Taylor TX180S Maintenance Manual
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Taylor TX180S Maintenance Manual

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Maintenance Manual
Maintenance Manual
 TX180S – 360L
 TX180S – 360L
 TXH300L, TXH350L, TXH400L
 TXH300L, TXH350L, TXH400L
 TXB180S – 300L
 TXB180S – 300L
https://www.forkliftpdfmanuals.com/
 
 

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Summary of Contents for Taylor TX180S

  • Page 1     Maintenance Manual Maintenance Manual  TX180S – 360L  TX180S – 360L  TXH300L, TXH350L, TXH400L  TXH300L, TXH350L, TXH400L  TXB180S – 300L  TXB180S – 300L     https://www.forkliftpdfmanuals.com/...
  • Page 2     TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) https://www.forkliftpdfmanuals.com/...
  • Page 3       Observe The Following Precautions For Maximum Safety Of Machine Operation Observe The Following Precautions For Maximum Safety Of Machine Operation Only trai Only trained and res ned and responsib ponsible operat operators shal shall be permit l be permitted to han ted to...
  • Page 4 Taylor parts, labor, and travel time to replace or repair any part furnished by Taylor and found will provide genuine Taylor parts, labor, and travel time to replace or repair any part furnished by Taylor and found...
  • Page 5 https://www.forkliftpdfmanuals.com/...
  • Page 6 Taylor Machine Works, Inc. to assemble a maintenance manual with the maintenance instructions enables Taylor Machine Works, Inc. to assemble a maintenance manual with explicit instructions on the exact equipment installed on the machine.
  • Page 7       Use only genuine T Use only genuine Taylor replacement parts. aylor replacement parts. Lesser quality parts may fail, Lesser quality parts may fail, resulting in property damage, personal injury or death. resulting in property damage, personal injury or death.
  • Page 8 Taylor dealer from which fee from the authorized Taylor dealer from which the equipment was initially purchased. the equipment was initially purchased.
  • Page 9 The battery The battery at a nominal fee from the authorized Taylor at a nominal fee from the authorized Taylor should be locked-out / tagged-out to prevent acci- should be locked-out / tagged-out to prevent acci- dealer from which the equipment was initially...
  • Page 10   Use only genuine Taylor Use only genuine Taylor replacement p replacement parts. arts. Lesser quality...
  • Page 11     explosion. explosion. Stored energy, such as that in capacitors, Stored energy, such as that in capacitors, springs, elevated crane members, rotating fly- springs, elevated crane members, rotating fly- Keep all m Keep all meta etal too tools aw away fr from bat batter...
  • Page 12     Major Components Locations Major Components Locations RADIATOR RADIATOR TILT CYINDERS TILT CYINDERS (Section 5) (Section 5) (Section 22) (Section 22) STEER AXLE STEER AXLE (Section 13) (Section 13) MAST MAST (Section 27) (Section 27) HYDRAULIC TANK  HYDRAULIC TANK  (Section 22) (Section 22) CARRIAGE...
  • Page 13     https://www.forkliftpdfmanuals.com/ (Rev. 11/94) (Rev. 11/94)

  • Page 14: Table Of Contents

        Contents Contents Maintenance Manual Maintenance Manual Section Section Introduction Introduction ..............
  • Page 15 https://www.forkliftpdfmanuals.com/...
  • Page 16      Air Conditioning System  Air Conditioning System ...........
  • Page 17 https://www.forkliftpdfmanuals.com/...

  • Page 18: Introduction

        Section 1 Section 1 Engine Engine FILLER FILLER DRAIN DRAIN PLUG PLUG FILTER FILTER DIPSTICK  DIPSTICK  Illustration 1-1. Illustration 1-1. Cummins Cummins QSB6.7 Engine QSB6.7 Engine Service Points Service Points Introduction. Introduction.    The Cumm Cummins QSB6.7 ins QSB6.7 engine is engine is Changing The Oil and Filter...
  • Page 19     starting aid. starting aid. Use of ether Use of ether to start an to start an engine engine Clean the a an the area of t rea of the fil filter b base t that w will co con- equipped with an electric heater starting aid equipped with an electric heater starting aid...
  • Page 20 T contact a Taylor Machine Works, Inc. aylor Machine Works, Inc. authorized authorized with the thumb at a point midway between the two with the thumb at a point midway between the two dealer for service.
  • Page 21 This icon is also used to flash out the fault  This icon is also used to flash out the fault  engine diagnostic icons, displayed by the Taylor engine diagnostic icons, displayed by the Taylor code number in the diagnostic mode.
  • Page 22     Illustration 1-5. Illustration 1-5. Engine Fault Engine Fault Code Dialog Code Dialog Screen Screen Diagnostic Fault Codes Diagnostic Fault Codes (Illustration 1-4)  (Illustration 1-4). If the If the the Diagnostic Mode Status to the On position. the Diagnostic Mode Status to the On position. red icon icon (Engine Shutting Down) or  (Engine Shutting Down) or...
  • Page 23     Cummins QSB6.7 Engine Fault Cummins QSB6.7 Engine Fault Code Information Code Information Data Erratic, Intermittent, or incorrect Data Erratic, Intermittent, or incorrect of two signals from the magnetic pickup of two signals from the magnetic pickup sensor sensor Source Source Source...
  • Page 24     Range – Moderately Severe Level Range – Moderately Severe Level 212 - -      Y  Yellow ellow Engine Oil Engine Oil emperature Se emperature Sensor 1 Circuit nsor 1 Circuit Volt Voltage Above Norm age Above Normal, or Short al, or Shorted to High ed to High...
  • Page 25     Source Source or Out of Adjustment or Out of Adjustment or Out of Adjustment or Out of Adjustment Voltage Below Normal, or Shorted to Low Voltage Below Normal, or Shorted to Low Supply Voltage Circuit Supply Voltage Circuit Source Source Received Network Data In Error...
  • Page 26     Source Source Voltage Above Normal, or Shorted to High Voltage Above Normal, or Shorted to High Supply Voltage Circuit Supply Voltage Circuit Source Source – – Most Severe Level Most Severe Level Normal Operational Range Normal Operational Range Range –...
  • Page 27     Range – Moderately Severe Level Range – Moderately Severe Level Range – Moderately Severe Level Range – Moderately Severe Level Source Source Source Source Range – Moderately Severe Level Range – Moderately Severe Level Range – Moderately Severe Level Range –...
  • Page 28     or Out of or Out of Adjustment Adjustment or Out of or Out of Adjustment Adjustment or Out of or Out of Adjustment Adjustment or Out of or Out of Adjustment Adjustment or Out of or Out of Adjustment Adjustment Voltage Above Normal, or Shorted to High...
  • Page 29     Source Source Source Source Range – Moderately Severe Level Range – Moderately Severe Level Data Valid but Below Normal Operational Data Valid but Below Normal Operational than expected than expected Range – Moderately Severe Level Range – Moderately Severe Level  Abnormal Rate  Abnormal Rate of Change...
  • Page 30     Engine Engine roubleshooting roubleshooting The following chart includes some of the problems The following chart includes some of the problems noise. noise. Use the follow Use the following information as ing information as a guide to a guide to that an operator may encounter during the service that an operator may encounter during the service diagnosing engine noise.
  • Page 31     Engi gine w wil ill n Batter tery di disc sconne onnect s swi witch i is tur turned urn ba batte ttery di disco sconne nnect sw switc itch on. h on. crank or cranks crank or cranks off.
  • Page 32     Engi gine di fi ficu cult t Low f uel l evel el. Fi Fill th the f uel t ank. start or will not start or will not Electr ctronic onic fault c code odes are s are active ive.
  • Page 33     Engi gine s sta tart rts, Low f uel l evel el. Fi Fill fu fuel ta tank will not keep will not keep Batter tery vo volta ltage s suppl upply to t y to the el elec- Check batter...
  • Page 34     Engi gine ru runs ro roug Fuel sup supply l line o or pas passag sage res restri tric- Check fuel su suppl pply l line or misfires or misfires tion between the fuel pump and tion between the fuel pump and passage for restriction.
  • Page 35     Lubric Lubricating oil ating oil Bulk oi oil supp pply onta tam in inat ated Chec bulk oi oil supp pply ly. ra rain th the oi oil contaminated contaminated and replace with non-contaminated and replace with non-contaminated (Continued) (Continued) oil.
  • Page 36     Coolan Coolant tem tempera- pera- Radiat Radiator core is internall or core is internally Inspe Inspect the radiat ct the radiator and clean if  or and clean if  ture is above ture is above obstructed or damaged. obstructed or damaged. necessary.
  • Page 37     Coola Coolant loss nt loss – – Coolan lant fi fill l line is r rest estric ricted Check t the c cool oolant fil fill li line f External External obstructed. obstructed. restrictions or obstructions. restrictions or obstructions. (Continued) (Continued) Engi gine is ov...
  • Page 38     Engine vib Engine vibration ration Engi gine m ount nts ar are wo worn o Repl plac ace en engi gine moun unts ts. excessive excessive damaged. damaged. (Continued) (Continued) loose, damage aged, Check fan. Replac lace if  if ...
  • Page 39     Engine powe power Check t the fu fuel li lines nes, fu fuel c conne onnec- output is low output is low tions, and fuel filter(s) for leaks. tions, and fuel filter(s) for leaks. (Continued) (Continued) Check the fuel lines to the fuel Check the fuel lines to the fuel tank.
  • Page 40     Engine no Engine noise Engi gine m ount nts ar are wo worn o Repl plac ace en engi gine moun unts ts. excessive excessive damaged. damaged. (Continued) (Continued) In Inco corr rrec ect eng engin ine oil l e oil evel el.
  • Page 41     Exces Excessive w sive white hite Engi gine cold ld. Allow t the e engi ngine t to w warm oper oper- smoke smoke ating ating temperature. temperature. engine engine will will not reach operating tempera-  reach operating tempera- ture, refer to Problem 16.
  • Page 42     Engine Engine accel accelera- era- Check t the f fuel lines, fuel co conne nnec- tion or response is tion or response is tions, and fuel filters for leaks. tions, and fuel filters for leaks. poor (Continued) poor (Continued) Intake m mani anifol...
  • Page 43     Fault c Fault code wa warning rning Igniti ition s swit witch i is in t s in the OF OFF pos posi- urn t the ig ignit nition s swit witch to ch to lamps do not illu- lamps do not illu- tion.
  • Page 44     Intak Intake mani manifold fold intake exhaus aust l leak eaks. Refer t to Co Corre rrecti ction 4 4. of . of Proble blem pressure (boost) is pressure (boost) is 20. in this troubleshooting chart. 20. in this troubleshooting chart. below normal below normal intake...
  • Page 45     Turbocha rbocharger rger Engine being operat rated Oper erat ate eng engin ine und under lo load aded leaks engine oil or leaks engine oil or extended periods under light or no extended periods under light or no conditions.
  • Page 46     Engine no Engine noise Connec nectin ting ro rod an and be beari arings Inspec pect t connec nectin ting r excessive excessive damaged or worn, are not damaged or worn, are not bearings. bearings. Replace Replace damaged damaged parts parts...
  • Page 47     Engine noise is ine noise is Connec nectin ting ro rod is d is bent or t or of  of  Refer t to Co Corre rrecti ction 8 8. of . of Proble blem excessive excessive alignment. alignment. 39.
  • Page 48 1 30 1 30 TX / TXH / TXB 180S 400L (Rev. 4/23/07) TX / TXH / TXB 180S 400L (Rev. 4/23/07)     Air com compress pressor air or air Carbon b buil uildup is ex exces cessiv sive in t e in Check f for c...
  • Page 49 TX / TXH / TXB 180S 400L (Rev. 4/23/07) TX / TXH / TXB 180S 400L (Rev. 4/23/07) 1 31 1 31     Air co compres mpressor is sor is Carbon b buil uildup i is ex exces cessiv sive in t e in Refer t...

  • Page 50: E N G I N E

    TX / TXH / TXB 180S 400L (Rev. 4/23/07) TX / TXH / TXB 180S 400L (Rev. 4/23/07) 1 32 1 32     Cummins QSB6.7 Diesel Engine Cummins QSB6.7 Diesel Engine          *Lubrication oil temperature maximum  *Lubrication oil temperature maximum Air System Air System...
  • Page 51 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-33 1-33     Hoist Circuit Hoist Circuit https://www.forkliftpdfmanuals.com/...
  • Page 52 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-34 1-34         Hoist Circuit Hoist Circuit PLACE THE FOLLOWING ILLUSTRATIONS IN PLACE THE FOLLOWING ILLUSTRATIONS IN FOLDER ENVELOPES: FOLDER ENVELOPES: Illustration 1-6 - 06B-2234 (Engine Electrical ANSI)
  • Page 53 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 1-35 1-35 https://www.forkliftpdfmanuals.com/...
  • Page 54     Hoist Circuit Hoist Circuit https://www.forkliftpdfmanuals.com/...
  • Page 55 1-36 1-36 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 2 Section 2 Fuel System Fuel System Introduction. Introduction.    Fuel is Fuel is drawn from drawn from the fuel t the fuel...
  • Page 56 (refer to the (refer to the Preventive Maintenance Preventive Maintenance chart in the  chart in the Draining The Fuel / Water Separator Draining The Fuel / Water Separator (Illustration (Illustration Appendices Appendices for fuel / water separator and fuel  for fuel / water separator and fuel 2-1) 2-1).
  • Page 57   Death or serious injury could Death or serious injury could result from high pr result from high pressure fuel spray essure fuel spray. Do not Do not open high open high pressure fuel pressure fuel system. system. Only use Only use priming pump handle to prime the fuel priming pump handle to prime the fuel...
  • Page 58 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     FUEL LEVEL FUEL LEVEL SENDING UNIT SENDING UNIT FILLER FILLER FILLER FILLER     NECK  NECK  https://www.forkliftpdfmanuals.com/...
  • Page 59 FUEL TANK  FUEL TANK  Illustra Illustration tion 2-3. 2-3. Fuel Fuel TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 3 Section 3 Air Intake System Air Intake System SAFETY SAFETY...
  • Page 60 LATCH LATCH IF EQUIPPED IF EQUIPPED Illustration 3-1. Illustration 3-1. Air Intake Air Intake System Com System Components ponents Introduction. Introduction.    The air The air cleaner is cleaner is designed to designed to Major Components Major Components (Illustration 3-1)  (Illustration 3-1).
  • Page 61 on indicator is red) is required or the service on indicator is red) is required or the service interval has occurred, unlatch and remove the interval has occurred, unlatch and remove the cover. cover. Remove Remove primary primary filter filter. high high humidity situations, the air restriction indicator...
  • Page 62 Damaged aged loose connec nectio tions Replac lace o or r repa epair connec nectio tions. between air cleaner body and between air cleaner body and engine. engine. In Inco corr rrec ect f fil ilte ter us used. Replac lace w with proper...

  • Page 63: Exhaust System

    TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 4 Section 4 Exhaust System Exhaust System Introduction. Introduction. The exhaust system is responsible The exhaust system is responsible Keep exh exhaus aust sy...
  • Page 64 Wash t the ex exhaust haust purif purifier b by us using s steam team employer, and obtain medical attention. employer, and obtain medical attention. high pressure water [not greater than 100 psi high pressure water [not greater than 100 psi (7 bar)], keeping the tip of the nozzle at least 2 (7 bar)], keeping the tip of the nozzle at least 2 ...

  • Page 65: Cooling System

    TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 5 Section 5 Cooling System Cooling System Introduction. Introduction.    The engine The engine cooling sys cooling system cools tem cools engine.
  • Page 66     Charge Air Cooler Charge Air Cooler (Illustration 5-3) (Illustration 5-3).     engine engine the radiator cap or drain cock. the radiator cap or drain cock. is equipped with a turbocharger which is driven by is equipped with a turbocharger which is driven by engine exhaust.
  • Page 67 Belt Tension Belt Tension in Section 1 Section 1 for the proper tension  in  for the proper tension values. values.   When freezing weather is When freezing weather is expected, any cooling system not adequately expected, any cooling system not adequately Fan Ring Positioning Fan Ring Positioning (Illustration 5-2)
  • Page 68 BOLT BOLT  A  A Illustration Illustration 5-2. 5-2. Ring Ring Positioning Positioning TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     16 PSI (110 kPa) 16 PSI (110 kPa) DEAERATION DEAERATION PRESSURE CAP...
  • Page 69 FAN RING FAN RING RADIATOR RADIATOR SHROUD SHROUD Illustration Illustration 5-3. 5-3. Cooling Com Cooling Components I ponents Identification dentification TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 70 CUMMINS QSB6.7 CUMMINS QSB6.7 ENGINE ENGINE COOLANT FLOW COOLANT FLOW MAIN FLOW, THERMOSTAT OPEN MAIN FLOW, THERMOSTAT OPEN DEAERATION REMOVES UNWANTED AIR FROM COOLING CIRCUIT DEAERATION REMOVES UNWANTED AIR FROM COOLING CIRCUIT 05-2374 05-2374 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.

  • Page 71: Electrical System

    TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 6 Section 6 Electrical System Electrical System Introduction. Introduction.    This This machine inc machine incorporates a orporates a 12-Volt 12-Volt...
  • Page 72 routed and clamped after servicing the vehicle. routed and clamped after servicing the vehicle.  NOTE:  NOTE:    If the truck If the truck is to be inoperativ is to be inoperative or idle for  e or idle for  Battery. Battery.   ...
  • Page 73 nals, which are always hot regardless of whether nals, which are always hot regardless of whether or not the engine is running or accidentally revers- or not the engine is running or accidentally revers- ing of the battery polarity, will destroy the diodes. ing of the battery polarity, will destroy the diodes.
  • Page 74 Illustration Illustration 6-1. 6-1. Dash Dash Panel Panel TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     CB15 CB15 CB13 CB13 CB11 CB11 CB19 CB19 CB17 CB17 (10 AMP) (10 AMP) (15 AMP)
  • Page 75 CB14 CB14 CB12 CB12 CB20 CB20 CB18 CB18 CB16 CB16 (15 AMP) (15 AMP) (30 AMP) (30 AMP) (10 AMP) (10 AMP) (20 AMP) (20 AMP) (20 AMP) (20 AMP) KILL ENGINE KILL ENGINE DEFROSTERS DEFROSTERS FUEL GAUGE, FUEL GAUGE, TOP &...
  • Page 76 CONDENSER CONDENSER CB25, CB26 CB25, CB26 (10 AMP) (10 AMP)  ACCESSORY (CB,  ACCESSORY (CB, RADIO, ETC.) RADIO, ETC.) Illustration 6-3. Illustration 6-3. Control Stand Control Stand Circuit Breakers Circuit Breakers Component Troubleshooting Component Troubleshooting VDC, the alternator is defective and requires VDC, the alternator is defective and requires replacing.
  • Page 77 Turn the n the ignit ignition ke key to y to Igniti Ignition p positio osition. 30, 87, and 30, 87, and 87A. 87A. In a de-energized In a de-energized state, ensure state, ensure that pins 30 and 87A have continuity between that pins 30 and 87A have continuity between If th the cir...
  • Page 78 is released, the is released, the circuit will open. circuit will open. This switch This switch readings should indicate a higher ohm resistance readings should indicate a higher ohm resistance checked like an On-Off switch with the exception checked like an On-Off switch with the exception in one direction opposed to the other direction in one direction opposed to the other direction that the switch must be held closed to complete...
  • Page 79 ing the slip connectors at the ing the slip connectors at the alternator and connections at alternator and connections at the battery. the battery. Defective alternator Defective alternator. Replace Replace alternator. alternator. High o outp utput voltag tage ( (vol voltag tage Defect...
  • Page 80 turned fully off to reset the ignition turned fully off to reset the ignition switch, allowing the B (Battery) switch, allowing the B (Battery) and S (Start) contacts to close. and S (Start) contacts to close. This is a momentary position that This is a momentary position that should only make contact when should only make contact when...
  • Page 81 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-10 6-10         Hoist Circuit Hoist Circuit PLACE THE FOLLOWING ILLUSTRATIONS IN PLACE THE FOLLOWING ILLUSTRATIONS IN FOLDER ENVELOPES: FOLDER ENVELOPES: Illustration 6-6 - 06-2485 SHT.
  • Page 82 Illustration 6-10 - 06-2485 SHT. 6 (Truck Electrical Box Illustration 6-10 - 06-2485 SHT. 6 (Truck Electrical Box  ANSI)  ANSI) Illustration 6-11 - 06-2485 SHT. 7 (Top Cab and Illustration 6-11 - 06-2485 SHT. 7 (Top Cab and  A-Frame ANS  A-Frame ANSI) Illustration 6-12 - 06L-0123 (Work Lights ANSI)
  • Page 83 https://www.forkliftpdfmanuals.com/...
  • Page 84 https://www.forkliftpdfmanuals.com/...
  • Page 85 https://www.forkliftpdfmanuals.com/...
  • Page 86     https://www.forkliftpdfmanuals.com/...
  • Page 87 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-12 6-12     aylor Integrated aylor Integrated Control System (TICS) Control System (TICS) Components Components https://www.forkliftpdfmanuals.com/...
  • Page 88 TICS Display Module TICS Display Module The Taylor Integrated Control System (TICS) Display The Taylor Integrated Control System (TICS) Display Module. Module.    The TICS The TICS Display Module Display Module is an is an electronic display sys electronic display...
  • Page 89 PRESSURE LOW BRAKE LOW BRAKE PRESSURE PRESSURE STOP STOP Taylor Integrated Control System (TICS) Display Module Main Screen Taylor Integrated Control System (TICS) Display Module Main Screen The Taylo Taylor Integrated Control System r Integrated Control System (TICS) (TICS) MPH - T...
  • Page 90 F1 - Depress this F1 - Depress this button to view t button to view the Diagnos- he Diagnos- maintenance personnel. maintenance personnel. tics Select screen. tics Select screen. F2 - Depress F2 - Depress this button to this button to view Active view Active when the engine oil pressure has fallen below...
  • Page 91 TICS Module TICS Module TICS Module. TICS Module.    The TICS Module st The TICS Module status is indicated by atus is indicated by the following LEDs: the following LEDs: Green LED Green LED - When thi - When this LED is il s LED is illumin luminated, it...
  • Page 92  ADDRESS T  ADDRESS PROTECTIVE PROTECTIVE COVER COVER TICS Module Wire Harness Plug TICS Module Wire Harness Plug TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-17 6-17     PIN #42 PIN #42 PIN #29...
  • Page 93 NOTE: NOTE:    The TICS sys The TICS system of this tem of this truck employs truck employs XA2 modules. XA2 modules. Always replace each module with the Always replace each module with the correct module. correct module. Refer to the following illustration for truck control module locations. Refer to the following illustration for truck control module locations.
  • Page 94 To access the Maintenance Groups inside the Taylor Integrated Control System (TICS) display module, To access the Maintenance Groups inside the Taylor Integrated Control System (TICS) display module,...
  • Page 95 MEASURE /  MEASURE /   ADJUST  ADJUST GROUPS GROUPS Main Display Screen Main Display Screen From th From the Main Dis e Main Display sc play screen, de reen, depress t press the Meas Measure / Adjus ure / Adjust Groups b t Groups button ( utton (...
  • Page 96 Main Measure / Adjust Screen Main Measure / Adjust Screen At the Ma At the Main Meas Measure / Adju ure / Adjust scre screen, depr depress th the F2 (Meas e F2 (Measure) but ure) button. ton. This w This will disp display the M...
  • Page 97 6-22 6-22 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     THESE WILL VARY BASED THESE WILL VARY BASED ON THE NUMBER OF ACCESSORY  ON THE NUMBER OF ACCESSORY  FUNCTIONS FUNCTIONS ACTIVA...
  • Page 98 Maintenance and Measure Groups Maintenance and Measure Groups SENSOR SENSOR COMMUNICATION COMMUNICATION STATUS STATUS STATUS STATUS DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Hydraulic Maintenance Group Hydraulic Maintenance Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 99 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Engine Maintenance Group Engine Maintenance Group 6-24 6-24 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 100 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Cab Maintenance Group Cab Maintenance Group DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Transmission Maintenance Group Transmission Maintenance Group TX / TXH / TXB 180S - 400L (Rev.
  • Page 101 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Brake Maintenance Group Brake Maintenance Group DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Fuel Usage Information Group Fuel Usage Information Group 6-26 6-26...
  • Page 102 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES  ACC1  ACC1 Maintenance Group Maintenance Group NOTE: NOTE:    Additional accessory hy Additional accessory hydraulic maintenance groups (ACC draulic maintenance groups (ACC2, ACC3, etc. 2, ACC3, etc.) have the typic ) have the...
  • Page 103 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Joystick Measure Group Joystick Measure Group 6-28 6-28 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 104 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Joystick Measure Group Joystick Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-29 6-29  ...
  • Page 105 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Engine Measure Group Engine Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-30 6-30  ...
  • Page 106 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Engine Measure Group Engine Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-31 6-31  ...
  • Page 107 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Cab Measure Group Cab Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-32 6-32  ...
  • Page 108 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Transmission Measure Group Transmission Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-33 6-33  ...
  • Page 109 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Transmission Measure Group Transmission Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-34 6-34  ...
  • Page 110 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Transmission Measure Group Transmission Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-35 6-35  ...
  • Page 111 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Transmission Measure Group Transmission Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-36 6-36  ...
  • Page 112 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Display Data Measure Group Display Data Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-37 6-37  ...
  • Page 113 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Display Data Measure Group Display Data Measure Group 6-38 6-38 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 114 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES  APC Interface  APC Interface Measure Group Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-39 6-39  ...
  • Page 115 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES  APC Interface  APC Interface Measure Group Measure Group 6-40 6-40 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 116 (Continued) (Continued) DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Engine Fault Code Measure Group Engine Fault Code Measure Group TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 6-41 6-41  ...
  • Page 117 T set by Taylor personnel during the initial set up of the truck. aylor personnel during the initial set up of the truck. It may be necessary to adjust these settings It may be necessary to adjust these settings...
  • Page 118 MEASURE /  MEASURE /   ADJUST  ADJUST GROUPS GROUPS Operational Display Operational Display From th From the Main Dis e Main Display sc play screen, de reen, depress t press the Measu Measure / Adjus re / Adjust Groups b t Groups button ( utton ( This...
  • Page 119 PIN code must be entered before the software will allow any adjustments to be made. NOTE: NOTE: Taylor personnel will provide qualified maintenance personnel with the Pin Code necessary to make Taylor personnel will provide qualified maintenance personnel with the Pin Code necessary to make adjustments within adjust groups.
  • Page 120 Lift / Tilt Adjust Group Screen Lift / Tilt Adjust Group Screen Depres Depress the UP or DOWN but s the UP or DOWN button to sele ton to select the func ct the function in whic tion in which settin setting adjustm adjustments are to be mad ents are to be...
  • Page 121 Lift (Max Setting) Screen Lift (Max Setting) Screen The Max par The Max parameter of L ameter of Lift is use ift is used to calibr d to calibrate the max ate the maximum am imum amount of cur ount of current sent t rent sent to the lift va...
  • Page 122 Measure / Adjust Measure / Adjust Groups Button Groups Button At the Main sc At the Main screen of the TI reen of the TICS displa display module, de y module, depress th press the the Measu e the Measure / Adjust Gro re / Adjust Groups butt button (...
  • Page 123 Select t Select the Perce Percent Ground Sp nt Ground Speed Allow Allowed adjust g ed adjust group by dep roup by depressi ressing the UP or Dow ng the UP or Down button (a n button indicated by the arrows above) and depres indicated by the arrows above) and depress the OK button to view s the OK button to view...
  • Page 124 Depres Depress the UP or Down but s the UP or Down button (as indi ton (as indicated by th cated by the arrows abo e arrows above) to adjus ve) to adjust the perce t the percentage of ntage of  Allowed Ground  Allowed Ground Speed.
  • Page 125 Depres Depress the F1 button (as ind s the F1 button (as indicate icated by arrow above d by arrow above) to access th ) to access the Select Dia e Select Diagnost gnostic Option sc ic Option screen. reen. Depres Depress the F2 butt s the F2...
  • Page 126 BACK  BACK  After view After viewing the Maxi ing the Maximum Grou Ground Speed (indi nd Speed (indicated to th cated to the left of the arro e left of the arrow illust illustrated on the abo rated on the above screen), depress the BACK ( screen), depress the BACK (...
  • Page 127 DIAGNOSTICS DIAGNOSTICS BUTTON BUTTON Main Display Screen Main Display Screen Turn the ignit n the ignition key to it ion key to its acces accessory pos sory position (f ition (first cli irst click). ck). From th From the Main Disp e Main Display scr screen, depr...
  • Page 128 Maintenance Timer Reset Screen Maintenance Timer Reset Screen At the Engine Inf At the Engine Informat ormation scree screen, depress t n, depress the F3 button (Re he F3 button (Reset Servi Service Ti Timer) to acc mer) to access the Ma ess the Mainte- inte-...
  • Page 129 Maintenance Timer Reset Screen Maintenance Timer Reset Screen After th After the Pin Code numb e Pin Code number has been ent er has been entered, dep ered, depress th ress the Down Butt e Down Button to reset t on to reset the Mainte Maintenance...
  • Page 130  e  e r  r   a  a  s  s  a  a  d   d   o  o  t    t   i    i    o  o r  r   s  s https://www.forkliftpdfmanuals.com/...

  • Page 131: Closed Circuit Tv Cameras And Monitors

        Section 6A Section 6A Closed Circuit TV Cameras and Monitors Closed Circuit TV Cameras and Monitors Introduction. Introduction. The camera system (if equipped) The camera system (if equipped)  Volu  Volume Buttons. Buttons.    Depress Depress upper butt upper button gives the operator a vantage view from a remote gives the operator a vantage view from a remote...
  • Page 132 Monitor. Monitor.    The orientation The orientation of the of the image being dis image being dis- played by the monitor is controlled by a magnetic played by the monitor is controlled by a magnetic plug located in the rear of the camera (see Illustra- plug located in the rear of the camera (see Illustra- tion 6A-1).

  • Page 133: Transmission

    06C-0108 06C-0108 6A-2 6A-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 9 Section 9 Transmission Transmission FILLER FILLER CHARGING CHARGING PUMP PUMP BRAKE BRAKE PUMP PUMP https://www.forkliftpdfmanuals.com/...
  • Page 134 MAIN / STEERING MAIN / STEERING DIPSTICK  DIPSTICK  PUMP PUMP CONTROL CONTROL VALVE VALVE OIL SUMP OIL SUMP SCREEN SCREEN DRAIN PLUG DRAIN PLUG Illustration Illustration 9-1. 9-1. TC-32 TC-32 Transmis Transmission sion Introduction. Introduction. The TC-32 transmission is a pow- The TC-32 transmission is a pow- mission’s converter charging pump draws trans- mission’s converter charging pump draws trans-...
  • Page 135 impeller element. impeller element. Illustration 9-3. Illustration 9-3. Transmiss Transmission Oil ion Oil Filter Filter ransmission Oil ransmission Oil Filter Replacement Filter Replacement (Illustra- (Illustra- located below the drive located below the drive tion 9-3) tion 9-3). The oil filter, The oil filter, line spring brake line spring...
  • Page 136 Operat rate the e the engine a and ch check f for le leaks aks. provide a suitable container to catch any provide a suitable container to catch any When the transmission’s oil temperature When the transmission’s oil temperature draining oil, and unscrew filter and dispose of  draining oil, and unscrew filter and dispose of ...
  • Page 137 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     CLUTCH PRESSURE CHECK  CLUTCH PRESSURE CHECK  POINT 240 PSI [16.6 bar (LOW IDLE)] - POINT 240 PSI [16.6 bar (LOW IDLE)] - 300 PSI [20.7 bar (HIGH IDLE)] 300 PSI [20.7 bar (HIGH IDLE)] INSTALL PRESSURE...
  • Page 138 CONVERTER OUT TO CONVERTER OUT TO COOLER [25 PSI (1.7 bar) MIN. - COOLER [25 PSI (1.7 bar) MIN. - 70 PSI (4.8 bar) 70 PSI (4.8 bar) MAX. AT MAX. AT RATED RPM] RATED RPM] COOLER COOLER TEMPERATURE TEMPERATURE TRANSDUCER TRANSDUCER IN FROM COOLER...
  • Page 139 INDICATES FLUID FLOW INDICATES FLUID FLOW Illustration 9-5. Illustration 9-5. Transmis Transmission Oil sion Oil Flow Flow TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Transmission Troubleshooting Transmission Troubleshooting Electrical / Mechanical Checks.
  • Page 140 Ensure t that t the in inchi ching va valve i is not e s not enga ngaged quarter throttle for 30 seconds, let off accelera- quarter throttle for 30 seconds, let off accelera- nor sticking. nor sticking. tor for 10 seconds. tor for 10 seconds.
  • Page 141 chargi rging pump pressu ssure. Refe fer t to P Pro robl blem 2. 2. of this trouble-  of this trouble- shooting chart. shooting chart. Excess essive intern ernal l leak eakage Rebuil uild or d or replac lace t trans ransmis missio sion.
  • Page 142 engine. engine. If the If the truck tries truck tries to move to move in reverse, clutch plates are fused in reverse, clutch plates are fused together. together. Replace Replace rebuild rebuild transmission. transmission. Defect ective regula ulator tors in s in modu- Repl plac...
  • Page 143 Defe fect ctiv ive di diff ffer eren enti tial al. Repa pair di diff ffer erent entia ial. Output shaft i in tr trans ansmis missio sion is n is Repair tighte hten o outp utput shaft. loose. loose. rans ransmis missio...
  • Page 144  o  o l   l    e  e r  r  https://www.forkliftpdfmanuals.com/...
  • Page 145     Section 9A Section 9A Transmi Transmission ssion Cooler Cooler CHARGE AIR CHARGE AIR COOLER COOLER https://www.forkliftpdfmanuals.com/...
  • Page 146 RADIATOR RADIATOR TRANSMISSION TRANSMISSION OIL COOLER OIL COOLER INDICATES HYDRAULIC FLUID FLOW INDICATES HYDRAULIC FLUID FLOW Illustration 9A-1. Illustration 9A-1. Transmiss Transmission Oil Cooler Hose ion Oil Cooler Hose Flow Diagram Flow Diagram Introduction. Introduction.    The t transmission ransmission oil cooler oil cooler failure requiring a new or rebuilt transmission,...
  • Page 147 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9A-2 9A-2     https://www.forkliftpdfmanuals.com/...
  • Page 148  9   9   C   C  T  T  r  r   a  a  s  s i   i    s  s  s  s i   i    o  o  C   C   o  o  t    t   r  r   o  o l   l    s  s https://www.forkliftpdfmanuals.com/...
  • Page 149 Taylor Integrated Control System’s MD3 module, Taylor Integrated Control System’s MD3 module, that is located in the instrument panel, to automat- that is located in the instrument panel, to automat- ically shift the transmission.
  • Page 150 nated by nated by the purchaser the purchaser of the of the vehicle. vehicle. The pin The pin code can be changed by authorized personnel. code can be changed by authorized personnel. Tr Transmission Shift Mode ansmission Shift Mode Selection Selection (Illustrations  (Illustrations 9C-2 through 9C-6)
  • Page 151 Illustration 9C Illustration 9C-3. Adjust Adjust Screen Screen At the Adjust scr At the Adjust screen (Illus (Illustrati tration 9C-3), sele on 9C-3), select Tr Transmi ansmission Adju ssion Adjust Group by depres st Group by depressing the UP or sing the UP or DOWN button to highlight the selection (if the selection is not already highlighted).
  • Page 152 Illustration 9C-5. Illustration 9C-5. Transmis Transmission Adjust Group sion Adjust Group Screen Screen At the Tr At the Transmi ansmission Adju ssion Adjust Group scree st Group screen, select Shif n, select Shift Mode Select (Illu t Mode Select (Illustrat stration 9C-5) by depress ion 9C-5) by depressing...
  • Page 153 perform the following steps: perform the following steps: At the Main Displ At the Main Display screen (Il ay screen (Illustr lustration 9C-7 ation 9C-7), depres depress the Diagnos s the Diagnostics butt tics button (F1) to access th on (F1) to access Diagnostics Select screen.
  • Page 154 Illustration 9C-8. Illustration 9C-8. Diagnostics Diagnostics Select Select Screen Screen At the Tr At the Transmi ansmission Inf ssion Informati ormation screen (Ill on screen (Illustrat ustration 9C-9), depr ion 9C-9), depress the Shift Mode Selec ess the Shift Mode Select button (F2) t button (F2) to select the shift...
  • Page 155 GROUP. GROUP. Illustration 9C-10. Illustration 9C-10. Transmiss Transmission Adjust Group ion Adjust Group Screen Screen At the Tr At the Transmi ansmission Adju ssion Adjust Group scre st Group screen, selec select Forward Ala t Forward Alarm Contro Control (Illust (Illustration 9C ration 9C-10) by...
  • Page 156 The APC The APC module controls shift module controls shifting parameters. ing parameters. The T Taylor aylor Integrated Control System (TICS) monitors the Integrated Control System (TICS) monitors the  APC module via CAN-bus.  APC module via CAN-bus. The TICS system will...
  • Page 157  APC Module  APC Module SPICER OFF–HIGHWAY SPICER OFF–HIGHWAY  APC  APC 4 red 7–segment LED digits 4 red 7–segment LED digits 3 status LED lamps (”D”,”E”,”F”) 3 status LED lamps (”D”,”E”,”F”) 2 push buttons ’M’ and ’S’ for display mode selection. 2 push buttons ’M’...
  • Page 158 The second group shows the shift lever position and some other less used but nevertheless quite relevant The second group shows the shift lever position and some other less used but nevertheless quite relevant values (see below). values (see below). The third display accessed with the ’M’...
  • Page 159  APC User Interface On TICS Transmission Information  APC User Interface On TICS Transmission Information Screen Screen  Display mode  Display mode Comment  Comment  GPOS GPOS Reflects the actually engaged transmission direction and range. Reflects the actually engaged transmission direction and range. VSPD VSPD Shows vehicle s...
  • Page 160 Diagnostic Mode Diagnostic Mode This mode is selected when the ‘S’ mode switch (F4) is pressed at power up. This mode is selected when the ‘S’ mode switch (F4) is pressed at power up. Limp Home Mode Limp Home Mode Defaulted to if either of following conditions occurs: Defaulted to if either of following conditions occurs: a single fault on a transmission control output is detected...
  • Page 161  Also when a  Also when a fault, related to fault, related to the parameter settings, located the parameter settings, located in FLASH memory in FLASH memory is detected, the is detected, the controller controller reverts to shutdown mode. reverts to shutdown mode. The GPOS / CPOS display indicates the letters ‘Sd’...
  • Page 162 Self Diagnostic Functions Self Diagnostic Functions The APC has special circuitry to help verify its operation. The APC has special circuitry to help verify its operation. Six self–test groups are built into the APC control programs: Six self–test groups are built into the APC control programs:  ...
  • Page 163 Display Test and Display Test and Version sion When selecting this group, the display shows: When selecting this group, the display shows: When pressing the S switch (F4), the display changes to: When pressing the S switch (F4), the display changes to: Releasing the switch engages a scrolling text display that shows the part number and the version.
  • Page 164 digital digital pull to ground pull to ground inputs). inputs). Digital inputs numbered 0 – 9 are shown on the segments as shown below Digital inputs numbered 0 – 9 are shown on the segments as shown below. Analog inputs 0 – 3 are Analog inputs 0 –...
  • Page 165 F4). F4). While pressing the switch, sim While pressing the switch, similar to the display of digital inputs, the left ilar to the display of digital inputs, the left side of the display gives side of the display gives information about which input is information about which input is tested;...
  • Page 166  A blinking  A blinking segment indicates a segment indicates a fault at a fault at a certain output. certain output. In total, there are 11 outputs: In total, there are 11 outputs:       Outputs 0 – 6 are analog Outputs 0 –...
  • Page 167  J154  J154 J155 J155  APC Rear  APC Rear Connector Connector APC Module Harness Connector Pin APC Module Harness Connector Pin and Wire Assignments and Wire Assignments (see Illustration above for Rear Harness (see Illustration above for Rear Harness Connector Wiring Pin–out). Connector Wiring Pin–out).
  • Page 168 Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-19 9C-19  ...
  • Page 169 Controller reverts to Controller reverts to Stop machine & Stop machine & Hardware related Hardware related Contact Spicer Off–  Contact Spicer Off–  related to the system related to the system a ”shut down” mode a ”shut down” mode Contact mainte- Contact mainte- fault –...
  • Page 170 pattern. pattern. signals. signals. Controller will flag Controller will flag Contact mainte- Contact mainte- The transmission The transmission Check the transmis- Check the transmis- sion ratio is too low. sion ratio is too low. the fault – this fault is the fault –...
  • Page 171 The controller will The controller will Contact mainte- Contact mainte- Invalid pattern for the Invalid pattern for the Check the inching Check the inching inching mode digital inching mode digital select the mode ”no select the mode ”no nance for trouble- nance for trouble- inching mode digital inching mode digital...
  • Page 172  A29) relate  A29) related fault : d fault : the fault, and will use the fault, and will use nance for trouble- nance for trouble-  ANI2 is not  ANI2 is not con- con- between the control- between the control- analog input is not analog input is not the lowest clipped the lowest clipped...
  • Page 173 shorted to ground. shorted to ground. value in its settings. value in its settings. input value is below input value is below connected to this connected to this the minimum value the minimum value analog analog input. input. Check Check (corresponding with (corresponding with this device con-...
  • Page 174 limp home mode. limp home mode. When only 1 speed When only 1 speed Contact mainte- Contact mainte- Speed channel Speed channel Check the wiring Check the wiring (wire A22) related (wire A22) related channel has a fail- channel has a fail- nance for trouble- nance for trouble- SPC0 is not con-...
  • Page 175 limp home mode. limp home mode. When a speed chan- When a speed chan- Contact mainte- Contact mainte- Speed channel is not Speed channel is not Check the speed Check the speed Invalid signal. Invalid signal. nel has a failure, the nel has a failure, the nance for trouble- nance for trouble-...
  • Page 176 is shorted to ground. is shorted to ground. the engine speed the engine speed sensor connected to sensor connected to channel, the control- channel, the control- speed channel 3. speed channel 3. ler will calculate what ler will calculate what Check the speed Check the speed the missing speed...
  • Page 177 ured as digital out- ured as digital out- taken. taken. wiring between the wiring between the put: put: controller and the controller and the the output is shorted the output is shorted other device, Check other device, Check to ground. to ground.
  • Page 178 taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will de  Action will depend pend “limp home“ mode: “limp home“ mode:  – wires A04 &  –...
  • Page 179 taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will dep  Action will depend “limp home“ mode: “limp home“ mode:  – wires A04 &  –...
  • Page 180 battery +, battery +, or the or the taken. taken. wiring between the wiring between the output is not con- output is not con- controller and the controller and the nected. nected. other device, Check other device, Check the other device. the other device.
  • Page 181 ured as digital out- ured as digital out- taken. taken. shorted to ground. shorted to ground. wiring between the wiring between the put: put: controller and the controller and the the output is shorted the output is shorted other device, Check other device, Check to ground.
  • Page 182 taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will de  Action will depend pend “limp home“ mode: “limp home“ mode:  – wire B01 co  –...
  • Page 183 taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will dep  Action will depend “limp home“ mode: “limp home“ mode:  – wire B01 con  –...
  • Page 184 to battery +, or the to battery +, or the taken. taken. controller and the controller and the output is not con- output is not con- other device, Check other device, Check nected. nected. the other device.” the other device.”  Action will de  Action will depend...
  • Page 185 no actions will be no actions will be device: Check the device: Check the taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device.” the other device.”  Action will dep  Action will depend...
  • Page 186 no actions will be no actions will be device: Check the device: Check the taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will de  Action will depend...
  • Page 187 no actions will be no actions will be device: Check the device: Check the taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will dep  Action will depend...
  • Page 188 no actions will be no actions will be device: Check the device: Check the taken. taken. wiring between the wiring between the controller and the controller and the other device, Check other device, Check the other device. the other device.  Action will de  Action will depend...
  • Page 189 flash may be corrupt flash may be corrupt (contact Spicer Off–  (contact Spicer Off–  Highway). Highway). The controller reverts The controller reverts Flash the correct Flash the correct Wrong firmware is Wrong firmware is Flash the correct Flash the correct flashed into the APC.
  • Page 190 vehicle speed. vehicle speed. vehicle speed limit. vehicle speed limit. The controller detected an abnor- The controller detected an abnor- The driver should slow down, in The driver should slow down, in detected. detected. mal deceleration, and will disable mal deceleration, and will disable order that the wheels can not order that the wheels can not slip...
  • Page 191 9C-42 9C-42 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)         Hoist Circuit Hoist Circuit https://www.forkliftpdfmanuals.com/...
  • Page 192 PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN  A FOLDE  A FOLDER ENVE ENVELOPE: LOPE: Illustration 9C-13 - 09C-2343 (SHIFT ANSI) Illustration 9C-13 - 09C-2343 (SHIFT ANSI) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 9C-43 9C-43 https://www.forkliftpdfmanuals.com/...
  • Page 193     https://www.forkliftpdfmanuals.com/...

  • Page 194: Drive Shaft

    9C-44 9C-44 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 11 Section 11 Drive Shaft Drive Shaft TRANSMISSION TRANSMISSION TO AXLE TO AXLE DRIVE SHAFT DRIVE SHAFT CROSS CROSS...
  • Page 195 Introduction. Introduction. The drive shaft connects the trans- The drive shaft connects the trans-  shaft, must be align  shaft, must be aligned as shown ed as shown in Illustration in Illustration mission to the mission to the drive axle. drive axle. It is important It is important to always...

  • Page 196: Steer Axle

    11-2 11-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 13 Section 13 Steer Axle Steer Axle Introduction. Introduction. The steer axle is mounted to the The steer axle is mounted to the Mounting Bolts Check Mounting Bolts...
  • Page 197 STEER AXLE STEER AXLE MOUNTING BOLT MOUNTING BOLT STEER CYLINDER STEER CYLINDER MOUNTING BOLT MOUNTING BOLT Illustration Illustration 13-1. 13-1. Steer Steer Axle Axle TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 13-1 13-1  ...
  • Page 198 BRAKE COOLING BRAKE COOLING DRAIN PLUG DRAIN PLUG BREATHER BREATHER FILL FILL PLUG PLUG DRAIN PLUG DRAIN PLUG https://www.forkliftpdfmanuals.com/ Illustration 14-1. Illustration 14-1. Wet Disc Brakes Wet Disc Brakes Drive Axle (TX180S-360L, TXB180S-300L, TXH300L, TXH350L) Drive Axle (TX180S-360L, TXB180S-300L, TXH300L, TXH350L)
  • Page 199 Introduction. Introduction.    The drive The drive axle is axle is equipped with equipped with Preventive Maintenance Preventive Maintenance chart in the  chart in the Appen- Appen- double reduction double reduction gearing. gearing. The first The first gear reduction gear reduction dices dices for oil  for oil...

  • Page 200: Maintenance Manual

    15). fluid in accordance with federal and local regu- fluid in accordance with federal and local regu- lations. lations. Oil Capacities Oil Capacities TX180S-360L,TX180S-300L, TX180S-360L,TX180S-300L, Park the t k the truc ruck on a ha k on a hard, l...
  • Page 201 When the housing is filled, the vent plug port When the housing is filled, the vent plug port permits air to be removed. permits air to be removed. Fill the h l the hydr ydrauli aulic tan tank wit with the s h the spec pecifi ified...
  • Page 202 BREATHER BREATHER BLEEDER BLEEDER VALVE VALVE DRAIN PLUG DRAIN PLUG Illustration 14-2. Illustration 14-2. Wet D Disc Brakes isc Brakes Drive Axle (T Drive Axle (TXH400L) XH400L) 14-4 14-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 203 the splines to bring the flanges into the splines to bring the flanges into alignment. alignment. If this If this is not is not followed, followed, the drive shaft will be out of phase, the drive shaft will be out of phase, and vibration and noise may occur.
  • Page 204 continuously low continuously low leaking. leaking. with no signs of with no signs of external leakage external leakage Gear oi oil l evel Seal b betw etween brak brake h hous ousing Repl plac ace s eal. hub is continuous- hub is continuous- wheel hub may be leaking.
  • Page 205 replaced before the brake lining friction material replaced before the brake lining friction material depressed, the transmission will be disengaged depressed, the transmission will be disengaged reaches a thic reaches a thickness of kness of .031 inch (.8 .031 inch (.8 mm).
  • Page 206 MANIFOLD MANIFOLD (Illustrati (Illustration 15-4) 15-4)  ACCUMULA  ACCUMULATORS TORS (Illustrati (Illustration 22-19) 22-19) PARKING BRAKE PARKING BRAKE (Illustrati (Illustration 15-4) 15-4) Illustration 15-2. Illustration 15-2. Brake Control Brake Control System Com System Components Identification ponents Identification TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 207 periodically (refer to the periodically (refer to the Preventive Maintenance Preventive Maintenance the wheels of the truck in both directions, the wheels of the truck in both directions, chart in the chart in the Appendices Appendices for parking brake linings  for parking brake linings place the parking brake in the released posi- place the parking brake in the released posi- wear inspection...
  • Page 208 30-35 ft-lbs (41-48 N 30-35 ft-lbs (41-48 N ⋅ ⋅ Park the tr k the truck on a ha uck on a hard, le level s surf urface ace, blo block Positi ition th the tru truck w with a r ith a rate ated loa...
  • Page 209 nated and can cause incorrect operation. nated and can cause incorrect operation. Damage to components can result. Damage to components can result. Park the t k the truc ruck on a ha k on a hard, l leve evel sur surfac face, ap apply...
  • Page 210 parking brake solenoid of the manifold can be parking brake solenoid of the manifold can be maintaining maintaining the service the service brakes. brakes. Improper Improper manually activated to release the parking brake. manually activated to release the parking brake. maintenance procedures may lead to decreas- maintenance procedures may lead to decreas- ed service life, decreased performance, or...
  • Page 211 Defect ective servic vice bra brake v valv alve(s e(s). Replac lace se servi rvice b brak rake va valve lve(s) (s). Brak akes wi will release release Worn o or da damag maged d disc isc(s) in b brak rake Refer t to th...
  • Page 212 Defect ective parkin king br brake switch tch. Replac lace pa parki rking brake switch tch. Park rkin ing b bra rak does not release does not release Loose, broken ken, or , or shorte rted wi wire( re(s). Is Isol olat ate and r e and epai air wir wire( e(s) s).
  • Page 213 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-9 15-9     https://www.forkliftpdfmanuals.com/...
  • Page 214 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 15-10 15-10     https://www.forkliftpdfmanuals.com/...
  • Page 215     1  1   5   5   C   C   C   C   o  o  o  o  e  e  t    t   l   l   i   i   i   i    s  s  g  g  c  c  S   S   y  y r  r   s  s  a  a  t  ...
  • Page 216     Section 15C Section 15C https://www.forkliftpdfmanuals.com/...
  • Page 217 Wet Disc Brakes Cooling System Wet Disc Brakes Cooling System Introduction. Introduction.    The brakes The brakes cooling sys cooling system main- tem main- tains a safe operating temperature by cooling the tains a safe operating temperature by cooling the hydraulic fluid in the wet disc brake system.
  • Page 218 Wet Disc Brakes Wet Disc Brakes Cooling System Troubleshooti Cooling System Troubleshooting Brak akes Over erhe heat Low co cool olin ing fl fluid fl flow Refer t to Pr Probl oblem 2 2. of . of this tr troub ouble- shooting chart.
  • Page 219 Steering System Steering System Introduction. Introduction. The steering system provides guid- The steering system provides guid- ance control of the truck. ance control of the truck. Major Components Major Components (Illustration 16-1)  (Illustration 16-1). The steer- The steer- ing system consists of the main pump, manifold, ing system consists of the main pump, manifold, steering valve, steer cylinder, hoses and various steering valve, steer cylinder, hoses and various...
  • Page 220 PRELIMINARY  PRELIMINARY  16-2 16-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)         https://www.forkliftpdfmanuals.com/ Hoist Circuit Hoist Circuit...
  • Page 221 Hoist Circuit Hoist Circuit PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN  A FOLDE  A FOLDER ENVE ENVELOPE: LOPE: Illustration 16-1 - 16-2364 SHT. 2 (ANSI) Illustration 16-1 - 16-2364 SHT. 2 (ANSI) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 222     Hoist Circuit Hoist Circuit https://www.forkliftpdfmanuals.com/...
  • Page 223 PRELIMINARY  PRELIMINARY  16-4 16-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 17 Section 17 Tires and Wheels Tires and Wheels Introduction. Introduction. This section contains safety warn- This section contains safety warn-  ...
  • Page 224     All tire All tire related safety related safety warnings in warnings in the Safety  Safety   lead to the underinflated tire rubbing the other tire lead to the underinflated tire rubbing the other tire Check 2nd Edition Check 2nd Edition booklet and this section booklet and this section which could lead...
  • Page 225 Illustration 17-1. Illustration 17-1. Drive Axle Wheel Drive Axle Wheel Nuts T Nuts Torquing Sequence (TX180S - 360L) orquing Sequence (TX180S - 360L) Torquing Procedure Torquing Procedure (Illustrations 17-1 through (Illustrations 17-1 through Inspection Inspection 17-4) 17-4).     Perform the...
  • Page 226 Illustration 17-2. Illustration 17-2. Drive Axle Drive Axle Wheel Nuts Wheel Nuts orquing Sequence orquing Sequence (TXH400L) (TXH400L) Any r rim or r im or rim co compo mponent nent which is ch is bent bent out o of  f  Rims hav have a usef useful ser...
  • Page 227 Steer Axle Wheel Steer Axle Wheel Nuts T Nuts Torquing orquing apart with explosive force during inflation. apart with explosive force during inflation. Sequence (TX180S-360L) Sequence (TX180S-360L)     Do not Do not seat rings b seat rings by hammering...
  • Page 228       Remove the Remove the bead seat band bead seat band slowly to p slowly to pre- vent it from dropping off and crushing your vent it from dropping off and crushing your toes. toes. Support the Support the band on your band on your...
  • Page 229  in the Appendices Appendices) without prior written approval without prior written approval from Taylor from Taylor Follow the OSHA rules, 29 CFR, 1910.178 (Q)(1), Follow the OSHA rules, 29 CFR, 1910.178 (Q)(1), Machine Works, Inc. Engineering Department, Machine Works, Inc. Engineering Department, should the chassis be modified, i.e.
  • Page 230 Refer t to Co Corre rrecti ction 1 1. a abov bove an avoid overloading the truck. avoid overloading the truck. Notify Taylor Notify Taylor Machine Works, Machine Works, Roug ugh te terr rrai ain. Refer t to Co Corre rrecti ction 1.
  • Page 231 Note: Note: Photocopy this sketch to identify fatigue cracks or Photocopy this sketch to identify fatigue cracks or structural damage t structural damage to the chassis. o the chassis. Be very descript Be very descriptive of  ive of  damage to the chassis, i.e. location, depth, length. damage to the chassis, i.e.
  • Page 232 Illustration Illustration 20-1. 20-1. Introduction Introduction (Illustration 20-1)  (Illustration 20-1). The cab has The cab has door door latch latch must must always always funct function p properl roperly been carefully designed with the operator’s safety been carefully designed with the operator’s safety The t tilt steeri...
  • Page 233 20-2 20-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)         2  2   0   0   S   S   y  y i   i   r  r   s  s  t  ...
  • Page 234 https://www.forkliftpdfmanuals.com/...
  • Page 235     Section 20A Section 20A Air Conditioning System Air Conditioning System Introduction. Introduction. The air conditioning / heating sys- The air conditioning / heating sys- warm, high pressure liquid (to the expansion warm, high pressure liquid (to the expansion tem provides the operator with a comfortable tem provides the operator with a comfortable valve).
  • Page 236  approved  approved agency agency. sure gas. sure gas. The cold, The cold, low pressure low pressure gas is sent gas is sent back back into the expans into the expansion valve. ion valve. The temperature The temperature of this of this Compressor.
  • Page 237 FASTENERS FASTENERS COVER COVER FILTER FILTER Illustration 20A-1. Illustration 20A-1. Air Conditioner Air Conditioner / Heater / Heater Unit Unit Heater Shut-off Heater Shut-off alve alve (Illustration 20A-1)  (Illustration 20A-1). air conditioner filters should be cleaned every air conditioner filters should be cleaned every heater shut-off valve controls the circulation of ...
  • Page 238 Check th the con conden denser f for deb debris a and cl clean if ean if required. required. Check all el ck all elect ectric rical con connec nectio tions and ens ns and ensure that the circuit breakers are set. that the circuit breakers are set.
  • Page 239 Evap apor orat ator c coi oil is i l is ced up Thermo rmosta stat defect ective ive. Replac lace thermostat. thermostat. conden denser seized Unseiz eize fa fan, r repl eplace or c chec heck wi wir- defective. defective.
  • Page 240 oola lant nt. Chec eck an and fi fill r adia iato tor Engine rise t to op opera eratin ting Allow engi engine e enou nough t time to r reac each temperature. temperature. operating temperature. operating temperature. TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 241 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20A-6 20A-6         Hoist Circuit Hoist Circuit https://www.forkliftpdfmanuals.com/ PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN...
  • Page 242  A FOLDE  A FOLDER ENVE ENVELOPE: LOPE: Illustration 20A-2 - 20A-2367 SHT. 1 (A.C. ANSI) Illustration 20A-2 - 20A-2367 SHT. 1 (A.C. ANSI) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20A-7 20A-7 https://www.forkliftpdfmanuals.com/...
  • Page 243     https://www.forkliftpdfmanuals.com/...
  • Page 244 20A-8 20A-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     2  2   0   0   e  e  a  a  t    t   i   i    g  g  S   S   y  y  s...
  • Page 245 https://www.forkliftpdfmanuals.com/...
  • Page 246     Section 20H Section 20H Heating System Heating System Introduction. Introduction. The heating system provides a The heating system provides a cleaned or cleaned or changed. changed. Perform the Perform the following proce- following proce- comfortable working environment in a cold climate comfortable working environment in a cold climate dures to remove filters for cleaning or replace- dures to remove filters for cleaning or replace-...
  • Page 247 air volume and therefore the filter should be air volume and therefore the filter should be TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20H-1 20H-1     Heating Sy Heating System Troubleshootin...
  • Page 248 20H-2 20H-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)         Hoist Circuit Hoist Circuit PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN  A FOLDE  A FOLDER ENVE...
  • Page 249 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 20H-3 20H-3     https://www.forkliftpdfmanuals.com/...
  • Page 250 20H-4 20H-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Section 22 Section 22 Hydraulic System Hydraulic System Steering Logic Steering Logic (Illustration 22-20 and 22-14) (Illustration 22-20 and 22-14).
  • Page 251 causes LC2 to open and LC3 to close enough to causes LC2 to open and LC3 to close enough to ORF1 and check valve (CK1) to start the accumu- ORF1 and check valve (CK1) to start the accumu- lator charging lator charging process.
  • Page 252 SYSTEM COOLER SYSTEM COOLER (Illustration 5-3) (Illustration 5-3) ORBITROL ORBITROL (Illustrati (Illustration 22-14) 22-14) HYDRAULIC HYDRAULIC TANK  TANK  (Illustratio (Illustration 22-16) 22-16) PILOT FILTER PILOT FILTER (Illustrati (Illustration 22-13) 22-13) MANIFOLD MANIFOLD (Illustration 22-6) (Illustration 22-6)  ACCUMULA  ACCUMULATORS TORS (Illustratio (Illustration 22-12) 22-12)
  • Page 253 PRV1 PRV1 ACC2 ACC2 ORF3 ORF3 PARKING BRAKE SOLENOID PARKING BRAKE SOLENOID Illustration 22-2. Illustration 22-2. Manifold Manifold (Engine (Engine Side) Side) Illustration 22-3. Illustration 22-3. Manifold Manifold (Mast (Mast Side) Side) PB - (Parking Brake) Supply connection to the  - (Parking Brake) Supply connection to the - (Logic Control) Controls flow to steering.
  • Page 254 pressure check. pressure check. ORF4 ORF4 PP - (Pilot Pressure) Pilot pressure check port.  - (Pilot Pressure) Pilot pressure check port. ACCM ACCM ORF2 ORF2 UNL1 UNL1 - (Unloader Valve number one) Controls  - (Unloader Valve number one) Controls accumulator charge pressure high and low limits. accumulator charge pressure high and low limits.
  • Page 255 LIFT LIFT MANIFOLD MANIFOLD SIDE SHIFT PORT SIDE SHIFT PORT RELIEFS RELIEFS MANUAL MANUAL  ACCESSORY  ACCESSORY OVERRIDE OVERRIDE MAIN RELIEF MAIN RELIEF Illustration 22-6. Illustration 22-6. Accessory / Manifold / Lift Accessory / Manifold / Lift / Tilt / Tilt Valves Valves Manual Override...
  • Page 256 BOLTS BOLTS TORQUE TORQUE TO 75 FT- TO 75 FT- LBS. 9/16” LBS. 9/16” SOCKET SOCKET Illustration 22-7. Illustration 22-7. Valve Valve Bank Through Bolts (Lift Bank Through Bolts (Lift / Tilt / Tilt Side) Side) BOLTS BOLTS TORQUE TORQUE TO 32 FT- TO 32 FT- LBS.
  • Page 257 FLOW RATE @ 2200 RPM = 4.8 GPM / 18 LPM FLOW RATE @ 2200 RPM = 4.8 GPM / 18 LPM FLOW RATE @ 2200 RPM = 46 GPM / 174 LPM FLOW RATE @ 2200 RPM = 46 GPM / 174 LPM FLOW RATE @ 750 RPM = 1.6 GPM / 6 LPM FLOW RATE @ 750 RPM = 1.6 GPM / 6 LPM FLOW RATE @ 750 RPM = 15 GPM / 57 LPM...
  • Page 258  C), a normally closed (NC) switch will open. C), a normally closed (NC) switch will open. head. head. This will signal the TICS (T This will signal the TICS (Taylor Integrated aylor Integrated Control Control Insta Install fi filter...
  • Page 259 Ensure f filt ilter is c er is cool t to the t o the touc ouch and pr h and provi ovide a de a suitable container to catch any draining fluid. suitable container to catch any draining fluid. Checking The Fluid Level Checking The Fluid Level (Illustration 22-15)
  • Page 260 (14-16 N (14-16 N ⋅ ⋅   Plug all hoses when they are Plug all hoses when they are COVER COVER disconnected to prevent foreign matter from disconnected to prevent foreign matter from entering the hydraulic system. entering the hydraulic system. Park t Park the tr...
  • Page 261 FILLER CAP FILLER CAP w/DIPSTICK  w/DIPSTICK  STRAINER STRAINER RETURN FILTER RETURN FILTER (10 MICRON) (10 MICRON) BREATHER BREATHER FILTER FILTER (10 MICRON) (10 MICRON) HYDRAULIC HYDRAULIC FLUID TEMPERA- FLUID TEMPERA- TURE SENDER TURE SENDER Illustration 22-16. Illustration 22-16. Hydraulic T Hydraulic Tank TX / TXH / TXB 180S - 400L (Rev.
  • Page 262 COLLAR COLLAR LOCK  LOCK  PLATE PLATE VALVE VALVE STEM STEM Illustration 22-17. Illustration 22-17. Detecting Detecting Hydraulic Hydraulic Leaks Leaks   Do Not   Do Not    use hands to check  use hands to check for hydr hydraulic leaks. aulic leaks. Because the Because the hydraulic...
  • Page 263 open port. open port. This could This could cause severe bodi cause severe bodily point toward the sides of the valve block (note point toward the sides of the valve block (note injury. injury. position of valve stem in Illustration 22-19). position of valve stem in Illustration 22-19).
  • Page 264 the port relief located on the A port side of the the port relief located on the A port side of the Turn th the set e set screw screw clock clockwise wise to i increas ncrease th inlet section of the accessory valve. inlet section of the accessory valve.
  • Page 265 Shut the tr t the truck o off an and turn t d turn the ign igniti ition sw switc itch the orbitrol. the orbitrol. to it’s to it’s ignition position (1st ignition position (1st click). click). Continue to Continue to Troubleshooting Common Brake Problems.
  • Page 266 Lower Lower ators seat. ators seat. Defect ective soleno enoid or id or cartri tridge Activa ivatio tion of t n of the m manu anual ov overri erride the lift valve. the lift valve. switch will confirm defective sole- switch will confirm defective sole- noid.
  • Page 267 calibrated. calibrated. Loos ose or b e or bro roke ken pl plug ugs / pi pins /  ns /  Is Isol olat ate a Repa pair ir. wires between the TICS compo- wires between the TICS compo- nents (i.e. display / modules / joys- nents (i.e.
  • Page 268 Main re relie lief (R (RV1) i is de defec fectiv tive. Worn or defectiv n or defective pump. e pump. Replac lace. Defec Defective orbi tive orbitrol. trol. Replac lace. Logic C Cont ontrol ( (LC1 LC1) is r ) is rest estric...
  • Page 269 parkin king br brake accumu umulat lator i Charge parkin king br brake accumu umu- defective. defective. lator to 500 psi with dry-nitrogen. lator to 500 psi with dry-nitrogen. Defect ective servic vice br brake pedal. Is Isol olat ate repla lace Parkin king br...
  • Page 270 22-20 22-20 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)         Hoist Circuit Hoist Circuit https://www.forkliftpdfmanuals.com/...
  • Page 271 PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN  A FOLDE  A FOLDER ENVE ENVELOPE: LOPE: Illustration 22-20 - 22-2896 SHT. 2 (Main Hyd. ANSI) Illustration 22-20 - 22-2896 SHT. 2 (Main Hyd. ANSI) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 272     https://www.forkliftpdfmanuals.com/...
  • Page 273 22-22 22-22 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     2  2  2  2  E  E   c  c  c  c  u  u  u  u l   l    a  a  t  ...
  • Page 274 https://www.forkliftpdfmanuals.com/...
  • Page 275 (a into position giving an accurate pressure read- into position giving an accurate pressure read- charging kit is charging kit is available from Tay available from Taylor, part number lor, part number ing. ing. 1000-503). 1000-503). See Illustration...
  • Page 276 Check t the va valve s stem f for le leaks w with a s ith a soap oapy to the gauging head assembly (1) unless free to the gauging head assembly (1) unless free water solution water solution or oil. or oil.
  • Page 277 ALVE A SSEMB EMBL BLEE EEDE DER V ALVE SWIV IVEL CO CONN NNEC HARG NG H GLAN GLAN AND NU Illustration Illustration 22E-1. 22E-1. Charging Charging Accumulator Accumulator 22E-2 22E-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 278 Taylor from Taylor flat spot will be worn on the rollers and the flat spot will be worn on the rollers and the Machine Works, Inc. Engineering Department, Machine Works, Inc.
  • Page 279 ance is 1/16 to ance is 1/16 to 1/32 inch (1.6 t 1/32 inch (1.6 to .8 mm). o .8 mm). (See (See odically (refer to the odically (refer to the Preventive Maintenance Preventive Maintenance  NOTE  NOTE below procedure 5.) below procedure 5.) chart in the chart in the...
  • Page 280 (Refer to SIRR SIRR in the  in the sible, avoid operating truck on sible, avoid operating truck on Appendices Appendices) rough terrain. rough terrain. Notify Taylor Notify Taylor ravell elling w with l load i in an un n an unrec recom-...
  • Page 281 BACK REST BACK REST SLIDE BLOCK  SLIDE BLOCK  Illustration 27-2. Illustration 27-2. Back Rest Back Rest Slide Blocks Slide Blocks 27-4 27-4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 282 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 27-5 27-5     CHAIN CHAIN OUTER MAST OUTER MAST ROLLER ROLLER SLIDE BEARING SLIDE BEARING BLOCK  BLOCK  LIFT LIFT CYLINDER CYLINDER INNER...
  • Page 283 ROLLERS ROLLERS SLIDE SLIDE BEARING BEARING BLOCKS BLOCKS OUTER OUTER MAST MAST Illustration Illustration 27-4. 27-4. Mast Mast Assembly Assembly Components Components TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 27-6 27-6  ...
  • Page 284 Note: Note: Photocopy this sketch t Photocopy this sketch to identify fatigue cracks o identify fatigue cracks or structural damage to the or structural damage to the mast. mast. Be very Be very descriptive of damage to the mast, i.e. location, depth, length. descriptive of damage to the mast, i.e.
  • Page 285 Under no circumstances, der (if equipped). der (if equipped). without prior written approval without prior written approval from Taylor from Taylor Structural Inspection, Reporting, and Repair Structural Inspection, Reporting, and Repair Machine Works, Inc. Engineering Department, Machine Works, Inc. Engineering Department, Procedure Procedure (Refer to...
  • Page 286 SLIDE BEARING SLIDE BEARING BLOCKS BLOCKS Illustration Illustration 28-1. 28-1. Standard Standard Carriage Carriage TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 28-1 28-1     MAIN MAIN ROLLERS ROLLERS SLIDE BEARING...
  • Page 287 Illustration 28-2. Illustration 28-2. Optional Carriage With Side Optional Carriage With Side Shift and Fork Shift and Fork Positioners Positioners Maintenance / Inspection. Maintenance / Inspection. There are several There are several grease fittings for the main rollers can be found on grease fittings for the main rollers can be found on inspectional requirements which must be per- inspectional requirements which must be per-...
  • Page 288 Refer t to Co Corre rrecti ction 1 1. an and av avoid overloading the truck. overloading the truck. Notify Taylor Notify Taylor Machine Works, Machine Works, ough t ter erra rain in. Refer t to Co Corre rrecti ction 1 1.
  • Page 289 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07) 28-4 28-4     Contents Contents Appendices Appendices Page Page ..............
  • Page 290 TX / TXH / TXB 180S - 400L ( /07) TX / TXH / TXB 180S - 400L ( /07) https://www.forkliftpdfmanuals.com/...
  • Page 291 Any existing Any existing fatigue cracks should be reported to the Taylor Machine Works, Inc. fatigue cracks should be reported to the Taylor Machine Works, Inc. engineering department imm engineering department immediately ediately.
  • Page 292 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-1  A-1     https://www.forkliftpdfmanuals.com/...
  • Page 293  A-2  A-2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     These symbols are in accordance with AWS These symbols are in accordance with AWS    A2.4-76, “Symbols for  A2.4-76, “Symbols for Non-Destructive T...
  • Page 294 tude, these cracks will grow tude, these cracks will grow. This is known as This is known as you have you have prior written approval prior written approval of the manufac-  of the manufac- fatigue crack fatigue crack growth. growth. No matter No matter how low the how low the...
  • Page 295 Inspection Locations. The following illustrations The following illustrations are a representative set for the general welds are a representative set for the general welds used used on T Taylor Mac aylor Machine W hine Works t orks trucks. rucks. They are...
  • Page 296 ............
  • Page 297 Detail 1 Detail 1 Detail 4 Detail 4 Illustration 1. Illustration 1. Inner and Inner and Outer Mast Outer Mast Arrangement Arrangement  A-6  A-6 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 298  VT (3)  VT (3) MT (FS) MT (FS) Illustration 2. Illustration 2. Inner Mast Inner Mast Details 1 Details 1 and 2 and 2 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-7  A-7  ...
  • Page 299  VT (3)  VT (3) MT (FS) MT (FS) Detail 3 Detail 3 Illustration 3. Illustration 3. Outer Mast Outer Mast Detail 3 Detail 3  A-8  A-8 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  ...
  • Page 300 Illustration 4. Illustration 4. Outer M Outer Mast D Detail 4 etail 4 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-9  A-9     Carriage Detail Carriage Detail  VT (3)  VT (3) MT (FS)
  • Page 301  VT (3)  VT (3) MT (FS) MT (FS) Illustration 5. Illustration 5. Carriage Carriage Detail Detail  A-10  A-10 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     Chassis Arrangement Chassis Arrangement Detail 5...
  • Page 302 Detail 2 Detail 2 Detail 1 Detail 1 Illustration Illustration Chassis Chassis Arrangement Arrangement TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-1  A-11     Chassis Details Chassis Details Detail 1 Detail 1...
  • Page 303  VT (3)  VT (3) MT (FS) MT (FS) Illustration 7. Illustration 7. Chassis Chassis Detail Detail TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-12  A-12     Chassis Details Chassis Details  VT (3)
  • Page 304  VT (3)  VT (3) MT (FS) MT (FS) Illustration 8. Illustration 8. Chassis Chassis Detail Detail TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-13  A-13     Chassis Details Chassis Details Detail 3...
  • Page 305 Illustration 9. Illustration 9. Chassis Chassis Detail Detail TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-14  A-14     Chassis Details Chassis Details  VT (3)  VT (3) MT (FS) MT (FS) Detail 4...
  • Page 306  VT (3)  VT (3) MT (FS) MT (FS) Illustration 10. Illustration 10. Chassis Chassis Detail Detail TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-15  A-15     Chassis Details Chassis Details Detail 5...
  • Page 307  VT (3)  VT (3) MT (FS) MT (FS) Illustration 1 Illustration Chassis D Chassis Detail 5 etail 5 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)  A-16  A-16  ...
  • Page 308 repaired for continued use, and the repairs shall repaired for continued use, and the repairs shall the fork carrier including bolt type mountings and the fork carrier including bolt type mountings and only be carried out by such parties. only be carried out by such parties. forged upper mounting arrangements for hook forged upper mounting arrangements for hook and shaft type...
  • Page 309 This wide variety of variables makes it impossible for Taylor to accurately predict an exact service life This wide variety of variables makes it impossible for Taylor to accurately predict an exact service life...
  • Page 310 Taylor’s recommendation to replace the chain at 4,000 hours is based on typical service duty cycles. Taylor’s recommendation to replace the chain at 4,000 hours is based on typical service duty cycles. Experience in a specific application may allow this interval to be increased or may require that it be Experience in a specific application may allow this interval to be increased or may require that it be decreased.
  • Page 311 exceeds 5% of plate height of unused plate, exceeds 5% of plate height of unused plate, replace entire length of chain. replace entire length of chain. 7). Worn Outside Links or Pin Heads. 7). Worn Outside Links or Pin Heads.   ...
  • Page 312 from hostile environment by from hostile environment by cyclic stress necessary) cyclic stress necessary) lubricating more frequently lubricating more frequently 5. Cracked Plates (Corrosion Fatigue) 5. Cracked Plates (Corrosion Fatigue) Perpendicular to Pitch Line, plus rust Perpendicular to Pitch Line, plus rust or other evidence of chemical or other evidence of chemical corrosion...
  • Page 313 and chain roller pin. and chain roller pin.   Use p pro rope per s saf afet ety p pre reca caut utio ions Alway Always lower the ma s lower the mast and carri st and carriage to its low age to its lowest posi position befo...
  • Page 314 Once a crack is found in the truck trical connectors that must be disconnected trical connectors that must be disconnected structure, it is advisable that you contact Taylor structure, it is advisable that you contact Taylor before welding include the TICS control modules before welding include the TICS control modules Machine Works, Inc.
  • Page 315 connectors from these components may connectors from these components may lead to damage. lead to damage.     Should any Should any truck equipped truck equipped with an A with an   module require welding on its structural module require welding on its structural members, the RS connector must be members, the RS connector must be unplugged from the APC module prior to any...
  • Page 316  A-26  A-26 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     TICS MD3 TICS MD3 DISPLAY MODULE DISPLAY MODULE https://www.forkliftpdfmanuals.com/...
  • Page 317 CAB MODULE CAB MODULE -A1) -A1) CHASSIS MODULE CHASSIS MODULE -A0) -A0) Illustration 2 Illustration 2 TICS Control Module TICS Control Module and Main Display Loc and Main Display Locations On The T ations On The Truck ruck TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev.
  • Page 318  A-28  A-28 TX / TXH / TXB 180S - 400L (Rev. 4/23/07) TX / TXH / TXB 180S - 400L (Rev. 4/23/07)     orque Chart - orque Chart - Nuts and Bolts Nuts and Bolts Force - 100 lbs. Force - 100 lbs.
  • Page 319 9/16 - 18 9/16 - 18 (146 (146 163) 163) (208 (208 231) 231)     5/8 - 18 5/8 - 18 (220 (220 244) 244) (293 (293 325) 325) (367 (367 408) 408) 3/4 - 16 3/4 - 16 (366 (366 407)
  • Page 320 on tapered Timken on tapered Timken    bearings (found on the mast  bearings (found on the mast mast and carriage main roller assemblies) mast and carriage main roller assemblies) and carriage main rollers): and carriage main rollers): Torque Torque The b bolt olts and t...

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