
Cooling System
Introduction. The cooling system cools the
engine.
engin e. Refer to Section 9A for transmission
Refer to CAUTION: Coolant containing anti-leak
cooling and Section 15C for the wet disc brakes additives must not be used with the coolant
cooling system to find more detailed cooling infor- filter because it will clog the element.
mation on these particular systems.
Major Components (Illustration 5-5).5-5). The engine

cooling system consists of coolant, radiator /
charge air cooler, piping connecting the radiator to CUT-OFF
the engine and a water pump to circulate the cool- VALVES
ant. A coolant filter
filter,, remote mounted,
mounted, is used to
filter and condition the coolant.
Operation (Illustration 5-5).
5-5). When the engine is
started, the water pump draws coolant from the
radiator into
into the engine block. The coolant is cir-
cir-
culated through the engine and the coolant filter
until it reaches a temperature of approximately
180 _F, at which point the thermostat will start to
open. This willwill allow coolant
coolant flow back
back into the top
of the radiator core.
core. Air trapped in the cool
coolant
ant will
travel to the top of the deairation space by means COOLANT
of the deaeration line and an internal deaeration FILTER
stand tube. Coolant is made available
available from the
the
deaeration tank to displace the removed air by
way of the make-up line.
Coolant. The cooling system of this equipment is
protected to -34_F (-36_C) and 228_F (108.9_C).
The solution is a 50 - 50 mixture of ethylene glycol Illustration
Illustration 5-1. Coolant Filter
Filter
base antifreeze
antifreeze to water solution.
solution. Use soft water
water
in the coolant mixture.
mixture. It is recommended
recommended that Radiator / Charge Air Cooler (Illustration 5-4).
5-4).
50% solution be maintained year round. The radiator is comprised of a deaeration tank,
core, and a charge air cooler
cooler.. The deaeration
A proper coolant / SCA (Supplemental
(Supplement al Coolant
tank functions
functions as a coolant
coolant storage tank.
tank. When
Additive) additive concentration must be main-
adding coolant to the system, coolant should be
tained to prevent liner pitting, corrosion and scale
added to the deaeration
deaeration tank. Access to to the
deposits in the cooling
cooling system.
system. Refer to the
deaeration tank is supplied through a 7 psi radia-
Cummins QSM11 Engine Operation and Mainte- tor cap located on the left side of the radiator,
nance Manual for coolant additive concentration.
above the radiator
radiator sight glasses.
glasses. The radiator
The coolant additive concentration level may be coolant level is to be maintained by the coolant
tested with a coolant test kit, Taylor part number sight glasses below the 7 psi radiator cap.
1006-175.
The radiator is force-air-
force-air-cooled.
cooled. Access to the
core is supplied through a 15 psi radiator cap
CAUTION: Insufficient concentration of located on the right side
side of the radiator.
radiator. When the
the coolant additives will result in liner pitting cooling system has been completely drained, the
and engine failure.
failure. 15 psi radiator cap neck will allow a quicker, more
efficient method of refilling the cooling system.
Coolant Filter (Illustration 5-1).
5-1). The coolant filter
is used in the cooling system to control the water Charge Air Cooler (Illustration 5-4).
5-4). The QSM11
acidity, soften the water to reduce scale formation, engine is equipped with a trubocharger. The
filter out suspended materials and add a corrosion turbocharger is driven by the exhaust from the
engine. The exhaust turbine of the turbocharger is
inhibiting chemical
protective to water
film on the the coolant which provides a
passages. coupled to the intake
intake turbi
turbine.
ne. The exhaust turbine
turbine
drives the intake turbine. The intake turbine com-
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 5-1
presses the intake

intake air.
air. The act of compressing
compressing the
intake air generates heat and causes the air mole- CAUTIONS:
cules to expand. ToTo increase
increase combustion
combustion efficien-
efficien- S Dispose of coolant
coolant filter in accordance with
cy, a charge air cooler is integrated into the radia- federal and local regulations.
regulations.
tor
tor.. The charge air cooler is an air to air cooler.
cooler. S Do not use a strap wrench to tighten the
By reducing the temperature of the intake air
before it enters the piston chamber, the air coolant filterthe
filter.
may distort . Mechanical
Mechani
threadscal
or over-tightening
over-tight
damage theening
filter
becomes denser (the air molcules get smaller). gasket.
The denser the air, the more oxygen that will be
present in the piston chamber during combustion. 1. Close both
both cut-off
cut-off valves
valves (Illustrat
(Illustration
ion 5-1).
The more oxygen in the chamber, the hotter the 2. Remove
Remove the coolan
coolantt filter
filter.. It may
may be possibl
possible
e
combustion
combust ion cycle becomes.
becomes. This resul
results
ts in a more to unscrew the coolant filter by hand; however,
complete burning of the fuel, emitting fewer pollu- a band type filter wrench may be used if nec-
tants. This increase
increase in combustion efficiency
efficiency also essary.
creates lower engine operating temperatures,
which pro-long the life of the engine and it’s com- 3. Clean
Clean the gasket
gasket surface
surface of the
the filter
filter base.
base.
ponents. 4. Apply a light
light film
film of lubricati
lubricating
ng oil to the gasket
gasket
Checking The Coolant Level (Illustration 5-2).
Checking 5-2). sealing surface of the new coolant filter.
The coolant level should be checked daily with the 5. Screw
Screw the new coolant
coolant filt
filter
er onto the
the filter
filter
engine cool. The coolant level
level is full when
when the base until the gasket comes in contact with the
coolant is visible
sight glass on theatradiator.
the center
radiator of the
. If the upperlevel
coolant coolant
is filter base and then tighten filter 1/2 to 3/4 turn
by hand only.
visible at the lower coolant sight glass, add cool-
ant until the coolant level is visible at the center of 6. Open the
the cut-of
cut-offf valves
valves..
the upper coolant sight glass on the radiator. 7. Start
Start up engine
engine and check
check for leaks
leaks at the
the
Cooling Requirements. The following require- coolant filter base.
ments must be followed for trouble-free operation Draining / Flushing
Draining Flushing The Cooling
Cooling System. The
of the cooling system. cooling system should be drained and flushed
1. Always use a properly corrosion
corrosion inhibited
inhibited every 2 years or 6000 hours, whichever comes
coolant. first.. The cooling system
first system is drained
drained by opening
the drain cock on the bottom of the radiator.
2. Maintain prescribed
prescribed inhibitor
inhibitor strength. Removal of the 15 psi radiator cap will allow air to
3. Use low silicate
silicate antifreeze
antifreeze with
with an ethylene
ethylene enter the cooling passages, decreasing drain time
glycol base. and ensuring that the coolant drains completely
from the system.
system. Leave the drain cock open until
until
4. Always follow the manufacturer’s
manufacturer’s recommen-
recommen- all coolant has been allowed to drain from the sys-
dations on inhibitor
inhibitor usage and handling.
handling. Refer tem.
to the engine operation and maintenance
manual for coolant requirements.
5. Do Not
Not use
use solubl
soluble
e oil!
oil! WARNINGS:
S Shut down the engine and allow the engine
6. Sealer
Sealer type antifr
antifreeze
eeze should
should Not
Not be used. to cool before opening the radiator cap and
Changing the Coolant Filter. Refer to the engine the drain cock to drain the cooling system.
operation and maintenance manual for the coolant S Coolant
Coolant should only be added to the cooling
filter change
change interval. Perform the following
following proce- system when the engine has been shut down
dures to replace the coolant filter. and allowed
allowed to cool.
cool. Failure
Failure to do so may
result in personal injury from heated coolant
spray.
WARNING: Shut down the engine and
allow the engine to cool before changing the S Dispose of coolant
coolant in accordance with
coolant filter. federal and local regulations.
regulations.
5-2 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
gauge should be in the green temperature area

CAUTION: When freezing weather is (180_F - 210_F). The thermostat
thermostat will start to open
expected, any cooling system not adequately at approximately 180_F and fully open when the
protected
protected by antifreeze should be drained
drained.. coolant temperature reaches approximately
201 _F.
Filling The Cooling System. Before starting the
engine, close the drain cock of the radiator and fill General Information
the cooling system.
system. Remove the 15 psi radiator
radiator
cap and fill the core of the
the radiator.
radiator. Remove the Coolant Capacity 17 Gallons
7 psi cap and fill the deaeration tank to the upper
sight glass.
glass. Start the engine to remove
remove air from Inspection. Components of the cooling system
the coolant. Recheck the the coolant level at the
the sight should be checked periodically to keep the engine
glasses and add coolant as required to obtain the operating at peak efficiency
efficiency.. The radiator should
should
proper level. be inspected externally for excessive dirt or oil
buildup. The radiator should be cleaned
cleaned external-
ly as conditions
conditions warrant.
warrant. The cooling system
system
WARNING: Coolant should only be added hoses should be inspected and any hose that is
to the cooling system when the engine has abnormally hard or soft should be replaced imme-
been shut down
down and allowed to cool.
cool. Failur
Failure
e diately.. Check the hose clamps to make
diately make sure they
to do so may result in personal injury from are tight. All external
external leaks should
should be corrected
heated coolant spray. as soon as detected.
detected. The shroud
shroud should be tight
against the radiator core to prevent recirculation of
air which may lower cooling
cooling efficiency
efficiency. Check the
CAUTION: The 15 psi radiator cap is a fan belts for proper tension.
sealing cap. Be sure it is installed
installed securely
securely Drive Belt Tension. The proper tension should
after the coolant has been added. be maintained on drive belts. Refer to Drive
on all drive
Belt Tension in Section 1 for the proper tension
Coolant Temperature. When the engine warms values.
up, the indicator for the coolant temperature
15 PSI
DEAERATION PRESSURE
CAP
7 PSI
PRESSURE
CAP
COOLANT
LEVEL
SENSOR
MAKE-UP ADD LEVEL

LINE FULL LEVEL SIGHT GLASS
SIGHT GLASS
Illustration
Illustration 5-2. Checking
Checking The Coolant Level
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 5-3
15 PSI PRESSURE CAP
RADIATOR / CHARGE 7 PSI PRESSURE CAP

AIR COOLER TRANSMISSION
OIL COOLER
WET DISC BRAKES
OIL COOLER
SHROUD
FAN
PLATE
FUEL
COOLER
Illustration
Illustration 5-3. Cooling Components
Components Identific
Identification
ation
CHARGE AIR
COOLER
RADIATOR
Illustration
Illustration 5-4. Radiator / Charge
Charge Air Cooler
Cooler
5-4 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Illustration
Illustration 5-5. Cooling
Cooling System Circuit
Circuit
COOLANT DEAERATION LINE

FILTER
UPPER RADIATOR
HOSE
MAKE-UP
LINE
RADIATOR
CUMMINS QSM11-C330
ENGINE
LOWER RADIATOR
HOSE
COOLANT FLOW
MAIN FLOW, THERMOSTAT OPEN
DEAERATION REMOVES UNWANTED AIR FROM COOLING CIRCUIT 05-2290
COOLANT FILTER FLOW
MAKE UP FLOW
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 5-5
Section 6
Electrical System
Introduction. This machine incorporates a parts. Clean and re-apply
re-apply a light
light coating of
12-volt DC electrica
electricall system. Optional equipment
equipment grease to the terminals and cable clamps
selected by the customer will determine the elec- when necessary.
trical equipment to be installed in addition to the
standard electrical
electrical system.
system. NOTE: A number of devices and applications are
available on the commercial market to deter corro-
Major
systemComponents.
consists of twoThe 12 voltbattery
batteries, DC electrical
charging sion on battery terminal connections.
alternator, voltage regulator, starter switch, starter 4. Check the
the electrical
electrical system
system if the battery
battery
and starter solenoid.
solenoid. The remainder of the electri-
electri- becomes discharged repeatedly.
cal system consists of lights and / or gauges,
switches,
switc hes, circuit breakers and accessory
accessory circuits. 5. If the battery
battery indicator
indicator illuminates,
illuminates, the alterna-
The above items are included as standard equip- tor or alternator circuit is defective.
ment in the electrical
electrical system.
system. Refer to Illustrations
Illustrations
6-1 through 6-16 for location of components and NOTE: If the truck is to be inoperative or idle for
wiring diagrams. more than 30 days, remove the battery. The bat-
Batteries. This machine is equipped with two tery should
should be stored
stored in a cool, dry place.
place. The
industrial
industrial type, long life
life batteries.
batteries. The batteries electrolyte level should be checked regularly and
are perishable and require servicing on a regular the battery kept fully charged.
basis. Batteries that areare properly cared
cared for can be Booster Battery Connection Procedure. Acci-
expected to give long
long trouble-fr
trouble-free
ee service.
service. Per- dentally reversing the battery connections must be
form
teriesthe
in afollowing procedures
serviceable to maintain the bat-
condition. avoided. If a booster battery
battery is to be used, first
first
connect the positive (+) terminal of booster battery
to the positive (+) terminal of discharged battery
WARNINGS: and then connect the negative (-) terminal of
S Under no circumstances allow any sparks or booster battery to engine or body ground (-)
open flames
flames around batteries.
batteries. No smoking.
smoking. (Refer to the decal below).
below). Never cross
cross polarity
polarity of
Batteries produce a highly flammable gas the battery terminals.
terminals. Disconnect
Disconnect cables inin the
which could lead to battery explosion if exact reverse order from above.
ignited.
S Never check the battery by placing a metal DANGER
object across the battery posts.
CAUTION: Overfilling cells of the battery

can cause poor performance or early failure. SMOKING, FLAMES, ARCS, OR SPARKS MAY RESULT IN BATTERY EXPLOSION.
KEEP METAL TOOLS AWAY FROM BATTERY

BATTERY TERMINALS.
1. The battery’s
battery’s electrolyte
electrolyte level
level should
should be BATTERY CONTAINS SULFURIC ACID WHICH WILL BURN SKIN ON CONTACT;
checked monthly or every 250 hours, whichev- WEAR RUBBER GLOVES AND EYE PROTECTION WHEN WORKING WITH BATTERY.
FLUSH WITH WATER AND SEEK MEDICAL ATTENTION IN CASE OF CONTACT.
er comes first.
first. Add distilled
distilled water if necessary
necessary
to bring the electrolyte level to 3/8 inch above WHEN JUMP STARTING:
STARTING:
the separator plates. Do not overfill.

overfill. DO NOT LEAN OVER BATTERY WHEN MAKING CONNECTION.
FIRST CONNECT POSITIVE (+) TERMINAL OF BOOSTER BATTERY TO
POSITIVE (+) TERMINAL OF DISCHARGED BATTERY.
BATTERY.
2. Keep the top of the
the battery
battery, terminal
terminals
s and THEN CONNECT NEGATIVE (-) TERMINAL OF BOOSTER BATTERY TO ENGINE OR
cable clamps clean.
clean. When necessary
necessary, wash BODY GROUND (-).
(-). NEVER CROSS POLARITY OF TERMINALS.
TERMINALS.
them with a solution of baking soda and water, DISCONNECT CABLES IN EXACT REVERSE ORDER.
3375 245
and rinse with clean water.

Alternator. The standard alternator for the Cum-
mins QSM11-C330 engine is a 100 amp alterna-
CAUTION: Do not allow the soda and tor
tor.. It should be expected
expected to give long, trouble-
trouble-
water solution to enter the battery cells. free service; however, the diodes and transistors
3. Inspect
Inspect the cables
cables,, clamps
clamps and hold down
down in the alternator circuit are very sensitive and can
be easily destroyed.
destroyed. The following
following precautions
precautions
bracket regularly
regularly.. Replace any damaged
damaged
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-1
should be observed when working on or around Never disconnect the battery while the alternator
the alternator. is in operation.
operation. Disconnecting
Disconnecting the battery
battery will
result in damage to the diodes, caused by the
Avoid grounding the output wires or the field wires
momentary high voltage and current induced by
between the alternator
alternator and the regulator
regulator.. Never
the instantaneous collapse of the magnetic field
run an alternator on an open circuit.
Grounding an alternator’s output wires or termi- surrounding the field windings.
nals, which are always hot regardless of whether
or not the engine is running or accidentally revers- CAUTION: Accidentally reversing the
ing of the battery polarity, will destroy the diodes. battery polarity will destroy the diodes of the
Grounding the field circuit will also result in the alternator circuit.
destruction
destruct ion of the diodes.
diodes. Some voltage
voltage regula-
tors provide protection against some of these cir- NOTE: It is normal for the alternator light to stay
cumstances;
cumstanc es; however, it is recommended that on when the engine
engine is started.
started. Once the engine
engine is
extreme caution be used. accelerated, the light should go out.
06-2366
06-2366 SHT
SHT.. 01
Illustration
Illustration 6-1.
6-1. Dash Panel
Panel
6-2 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
CB5 CB4 CB24 CB3 CB2

(15 (20 (15 (15 (10
amp) amp) amp) amp) amp)
GAUGES, FRONT REAR TOP IGNITION

PANEL LIGHT, WIPER WIPER WIPER SWITCH
DIAGNOSTIC
LIGHTS POWER,
& BUZZER
FRONT RIGHT SIDE
CB6 CB7 CB8 CB9 CB10

(15 (20 (15 (15 (10
amp) amp) amp) amp) amp)
WORK ECM HEATER ELECTRIC

LIGHTS POWER SHIFT
DEFROSTER
FRONT LEFT SIDE
Illustration
Illustration 6-2. Dash Circuit
Circuit Breakers
Breakers
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-3
CB13 (15 amp) DOME LIGHT, CAB FANS
CB14 (15 amp) AIR SEAT, AUTOSHIFT
CB15 (15 amp) BACK ALARM, ENABLE

RELAY, STROBE, HORN RELAY
CB16 (38 amp) AIR CONDITIONER

HEATER UNIT/
CB11 (20 amp) REAR CAB LIGHTS
CB12 (20 amp) FRONT CAB LIGHTS
AUX. LIGHTS
AUX. LIGHTS
Illustration
Illustration 6-3. Cab Rear Panel Circuit
Circuit Breakers
6-4 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Component Troubleshooting Circuit Breakers. Circuit breakers are employed

in the electrical system and act similar to fuses,
Alternator. The alternator provides 13.8 - 14.4
protecting the electrical circuits and valuable com-
VDC at 100 amps of power for the electrical sys-
ponents from overloads which could damage
tem and trickle charges the battery when the
them. Perform the the following
following troubleshooting
troubleshooting pro-
engine is being operated.
operated. When the alternator
alternator is
started, it will output 6 VDC to a relay (K3), ener- cedures to troubleshoot a circuit breaker.
gizing the relay and taking away the ground from 1. Turn
Turn the ignition
ignition key to the “Ignition”
“Ignition” position.
(DS3 , Illustration 6-16) on the
the Battery light (DS3,
2. If the circuit
circuit breaker
breaker is tripped,
tripped, reset the circuit
circuit
instrument
instrum ent panel.
breaker.
The most effective way to troubleshoot an alterna-
3. If the circuit
circuit breaker immediately
immediately retrips,
retrips,
tor is with an ammeter on the output of the alter-
remove all wires from the output side (load
nator.. Another good check is
nator is with a voltmeter
voltmeter
side) of the circuit breaker.
across the battery
battery.. With the engine operating
operating at a
moderate speed, the voltmeter reading should 4. Reset
Reset the circu
circuit
it breaker
breaker.. If the circu
circuit
it breaker
breaker
never exceed 15.5
15.5 VDC. If reading exceeds
exceeds 15.5 retrips, the circuit breaker is bad and must be
VDC, the alternator is defective and requires replaced.
replacing. Should the alternator
alternator output drop
5. If the circui
circuitt breaker
breaker maintai
maintains
ns a set state, one
one
below 12 VDC, the alternator is defective and
of the output circuits
circuits is shorted.
shorted. Reconnect
requires replacing.
replacing.
the wires one by one to the output side (load
Perform the following
mal charging procedures below for abnor-
system operation. side) until
shoot the circuit
circuit
the circuit breaker
of the trips.
trips.
wire, that Tr
Trouble-
ouble-
tripped the
circuit
circuit breaker, for a short.
1. Insure that the undercharged condition (below
12 VDC) has not been caused by accessories 6. Isolate
Isolate and remove
remove the short
short from the
the circuit.
circuit.
having been left on for extended periods of
Automatic 90 amp Circuit Breaker (Illustration
time.
1-5).. The automatic circuit breaker (CB1) is
1-5)
2. Check
Check the drive
drive belt for proper
proper tension
tension (refer
(refer to located on the right side side of engine. It will automat-
automat-
Alternator Drive Belt Tension in Section 1).1). ically reset
reset itself if itit trips. If the circuit
circuit breaker
cannot maintain a set state, perform the following
3. Ensure
Ensure that battery
battery is
is good and capabl
capable
e of
troubleshooting procedures to troubleshoot the
holding a charge.
automatic circuit breaker.
4. Inspect
Inspect the
the wiring
wiring for defect
defects.
s. Chec
Checkk all con-
1. Turn the igniti
ignition
on key to the Off
Off position
position..
nections for tightness and cleanliness, includ-
ing the slip connectors at the alternator and 2. Remove
Remove all wire
wires
s from the
the output side
side (load
(load
connections at the battery.
battery. side) of the circuit breaker.
5. With
With the ignition
ignition switc
switch
h on and all wiring
wiring har-
har- 3. Turn
Turn the ignition
ignition key to the “Ignition”
“Ignition” position.
ness leads connected, connect a voltmeter If the circuit breaker retrips, the circuit breaker
from: is bad and must be replaced.
a. alternator “BAT”
“BAT” terminal
terminal to ground 4. If the circui
circuitt breaker
breaker maintai
maintains
ns a set state, one
one
of the output circuits
circuits is shorted.
shorted. Reconnect
b. alternat
alternator
or #1 term
terminal
inal to
to ground
ground
the wires one by one to the output side (load
c. alternat
alternator
or #2 term
terminal
inal to ground
ground side) until the circuit
circuit breaker trips.
trips. Tr
Trouble-
ouble-
shoot the circuit of the wire, that tripped the
An infinity reading indicates an open circuit circuit
circu it breaker, for a short.
between the voltmeter connection and bat-
5. Isolate
Isolate and remove
remove the short
short from the
the circuit.
circuit.
tery.. Repair ifif required.
tery required.
Single-Pole, Single-Throw
Single-Pole, Single-Throw 30 amp Relays
6. With all
all accessories
accessories turned off,
off, connect
connect a volt-
volt-
6-4). A relay is nothing more than an
(Illustration 6-4).
meter across
across the battery.
battery. Operate engine at
electrically
electri cally controlled
controlled switch.
switch. Relays are always
moderate
mode rate
higher, speed.
speed.
replace theIfalternator.
voltage
voltage is 15.5 VDC or shown on electrical circuits in a de-energized
state. The internal switch,
switch, common
common at pin 30,
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-5
toggles between pins 87A (when de-energized) VDC required at pin 86 was or was not present, or
and 87 (when energiz
energized).
ed). Pins 86 and 85 of the ground signal at pin 85 was or was not present,
relay will
will energize the coil of the relay.
relay. Pin 85, in dependant on the desired state of relay (ener-
all cases, is always the ground side and pin 86, in gized or de-energized), the relay is bad and must
all cases,
cases, is always
always the hot side. Either signal
signal can be replaced.
be is
85 sent to the grounded,
properly relay to energize
energi
whenzerequired,
it. Ensure
Ensure that
and pin
/ or Single-Pole,
Single- Pole, Single-Throw
Single-Throw 10 amp Relays with
L.E.D.s (Illustrati
(Illustration 6-5). A relay is nothing more
on 6-5).
that 12 VDC is present at pin 86 when it is
than an electrically
electrically control
controlled
led switch.
switch. Relays areare
required.
always shown on electrical circuits in a de-ener-
When the relay is de-energized, the internal gized state. The positive
positive side of the relay coil
coil is
switch connects pins 30 and 87A completing the pin 14 while the negative side of the coil is pin 13.
circuit
circuit of the two pins. When the relay is
is ener- Either signal, 12 VDC or ground (or both), can be
gized, the coil shifts the switch, connecting pins sent to the relay coil to energize the relay.
30 and 87 completing the circuit of the two pins.
When the relay is de-energized, the internal
The most effective way to troubleshoot the relay is switch connects pins 9 and 1 completing the cir-
with an ohmmeter.
ohmmeter. This can be accomplished
accomplished by cuit of the two pins.
pins. When the relay is
is energized,
removing the female spade connectors from pins the coil shifts the switch, connecting pins 9 and 5
30, 87, and 87A. In a de-energi
de-energized
zed state,
state, ensure
ensure completing the circuit of the two pins.
that pins 30 and 87A have continuity between
When the L.E.D. is illuminated, the coil of the relay
them. With an ohmmeter,
ohmmeter, check the resistance
resistance
between
betw een pins 30 and 87a. The ohmmeter
ohmmeter should
should is energized.
energiz
tact pointsed. This
of the does not
internal indicate
indicate
switches arethat the con-
functioning
indicate
indicate a reading
reading of 0 - 40 ohms. Energize
Energize the
properly.. Do not rely on the L.E.D.
properly L.E.D. to give the full
relay and check the resistance between pins 30
operational status of the relay.
and 87. The ohmmeter
ohmmeter should indicate
indicate a reading
reading
of 0 - 40 ohms.
ohms. If these
these two checks
checks are good, the
the The most effective way to troubleshoot this type
relay
relay is good. If one of these checks
checks fa
fails
ils and 12 relay is with
with an ohmmeter.
ohmmeter. This can be accom-
plished by removing the wires at relay socket ter-
Normally Closed minals
min als 9, 5, and 1. In a de-energize
de-energized d state, en-
Common Contact (when relay sure that terminals 9 and 1 have continuity
Contact is de-energized) between them. With an ohmmeter
ohmmeter,, check the re-
Normally Open
sistance
sistanc e between terminals
terminals 9 and 1. The ohmme-
Contact (when relay ter should
should indicate
indicate a reading
reading of 0 - 40 ohms. En-
is de-energized) ergize the relay and check the resistance between
terminals
termi nals 9 and 5. The ohmmeter should should indicate
a reading
reading of 0 - 40 ohms. If these
these two checks
checks are
good, the relay
relay is good.
good. If one of these checks
checks
fails and 12 VDC required at terminal 14 was or
was not present, or ground signal at terminal 13
was or was not present, dependant on the desired
state of relay (energized or de-energized), the
relay is bad and must be replaced.
Double-Pole, Double-Throw 10 amp Relays
with L.E.D.s (Illustration 6-6).
6-6). A relay is nothing
more than an electrically
electrically contr
controlled
olled switch.
switch. Relays
are always shown on electrical circuits in a de-en-
ergized state.
state. The positive
coil is
pin 14 while the negative side of the coil is pin 13.
Either signal, 12 VDC or ground (or both), can be
sent to the relay coil to energize the relay.
When
switch the relay ispins
connects de-energized, thepins
(9 and 1) and internal
(12 and
Illustration
Illustration 6-4. SP,
SP, ST 30 amp Relay
4) completing the circuit of both sets of pins.
6-6 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
indicate
indicate a reading
these two
checks
chec ks are good,
good, the relay is good.
good. If one of
these checks fails and 12 VDC required at termi-
nal 14 was or was not present, or ground signal at
terminal 13 was or was not present, dependant on
the desired
gized), stateis
the relay ofbad
relay (energized
and or de-ener-
must be replaced.
5
1
14
13
5 1
4
8
14 13
Illustration
Illustration 6-5. SP,
SP, ST 10 amp Relay
When the relay is energized, the coil shifts the

switch, connecting pins (9 and 5) and pins (12 and
8) completing the circuit of both sets of pins. 9
When the L.E.D. is illuminated, the coil of the relay
is energized.
energiz
tact pointsed. This
of the does not
internal indicate
indicate
switches arethat the con-
functioning
properly.. Do not rely on the L.E.D.
properly L.E.D. to give the full 12
operational status of the relay.
Illustration
Illustration 6-6. DP,
DP, DT 10 amp Relay
The most effective way to troubleshoot this type
relay is with
with an ohmmeter.
plished by removing the wires at relay socket ter- Double-Pole, Double-Throw 15 amp Relays
minals (12, 8, and 4) and terminals (9, 5, and 1). 6-7). A relay is nothing more than an
(Illustration 6-7).
In a de-energized state, ensure that terminals (9 electrically
controlled switch.
switch. Relays are always
and 1) and terminals (12 and 4) have continuity shown on electrical circuits in a de-energized
between them. With an ohmmeter
ohmmeter,, check the state. The positive
coil is pin 14
resistance between terminals (9 and 1) and termi- while
whi le the negative
negative side of the coil is pin 13. Either
Either
nals (12 and 4).
4). The ohmmeter
ohmmeter should indicate
indicate a signal, 12 VDC or ground (or both), can be sent to
reading
readi ng of 0 - 40 ohms. Energiz
Energizee the relay and the relay coil to energize the relay.
check the resistance between terminals (9 and 5) When the relay is de-energized, the internal
and terminals
terminals (12 and 8). The ohmmeter
ohmmeter should switch connects pins (9 and 1) and pins (12 and
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-7
4) completing the circuit of both sets of pins. minal 14 was or was not present, or ground signal
When the relay is energized, the coil shifts the at terminal 13 was or was not present, dependant
switch, connecting pins (9 and 5) and pins (12 and on the desired state of relay (energized or de-en-
8) completing the circuit of both sets of pins. ergized), the relay is bad and must be replaced.
The most effective way to troubleshoot this type Double-Pole, Double-Throw Latching Relays
relay is with
with an ohmmeter.
ohmmeter. This can be accom- 6-8). A relay is nothing more than an
(Illustration 6-8).
plished by removing the wires at relay socket ter- electrically
controlled switch.
switch. This type of relay is
minals (12, 8, and 4) and terminals (9, 5, and 1). shown
show n in a reset
reset state.
state. A latching
latching relay has a
In a de-energized state, ensure that terminals (9 power saving
saving feature. It does not require
require the relay
and 1) and terminals (12 and 4) have continuity coil to be energized at all times to maintain the set
between them. With an ohmmeter
ohmmeter,, check the state. The positive
coil is pin 14
resistance between terminals (9 and 1) and termi- while the negative side of the coil is pin 13 for the
nals (12
(12 and 4). The ohmmeter
ohmmeter should
should indicate
indicate a set state of the relay
relay.. The internal red
red flag of the
reading
read ing of 0 - 40 ohms.
ohms. Energize
Energize the relay
relay and relay will be visible in the small window, located at
check the resistance between terminals (9 and 5) the top of relay’s cover
cover,, indicating a set state. In a
and terminals
terminals (12 and 8).
8). The ohmmeter
ohmmeter should set state, pins (10 and 5) and pins (6 and 8) of the
indicate
indicate a reading
these two relay will be closed and continuity exists between
checks
chec ks are good, the
the relay is good.
good. If one of each set of pins. In a reset state, tthe he positive side
side
these checks fails and 12 VDC required at ter- of the relay coil is pin 12 while the negative side of
the coil
coil is pin 9. In a reset state,
state, pins
pins (10 and 1)
and pins (6 and 4) of the relay will be closed and
continuity
continuity exists between
between each set of pins.
pins. The
internal red flag of the relay will not be visible in
the small window in the top of the relay’s cover,
indicating
indicating a reset state. A constant 12 VDC signalsignal
is not required to set or reset the latching
latching relay.
relay. A
momentary 12 VDC signal is required at either the
set or reset coil, depending on the desired state of
the relay, to set or reset the relay.
The most effective way to troubleshoot this type
relay is with
with an ohmmeter.
plished by removing the wires at relay socket ter-
minals
min als (10,
(10, 1, and 5) and (6, 8, and
and 4). Set the
relay
relay by apply
applying
ing 12 VDC to pin 14. In a set state
5 (the internal red flag is visible in the window),
4 1 ensure that terminals (10 and 5) and (6 and 8)
have continuity
continuity between them. With an ohmme-ohmme-
ter, check the resistance between terminals (10
8
14 and 5) and then terminal
terminalss (6 and 8). The ohmme-
ohmme-
13
ter should indicate a reading of 0 - 40 ohms.
Reset the relay by applying 12 VDC to pin 12 (the
internal red flag should not be visible in the win-
dow). Check the resistance
resistance between terminals
terminals (6
and 4) and then terminal
terminalss (10 and 1). The ohm-
ohm-
meter
met er should
should indicate
indicate a reading
reading of 0 - 40 ohms. If
9 these four checks
checks are
are good, the relay is good. If
one of these checks fails and 12 VDC required at
terminals (14 or 12) was or was not present and
ground signal at terminals (13 or 9) was present,
12 dependant on the desired state of relay (set or
reset), the relay is bad and must be replaced.
Illustration
DP, DT 15 amp Relay
6-8 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
and orange wires.

wires. The white
white and orange wires
wires
will have continuity between them only as long as
the proximity
proximity switch
switch senses its target.
target. The maxi-
mum targeting distance is approximately 3/8”.
The most effective way to troubleshoot the prox-
imity switch
switch is with
with an ohmmeter.
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.
weatherpack. The ohmmeter
ohmmeter should
indicat
indicatee a reading
reading of 0 - 40 ohms. Remove
Remove the
target from the proximity switch and with an ohm-
meter, check the continuity between the white and
orange wires.
wires. The ohmmeter
ohmmeter should now read
2
5 1 infinity If these two checks are
are good, the proximity
6 switch
switc h is good. If one of these checks
checks fails, the
the
4 14 proximity switch
proximity switch is bad and must be replaced.
replaced. Do
13 not rely on the red L.E.D. as a sole indicator that
the internal switch
switch did, in fact,
fact, close. Always
8
check the continuity between the white and
orange wires as described above.
L.E.D.
10
12
Illustration
DP, DT Latching Relay
30mm Proximity Switches (Illustration 6-9).

6-9). The
proximity
proxim ity switches employed on Taylor equipment
are state-of-the-art
state-of-the-art switching
switching devices.
devices. The red
wire of the proximity switch powers the proximity
switch itself and also powers the red L.E.D. on the
cable side of the proximity
proximity switch.
switch. The black wire
wire
is the ground side of the proximity switch while the
white wire is the common post of the internal
switch.
switc h. The blue wire
wire is the normal closed
closed post of
the internal switch and the orange wire is the nor- RED BLUE
NC
mally open post of the internal switch. WHITE
COM.
The proximity switch will be energized when the BLACK ORANGE NO
proximity
proxim
pens, ity switch
the swi
redtch senses
L.E.D. will its target.
target. and
illuminate Once this
the hap-
internal
switch will switch, closing the circuit of the white Illustration
Illustration 6-9. Proximity
Proximity Switch
Switch
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-9
Single-Pole, Single-Throw, Maintain Contact Exercise care not to reverse polarity because
Switches. A switch is designed with the purpose some solenoids employ internal diodes which can
of controlling an electrical circuit by completing or be destroyed when the polarity
polarity is rreversed.
eversed. The
opening the circuit.
circuit. With an ohmmeter
ohmmeter,, check the solenoids employed on the transmission control
resistance between the contact points of the valve contain
contain diodes. The black wire
wire of the coil
switch.
switch. the
circuit), Withohmmeter
the switch
switchreading
closed should
(completing
(completing the0 -
indicate connects to the
red wire goes toground side of
the positive theofcircuit
side while the
the circuit.
40 ohms. With the switch
switch open (opening the cir- cir-
Diodes (Illustration 6-10).
6-10). Diodes are one-way
cuit), the ohmmeter
ohmmeter reading should be infinity
infinity.. If
conductors that provide isolation.
conductors isolation. Current flow
flow
the above checks
checks are good, the switch
switch is good. If
through
through a diode is from
from anode to cathode.
cathode. They
any of the above checks fail, the switch is bad and
are easily proven good by using an ohmmeter.
must be replaced.
When using the ohmmeter, place the leads of the
Single-Pole, Double-Throw, Momentary Rocker ohmmeter on the opposite ends of the diode.
Switches. This type of switch operates on the Observe the ohmmeter
ohmmeter reading. Then reverse
reverse the
principle that the circuit is closed only when the ohmmeter leads on the ends of the diode.
switch
swit ch is held in the closed
closed state. Once the switch
switch Observe thethe ohmmeter reading. The ohmmeter
ohmmeter
is released, the circuit
circuit wi
willll open. This switch
switch is readings should indicate a higher ohm resistance
checked like an On-Off switch with the exception in one direction opposed to the other direction
that the switch must be held closed to complete because the current generated by the ohmmeter
resistance checks. is sufficient enough to forward-bias the diode.
Solenoids. A solenoid is an electrical compo-
nent. When electricity
electricity is applied to the coil,
coil, the Currentt Flow
Curren
solenoid will
will form an electromagnet
electromagnet.. The magnet-
ic field will pull or push an armature into the coil
(based on application).
application). The armature
armature can be con-
nected to a switch in electrical circuits to turn the
switch
swi tch on or off. An armature
armature can also be used to
open or close valves.
Solenoids employed as electrical switches can be Cathode Anode
troubleshot
troublesh ot with an ohmmeter.
ohmmeter. Remove the two
wires from the two larger posts of the solenoid.
Energize the solenoid.
solenoid. With an ohmmeter,
ohmmeter, check Illustration
Illustration 6-10. Diode
the resistance
resistance between the two larger
larger posts. The
ohmmeter should indicate between 0 - 40 ohms
nominally.
Solenoids employed as hydraulic switches are
used to open and closeclose spools of valvalves.
ves. The
simplest way to prove the solenoid coil good is to
energize the solenoid and then, with a metal
object, touch the nut that secures the coil to the
cartridge.
cartridge. The magnetic field field generated when the
coil becomes an electromagnet will be significant
enough to pull the metal object to the nut (some
solenoids employ a metal nut encased in plastic
and will require removal in order to detect the
magnetic field).
field). This will
will prove the coil good; how-
ever,, the armature may be stuck.
ever stuck. If the hydraulic
circuit is still defective at this point, remove the coil
and cartridge.
cartridge. Now energize
energize the coil, the arma-
arma-
ture inside
inside the cartridge
cartridge should shift. If the arma-
ture inside the cartridge did not shift and the coil is
magnetized,
magnetize d, replace the cartridge.
cartridge.
6-10 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Refer to Illustration 6-16 for component reference
Component Problem Correction
1. Bat
Batter
tery
y 1. Low voltage. 1.
a. Low electrolyte
electrolyte level.
level. Check
electrolyte
electrolyte level in battery,
battery, fill
with distilled water as required,
and recharge battery.
battery.
b. Alternator
Alternator output
output is bad. Refer
Refer
to the Alternator troubleshoot-
ing section below.
c. Loose, broken, or corroded
wires.. Repair or replace wires.
wires wires.
d. Ensure that low voltage condi-
tion has not been caused by
accessories having been left
on for extended periods of

time.
2. Alt
Altern
ernato
atorr 1. Low output
output voltage
voltage (voltag
(voltage
e is 1.
below 12 VDC).
a. Ensure drive belts are tight.
b. Inspect the wiring for defects.
Check all connections for tight-
ness and cleanliness, includ-
ing the slip connectors at the
alternator and connections at
the battery.
c. Defective
Defective alternator.
alternator. Replace
alternator.
2. High
High output
output volta
voltage
ge (volta
(voltage
ge 2. Defecti
Defective
ve alternat
alternator
or.. Replace
Replace
exceeds 15.5 VDC). alternator.
3. Battery
Battery Disconne
Disconnect
ct 1. When key swit
switch
ch is in the
the ON 1. Remove
Remove wires
wires from
from the swit
switch,
ch,
Switch position, contact points of switch turn the switc
switch
h on. With
With an ohm-
do not close. meter, check the resistance across
the contact
contact points. The ohmmeter
ohmmeter
reading should indicate 0 - 40
ohms.
2. When key
key switc
switch
h is in
in the OFF
OFF 2. Remove
Remove wires
wires from
from the swit
switch,
ch,
position, contact points of switch turn the switch
switch off.
off. With an ohm-
ohm-
do not open. meter, check the resistance across
contact points. The ohmmeter
ohmmeter
reading should indicate infinity.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-11
4. Ignition
Ignition Switch
Switch 1. Ignition
Ignition switc
switch
h (S1) does not close 1. On the ba
not close back
ck of the igniti
ignition
on switc
switch
h
(accessory position). (S1), at the B terminal, check for
12 VDCEnsure
(CB2). from circuit
that breaker
that the battery
disconnect switch (S54, Illust
Illustration
ration
1-6) is
is in the On position
position.. If 12
VDC is not present, ensure that
circuit breaker (CB2) is set.
Ensure that Deutsch connector
(EC1)
(EC 1) is not loose
loose or that pin 6 or
11 is backed out of this connector.
Ensure that all battery cables are
connected to the terminals of the
batteries.. Ensure that the batter-
batteries
ies are charged. Ensure that cir-
cuit breaker (CB1) can maintain a
set state.
state. If 12 VDC is is present
present at
the B terminal,
ignition turn
position, the Ikey
at the to the
terminal,
you should see 12 VDC; if not,
remove the wire from the I termi-
nal and recheck
recheck volta
voltage.
ge. If 12
VDC is now present, there is a
short between the ignition switch
(S1) and the truck power solenoid
(L1);; isolate
(L1) isolate and repair short.
short. If 12
VDC is not present and 12 VDC
was present at the B terminal,
replace the ignition switch (S1).
2. Ignition
Ignition switc
switch
h (S1) does not close 2. The tr
not close truck
uck is
is equipped
equipped with
with an anti-
anti-
(start position). restart ignition switch (S1).
Should the truck fail to start on the
first
turnedattempt,
fully offthe
to key must
reset the be
ignition
switch, allowing the B (Battery)
and S (Start) contacts to close
when the ignition switch is turned
to the Start positi
position.
on. This
This is a
momentary position that should
only make contact when the key is
fully
fully turned.
turned. On the back of the the
ignition switch (S1), ensure that 12
VDC is present at the B terminal.
If 12 VDC is not present, ensure
that circuit breaker (CB2) is set.
Ensure that Deutsch connector
(EC1)
(EC 1) is not loose
loose or that pin 7 is
continued backed out of

Ensure that allthis connector.
battery cables are
(continued)
6-12 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
4. Ignition
Ignition Switch
Switch (Continued)
(Continued) connected to the terminals of the
batteries
batteries.. EnsureEnsure
ies are charged. that thethat
batter-
cir-
cuit breaker (CB1) can maintain a
set state. If 12 VDC is present,
present,
turn the ignition switch (S1) to the
Start position.
position. Check the
the S termi-
termi-
nal of the ignition switch for 12
VDC. If not present,
present, remove
remove the
wire from the S terminal; turn the
ignition switch to the Start position
and check for 12 VDC at the S ter-
minal.
min al. If 12 VDC is present
present,, the
ignition switch is good.
5. Wi
Wire
res
s 1. Wire ha
has
s los
ostt con
onti
tinu
nuiity. 1. Isola
olate the wire from the circuit
uit
(ohm out the wire).
wire). Ohms will
will vary
according to the length of the wire.
Expect to see low ohms if wire is
good.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-13
Electrical System Troubleshooting gauge indicates above 75 psi, remove wire #31
from the low air
air pressure
pressure switch
switch (S13). If the low
Some of the components described in this section
air light (DS7) does not go out, wire #31 is shorted
are optional equipment.
out.
Eng Oil light (DS1, Illustration 6-16). The engine
Illustration 6-16).
Brake Fault light (DS8, Illustration 6-16) (if
oil light
switch
swit will illuminate
ch (S17, when
Illustration
Illustration 1-6)engine oil pressure
has closed. The equipped).. There are three signals in parallel
equipped)
capable of illuminating the brake fault light (DS8).
engine oil pressure switch will close between 7 -
10 psi on falling engine oil pressure. It is imperative that the technician understand how
these switches work to isolate the source of the
Battery light (DS3, Illustration 6-16).
6-16). When the
failure. The simplest
simplest way to troubleshoot
troubleshoot is to
battery light illuminates, it lets the operator know
remove the signal wire #32 from the switches
that there is a problem with
with the alternator.
alternator. Refer
(S23,, S24, and S27), one switch
(S23 switch at a time. Start
Start
to the Component Troubleshooting of the Alter-
the engine and see if the brake fault light (DS8) is
nator found earlier in this section.
illuminated.
illum inated. By removing
removing the signal wire
wire #32 from
Seat Belt light (DS4, Illustration 6-16).
6-16). The seat the switch (S23, S24, or S27), the switch will be
belt light (DS4) will only illuminate when the key is eliminated
elimi nated from the circuit.
circuit. Once the defective
in the ignition position and the seat belt is unfas- circuit has been removed, the brake fault light
tened. With the seat
seat belt fastened,
fastened, the seat belt
belt (DS8) will
will not illuminate.
illuminate. Next, the technician
technician
switch (S18) will send a ground through wire #38, must determine if the switch is bad or if the circuit,
energizing the seat belt relay (K2) and breaking the switch (S23, S24, or S27) is monitoring, is at
the contact between pins #30 and #87A of relay fault.
(K2), removing the ground from the seat belt light
Troubleshoot the switches (S23, S24, and S27) as
(DS4).
follows:
Shift Fail light (DS6, Illustration 6-16, if equipped
1. The power cluster overstroke
overstroke indicator
indicator switch
switch
70). The shift fail light (DS6) is con-
with APC 70).
(S27) is located on the end cover between the
trolled by the APC 70 and will illuminate only when
shell assembly and the tube cylinder of the
the operator has attempted an improper shifting
power cluster.
cluster. The overstroke
overstroke indicator switch
switch
procedure. The only purpose of this this light is tto
o let
is a normally
normally open switch.
switch. A visual inspection
inspection
the operator know that he or she is outside of the
of the switch will confirm overstroke condition.
operating parameters.
parameters.
The brass colored indicator rod will be protrud-
Low Air light (DS7, Illustration 6-16). The low air
Illustration 6-16). ing from the end cover approximately 3/4” to
light (DS7) will illuminate when the air pressure 1”. The indicato
indicatorr rod must be physically
physically
falls below 75 psi. The low air pressur
pressuree switch reseated. The most common cause cause of the
(S13), a normally closed switch, will close when brake fault light (DS8) illuminating is when an
the air pressure drops below 75 psi, sending overstroke
overstr oke condition has occurred.
occurred.
ground through wire #31 (Illustration 6-16) com-
2. The brake
brake coolant temperature
temperature switch
switch (S24,
(S24,
pleting the circuit
circuit to the low air light (DS7).
(DS7). In
Illustration 6-16) is located in the brake cooling
addition to the low air light being illuminated, an
valve. The brake coolant temperature
temperature switch
switch
audible alarm will be heard from the low air / shut
is a normally open switch that will close at
down buzzer (LS5). When the air pressure pressure drops
190 _F. The simplest way to check this sw switch
itch
to 60 psi, the parking brake valve will pop out,
is to turn the truck off and allow the truck to
applying the parking brake, closing the parking
cool. With an ohmmeter,
ohmmeter, measure the resis resist-
t-
brake switch
switch (S11). As a result, this will energize
energize
ance between the posts on the switch and the
the brake saver relays (K23 and K31, Illustration
chassis ground. The ohmmeter
ohmmeter reading
9C-2), taking away the 12 VDC signal from the
should indicate
indicate infinity (open circuit).
circuit). If the
forward and reverse solenoids of the control valve
ohmmeter reading indicates a short, then the
that is located on the transmission.
transmission. This inhibits
inhibits
brake coolant temperature switch (S24) must
the operator from
from driving
driving through the brakes. The
be replaced. Care must must be taken to insure
insure
air pressure gauge in the instrument panel will
that a good chassis ground is obtained.
assist in determining if the low air switch (S13) is
defective, if a short exists on wire #31, or if a low 3. The brake
brake coolant pressure switch
switch (S23,
air pressure
pressure problem exists.
exists. If the air pressure Illustration 6-16) is located in the brake man-
6-14 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
ifold valve.
valve. The brake coolant pressure
pressure switch
switch present on the green wire when the wiper switch
is a normally closed switch that will open at (S7) is in the Park position.
10 psi. The purpose of this switc
switch
h is to moni-
Top and Rear Wiper Circuits (Illustration 6-16).
6-16).
tor for a low pressure problem in the brake
The top and rear wiper circuits are comprised of a
cooling circuit.
circuit. When the pressure
pressure drops
circuit breakers (CB3 and CB24), wiper switches
below
pleting10
thepsi, the switch
electrical willtothen
circuit the close
brakecom-
fault (S8 and S9) and wiper
wiper motors
motors (B8 and B9). 12
VDC power is supplied from circuit breaker (CB3)
light (DS8).
(DS8). It must now be determined
determined if the
to the B (Battery) post of the wiper switch (S8)
switch (S23) is defective or if a low pressure
while 12 VDC power is supplied from circuit break-
problem exists in the brake cooling circuit.
er (CB24) to the B (Battery) post of the wiper
There is a pressure test coupling (pressure
switch
swi tch (S9).
(S9). There
There are 5 posts
posts on the back of the
check) located on the brake cooling manifold
wiper switches
switches (S8
(S8 and S9). The P (Park) postpost of
at port A. Plug a pressure
pressure gauge into into the test
the wiper switches are used for parking the wiper
port and with the engine running, observe the
motor (B9 and B8). When the wiper s switches
witches are
gauge reading. The maximum
maximum pressure
turned off, 12 VDC will be present at the P post.
observed should be no more than 600 psi (the
When the wiper switches are turned on, 12 VDC
pressure will be between 0 and 600 psi).
will be present at the L (Low) post or H (High) post
Remember it takes 10 psi to open the switch.
of the wiper switches, contingent on the speed
If the pressure indicated is above 10 psi, the
selected. 12 VDC willwill be present at the W (Wash-
(Wash-
brake coolant pressure switch (S23) is defec-
er) post of the wiper switches (S8 or S9) when the
tive and must be replaced.
wiper switch
switch is depressed. With the wiper switch
switch
If all three of the switches, described above, have (S8 or S9) turned off, 12 VDC is applied at the P
been proven
proven to be good and the brake fault light
light is terminal of the wiper motor (B9 or B8) to drive the
still illuminated, there is a short on the signal wire wiper motor
motor to the Park position.
position. With the wiper
wiper
#32. Isolate andand remove the short.
short. switch (S8 or S9) in the Low position, 12 VDC is
applied to the L terminal of the wiper motor (B9 or
Front Wiper Circuit (Illustration 6-16).6-16). The front
B8) for low speed.
speed. With the wiper
wiper switch
switch (S8 or
wiper circuit is comprised of a circuit breaker
S9) in the high speed position, 12 VDC is applied
(CB4), wiper
wiper switch
switch (S7) and wiper motor (B1). (B1). 12
to the H terminal of the wiper motor (B9 or B8) for
VDC power is supplied from circuit breaker (CB4)
high speed. The wiper motors
motors (B9 and B8) utilize
utilize
to the B (Battery) posts of the wiper switch (S7).
chassis ground.
There are 6 posts on the back of the wiper switch
(S7). The P (Park) postpost of the wiper switch
switch is Defroster Fan Motors (B2 and B4, Illustration
used for parking
parking the wiper motor (B1).(B1). When the 6-16).. The front defroster (B2) and the rear
6-16)
wiper switch is turned off, 12 VDC will be present defroster (B4) fan motors are controlled by
at the P post.
post. When the wiper wiper switch
switch is turned
turned on, defroster switch
switch (S6). Defroster
Defroster switch (S6) is
12 VDC will be present at the L (Low) or H (High) powered by circuit
circuit breaker
breaker (CB9). There is a
post of the wiper switch (depending on desired diode between circuit breaker (CB9) and defroster
speed).
speed ). 12 VDC will
will be present at the W (Wash-
(Wash- switch
switc h (S6). Its purpose is is to prevent an induced
er) post of the wiper switch (S7) when the wiper voltage generated by the defroster fan motors (B2
switch
switc h is depressed. Five wires wires are used on the and B4), which could prolong engine shut down,
wiper motor
motor (B1). The black wire wire of the wiper after the ignition switch (S1) is turned to the Off
motorr is used for ground.
moto ground. The blue wire wire of the position. With the defroster
defroster switch
switch (S6) in the Low
wiper
wip er motor (B1)
(B1) is is used for high speed. The position, 12 VDC will be present on wire #40A for
yellow wire of the wiper motor (B1) has a constant the front defroster motor (B2) or on wire #40 for
12 VDC supply to it at all times while the key is at the rear defroster
defroster motor (B4).
(B4). With the defroster
defroster
the accessory
accessory position.
position. The red wire of the wiperwiper switch (S6) in the High position, 12 VDC will be
motor (B1) isis used for low speed.
speed. In this applica-
applica- present on wire #41A for the front defroster motor
tion, 12 VDC will be applied to the red wire when (B2) or wire #41 for the rear defroster motor (B4).
the wiper switch
switch (S7) isis in the Low position.
position. The Both defroster motors (B2 and B4) utilize chassis
green wire of the wiper motor (B1) is used to drive ground.
the wiper motor to the Park position when the wip- Heater Fan Motor
Motor (B5, Illustration 6-16).
6-16). The
er switch
switch (S7) is turned
turned off. There will
will be 12 VDC
heater fan motor (B5) is controlled by heater
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-15
switch (S5). Heater switch

switch switch (S5) is powered
powered by cir- tion, the contacts
contacts of the switch
switch are closed.
closed. When
cuit breaker
breaker (CB8). There is a diode between
between cir- the forward alarm mode key switch (S14) is off
cuit breaker
breaker (CB8) and heater switc
switchh (S5). Its pur- (Operator Controlled Mode), the contacts of the
pose is to prevent an induced voltage generated switch
switch are open. With the forward
forward alarm mode
mode
by the heater fan motor (B5), which could prolong key switch (S14) turned to the Automatic Position,
engine shut
turned to thedown, after theWith
Off position.
pos ition. ignition
the switch
heater (S1)
switcis
switch
h the forward
sounding analarm (LS4)
audible willany
alarm always
timebetheenergized,
shifter is
(S5) in the Low / High position, 12 VDC will be placed in the forward
forward position.
position. With the forward
forward
present on wire #43 to the heater fan motor (B5) alarm override switch (S14) turned to the Operator
for low speed operation.
operation. With the heater switch
switch Controlled position, the forward alarm toggle
(S5) in the High position, 12 VDC will be present switch (S10) can activate the forward alarm circuit
on wire #44 to the heater fan motor (B5) for high when the shifter is in the forward
forward position. This
speed operation.
operation. The heater fan motor
motor (B5) is allows the operator to determine when or when
connected to the chassis
chassis ground by wi wire
re #11. The not to use the forward alarm circuit.
circuit. With the shift-
shift-
heater fan motor (B5) will circulate air through a er in the forward position, 12 VDC is sent on wire
heater coil (which is heated by the engine coolant) #306 to pin 14 of forward
forward relay
relay (K17).
(K17). Ground
Ground to
and into the cab. energiz
ener gize
e K17 is supplied
supplied by either S10
S10 or S14. 12
VDC is supplied by circuit breaker (CB19) at all
Air Conditioner
Conditioner / Heater Unit (B7, Illustration
times
tim es to pin 9 (common
(common pin) of K17. When K17
6-16).. The air conditioner / heater unit (B7) is
6-16)
energizes, the 12 VDC at pin 9 will pass out pin 5
powered by circuit
circuit breaker (CB16).
(CB16). Two power
to LS4 (forward alarm unit), energizing it.
wires #72 are sent from the circuit breaker (CB16)
to the air conditioner
conditioner / heater unit (B7).
(B7). This is
required to deliver the sufficient amperage to the WARNING: See the information in the
air conditioner
conditioner / heater.
heater. All controls
controls to the air con- Operator’s Guide and Safety Check concerning
ditioner / heater unit (B7) are internal to the air selecting the appropriate
appropriate mode of operation.
conditioner / heater unit (refer to Section 20A for
additional information on the air conditioner / heat- Reverse Alarm (LS3, Illustration
Illustration 6-16).
6-16). The
er unit). reverse alarm circuit is designed to emit an audi-
Forward Alarm (LS4, Illustrations 6-16, 9C-2, and ble alarm when the shifter is in the reverse posi-
29-30).. The forward alarm circuit is designed to
29-30) tion. The reverse alarm
alarm circuit
circuit is controlled
controlled by the
emit an audible alarm when the shifter is in the shifter.. With the shifter
shifter shifter in the reverse position,
position,
forward position and the forward alarm circuit has relay (K18) is energized.
energized. Circuit
Circuit breaker (CB15)
been activated. The forward alaralarm
m circuit
circuit is con- will supply 12 VDC to pin #30 of relay (K18).
trolled by two switches, the forward alarm key When relay (K18) energizes, the 12 VDC present
switch (S14) and the forward alarm toggle switch at pin #30 will pass out pin #87 through wire #39,
(S10). The forward
forward alarm mode key switch
switch (S14)
(S14) energizing
energizing the reverse alarm
alarm (LS3). Any time 12
is an on and off switch.
switch. When the forward
forward alarm VDC is present on wire #319 at relay (K18), pin
mode key switch (S14) is in the Automatic Posi- #86, the reverse alarm (LS3) should be energized.
Refer to Illustration 6-16 for component reference
1. Eng Oil light

light (DS1)
(DS1) 1. Engine
Engine oil pres
pressure
sure is
is below
below 7 - 10 1. Refe
Referr to Problem
Problem 36.
36. in the
the
is illuminated. psi. Engine Troubleshooting chart in
Section 1.1.
2. Defecti
Defective
ve engine
engine oil pr
press
essure
ure 2. Repl
Replace
ace engine
engine oil
oil pres
pressur
sure
e
switch (S17). switch (S17).
3. There
There is a shor
shortt on wire
wire #4. 3. Isol
Isolate
ate and
and repair
repair short.
short.
6-16 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
2. Battery
Battery light (DS3) is 1. Charge
light (DS3) Charge indicat
indicator
or relay
relay (K3)
(K3) iis
s 1. Replace
Replace charge
charge indic
indicator
ator relay
relay
illuminated. defective. (K3).. Refer
(K3) to Alternator of the
Refer to
Component Troubleshooting.
roubleshooting.
2. Defective
Defective alternator
alternator.. 2. Replace
Replace alternat
alternator
or..
3. There
There is a short
short on wire
wire #34. 3. Isolate
Isolate and
and repai
repairr w
wire
ire..
4. Wire
Wire #5 is open o
orr shorte
shorted.
d. 4. Isolate
Isolate and
and repai
repairr w
wire
ire..
3. Seat Belt light (DS4) 1. Seat belt is unfastened.

light (DS4) 1. Fasten seat belt.
is illuminated.
4. Seat Belt light (DS4) 1. Seat belt

light (DS4) belt relay
relay (K2)
(K2) is defecti
defective.
ve. 1. Re fer to the Component Trouble-
Refer
is illuminated with shooting found earlier in this sec-
the seat belt fas- tion.
tened.
2. Wire
Wire #35 frfrom
om Seat
Seat Belt
Belt light
light 2. Isolate
Isolate and
and repai
repairr s
short
hort..
(DS4) to seat belt relay (K2) has a
short on it.
3. Wire
Wire #38 or #35 from
from the
the enable
enable 3. Isolate
Isolate and repair
repair.
relay (K20) is open.
4. Defecti
Defective
ve seat belt
belt switc
switch
h (S18).
(S18). 4. Replace
Replace seat belt.
belt.
5. Shift
Shift Fail
Fail light (DS6) 1. Shift
light (DS6) Shift request
request is outsi
outside
de of shifting
shifting 1. Operate truck correctly
correctly (refer to
is illuminated. parameters. the Operator’s Guide for proper
(if equipped with shifting
shifting operations).
operations).
APC-70)
6. Low Air light

light (DS7)
(DS7) 1. Air pres
pressure
sure is
is below
below 75 psi.
psi. 1. Locate
Locate and repair
repair leak (chec
(check
k all
is illuminated
buzzer and
(LS5) is fittings,
vice brakehoses, seals,
valve, air tank,
de-clutch ser-
valve
energized. and brake actuators).
2. Wire
Wire #31 is shor
shorted
ted between
between the
the 2. Isolate
Isolate and repair
repair sshort
hort.. A good
good
low air pressure switch (S13) and indication of this problem will be
Low Air light (DS7). the air pressure gauge on the
instrument panel shows good air
pressure.
continued
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-17
9. Low Air light

light (DS7)
(DS7) 3. Defective
Defective low air pressure
pressure switch
switch 3. Allo
Allow
w truck
truck to build
build air pressur
pressure,
e,
is illuminated and (S13). shut down engine, and with an
buzzer (LS5) is
energized. ohmmeter read
nal of the low airacross
pressureeach termi-
switch
(Continued) (S13) to chassis ground. Ohmme-
ter readings on one terminal
should be 0 - 40 ohms while the
other terminal’s
terminal’s ohmmeter reading
should be infinity
infinity.. If the air pres-
pres-
sure gauge, located on the instru-
ment panel, shows good air pres-
sure and the ohmmeter readings
are not as described above,
replace low air pressure switch
(S13).
1. Overstroke
Overstroke indicator switch
switch (S27)
(S27) 1. Visually
Visually inspect the overstrok
overstroke
e
7. Brake
Brake is
(DS8) Fault
Fault light
lignated
ht
illuminated
illumi is overstroked. indicator switch
switch (S27). If an over-
stroked condition has occurred, a
brass colored indicator rod will be
protruding from the end cover of
the power cluster approximately
3/4” to 1”. To reset, push the indi-
indi-
cator rod back into the end cover.
2. Brake
Brake coolant
coolant pr
press
essure
ure switc
switch
h 2. Refer to the Electrical System
Refer
(S23) is defective. Troubleshooting of the Brake
Fault light found earlier in this
section.
3. Brake
Brake coolant
coolant pr
pressu
essure
re is below 3.
10 psi.
a. Leak in brake cooling circuit. a. Isolate leak and repair.

b. Defective pressure relief valve b. Replace the 175 psi pressure
in port 3 of the brake manifold relief valve in the brake man-
valve. ifold valve at port 3.
4. Brake coolant temperature
temperature switch
switch 4. Refer to the Electrical System
Refer
(S24) is defective. Troubleshooting of the Brake
Fault light found earlier in this
section.
5. Brake
Brake coolant
coolant ttempe
emperatu
rature
re 5. Refe
Referr to Problem the Wet
Problem 1. in the
exceeds 190_F. Disc Brakes Cooling System
Troubleshooting chart in Section
15C..
15C
6. There
There is a shor
shortt on wire
wire #32. 6. Isol
Isolate
ate and repair
repair
6-18 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
8. Left turn
turn lamp (DS9) 1. The left
lamp (DS9) left turn
turn lamp
lamp (interna
(internall to DS9
DS9)) 1. Replace
Replace left
left turn
turn lamp
lamp bulb.
bulb.
will not illuminate
illuminate is burned out.
when the turn
is activated a left 2. Circuit
forsignal Circuit breaker
breaker is
is tripped
tripped (this
(this will
will 2. Reset circuit
circuit breaker.
breaker.
turn affect DS11 as well).
(if equipped) 3. Defective
Defective flasher
flasher (this
(this will affect
affect 3. Replace
Replace flasher
flasher..
DS11 as well).
4. Defective
Defective turn
turn switch
switch (left
(left side).
side). 4. Replace
Replace turn
turn switc
switch.
h.
The turn switch is mounted on the
steering column.
5. Loose or broken
broken wire
wire.. 5. Check
Check all connec
connection
tions
s or repair
repair
wire.
9. Par
Park
k Brak
Brakee lligh
ightt 1. Parking
Parking brak
brake
e is applied.
applied. 1. Release
Release parking
parking brake.
brake.
(DS10) is illumi-
illumi-
2. Park brake
brake switc
switch
h (S11)
(S11) is defec-
defec- 2. Replace park brake switch
switch (S11).
(S11).
nated
tive.
3. Air pres
pressure
sure is
is below
below 60 psi.
psi. 3. Refer Problem 3. in the Brake
Refer to Problem
Control System Troubleshoot-
ing chart in Section 15.
15.
10. Right
Right turn lamp
lamp 1. The right
right tur
turnn lamp (inte
(internal
rnal to
to 1. Replace
Replace right
right turn
turn lamp
lamp bulb.
bulb.
(DS11) will not illu- DS11) is burned out.
minate when the
2. Circuit
Circuit breaker
breaker is is tripped
tripped (this
(this will
will 2. Reset circuit
circuit breaker.
breaker.
turn signal is acti-
affect DS9 as well).
vated for a right turn
(if equipped) 3. Defective
Defective flasher
flasher (this
(this will affect
affect 3. Replace
Replace flasher
flasher..
DS9 as well).
4. Defective
Defective turn
turn switch
switch (right
(right side). 4. Replace
Replace turn
turn switc
switch.
h.
The turn column.
steering switch is mounted on the
5. Loose or broken
broken wire
wire.. 5. Check
Check all connecti
connections
ons and repair
repair
wire if necessary.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-19
6-20 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Illustration
Illustration 6-11.
6-11. Truck Layout Wiring Diagram
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-21
6-22 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
06-2366
06-2366 SHT
SHT.. 03
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-23
Hoist Circuit
6-24 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Illustration
Illustration 6-12. Truck Control
Control ANSI Diagram
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-25
6-26 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
06-2366 SHT. 10
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-27
Hoist Circuit
6-28 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Illustration
Illustration 6-13. Main Control
Control Junction
Junction Box
06-2366 SHT. 06
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-29
Illustration
Illustration 6-14.
6-14. Cab Rear Panel
Panel Harness
I-1-29-0640
6-30 THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
Hoist Circuit
PLACE THE FOLLOWING ILLUSTRATIONS IN

FOLDER ENVELOPES:
Illustration 6-15 - 06 2366 SHT. 10 (Truck Control ANSI)
Illustration 6-16 - 06 2366 SHT. 9 (ANSI)
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) 6-31
6
L
u-A
x
il
a i
r
y
L
g i
h
ti
n
g

Taylor THDC THDCP 954 955 974 Forklift Trucks Maintenance Manual PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Taylor THDC THDCP 954 955 974 Forklift Trucks Maintenance Manual PDF

Uploaded by

Copyright:

Available Formats

Maintenance Manual

THDC / THDCP - 954 / 955 / 974

D OPERATOR MUST BE TRAINED AND KNOWLEDGEABLE OF

D CAPACITY GREATLY DECREASES WITH TILTING, HIGH

THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)

THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY:

TAYLOR MACHINE WORKS, INC.

Machine checks must be performed daily:

WARNING: Do not operate

• ANSI B56.1 rules for operating

• The Operator’s Guide for the machine

• The content and meaning of all

Intro THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)

Important Safety Instructions 1. Use of hois

THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) Safety-1

WARNING: Do not operate the vehicle or WARNING: Under no circumstances,

Safety-2 THDC / THDCP - 954 / 955 / 974 (Rev

Mounting and Dismounting:

WARNING: Do not start the engine if the WARNING:

WARNING: Do not operate the container

THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) Safety-3

Safety-4 THDC / THDCP - 954 / 955 / 974 (Rev

THDC / THDCP - 954 / 955 / 974 (Rev. 06/03) Safety-5

Safety-6 THDC / THDCP - 954 / 955 / 974 (Rev

NOTE: All circuit draw

https://www.forkliftpdfmanuals.com/THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)

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

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

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

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

Air Dryer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15D

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

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

Cab Tilt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22D

Illustration 1-1. Cummins

CAUTION: Do not adjust belt tension to

corrected as soon as possible. 1. Turn off the engine.

continued and repair.

11. Coolant tempera- 1. Electron

29. Fuel consumptio

proper oil (refer to Fuel

PLACE THE FOLLOWING ILLUSTRATIONS IN

cooled. Fuel is circulated

FILLER CAP FUEL LEVEL

Air Intake System

COTTER PIN INTERNAL PRECLEANER

INDICATES AIR FLOW

CAUTIONS: 9. Push the

CAUTION: Do not use flammable liquids

Air Intake System Troubleshooting

Major Components (Illustration 5-5).5-5). The engine

presses the intake

gauge should be in the green temperature area

MAKE-UP ADD LEVEL

15 PSI PRESSURE CAP

RADIATOR / CHARGE 7 PSI PRESSURE CAP

COOLANT DEAERATION LINE

CAUTION: Overfilling cells of the battery

KEEP METAL TOOLS AWAY FROM BATTERY

the separator plates. Do not overfill.

and rinse with clean water.

CB5 CB4 CB24 CB3 CB2