Manual de Servicio 821C

Section

1002 1002

CASE CORPORATION700 State StreetRacine, WI 53404 U.S.A.

CASE CANADA CORPORATION450 Sherman AvenueHamilton, ON L8N 4C4 CANADA Bur 7-13071

© 2000 Case CorporationPrinted in U.S.A.

April, 2000

FLUIDS AND LUBRICANTS

1002-2

Template Name: SM_2_colTemplate Date: 1994_04_05

Alt= to hide template informationAlt+ to display template information

TABLE OF CONTENTS

Bur 7-13071 Issued 4-00 Printed in U.S.A.

CAPACITIES AND LUBRICANTS ............................................................................................................................ 2

ENGINE OIL RECOMMENDATIONS....................................................................................................................... 3

DIESEL FUEL........................................................................................................................................................... 4

MAINTENANCE SCHEDULE ................................................................................................................................... 5

Engine oilCapacity with filter change.................................................................................... 20.8 litres (22 U.S. quarts)Type of oil .............................................. Case No. 1 Engine Oil - see engine oil recommendations on page 3

Engine cooling systemCapacity ................................................................................................................32.1 litres (34 U.S. quarts)Type of coolant .............Ethylene glycol and water mixed for lowest ambient temperature (at least 50/50 mix)

Fuel tankCapacity ........................................................................................................... 268 litres (70.8 U.S. gallons)Type of fuel....................................................................................... See diesel fuel specifications on page 4

Hydraulic systemHydraulic reservoir refill capacity ...........................................................................90 litres (95.2 U.S. quarts)Total system .........................................................................................................174 litres (184 U.S. quarts)

Type of oil ............................................................................................................................... MS-1209 Hy-Tran Ultra®

TransmissionRefill capacity with filter change ............................................................................12.3 litres (13 U.S. quarts)Total system capacity ............................................................................................26.5 litres (28 U.S. quarts)

Type of oil .......................................................................................................Case No. 1 Engine Oil (15W-40)

AxlesCapacity of center bowl

Front ......................................................... 18.9 litres (20 quarts) 135H EP Plus 1.9 litres (4 pints) B91246Rear .........................................................13.7 litres (14.5 quarts) 135H EP Plus 1.4 litres (3 pints) B91246

Capacity of planetary (each)Front ........................................................................................................... 6.0 litres (6.5 quarts) 135H EPRear ................................................................................................................ 5.5 litres (6 quarts) 135H EP

Type of lubricant ........................................................................... Case (MS1316) 135H EP (SAE 85W-140)Limited slip additive .................................................................................................................. Case B91246

Brake systemType of fluid (same as hydraulic system) ......................................................................... MS-1209 Hy-Tran Ultra®

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damagedas a result of using an alternate oil.

Conversion Formulas

Imperial quart = litres x 0.879877Imperial gallons = litres x 0.219969

CAPACITIES AND LUBRICANTS

1002-3



ENGINE OIL RECOMMENDATIONS


Engine Oil SelectionCase No. 1 Engine Oil is recommended for use in your Case engine. Case engine oil will lubricate your enginecorrectly under all operating conditions.

If Case No. 1 Multi-Viscosity or Single Grade EngineOil is not available, use only oil meeting API engineoil service category CE.

−40° −20° 0° 20° 40° 60° 80° 100° 120°−30° −10° 10° 30° 50° 70° 90° 110°

−34° −23° −12° −1° 10° 21° 32° 43°−40° −29° −18° −7° 4° 16° 27° 38° 49°

292L91

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTE: Do not put performance additives or other oil additive products in the engine crankcase. The oilchange intervals given in this manual are according to tests with Case lubricants.

MULTI-VISCOSITY OIL

SAE 20W - 50

SAE 20W - 40

SAE 15W - 40

SAE 10W - 40

SAE 10W - 30

SAE 5W - 30

SAE 5W - 20

SINGLE VISCOSITY OIL

SAE 40

SAE 30

SAE 20W - 20

SAE 10W

NOTE: Use of an engine oil pan heater or an engine coolantheater is required when operating temperatures are in theshaded area.

Temperature Celsius

Oil Viscosity / Temperature RangesTemperature Fahrenheit

A2723

1002-4



DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of enginepower and high fuel consumption.

In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See thefollowing Note.

NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuellowers below the cloud point (wax appearance point), wax crystals in the fuel will restrict the fuel filterand cause the engine to lose power or not star t.

The diesel fuel used in this machine must meet the specifications shown below in, “Specifications forAcceptable No. 2 Diesel Fuel”, or Specification D975-81 of the American Society for Testing and Materials.

Fuel Storage

.If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank.

Many engine problems are caused by water in the fuel.


Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storagecontainer at regular periods of time.

Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.

Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum .................................................................................................................................. 34Flash point, minimum ..................................................................................................................140°F (60°C)Cloud point (wax appearance point), maximum .................................................. -5°F (-20°C) See Note abovePour point, maximum ........................................................................................ -15°F (-26°C) See Note aboveDistillation temperature, 90% point ...................................................................... 540 to 640°F (282 to 338°C)Viscosity, at 100°F (38°C)

Centistokes .................................................................................................................................. 2.0 to 4.3Saybolt seconds universal ............................................................................................................. 32 to 40

Cetane number, minimum .................................................................. 43 (45 to 55 for winter or high altitudes)Water and sediment, by volume, maximum .................................................................................... 0.05 of 1%Sulphur, by weight, maximum ........................................................................................................... 0.5 of 1%Copper strip corrosion, maximum ........................................................................................................... No. 2Ash, by weight, maximum............................................................................................................... 0.01 of 1%

1002-5




MAINTENANCE SCHEDULEModel 821CInstructions

22 SERVICE THE AIR CLEANER IF THE AIR CLEANER WARNING LAMP ILLUMINATES........................... SEE OPERATORS MANUAL37 SERVICE AIR CLEANER PRECLEANER.................................................................................................. SEE OPERATORS MANUAL30 REPLACE THE TRANSMISSION FILTER

IF THE TRANSMISSION FILTER RESTRICTION WARNING LAMP ILLUMINATES ................................................ USE CASE FILTER19 CHECK THE RADIATOR COOLANT LEVEL IF THE WARNING LAMP ILLUMINATES .............................. SEE OPERATORS MANUAL6.REPLACE THE HYDRAULIC FILTERS IF THE HYDRAULIC FILTER WARNING LAMP ILLUMINATES................... USE CASE FILTERS20 CHECK THE FAN BELT CONDITION ............................................................................................................REPLACE AS REQUIRED

CHECK THE AIR CONDITIONING DRIVE TENSION (IF EQUIPPED) NOT SHOWN ...................................... ADJUST AS REQUIRED

16 CHECK THE ENGINE OIL LEVEL............................................................................................................. SEE OPERATORS MANUAL

1.CHECK THE COOLANT RESERVOIR FLUID LEVEL........................................................................ ETHYLENE GLYCOL AND WATER29 CHECK THE TRANSMISSION OIL LEVEL (ENGINE RUNNING AND OIL WARM) ................................... SEE OPERATORS MANUAL5.CHECK THE HYDRAULIC RESERVOIR FLUID LEVEL .............................................................................. SEE OPERATORS MANUAL15 LUBRICATE THE REAR AXLE TRUNNION PIVOTS (2 FITTINGS) .................................................. CASE MOLYDISULFIDE GREASE27 LUBRICATE THE CENTER DRIVE SHAFT SLIP JOINT (1 FITTING) ............................................... CASE MOLYDISULFIDE GREASE

10 LUBRICATE THE BUCKET PIVOT POINTS (3 FITTINGS) ............................................................... CASE MOLYDISULFIDE GREASE7.LUBRICATE THE STEERING CYLINDER PIVOTS - ROD AND CLOSED END (4 FITTINGS) ............ CASE MOLYDISULFIDE GREASE9.LUBRICATE THE LOADER PIVOT POINTS (10 FITTINGS) ............................................................... CASE MOLYDISULFIDE GREASE26 LUBRICATE THE FRONT DRIVE SHAFT SUPPPORT BEARING (1 FITTING) ................................ CASE MOLYDISULFIDE GREASE32 LUBRICATE THE REAR DRIVE SHAFT SLIP JOINT (1 FITTING) ................................................... CASE MOLYDISULFIDE GREASE35 LUBRICATE THE REAR DRIVE SHAFT SLIP JOINT (1) FITTING) .................................................. CASE MOLYDISULFIDE GREASE

19 CHECK THE RADIATOR COOLANT LEVEL ................................................................................... ETHYLENE GLYCOL AND WATER2.CHANGE THE ENGINE OIL AND REPLACE THE ENGINE OIL FILTER ..................................................... SEE OPERATORS MANUAL34 CHECK THE BATTERY FLUID LEVEL ...................................................................................................... SEE OPERATORS MANUAL36 CHECK THE TIRE CONDITION AND AIR PRESSURE............................................................................. SEE OPERATORS MANUAL12 CLEAN THE CAB AIR FILTERS (IF EQUIPPED)....................................................................................... SEE OPERATORS MANUAL25 REPLACE ENGINE COOLING SYSTEM FILTER ................................................................................................... USE CASE FILTER

3.REPLACE THE FUEL FILTERS .............................................................................................................................. USE CASE FILTERS33 DRAIN WATER AND SEDIMENT FROM THE FUEL TANK........................................................................ SEE OPERATORS MANUAL14 REPLACE THE IN-LINE FUEL FILTER ................................................................................................................. USE CASE FILTERS

21 CHECK THE ENGINE VALVE CLEARANCES ................................................................................................. SEE SERVICE MANUAL6.REPLACE THE HYDRAULIC FILTERS ................................................................................................................... USE CASE FILTERS30 REPLACE THE TRANSMISSION OIL FILTER....................................................................................................... USE CASE FILTERS28 CHANGE THE TRANSMISSION OIL......................................................................................................... SEE OPERATORS MANUAL23 CLEAN THE TRANSMISSION BREATHER ..................................................................................................... CLEAN WITH SOLVENT24 LUBRICATE THE UPPER AND LOWER CHASSIS PIVOTS (2 FITTINGS) ....................................... CASE MOLYDISULFIDE GREASE31 CHANGE THE FRONT/REAR AXLE DIFFERENTIAL AND PLANETARY OIL............................................ SEE OPERATORS MANUAL

4.CHANGE THE HYDRAULIC OIL AND CLEAN THE SCREEN ..................................................................... SEE OPERATORS MANUAL18 DRAIN, FLUSH AND REFILL THE ENGINE COOLING SYSTEM.................................................... ETHYLENE GLYCOL AND WATER22 REPLACE THE AIR CLEANER ELEMENTS.......................................................................................................... USE CASE FILTERS

AS REQUIRED

EVERY 10 HOURS OF OPERATION OR EACH DAY- WHICHEVER OCCURS FIRST

EVERY 50 HOURS OF OPERATION





EVERY 2000 HOURS OF OPERATION OR EACH YEAR - WHICHEVER OCCURS FIRST

NOTE: When you drain, flush and refill the engine cooling system, add one container (0.5L) ofCase cooling system treatment, and replace the cooling filter.

1002-6




MAINTENANCE SCHEDULEModel 821C

If you operate the machine in severe conditions, lubricate and service the machine more frequently. It isrecommended that you see your Case dealer for information on the System Guard Lubrication AnalysisSystem.

See your Operators manual for maintenance of safety related items and for detailed information of the serviceitems on this chart. Operators and service manuals are available for this machine from your Case dealer.

NOTE: The Case Company reserves the right to make improvements indesign or changes in specifications at any time without incurring anyobligation to install them on units previously sold.

GS98J100

0000-1SECTION INDEX - ELECTRICAL

Section Title

Section Number

Removal and Installation of Starter and Alternator ........................................................................................................ 4001

Electrical Specifications, Troubleshooting, and Schematics ............................................................................................ 4002

Batteries ................................................................................................................................................................ 4003

Starter and Starter Solenoid ....................................................................................................................................................... 4004

Information and Diagnostic Center.............................................................................................................................................. 4005

Alternator ................................................................................................................................................................................... 4007




April, 2000

Section4002 40

02


CASE CANADA CORPORATION3350 South Service RoadHamilton, ON L7N 3M6 CANADA Bur 7-12221

Copyright © 2000 Case CorporationPrinted in U.S.A.

April, 2000

ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING, AND SCHEMATICS

NOTES

4002-3

TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GRAPHIC SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

HOW TO USE THIS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, COLD START, IGNITION SWITCH AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Fuel Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Cold Start Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Ether Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Ether Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Ether Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Ignition Relay #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ignition Relay #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Accessory Relay #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Voltmeter Relay #12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Transmission Kick-down Switch (Located In Hydraulic Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Declutch Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Back-up Alarm Relay #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH . . . 21

Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23


4002-4

Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Program Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

TROUBLESHOOTING ENGINE OIL PRESSURE SENDER, PILOT CONTROL, PARKING BRAKE, ENGINE AUTOMATIC SHUTDOWN RELAY, AND REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . 28

Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Redundant Parking Brake Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Redundant Brake Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Engine Automatic Shutdown Relay Socket #11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

TROUBLESHOOTING BUCKET CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Detent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Bucket Control Valves Detent Electromagnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Height Control Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL . . . . . . . . . . . . . . . 34Secondary Steering Relay with Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Secondary Steering Relay with Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Secondary Steering Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Secondary Steering Pump/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Pin Engagement Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Pin Engage Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Hoist-up Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Bucket Dump Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Bucket Rollback Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Ride Engage Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Front Rotary Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND CONDENSER FANS . . . . . . . . . . . . . . 43Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Seat Compressor and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Resistor Board (Blower Motor Speed Resistors with Thermal Fuse) . . . . . . . . . . . . . . . . . . . . . . . . . . 45Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Compressor Clutch Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


4002-5

Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Condenser Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Not Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Condenser Fan Motor No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Condenser Fan Motor No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET, RADIOS AND SPEAKERS . 48

Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Power Converter (24 volt to 12 volt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Remote Radio or 24 Volt Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4912 Volt Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Radio Power Converter (24 volts to 12 volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Turn Signal, Hi/Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS . . 55Left Marker/Turn Signal (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Left Drive Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Left Flood Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Right Flood Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Right Drive Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Right Marker and Turn Signal (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Left Brake, Tail, and Directional Lights (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Right Brake, Tail, and Directional Lights (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58High/Low Beam Relay (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595 Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Left Front Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Left Rear Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Right Rear Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Right Front Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN MODELS . . . . . . . . . . . . . . . . . . . . 62Left Front Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Right Front Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Left Rear Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Right Rear Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Left Side Turn (Italy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Right Side Turn (Italy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Left Front Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Right Front Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Left Rear Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Right Rear Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Left Head Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Right Head Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Rear License Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67


4002-6

Engine Compartment Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Engine Compartment Lamp Switch (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

ELECTRICAL SCHEMATIC - SHEETS 29, 30, 31, and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

ELECTRICAL SCHEMATIC - SHEETS 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

ELECTRICAL SCHEMATIC - SHEET 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

ELECTRICAL SCHEMATIC - SHEETS 3, 4, and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89


4002-7

SPECIFICATIONS Electrical System ............................................................ Two 12 volt batteries connected in series, negative groundSystem Voltage........................................................................................................................Approximately 24 volts

BatteriesThe specifications are the same for the production battery and the replacement battery.Production Battery case P/N ............................................................................................... L51769 or BCM4DAWReplacement Battery Case P/N ..............................................................................................L13308 or BMC4DAGroup Size ......................................................................................................................................................... 4DReserve Capacity ................................................................................................................................ 310 minutesCold Cranking Capacity:

At -17°C (0°F)................................................................................................................................800 amperesAt -29°C (-20°F) ...........................................................................................................................650 amperes

Load of Capacity (Load) Test .............................................................................................................400 amperesPlates per Cell .....................................................................................................................................................23Approximate weight with electrolyte...................................................................................... 49.8 kg (110 pounds)Nonspill caps............................................................................................................................................ Standard

Alternator ..................................................................................................................................... 24 volt, 65 amperesVoltage Regulator ............................................................................................................. Solid State, Not AdjustableStarter................................................................................................................................ 24 volt, Solenoid ActuatedBucket Control Valves Detent Electromagnets.............................................................................................. 84 ohmsFuel Level Sender (E-F) .........................................................................................................................240-33 ohmsCoolant and Hydraulic Temperature Sender 20°C (68°F).......................................................................... 3521ohmsCoolant and Hydraulic Temperature Sender (Yellow Line) 105°C (221°F) ................................................. 154 ohmsCoolant and Hydraulic Temperature Sender (Red Line) 110°C (230°F) .................................................. 133.9 ohmsHydraulic Filter Restriction Switch closing setpoint ...........................................................................310 kPa (45 psi)Air Filter Restriction Switch closing setpoint..................................................................................6.4 kPa (0.928 psi)Low Brake Pressure Warning Switch opening setpoint ............................................................11 724 kPa (1700 psi)A/C High Pressure Switch closing setpoint .................................................... 28 Bar (400 psi) (increasing pressure)A/C Low Pressure Switch closing setpoint ....................................................... 0.3 Bar (4 psi) (decreasing pressure)Contacts 2 to 3 of thermostat switch close at initial turn of the rotary switch. Contacts 1 to 2 close with thermal setting.

Engine Oil Pressure Sender. Reference Resistance vs. Pressure1 Bar........................................................................................................................................................ 178 ohms3 Bar.......................................................................................................................................................... 90 ohms5.2 Bar....................................................................................................................................................... 38 ohms

Fuel Solenoid Resistance (pull in) .............................................................................................................. 0.82 ohmsFuel Solenoid Resistance (hold in)............................................................................................................. 11.3 ohms


4002-8

GRAPHIC SYMBOLS

GM98M003


4002-9

CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES

GM98M001

GM98M002

NOTES:NOTE: Diagram shown with vehicle parked, power off, and controls in off or neutral position.

NOTE: Sheet numbers refer to the number at the bottom center of each individual dashed block.

NOTE: Machine components that are being troubleshot are represented by this symbol.

NOTE: Wires that continue, uninterrupted, to the next sheet are represented by this symbol.

NOTE: Wires that continue, but are interrupted by several sheets, are located by specific text references asfollows: To instrument cluster cavity 2 on sheet 11


4002-10

HOW TO USE THIS SECTION

IMPORTANT: The troubleshooting procedures can be used with the Electrical and Hydraulic Schematic poster(rear pocket, 7-12720, 7-12730 and 7-13450) for the 621/721/821 C-series wheel loader.

All bold item numbers, 17 , as well asnumbers in parenthesis,(17), found in thetroubleshooting procedures, correspond to

the circled numbers found on the Electrical andHydraulic Schematic poster (rear pocket).

Items (90, Cigar Lighter) through (118, Cab DomeLight), Sheets 1 through 5 and 29 through 32, onlyappear on the foldout schematics in this section (seepages 67 through 97) and are not shown on theElectrical and Hydraulic Schematic poster (rearpocket).

The schematic poster is color coded to assist introubleshooting electrical circuits. Red denotescircuits that have constant power. Green denotescircuits that have power when the ignition switch inturned ON.

Components can be located on the Electrical andHydraulic Schematic poster (rear pocket) by itemnumber using the key at the bottom right of the rearpocket. Use the following index to find the sheet(dashed block) a component is located on.

GM98M004


4002-11

TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, COLD START, IGNITION SWITCH AND RELAYS

GM98M005

1. BATTERIES 6. START RELAY 10. ETHER START SWITCH2. MASTER DISCONNECT SWITCH 6A. FUEL RELAY 11. NEUTRAL START RELAY #83. FUEL SHUTOFF SOLENOID 7. COLD START TEMPERATURE SWITCH 12. IGNITION SWITCH4. ALTERNATOR 8. ETHER SOLENOID 13. IGNITION RELAY #15. STARTER MOTOR 9. ETHER START RELAY #6

1 – Batteries

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of theelectrical system. Use a Multimeter for the following tests.

NOTE: See Section 4003 and check the batteries.

1

8 3

7

5

66A

12

10

4

2

9

1113


4002-12

2 – Master Disconnect Switch

Check Points Reading Possible Cause of Bad Reading

NOTE: Disconnect the cables from both terminals of the master disconnect switch (main contact). Put the masterdisconnect switch in the ON position.

Between the terminals of the master disconnect switch

Continuity If there is no continuity, the master disconnect switch (2) is bad.

NOTE: Put the master disconnect switch in the OFF position.

Between the terminals of the master disconnect switch

No continuity If there is continuity, the master disconnect switch is bad.

NOTE: Use the same method to check the master disconnect switch (auxiliary contact).

3 – Fuel Shutoff Solenoid


Terminal for wire 0 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position.

Terminal for wire 13M to ground 24 volts Check circuit 13M, also check circuit to batteries. Bad master disconnect switch (2).

NOTE: Have another person hold the ignition switch in the START position.

Terminal for wire 23F to ground 24 volts Check circuit 23F. Bad fuel relay (6A).

NOTE: If the readings are good, replace the fuel shutoff valve (3).

4 – Alternator


Between housing of alternator and ground

Continuity Bad ground connection.


Between the negative terminal of alternator and ground

24 volts Check circuit to positive post of batteries.

NOTE: Put the ignition switch in the ON position.

Between the positive terminal of alternator and ground

24 volts Check circuit to positive post of batteries.

Terminal for wire 14 to ground 20 volts Check circuit to ignition relay #1 (13) and ignition relay #2 (14), also check 75 ohm resistor.

NOTE: If the readings are good, see Section 4007 to repair the alternator (4).


4002-13

5 – Starter Motor


Between housing of starter and ground

Continuity Bad ground connection.


Battery terminal to ground 24 volts Check circuit to batteries.

NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.

Terminal S to ground 24 volts Bad start relay (6). Also check circuit between starter (5) and start relay (6).

NOTE: If the readings are not good, see Section 4004 and repair the starter (5).

6 – Start Relay




Terminal 87 for red wire to ground 24 volts Check circuit to batteries.


Terminal for wire 21C to ground 24 volts Check neutral start relay (11), also check the circuit 21C.

Terminal for wire 8 to ground 24 volts Bad start relay (6).

6A – Fuel Relay




Terminal for wire 1 to ground 24 volts Check circuit 1, also check circuit to batteries.


Terminal for wire 21C to ground 24 volts Check neutral start relay (11), also check the circuit 21C.

Terminal for wire 23F to ground 24 volts Bad fuel relay (6A).

7 – Cold Start Temperature Switch


NOTE: The cold start temperature switch opens above 10°C (50°F).


NOTE: Disconnect the wires from the cold start temperature switch (7). Make sure the engine temperature isbelow 10°C (50°F).

Between terminals A and B Continuity Bad cold start temperature switch (7).


4002-14

8 – Ether Solenoid


Terminal for wire 28T to ether start temperature switch

Continuity Bad 28T circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Have another person push inand hold the ether start switch (10). Make sure the engine temperature is below 10°C (50°F).

Terminal for wire 28P to ground 24 volts Check the ether start relay (9). Also check circuit 28P.

NOTE: If the readings are good, replace the ether solenoid (8).

9 – Ether Start Relay




Terminal for wire 19E to ground 24 volts Bad 10 ampere fuse E, also check circuit 19E.

NOTE: Put the ignition switch in the ON position. Have another person push in and hold the ether start switch(10). Make sure the engine temperature is below 10°C (50°F).

Terminal for wire 28C to ground 24 volts Bad ether start switch (10), also check circuit 28C.

Terminal for wire 28P to ground 24 volts Bad ether start relay (9).

10 – Ether Start Switch


NOTE: Disconnect the wires from the ether start switch (10).

Between terminals of switch Continuity Bad ether start switch (10).

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Terminal for wire 25T to ground 24 volts Check circuit 25T.

11 – Neutral Start Relay



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the transmission isin NEUTRAL.

Terminal for wire 21K to ground 24 volts Check circuit 21K.

NOTE: Have another person hold the ignition switch in the START position.

Terminal for wire 25T to ground 24 volts Check circuit 25T.

Terminal for wire 21C to ground 24 volts Bad neutral start relay (11).


4002-15

12 – Ignition Switch



Terminal for wire 1A to ground 24 volts Check circuit 1A to Circuit Breaker A.

NOTE: Disconnect the connector from the ignition switch (12). Turn the switch to ON.

Between Bat and Ign Continuity Bad ignition switch (12).

Between Bat and Acc Continuity Bad ignition switch (12).

NOTE: Hold the ignition switch (12) in the START position.

Between Bat and Starter Continuity Bad ignition switch (12).

NOTE: Put the switch in the Acc position.

Between Bat and Acc Continuity Bad ignition switch (12).

13 – Ignition Relay #1



NOTE: Put the master disconnect switch in the ON position. Turn the ignition to the ON position.

Terminal for wire 1 to ground 24 volts Check circuit 1 to B+ stud.


Terminal for wire 13P to ground 24 volts Bad ignition relay #1 (13)


4002-16

TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY MODULE

GM98M006

14. IGNITION RELAY #2 16. VOLTMETER RELAY #1215. ACCESSORY RELAY #3 17. TIME DELAY MODULE

14 – Ignition Relay #2



NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.



Terminal for wire 13R to ground 24 volts Bad ignition relay #2 (14).

17 14

15

16


4002-17

15 – Accessory Relay #3



NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.



Terminal for wire 12P to ground 24 volts Bad accessory relay (15), also check circuit 12P.

16 – Voltmeter Relay #12



NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the ON position.

Terminal for wire 1 to ground 24 volts Check circuit 1 to Relay Box Junction Block.


Terminal for wire 13V to ground 24 volts Bad voltmeter relay (16). Also check circuit 13V.

17 – Time Delay Module



NOTE: Put the ignition switch in the OFF position.

Terminal for wire 1A to ground 24 volts Bad circuit breaker A, also check circuit 1A to B+ stud.

NOTE: Put the ignition switch in the ON position. Have another person press and hold the RESET switch (42).

Terminal for wire 37R to ground 24 volts Bad reset switch (42), also check circuit 37R.

Terminal for wire 13K to ground 24 volts Bad ignition switch (12), also check circuit 13K.

NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds timedelay an audible click will be heard.

Within 10 seconds of putting the ignition switch in the OFF position, check Terminal for wire 13D to ground

24 voltsKey ON

0 volts after 10 seconds

Bad Time Delay Module (17).

After 10 seconds of turning ignition switch to the OFF position, check Terminal for wire 13D to ground

0 volts Bad Time Delay Module (17).


4002-18

TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR,

AND BACK-UP ALARM,

GM98M007

18. OUTPUT SPEED SENSOR 27. DIAGNOSTIC CONNECTOR19. ENGINE SPEED SENSOR 28. TRANSMISSION KICK-DOWN SWITCH

(LOCATED IN HYDRAULIC CONTROLLER)

20. INTERMEDIATE SPEED SENSOR

21. TURBINE SPEED SENSOR 29. TRANSMISSION AUTO SWITCH22. FILTER MAINTENANCE SWITCH 30. DECLUTCH SWITCH23. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 31. DECLUTCH BRAKE SWITCH24. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 32. BACK-UP ALARM RELAY #725. TRANSMISSION ELECTRONIC CONTROL MODULE 33. BACK-UP ALARM DISABLE SWITCH26. TRANSMISSION SHIFTER 34. BACK-UP ALARM

18

29

30

33

25

27

32

28

34

2120

26

31

23

24

19

22


4002-19

NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information forItems 18 through 31.

18 – Output Speed Sensor

19 – Engine Speed Sensor

20 – Intermediate Speed Sensor

21 – Turbine Speed Sensor

22 – Filter Maintenance Switch

23 – Torque Converter Output Temperature Sender

24 – Transmission Solenoid Valve and Temperature Sensors

25 – Transmission Electronic Control Module

26 – Transmission Shifter

27 – Diagnostic Connector

28 – Transmission Kick-down Switch (Located In Hydraulic Controller)

29 – Transmission Auto Switch

30 – Declutch Switch

31 – Declutch Brake Switch

32 – Back-up Alarm Relay #7


NOTE: Remove the transmission electronic control module (25) quick disconnect.

Terminal for wire 35C to terminal 7 Continuity Bad circuit 35C.

NOTE: Put the master disconnect switch in the ON position, ignition switch to the ON position and the park braketo the OFF position. Depress brake pedal once and place gear selector in REVERSE.

Terminal for wire 35A to ground 24 volts Bad back-up alarm relay (32), also check circuit 35A.

Terminal for wire 19A to ground 24 volts Bad fuse A, also check circuit 19A, 13P, and ignition relay #1 (13).

Terminal for wire 19H to ground 24 volts Bad fuse H, also check circuit 19H and 13R and ignition relay #2 (14).


4002-20

33 – Back-up Alarm Disable Switch



NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFFposition. Depress brake pedal once. Move the transmission shift lever to REVERSE.

Terminal for wire 35A to ground 24 volts Bad back-up alarm relay (32), also check circuit 35A.

NOTE: The wire 35A jumper is connected in the North American models and open in the European models.(Back-up alarm switch enabled.)

Terminal for wire 35R to ground 24 volts Bad back-up alarm disable (33), also check circuit 35R and 35A.

34 – Back-up Alarm



NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFFposition. Depress brake pedal once. Move the transmission shift lever to REVERSE.

Terminal for wire 35R to ground 24 volts Bad back-up alarm disable (33), also check circuit 35R.

NOTE: If the readings are good, replace the back-up alarm (34).


4002-21

TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT CLUSTER, PILOT

CONTROL SWITCH, AND UP/DOWN COUNT SWITCH

GM98M008

35. BRAKE WARNING PRESSURE SWITCH 41. AIR FILTER RESTRICTION SWITCH36. COOLANT LEVEL SENDER 42. PROGRAM RESET SWITCH37. FUEL LEVEL SENDER 43. PARK BRAKE SWITCH38. HYDRAULIC OIL TEMPERATURE SENDER 43A.INSTRUMENT CLUSTER39. HYDRAULIC FILTER RESTRICTION SWITCH 44. PILOT CONTROL SWITCH40. ENGINE COOLANT TEMPERATURE SENDER 45. UP/DOWN COUNT SWITCH

35

42

43A

44

37

45

3640

4138

39


4002-22

35 – Brake Warning Pressure Switch


NOTE: Brake pressure warning switch opens at 11 724 kPa (1700 psi).


Terminal B for wire 0 to ground Continuity Bad ground circuit.

Terminal A for wire 33P to groundApproximately

11.5 volts Check circuit 33P.

NOTE: Disconnect the wires from the brake warning pressure switch (35).

Between terminals A and B of the switch

Continuity Bad brake warning pressure switch (35).

NOTE: Start and run the engine at idle.

Between terminals A and B of the switch

No continuity Bad brake warning pressure switch (35).

NOTE: If the readings are correct see hydraulic brake troubleshooting section to check brake pressures.

36 – Coolant Level Sender




Terminal A for wire 33P to groundApproximately 1.6 volts AC Check circuit 33P, also check the instrument cluster (43A).

NOTE: If the readings are correct replace the coolant level sender (36).

37 – Fuel Level Sender




Terminal A for wire 36F to groundApproximately

5 volts Check the instrument cluster (43A).

NOTE: If the readings are correct replace the fuel level sender (37).


4002-23

38 – Hydraulic Oil Temperature Sender




Terminal A for wire 36H to groundApproximately


NOTE: If the readings are correct replace the hydraulic oil temperature sender (38).

39 – Hydraulic Filter Restriction Switch


NOTE: Hydraulic filter restriction switch closes at 310 kPa (45 psi).

Check between the housing of the hydraulic filter restriction switch (39) and the ground.

Continuity Bad ground connection between the hydraulic filter restriction switch (39) and ground.


Terminal A for wire 31H to ground.Approximately

11.5 volts Check the instrument cluster (43A).

NOTE: If the readings are correct replace the hydraulic filter restriction switch (39).

40 – Engine Coolant Temperature Sender




Terminal A for wire 36C to groundApproximately


NOTE: If the readings are correct replace the engine coolant temperature sender (40).

41 – Air Filter Restriction Switch


NOTE: Air filter restriction switch closes at 6.4 kPa (1 psi).



Terminal A for wire 31F to groundApproximately

11.5 volts Check the instrument cluster (43A).

NOTE: If the readings are correct replace the air filter restriction indicator switch (41).


4002-24

42 – Program Reset Switch



NOTE: Put the master disconnect switch and the ignition switch in the ON position with the program/reset switch(42) held in the reset position.

Terminal for wire 37R to ground 24 volts Check instrument cluster (43A), also check circuit 37R.

NOTE: Put the program/reset switch (42) in the program position.

Terminal for wire 37P to ground 24 volts Check instrument cluster (43A), also check circuit 37P.

NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher.

Terminal for wire 49 to ground 24 volts Bad program/ reset switch (42), also check circuit 49.

Terminal for wire 1A to ground 24 volts Bad program/ reset switch (42), also check circuit 1A.

43 – Park Brake Switch




Terminal for wire 19A to ground 24 volts Check fuse A, also check circuit 19A.

NOTE: Apply parking brake switch (43).

Terminal for wire 33U to ground 24 volts Bad park brake switch (43).


Terminal for wire 49 to ground 24 volts Bad park brake switch (43), also check circuit 49.


4002-25

43A – Instrument Cluster


Connector terminal 3 to ground Continuity Bad circuit 33P, also check the brake warning pressure switch (35).

Connector terminal 4 to ground Continuity Bad circuit 31D, also check the coolant level sender (36).

Connector terminal 19 to ground 39 to 225 ohms Bad circuit 36F, also check the fuel level sender (37).

Connector terminal 5 to ground Continuity Bad circuit 35X, also check the secondary steering switch (61).

Connector terminal 20 to ground134 to 3521

ohmsBad circuit 36H, also check the hydraulic oil temperature sender (38).

Connector terminal 18 to ground134 to 3521

ohmsBad circuit 36C, also check the engine coolant temperature sender (40).

Connector terminal 6 to ground Continuity Bad circuit 31F, also check the air filter restriction switch (41).

Connector terminal 8 to ground Continuity Bad circuit 0 to ground.

Circuit 19V, at terminal 1 to fuse V Continuity Bad circuit 19V, also check fuse V.

Circuit 61R, at terminal 10, from point to point

Continuity Bad circuit 61R, also check the A/C - H/L pressure switches (81 and 82) and compressor clutch lockout relay (84).

Circuit 18G/42R, at terminal 12, from point to point

Continuity Bad circuit 18G/42R, also check the 5 position rotary lamp switch (112).

Circuit 46, at terminal 13, from point to point

Continuity Bad circuit 46, also check the beacon light switch (96).

Circuit 41F, at terminal 14, from point to point

Continuity Bad circuit 41F, also check the rear fog lights switch (110).

Circuit 18C, at terminal 15, from point to point

Continuity Bad circuit 18C, also check the high beam lights switch (111).

Connector terminal 39 to ground Continuity Bad ground circuit.

Connector terminal 9 to terminal 6 on park brake switch (43)

Continuity Bad circuit 33U, also check the park brake switch (43).

Connector terminal 24 to terminal 6 on program reset switch (42)

Continuity Bad circuit 37P, also check the program reset switch (42).

Connector terminal 25 to terminal 4 on program reset switch (42)

Continuity Bad circuit 37R, also check the program reset switch (42).


Continuity Bad circuit 45R, also check the RH turn signal (107).

Circuit 45L, at terminal 16, from point to point

Continuity Bad circuit 45L, also check the LH turn signal (102).

Connector terminal 21 to terminal 33 Continuity Bad circuit 50T.

Connector terminal 29 to terminal 6 on pilot control switch (44)

Continuity Bad circuit 31L, also check the pilot control switch (44).

Connector terminal 33 to terminal 21 Continuity Bad circuit 50T.



4002-26

43A – Instrument Cluster (Continued)


Circuit 36P, at terminal 22, from point to point

Continuity Bad circuit 36P, also check the engine oil pressure sender (46).


Continuity Bad circuit 33R, also check the redundant brake switches (51).


Continuity Bad circuit 23C, also check the engine automatic shutdown relay (52).


Continuity Bad circuit 53C, also check the pilot control relay (47).


Continuity Bad circuit 52C, also check the parking brake relay (48).


Continuity Bad circuit 44, also check the RH/LH brake lights (108 and 109).

Connector terminal 31 to terminals 26 and 27 on the transmission electronic control module (25)

Continuity Bad circuit 50L.

Connector terminal 32 to terminal 25 on the transmission electronic control module (25)

Continuity Bad circuit 50H.



Continuity Bad circuit 19S, also check the up/down count switch (45) and fuse S.

Circuit 37U, at terminal 26, from point to point

Continuity Bad circuit to pilot control switch (44), also check the pilot control switch (44).

Circuit 37D, at terminal 27, from point to point

Continuity Bad circuit 37D, also check the up/down count switch (45).

44 – Pilot Control Switch




Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.

Terminal for wire 31L to ground 24 volts Bad pilot control switch (44).


Terminal for wire 49 to ground 24 volts Bad circuit 49, also check the 5 position rotary lamp switch (112).

NOTE: If the readings are correct replace the pilot control switch (44).


4002-27

45 – Up/down Count Switch




Terminal for wire 19S to ground 24 volts Bad circuit 19S, also check instrument cluster (43A) and fuse S.

Terminal for wire 37D to ground 24 volts Bad circuit 37D, also check instrument cluster (43A).

Terminal for wire 37U to ground 24 volts Bad circuit 37U, also check instrument cluster (43A).


Terminal for wire 49 to ground 24 volts Bad circuit 49, also check 5 position rotary lamp switch (112).

NOTE: If the readings are correct replace the up/down count switch (45).


4002-28

TROUBLESHOOTING ENGINE OIL PRESSURE SENDER, PILOT CONTROL, PARKING BRAKE, ENGINE AUTOMATIC SHUTDOWN RELAY, AND

REDUNDANT BRAKE SWITCHES

GM98M009

46. ENGINE OIL PRESSURE SENDER 50. PILOT PRESSURE SOLENOID47. PILOT CONTROL RELAY #10 51. REDUNDANT BRAKE SWITCHES48. PARKING BRAKE RELAY #9 52. ENGINE AUTOMATIC SHUTDOWN RELAY #1149. PARKING BRAKE SOLENOID

46 – Engine Oil Pressure Sender


Between the engine oil pressure sender (46) and ground

Continuity Bad ground connection between the engine oil pressure sender (46) and the ground.


Terminal for wire 36P to groundApproximately

5 volts Bad circuit 36P, also check the instrument cluster (43A).

NOTE: If the readings are good, replace the oil pressure sender (46).

46

47

48

52

49

50

51


4002-29

47 – Pilot Control Relay


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch(44) is OFF.

Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.

Terminal for wire 53C to ground 0 volts Bad pilot control relay (47), also check circuit 53C and instrument cluster (43A).

Terminal for wire 53P to ground 24 volts Bad circuit 53P.

NOTE: If the readings are good, replace the pilot control relay (47).

48 – Parking Brake Relay


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the park brakeswitch (43) is OFF.

Terminal for wire 19D to ground 24 volts Bad fuse D, also check circuit 19D.

Terminal for wire 52C to ground 0 volts Bad parking brake relay (48), also check circuit 52C.

Terminal for wire 52P to ground 24 volts Bad circuit 52P.

NOTE: If the readings are good, replace the parking brake relay (48).

49 – Redundant Parking Brake Solenoids



Terminal A for wire 52P to terminal 87 on parking brake relay (48)

Continuity Bad circuit 52P, also check parking brake relay (48).

NOTE: If the readings are good, replace the parking brake solenoid (49).

50 – Pilot Pressure Solenoid



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot controlswitch (44) is OFF.

Terminal A for wire 53P to ground 24 volts Bad pilot control relay (47), also check circuit 53P.

NOTE: If the readings are good, replace the pilot pressure solenoid (50).


4002-30

51 – Redundant Brake Switches


NOTE: Redundant brake switches close at 6200 kPa.



Terminal A for wire 33R to groundApproximately

11.5 volts Bad instrument cluster (43A), also check circuit 33R.

NOTE: If the readings are good, replace the redundant brake switches (51).

52 – Engine Automatic Shutdown Relay Socket #11

NOTE: There are no electrical troubleshooting procedures for this relay socket.


4002-31

TROUBLESHOOTING BUCKET CONTROLS

GM98M010

53. DETENT SWITCH 56. RETURN TO DIG PROXIMITY SWITCH54. BUCKET CONTROL VALVES DETENT ELECTROMAGNETS 57. HEIGHT CONTROL PROXIMITY SWITCH55. RETURN TO TRAVEL/FLOAT SWITCH 58. RETURN TO TRAVEL PROXIMITY SWITCH

53 – Detent Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (44) inthe OFF position.


Terminal for wire 53P to ground 24 volts Bad pilot control relay (47), also check circuit 53P.

Terminal for wire 56 to ground 24 volts Bad detent switch (53), also check circuit 56.



NOTE: If the readings are good, replace the detent switch (53).

54

5355

5758

56


4002-32

54 – Bucket Control Valves Detent Electromagnets


NOTE: Disconnect the wires from the bucket control valve. Put the master disconnect switch and ignition switchin the ON position. Put the pilot control switch (44) in OFF position. Put the detent switch (53) in the ON position.

Terminal for wire 56 to ground 24 volts Bad detent switch (53), also check pilot control relay (47).

Circuit 53B, point to point Continuity Bad return to dig detent electromagnet.

Circuit 54B, point to point Continuity Bad height control detent electromagnet.

Circuit 55A, point to point, to return to travel/float switch (55)

Continuity Bad return to travel detent electromagnet.

NOTE: If the readings are good, replace the bucket control valves detent electromagnets (54).

55 – Return-To-Travel/Float Switch





NOTE: Put the return to travel/float switch (55) in the FLOAT position.

Terminal 5 and terminal 4 Continuity Bad return to travel/float switch (55).

NOTE: Put the return to travel/float switch (55) in the TRAVEL position.

Terminal 5 and terminal 6 Continuity Bad return to travel/float switch (55).

Circuit 55A, point to point Continuity Bad circuit 55A, also check bucket control valves detent electromagnets (54).

NOTE: If the readings are good, replace the return to travel/float switch (55).

56 – Return-To-Dig Proximity Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch(44) in the OFF position and the detent switch (53) in the ON position. Disconnect the connector from the returnto dig proximity switch (56).


Terminal A for wire 53B to ground 24 volts Bad bucket control valve detent electromagnets (54) or detent switch (53), also check circuit 53B.

Terminal C for wire 56 to ground 24 volts Bad detent switch (53), also check circuit 56.

NOTE: If the readings are good, replace the return to dig proximity switch (56).


4002-33

57 – Height Control Proximity Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch(44) in the OFF position and the detent switch (53) in the ON position. Disconnect the connector from the heightcontrol proximity switch (57).


Terminal A for wire 54B to ground 24 volts Bad bucket control valve detent electromagnets pressure(54) or detent switch (53), also check circuit 54B.


NOTE: If the readings are good, replace the height control proximity switch (57).

58 – Return-To-Travel Proximity Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch(44) in the OFF position and the detent switch (53) in the ON position. Put the return to travel/float switch (55) inthe RETURN TO TRAVEL position. Disconnect the connector from the return to travel proximity switch (58).


Terminal A for wire 55B to ground 24 volts Bad return to travel/float switch (55), also check circuit 55B.


NOTE: If the readings are good, replace the return to travel proximity switch (58).


4002-34

TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL

GM98M011

59. SECONDARY STEERING RELAY WITH LOCKOUT 63. RIDE CONTROL SWITCH60. SECONDARY STEERING RELAY WITH LOCKOUT 64. HOIST-UP PRESSURE SWITCH61. SECONDARY STEERING SWITCH 65. RIDE CONTROL RELAY #462. SECONDARY STEERING PUMP/MOTOR 66. BUCKET DUMP PRESSURE SWITCH62A.PIN ENGAGEMENT SWITCH 67. BUCKET ROLLBACK PRESSURE SWITCH62B.PIN ENGAGE SOLENOID 68. RIDE ENGAGE SOLENOID

65 67

66

62616059

63

62A

64

62B

68


4002-35

59 – Secondary Steering Relay with Lockout

60 – Secondary Steering Relay with Lockout



Terminal 7 of relay (59) to ground 24 volts Check fuse M, also check circuit 19M.

Terminal 8 of relay (60) to ground 24 volts Check fuse R, also check circuit 19R.

Terminal 7 of relay (60) to ground 24 volts Bad jumper wire between terminals 7 and 8 of relay (60).

Ground wires between relays (59 and 60) and ground

Continuity Bad ground circuit.

Connector for wire 51P at secondary steering switch (61) and terminal 3 of relay (59)

Continuity Bad circuit 51P.

Connector for wire 51 at the secondary steering pump/motor (62) and terminal 6 of relay (60)

Continuity Bad circuit 51.


Terminal 2 of relay (59) to ground 0 volts Bad relay (59), also check secondary steering switch (61).

Terminal 3 of relay (59) to ground 0 volts Bad jumper wire between terminals 2 and 3 of relay (59), also check secondary steering switch (61).

Terminal 6 of relay (59) to ground 24 volts Bad relay (59), also check instrument cluster (43A) and circuit 35X.

Terminal 8 of relay (59) to ground 24 volts Bad relay (60).

Terminal 2 of relay (60) to ground 24 volts Bad relay (59).

Terminal 3 of relay (60) to ground 24 volts Bad jumper wires, also check relay (59).

NOTE: Disconnect the wire from the fuel shutoff solenoid (3) to stop the engine. Keep the ignition switch in theON position.

Terminal 2 of relay (60) to ground 0 volts Bad relay (60), also check circuit 19R and 19M.

Terminal 6 of relay (60) to ground 24 volts Bad relay (60), also check circuit 19R.

61 – Secondary Steering Switch




Terminal for wire 35X to ground 24 volts Check the instrument cluster (43A), also check circuit 35X.


Terminal for wire 51P to ground 0 volts Check the secondary steering relays (59 and 60), also check circuit 51P.

NOTE: If the readings are good, replace the secondary steering switch (61).


4002-36

62 – Secondary Steering Pump/Motor


Ground circuit to ground Continuity Bad ground circuit.

NOTE: Start and run the engine for 2 minutes. Disconnect the wire from the fuel shutoff solenoid (3) to stop theengine. Keep the ignition switch in the ON position.

Terminal for wire 51 to ground. 24 volts Check the secondary steering relays (59 and 60), also check circuit 51.

Terminal for red wire to starter to ground

24 volts Check circuit to batteries.

Motor terminal of solenoid to ground 24 volts Bad secondary steering pump/motor or solenoid (62).

Motor terminal of motor to ground 24 voltsCheck the secondary steering pump/motor or solenoid (62), also check the connections between the solenoid and pump/motor.

NOTE: If the readings are good, replace the secondary steering pump/motor (62).

62A – Pin Engagement Switch


NOTE: This switch is found only in the 621C/721C/821C and CE models with optional quick disconnect coupler.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the 5 position rotary lampswitch (112) in position 3 or higher and the pin engagement switch (62A) in the ON position. Disconnect theconnector from the pin engagement switch (62A).

Terminal for wire 49 to ground 24 volts Check the 5 position rotary lamp switch (112), also check circuit 49.


Terminal for wire 19P to ground 24 volts Check fuse P, also check circuit 19P.

Between terminals for wires 19P and 57

Continuity Bad pin engagement switch (62A).

62B – Pin Engage Solenoid


NOTE: This solenoid is found only in the 621C/721C/821C and CE models with optional quick disconnectcoupler.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engagementswitch (62A) in the ON position.


Terminal for wire 57 to ground 24 volts Bad pin engagement switch (62A), also check circuit 57.

NOTE: If the readings are good, replace the pin engage solenoid (62B).


4002-37

63 – Ride Control Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the 5 position rotary lampswitch (112) in position 3 or higher and the ride control switch in the ON position.



Terminal for wire 19C to ground 24 volts Check fuse C, also check circuit 19C.

NOTE: Disconnect the connector from the ride control switch (63). Put the ride control switch (63) in the ONposition.

Between terminals for wires 19C and 58S

Continuity Bad ride control switch (63).

64 – Hoist-up Pressure Switch


Circuit 58H, point to point Continuity Bad circuit 58H.

NOTE: Put the master disconnect switch and ignition switch in the ON position. Start the engine. Push the ridecontrol switch (63). Pull back on the loader lever until the green light under the ride control switch (63) isilluminated.

Terminal for wire 58S to ground 24 volts Bad hoist-up pressure switch (64), also check the ride control switch (63).

65 – Ride Control Relay



NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Push the ridecontrol switch (63). Pull back on the loader lever until the green light under the ride control switch (63) isilluminated. The ride control relay (65) stays activated until the ride control switch (63) is placed in the OFFposition.

Terminal for wire 58S to ground 24 volts Check the ride control switch (63), also check circuit 58S.

Terminal for wire 58H to ground 24 volts Bad circuit 58H. Check the hoist -up pressure switch (64), also check the ride control switch (63).

66 – Bucket Dump Pressure Switch


Circuit 58D, point to point Continuity Bad circuit 58D.

NOTE: Put the master disconnect switch and ignition switch to the ON position. Star t the engine. Push the ride controlswitch (63). The bucket dump pressure switch (66) is normally closed and opens at 625 kPa (91 psi).

Terminal for wire 58H to ground 24 volts Bad ride control relay (65) or bad hoist-up pressure switch (64).

Terminal for wire 58D to ground 24 volts Bad bucket dump pressure switch (66).


4002-38

67 – Bucket Rollback Pressure Switch


Circuit 58, point to point Continuity Bad circuit 58.

NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Push the ridecontrol switch (63). The bucket rollback pressure switch (67) is normally closed and opens at 625 kPa (91 psi).

Terminal for wire 58D to ground 24 volts Bad bucket dump pressure switch (66), bad ride control relay (65), or bad hoist-up pressure switch (64).

Terminal for wire 58 to ground 24 volts Bad bucket rollback pressure switch (67).

68 – Ride Engage Solenoid


NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Put the ridecontrol switch (63) and hoist-up pressure switch (64) in the ON position.


Terminal for wire 58 to ground 24 volts Bad circuit 58, also check bucket rollback pressure switch (67).

NOTE: If the readings are good, replace the ride engage solenoid (68).


4002-39

TROUBLESHOOTING WIPER/WASHER

GM98M012

69. FRONT WIPER MOTOR 72. REAR WASHER PUMP MOTOR70. FRONT ROTARY WIPER AND WASHER SWITCH 73. REAR WIPER AND WASHER SWITCH71. FRONT WASHER PUMP MOTOR 74. REAR WIPER MOTOR

70

7371

74

69

72


4002-40

69 – Front Wiper Motor



NOTE: Make sure the rotary wiper and washer switch (70) is in the OFF position.

Between terminals B and D for wires 63C and 63L

Continuity Bad front rotary wiper and washer switch (70).


Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.

NOTE: Put the rotary wiper and washer switch (70) in the LOW position.

Terminal for wire 63L to ground 24 volts Check fuse J, also check circuit 19J.

Terminal for wire 63C to ground 24 volts Bad front rotary wiper and washer switch (70)

NOTE: Put the rotary wiper and washer switch (70) in the HIGH position.

Terminal for wire 63H to ground 24 volts Check fuse J, also check circuit 19J. Bad front rotary wiper and washer switch (70).

Terminal for wire 63C to ground 0 volts Bad front rotary wiper and washer switch (70).

NOTE: If the readings are good, replace the front wiper motor (69).

70 – Front Rotary Wiper and Washer Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the rotary wiperand washer switch (70) is in the OFF position.


Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.

NOTE: Put the rotary wiper and washer switch (70) in the LOW position.

Terminal for wire 63L to ground 24 volts Check fuse J, also check circuit 19J.

Terminal for wire 63C to ground 24 volts Bad front rotary wiper and washer switch (70)

NOTE: Put the rotary wiper and washer switch (70) in the HIGH position.

Terminal for wire 63H to ground 24 volts Check fuse J, also check circuit 19J. Bad front rotary wiper and washer switch (70).

Terminal for wire 63C to ground 0 volts Bad front rotary wiper and washer switch (70).


4002-41

71 – Front Washer Pump Motor


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front rotarywiper and washer switch (70) is in the OFF position.


NOTE: Put the front rotary wiper and washer switch (70) in the wash position.

Terminal for wire 63W to ground 24 volts Bad front rotary wiper and washer switch (70), also check circuit 63W.

NOTE: If the readings are good, replace the rear washer pump motor (71).

72 – Rear Washer Pump Motor


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the rear wiper andwasher switch (73) is in the OFF position.


NOTE: Put the rear wiper and washer switch (73) in the wash position.

Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68W.

NOTE: If the readings are good, replace the rear washer pump motor (72).

73 – Rear Wiper and Washer Switch


Circuit 68W, point to point Continuity Bad circuit 68W.

Between terminals for wires 68C and 68L

Continuity Bad rear wiper and washer switch (73).

NOTE: Put the master disconnect switch, the ignition switch, and the rotary lamp switch (112) in the ON position.Put the rear wiper switch in the ON position.

Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.

Terminal for wire 68 L to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68L.

Terminal for wire 49 to ground 24 volts Bad rotary lamp switch (112), also check circuit 49.

NOTE: Put the rear wiper and washer switch (73) in the wash position.

Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68W.


4002-42

74 – Rear Wiper Motor



NOTE: Make sure the rear wiper and washer switch (73) is in the OFF position.

Between terminals for wires 68C and 68L

Continuity Bad rear wiper and washer switch (73).


Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.

NOTE: Put the rear wiper and washer switch (73) in the ON position.

Terminal for wire 68L to ground 24 volts Bad rear wiper and washer switch (73).

Terminal for wire 68C to ground 0 volts Bad rear wiper and washer switch (73).

NOTE: If the readings are good, replace the rear wiper motor (74).


4002-43

TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND CONDENSER FANS

GM98013

75. HORN RELAY #5 80. BLOWER MOTOR 85. COMPRESSOR CLUTCH76. SEAT COMPRESSOR 81. LOW PRESSURE SWITCH (IN CAB) 86. CONDENSER FAN RELAY77. HORN 82. HIGH PRESSURE SWITCH (IN REAR CHASSIS) 87. NOT USED78. BLOWER SWITCH 83. THERMOSTAT SWITCH 88. CONDENSER FAN #1 MOTOR79. RESISTOR BOARD 84. COMPRESSOR CLUTCH LOCKOUT RELAY 89. CONDENSER FAN #2 MOTOR

75 – Horn Relay


Terminal for wire 19U to ground 24 volts Check fuse U, also check circuit 19U.

64C to horn switch (100) Bad circuit 64C, also check horn switch (100).

NOTE: Have another person push and hold the horn switch (100).

Terminal for wire 64 to ground 24 volts Check horn switch (100). If the horn switch (100) is good, replace the horn relay (75).

76

78

8375

7980

8582

778988

81878684


4002-44

76 – Seat Compressor and Switch


NOTE: This applies to models with air seat option only.



Terminal for wire 19N at seat switch 24 volts Check fuse N, also check circuit 19N.

NOTE: Put the seat compressor switch (76) in the ON position.

Terminal for wire from seat switch at compressor

24 volts Bad seat switch, also check circuit from seat switch to compressor.

NOTE: If the readings are good replace the seat compressor.

77 – Horn



NOTE: Disconnect the wire 64 from the horn relay (75). Push and hold the horn switch (100).

Terminals for wire 64 to ground. 24 volts Check the horn relay (75), also check circuit 64.

NOTE: If the readings are good replace the horn (77).

78 – Blower Switch



Terminals for wire 19G to ground 24 volts Check fuse G, also check circuit 19G.

NOTE: Turn the blower switch to LOW.

Terminals for wire 62L to ground 24 volts Bad blower switch (78).

Terminals for wire 61T to ground 24 volts Bad blower switch (78).

NOTE: Turn the blower switch to MEDIUM.

Terminals for wire 62M to ground 24 volts Bad blower switch (78).


NOTE: Turn the blower switch to HIGH.

Terminals for wire 62H to ground 24 volts Bad blower switch (78).



4002-45

79 – Resistor Board (Blower Motor Speed Resistors with Thermal Fuse)


NOTE: Disconnect the connector from the resistor board (79).

Between terminals 1 and 2Approximately

4.5 ohms Bad resistor board (79).

Between terminals 2 and 3Approximately

1.5 ohms Bad resistor board (79).

80 – Blower Motor


Terminals for wire 0 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (78) toHIGH.

Terminals for wire 62H to ground 24 volts Check the blower switch (78).

NOTE: If the readings are correct and the blower motor (80) does not run, replace the blower motor (80). Turn theblower switch (78) to LOW. If the blower motor (80) ran in HIGH but not in LOW or MEDIUM, check the resistorboard (79).

81 – Low Pressure Switch (In Cab)


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the blower switch (78) toHIGH and the thermostat switch (83) to COLD.

Terminal B for wire 61A to ground 24 volts Check the thermostat switch (83), also check circuit 61A.

Circuit 61R, point to point Continuity Bad circuit 61R.

NOTE: Disconnect the wires from the low pressure switch (81).

Between the terminals of the low pressure switch (81)

Open Bad low pressure switch (81), also check refrigerant charge level.

82 – High Pressure Switch (In Rear Chassis)



Terminals for wire 61A to ground 24 volts Check the thermostat switch (83), also check circuit 61A.

NOTE: Disconnect the wires from the high pressure switch (82).

Between the terminals of the high pressure switch (82)

Open Bad high pressure switch (82), also check for excessive refrigerant pressure.


4002-46

83 – Thermostat Switch


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the blower switch (78) toHIGH.

Terminals for wire 61T to ground 24 volts Check the blower switch (78), also check circuit 61T.

NOTE: Turn the thermostat switch (83) all the way to COLD.

Terminals for wire 61A to ground 24 volts Bad thermostat switch (83).

Terminals for wire 61M to ground 24 volts Bad thermostat switch (83).

84 – Compressor Clutch Lockout Relay




Terminals for wire 61A to ground 24 volts Check thermostat switch (83), also check circuit 61A.

Terminals for wire 61R to ground 0 volts Check low pressure switch (81) and high pressure switch (82).

Terminals for wire 61C to ground 24 volts Bad compressor clutch lockout relay (84).

85 – Compressor Clutch



Terminals for wire 61C to ground 24 volts Check the compressor clutch lockout relay (84), also check circuit 61C.

86 – Condenser Fan Relay




Terminals for wire 1 to ground 24 volts Bad circuit 1.

NOTE: Put the blower switch (78) to HIGH and the thermostat switch (83) to COLD.

Terminals for wire 61M to ground 24 volts Check the thermostat switch (83), also check circuit 61M.

Terminals for wire 12 to ground 24 volts Bad condenser fan relay (86).

87 – Not Used

NOTE: Component number 87 is not used at this time.


4002-47

88 – Condenser Fan Motor No. 1




Terminals for wire 19U to ground 24 volts Check 10 ampere circuit breaker U, also check circuit 19U.

NOTE: If readings are good, replace the condenser fan motor no. 1 (88).

89 – Condenser Fan Motor No. 2




Terminal for wire 19V to ground 24 volts Check 10 ampere circuit breaker V, also check circuit 19V.

NOTE: If readings are good, replace the condenser fan motor No. 2 (89).


4002-48

TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET, RADIOS AND SPEAKERS

GM98M014

90. CIGAR LIGHTER 93. REMOTE OR 24 VOLT RADIO 94. LEFT SPEAKER91. POWER CONVERTER 93A.12 VOLT RADIO 95. RIGHT SPEAKER92. POWER OUTLET 93B.RADIO POWER CONVERTER

90 – Cigar Lighter


Terminal for wire 19W to ground 24 volts Check fuse W, also check circuit 19W.


NOTE: If the readings are good replace the cigar lighter (90).

90

9291

95

94

93

93A

93B


4002-49

91 – Power Converter (24 volt to 12 volt)




Terminal for wire 19L to ground 24 volts Bad fuse L, also check circuit 19L.

Terminal for wire 1 to ground 24 volts Check circuit 1.

Terminal for wire 12V to ground 24 volts Bad power converter (91).

92 – Power Outlet



Terminal for wire 12V to ground 12 volts Bad power converter (91), also check circuit 12V.

NOTE: If the readings are good replace the power outlet (92).

93 – Remote Radio or 24 Volt Radio


Terminal in radio connector for wire 0 to ground


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on. Put thebalance control for the RH and LH speakers to the center position.

Terminal in radio connector for wire 65C to ground

12 volts Check fuse L, also check circuit 19L and 65C.

NOTE: Keep the ignition switch and radio ON. Disconnect the connectors at the RH and LH speakers (94 and95).

Terminal in radio connector for wire 65R to ground

Voltage Bad circuit between the radio and the connector or bad radio (93).

Terminal in radio connector for wire 65L to ground

Voltage Bad circuit between the radio and the connector or bad radio (93).


4002-50

93A – 12 Volt Radio


Terminal in radio connector for wire 0 to ground


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on. Rotate thebalance control for the RH and LH speakers to the center position.

Terminal in radio connector for wire 65C to ground

12 volts Check fuse L, also check circuit 19L and 65C. Also check the radio power converter (93B).

NOTE: Keep the ignition switch and radio ON. Disconnect the connectors at the RH and LH speakers (94 and95).

Terminal in radio connector for wire 65R to ground

Voltage Bad circuit between the radio and the connector or bad radio (93A).

Terminal in radio connector for wire 65L to ground

Voltage Bad circuit between the radio and the connector or bad radio (93A).

93B – Radio Power Converter (24 volts to 12 volts)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on.

Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (93B).

94 – Left Speaker


NOTE: Disconnect the connector from the left speaker (94). Put the master disconnect switch and the ignitionswitch in the ON position. Turn the radio (93 or 93A) on. Put the balance control for the RH and LH speakers tothe center position.

Speaker connector terminal for wire 65L to ground

Voltage Bad circuit between the left speaker (94) and the radio or a bad radio (93 or 93A).

Speaker connector terminal for wire 0 to ground

Continuity Bad circuit between the left speaker (94) and the radio (93 or 93A).

NOTE: If the readings are good, replace the left speaker (94).


4002-51

95 – Right Speaker


NOTE: Disconnect the connector from the right speaker (94). Put the master disconnect switch and the ignitionswitch in the ON position. Turn the radio (93 or 93A) on. Put the balance control for the RH and LH speakers tothe center position.

Speaker connector terminal for wire 65R to ground

Voltage Bad circuit between the right speaker (95) and the radio or a bad radio (93 or 93A).

Speaker connector terminal for wire 0 to ground

Continuity Bad circuit between the right speaker (95) and the radio (93 or 93A).

NOTE: If the readings are good, replace the right speaker (95).


4002-52

TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER

MODULE

GM98M015

96. BEACON SWITCH 98. STOP LAMP SWITCH 100. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH97. ROTATING BEACON 99. HAZARD SWITCH 101. FLASHER MODULE

96 – Beacon Switch



NOTE: Put the master disconnect switch in the ON position and the 5 position rotary lamp switch (112) in position3 or higher.


Terminal for wire 19X to ground 24 volts Check fuse X, also check circuit 19X.

NOTE: Put the beacon switch (96) in the ON position.

Terminal for wire 46 to ground 24 volts Bad beacon switch (96).

101

97

99

96

98

100


4002-53

97 – Rotating Beacon


Bulb Continuity Bad bulb.


NOTE: Put the master disconnect switch and the beacon switch (96) in the ON position.

Terminal for wire 46 to ground 24 volts Bad circuit between the beacon (97) and the beacon switch (96). Also check the beacon switch (96).

NOTE: If readings are good replace the rotating beacon (97).

98 – Stop Lamp Switch


NOTE: The stop lamp switch is located in the treadle valve below the cab. It closes with brake pedal angle.


Terminal for wire 1B to ground 24 volts Check circuit breaker B, also check circuit 1B.

NOTE: Have another person push down and hold the brake pedal.

Terminal for wire 44 to ground 24 volts Bad stop lamp switch (98) or the stop lamp switch (98) is not adjusted correctly.

99 – Hazard Switch



NOTE: Put the master disconnect switch in the ON position. Make sure the hazard switch (99) is OFF. Put the 5position rotary lamp switch (112) in position 3 or higher.


Terminal for wire 1B to ground 24 volts Check Circuit Breaker B, also check circuit 1B.

NOTE: Turn the hazard switch (99) ON

Terminal for wire 45H to ground 24 volts Bad hazard switch (99).


4002-54

100 – Turn Signal, Hi/Low Beam, and Horn Switch




Terminal for wire 19B to ground 24 volts Check fuse B, also check circuit 19B.

NOTE: Move the turn signal lever for right turn.

Terminal for wire 45B to ground 24 volts Bad turn signal switch (100).

NOTE: Move the turn signal lever for left turn.

Terminal for wire 45A to ground 24 volts Bad turn signal switch (100).

NOTE: Hold Hi/Low beam lever back.

Terminal for wire 64D to ground Continuity Bad turn signal switch (100), also check Hi/Low beam relay #13 (111) and circuit 64D.

NOTE: If the readings are good, replace the turn signal, Hi/Low beam, and horn switch (100).

101 – Flasher Module


NOTE: Jumper circuit 45N must be connected for North American Machines and disconnected for Europeanmachines.


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the hazard switch (99)ON.

Terminal for wire 45H to ground 24 volts Bad circuit 45H, also check hazard switch (99).

Terminal for wire 45L to groundIntermittent 24

volts Bad flasher module (101), also check circuit 45L.

Terminal for wire 45R to groundIntermittent 24

volts Bad flasher module (101), also check circuit 45R.

NOTE: Move the turn signal lever (100) for right turn.

Terminal for wire 45B to ground 24 volts Bad circuit 45B, also check turn signal lever (100).


volts Bad flasher module (101), also check circuit 45R.

NOTE: Move the turn signal lever (100) for left turn.

Terminal for wire 45A to ground 24 volts Bad circuit 45A, also check turn signal lever (100).


volts Bad flasher module (101), also check circuit 45L.

Terminal #2 to #12 wire 45N to ground (North American Only).

Continuity Bad 45N circuit.


4002-55

TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS

GM98M016

NOTE: Item numbers 102 through 109 are applicable to external lighting and signals for the North AmericanModels. See page 69, item numbers 119 through 132, for external lighting and signals for the European Models.Item numbers 110, 112 through 118 are applicable to both North American and European Models.

102. LEFT MARKER/TURN SIGNAL 111. HIGH/LOW BEAM RELAY (ON EUROPEAN MODELS ONLY)103. LEFT DRIVE LAMP 112. 5 POSITION ROTARY LAMP SWITCH104. LEFT FLOOD LAMP 113. LEFT FRONT CAB LAMP105. RIGHT FLOOD LAMP 114. LEFT REAR CAB LAMP106. RIGHT DRIVE LAMP 115. RIGHT REAR CAB LAMP107. RIGHT MARKER/TURN SIGNAL 116. RIGHT FRONT CAB LAMP108. LEFT BRAKE, TAIL AND DIRECTIONAL 117. COURTESY LIGHT109. RIGHT BRAKE, TAIL AND DIRECTIONAL 118.CAB DOME LIGHT110. FOG LIGHT SWITCH

108

109

112

117104

116

115

113118

114103

102

110

107

106

105111


4002-56

102 – Left Marker/Turn Signal (North American Models)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switchis OFF. Move the turn signal lever (100) for a left turn, put 5 position rotary lamp switch (112) in position 2 orhigher.

Bulb (Marker) Continuity Bad bulb.

Bulb (Turn signal) Continuity Bad bulb.

Terminal for wire 45 to groundIntermittent 24

voltsCheck the turn signal switch (100), flasher module (101), and also check circuit 45.

Terminal for wire 18F to ground 24 volts Check fuse F´, lamp switch (112), and also check circuit 18F.

103 – Left Drive Lamp (North American Models)



Put the master disconnect switch in the ON position. Put the lamp switch (112) in the drive lamp ON position.


Terminal for wire 18D to ground 24 volts Check fuse D´, check circuit 18D, check that jumper 41L to 41J is connected, also check 5 position rotary lamp switch (112).

104 – Left Flood Lamp (North American Models)



NOTE: Put the master disconnect switch in the ON position. Put the lamp switch (112) in the flood lamp ONposition.


Terminal for wire 42C to ground 24 volts Check 5 position rotary lamp switch (112), also check circuit 42C.

105 – Right Flood Lamp (North American Models)



NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in theflood lamp ON position.


Terminal for wire 42C to ground 24 volts Check the 5 position rotary lamp switch (112), also check circuit 42C.


4002-57

106 – Right Drive Lamp (North American Models)



NOTE: Put the master disconnect switch in the ON position. Put the lamp switch (112) in the drive lamp ONposition.


Terminal for wire 18E to ground 24 volts Check fuse E´, check circuit 18E, check that jumper 41L to 41J is connected, also check 5 position rotary lamp switch (112).

107 – Right Marker and Turn Signal (North American Models)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch(99) is OFF. Move the turn signal lever (100) for a right turn, put the 5 position rotary lamp switch (112) in position2 or higher.




voltsCheck the turn signal switch (100), flasher module (101), and check circuit 45.

NOTE: Turn on the marker lights.

Terminal for wire 18G to ground 24 volts Check fuse G´, check the 5 position rotary lamp switch (112), and check circuit 18G.

108 – Left Brake, Tail, and Directional Lights (North American Models)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch(99) is OFF. Move the turn signal lever (100) for a left turn.

Bulb (Brake and Tail) Continuity Bad bulb.

Bulb (Directional) Continuity Bad bulb.


voltsCheck the turn signal switch (100), flasher module (101), and check circuit 45L.

NOTE: Turn on the tail marker lights.

Terminal for wire 18F to ground 24 volts Check fuse F´, check the 5 position rotary lamp switch (112), and check circuit 18F.


Terminal for wire 44 to ground 24 volts Check the stop lamp switch (98), also check circuit 44.


4002-58

109 – Right Brake, Tail, and Directional Lights (North American Models)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch(99) is OFF. Move the turn signal lever (100) for a right turn.

Bulb (Brake and Tail) Continuity Bad bulb.

Bulb (Directional) Continuity Bad bulb.


voltsCheck the turn signal switch (100), flasher module (101), and check circuit 45R.

NOTE: Turn on the tail marker lights.

Terminal for wire 18G to ground 24 volts Check fuse G´, check the 5 position rotary lamp switch (112), and check circuit 18G.



110 – Fog Light Switch



NOTE: Put the master disconnect switch and the fog light switch in the ON position. Put the 5 position rotarylamp switch (112) in position 3 or higher.


Terminal for wire 19Y to ground 24 volts Check fuse Y, also check circuit 19Y.

Terminal for wire 41F to ground 24 volts Bad fog light switch (110).


4002-59

111 – High/Low Beam Relay (European Models)


NOTE: This relay is for use in European models only. In North American models the relay is removed. Jumper41L and 41J is connected. Put the master disconnect switch in the ON position.


NOTE: Hold Hi/Low beam lever back.

Terminal for wire 64D to ground Continuity Check circuit 64D, also check Hi/low beam switch (100).

Put the 5 position rotary lamp switch (112) in position 3 or 4.

Terminal for wire 41J to ground 24 volts Check circuit 41J. Bad 5 position rotary lamp switch (112).

NOTE: Put the low beams ON.

Terminal for wire 41L to ground 24 volts Bad hi/low beam relay (111), also check that jumper 41L and 41J is disconnected.

NOTE: Put the high beams ON.

Terminal for wire 41H to ground 24 volts Bad high/low beam relay (111).

112 – 5 Position Rotary Lamp Switch



Terminal for wire 1 24 volts Check circuit 1.

Terminal for wire 19Z 24 volts Check fuse Z, also check circuit 19Z.

Terminal for wire 18A 24 volts Check fuse A´, also check circuit 18A.


Terminal for wire 41T 24 volts Bad 5 position rotary lamp switch (112).


Terminal for wire 49 to ground 24 volts Bad 5 position rotary lamp switch (112).

NOTE: Put the 5 position rotary lamp switch (112) in position 3 or 4.

Terminal for wire 41J 24 volts Bad 5 position rotary lamp switch (112).

NOTE: Put the 5 position rotary lamp switch (112) in position 4 or 5.

Terminal for wire 42C 24 volts Bad 5 position rotary lamp switch (112).

Terminal for wire 42R 24 volts Bad 5 position rotary lamp switch (112).


4002-60

113 – Left Front Cab Lamp



NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) inposition 4 or 5.


Terminal for wire 42C to ground 24 volts Check the circuit 42C, also check 5 position rotary lamp switch (112).

114 – Left Rear Cab Lamp





Terminal for wire 42R to ground 24 volts Check the circuit 42R, also check 5 position rotary lamp switch (112).

115 – Right Rear Cab Lamp





Terminal for wire 42R to ground 24 volts Check the circuit 42R, also check 5 position rotary lamp switch (112).

116 – Right Front Cab Lamp





Terminal for wire 42C to ground 24 volts Check the circuit 42C, also check 5 position rotary lamp switch (112).


4002-61

117 – Courtesy Light



NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) inposition 2 or higher.


Terminal for wire 49 to ground 24 volts Check the circuit 49, also check 5 position rotary lamp switch (112).

118 – Cab Dome Light



NOTE: Put the master disconnect switch in the ON position. Put the cab dome light switch (118) in either ONposition.


Terminal for wire 19U to ground 24 volts Check the fuse U, also check the circuit 19U.

NOTE: If the readings are good, replace the cab dome light (118).


4002-62

TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN MODELS

GM98M017

NOTE: Item numbers 111, 119 through 132 are for external lighting and signals for the European Models. See page59 and 63 for the High/Low Beam Relay (111). See page 59, item numbers 102 through 109 for external lightingand signals for the North American Models.

119. LEFT FRONT MARKER LAMP 124. RIGHT SIDE TURN (ITALY) 129. LEFT HEAD LAMP120. RIGHT FRONT MARKER LAMP 125. LEFT FRONT COMBINATION LAMP 130. RIGHT HEAD LAMP121. LEFT REAR MARKER LAMP 126. RIGHT FRONT COMBINATION LAMP 131. REAR LICENSE LAMP122. RIGHT REAR MARKER LAMP 127. LEFT REAR COMBINATION LAMP 132. ENGINE COMPARTMENT LAMP123. LEFT SIDE TURN (ITALY) 128. RIGHT REAR COMBINATION LAMP

127

128

132

129

121

125

123

122

130

126

124

131

120

119


4002-63

119 – Left Front Marker Lamp (European Models)





Terminal for wire 18F to ground 24 volts Check fuse F´, also check circuit 18F and 5 position rotary lamp switch (112).

120 – Right Front Marker Lamp (European Models)





Terminal for wire 18G to ground 24 volts Check fuse G´, also check circuit 18G and 5 position rotary lamp switch (112).

121 – Left Rear Marker Lamp (European Models)





Terminal for wire 18G to ground 24 volts Check fuse F´, also check circuit 18F and 5 position rotary lamp switch (112).

122 – Right Rear Marker Lamp (European Models)





Terminal for wire 18G to ground 24 voltsCheck fuse G´, also check circuit 18G and 5 position rotary lamp switch (112).


4002-64

123 – Left Side Turn (Italy)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switchis OFF. Move the turn signal lever (100) for a left turn.



voltsCheck circuits 45 and 45L, also check turn signal switch (100). Bad flasher module (101).

124 – Right Side Turn (Italy)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switchis OFF. Move the turn signal lever (100) for a right turn.



voltsCheck circuits 45 and 45R, also check turn signal switch (100). Bad flasher module (101).

125 – Left Front Combination Lamp (European Models)






Terminal for wire 45 to groundIntermittent 24 volts

Check circuits 45 and 45L, also check turn signal switch (100). Bad flasher module (101).


Terminal for wire 18F to ground 24 voltsCheck fuse F´, also check circuit 18F. Bad 5 position rotary lamp switch (112).


4002-65

126 – Right Front Combination Lamp (European Models)







voltsCheck circuits 45 and 45R, also check turn signal switch (100). Bad flasher module (101).


Terminal for wire 18G to ground 24 volts Check fuse G´, also check circuit 18G. Bad 5 position rotary lamp switch (112).

127 – Left Rear Combination Lamp (European Models)




Bulbs Continuity Bad bulb(s).


voltsCheck circuits 45 and 45L, also check turn signal switch (100) and flasher module (101).


Terminal for wire 41T and 18F to ground

24 volts Check fuse F´, also check circuit 41T and 18F and 5 position rotary lamp switch (112).

NOTE: Put the fog lights ON.

Terminal for wire 41TF and 41F to ground

24 volts Check circuit 41TF and 41F, also check fog light switch (110).




4002-66

128 – Right Rear Combination Lamp (European Models)




Bulbs Continuity Bad bulb(s).


voltsCheck circuits 45 and 45R, also check turn signal switch (100) and flasher module (101).


Terminal for wire 41T and 18G to ground

24 volts Check fuse G´, also check circuit 41T and 18G, also check 5 position rotary lamp switch (112).

NOTE: Put the fog lights ON.

Terminal for wire 41TF and 41F to ground

24 volts Check circuit 41TF and 41F, also check fog light switch (110).



129 – Left Head Lamp (European Models)



NOTE: Put the master disconnect switch in the ON position. Put the low beams ON.


Terminal for wire 18D to ground 24 volts Check fuse D´, also check circuit 18D and hi/low beam relay (111).

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the high beams ON.

Terminal for wire 18B to ground 24 volts Check fuse B´, also check circuit 18B and hi/low beam relay (111).

130 – Right Head Lamp (European Models)



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the low beams ON.


Terminal for wire 18E to ground 24 volts Check fuse E´, also check circuit 18E and hi/low beam relay (111).

NOTE: Put the master disconnect switch in the ON position. Put the high beams ON.

Terminal for wire 18C to ground 24 volts Check fuse C´, also check circuit 18C and hi/low beam relay (111).


4002-67

131 – Rear License Lamp (European Models)



NOTE: Put the master disconnect switch in the ON position. Put the rear license lamp ON.


Terminal for wire 18F to ground 24 volts Check fuse F´, also check circuit 18F and 5 position rotary lamp switch (112).

132 – Engine Compartment Lamp (European Models)



NOTE: Put the master disconnect switch in the ON position. Put the engine compartment lamp ON.


Terminal for red wire to ground 24 volts Check fuse U, also check circuit 19F/U, and engine compartment lamp switch (133).

133 – Engine Compartment Lamp Switch (European Models)


NOTE: Put the master disconnect switch in the ON position. Open the right side engine compartment door toclose switch. Remove both switch harness connections to check continuity.

Terminal A on connector 135 to terminal a on connector 137

Continuity Bad engine compartment lamp switch (133), also check circuit 19F/U and fuse U.


4002-68

CONNECTORS

GM98M018


4002-69

GM98M019


4002-70

GM98M020


4002-71

GM98M021


4002-72

GM98M022


4002-73

GM98M023


4002-74

GM98M024


4002-75

GM98M025


4002-76

GM98M026


4002-77

GM98M027


4002-78

GM98M028


4002-79

GM98M029


4002-80

GM98M030


4002-81

GM98M031


4002-82

GM98M032


4002-83


ELECTRICAL SCHEMATIC - SHEETS 29, 30, 31, AND 32

BC00E078

O/W

(65L

) 0

.8

O/W

(65R

) 0

.8

O/W

(65C

) 0

.8

O/W (65C) 0.8

O (1

9W)

1.0

O (1

9W)

3.0

R (12V) 5.0

1

4

1

4

SHEET 29 SHEET 30 SHEET 31 SHEET 32

CAB NEGATIVE STUD

CAB POSITIVE STUD

B (0

) 3

.0

TO FUSE "W"SHT 2

24V IGN

12VGND

O (1

9L)

1.0

R (1

2V)

3.0

FUSEBLOCK"C6","C12","C18"

REMOTE RADIO

RADIO HARN

JUMPER HARN

R (1

) 5

.0

TO 24V RADIO TO 12V RADIO

RADIOHARN

JUMPERHARN

24V 12VAB

RADIOHARNESS

6 3 1 2 5 4

14 5 11 4 9 2 1 3 6 7 8 10 12 13

A B

A B

AB

6 3 1 2 5 4

A B

A B

AB

6 3 1 2 5 4

A B

A B

AB

115

116

109

110

112

111

114

113

109

110

114

109 110

114

RADIOHARN

JUMPERHARN

B (0

) 5

.0

B (0

) 3

.0

FUSEBLOCK"C16"

FUSEBLOCK"C11"

O (1

9L)

1.0

TO FUSE "L"SHT 2

90

91

93

92 94

95

94

95

94

95

93A

93B

93

O (1

9L)

1.0

B (0

) 1

.0

B (0) 0.8

O/W (65C) 0.8

B (0

) 0

.8

O/W

(65C

) 0

.8

B (0

) 0

.8

B (0

) 0

.8

O/W

(65R

) 0

.8

O/W

(65L

) 0

.8

FUSEBLOCK"C5"

O (1

9L)

1.0

TO FUSE "L"SHT 2

B (0

) 0

.8

B (0

) 0

.8

O/W

(65R

) 0

.8

O/W

(65L

) 0

.8

B (0

) 1

.0

RADIOHARNESS

B (0) 0.8

B (0

) 0

.8

B (0

) 0

.8

B (0

) 0

.8

O/W

(65L

) 0

.8

O/W

(65R

) 0

.8

B (0

) 0

.8

B (0

) 0

.8

O (1

9L)

1.0

O (1

9L)

1.0

FUSEBLOCK"C5"

TO FUSE "L"SHT 2

RADIOHARNESS

O (1

9L)

1.0

O (1

9L)

1.0

FUSEBLOCK"C5"

TO FUSE "L"SHT 2

RADIOHARNESS

O/W

(65R

) 0

.8

O/W

(65C

) 0

.8

B (0

) 0

.8

B (0

) 0

.8

B (0

) 0

.8

O/W

(65L

) 0

.8O

/W (6

5L)

0.8

O/W (65C) 0.8

B (0) 0.8

O/W

(65R

) 0

.8

B (0

) 0

.8

B (0

) 0

.8

B (0

) 1

.0

CIGARLIGHTER

POWERCONVERTER

POWEROUTLET

REMOTERADIO

LEFTSPEAKER

RIGHTSPEAKER

24 VOLTRADIO

112

111LEFTSPEAKER

RIGHTSPEAKER

112

111LEFTSPEAKER

RIGHTSPEAKER

RADIOPOWER

CONVERTER

12 VOLTRADIO

4002-84


NOTES

4002-85


ELECTRICAL SCHEMATIC - SHEETS 1 AND 2

BC00E079

B (0) 1.0

DBr/LG (45L) 1.0 DBr/Y (45L) 1.0

T (44) 1.0DBr/LG (45R) 1.0

DBr/LG (45R) 0.8DBr/Y (45L) 0.8

T (44) 0.8

T (44) 0.8

DBr/Y (45L) 0.8

O/LB (64C) 0.8

B (0

) 0

.8

O/LB (64C) 0.8

O/LB (64D) 0.8

B (0) 0.8

B (0

) 1

.0

DBr (45N) 0.8

DBr (45H) 0.8

DBr/LG (45R) 1.0

DBr/Y (45A) 0.8

DBr/Y (45L) 0.8

DBr/LG (45B) 0.8

DBr/LG (45R) 0.8

DBr (45N) 0.8

B (0) 1.0

B (0) 1.0

B (0) 1.0

R (1B) 0.8R (1B) 0.8

DBr (45H) 0.8

DBr/Y (45A) 0.8

DBr/LG (45B) 0.8

B (0) 0.8

45 31

54

AB

1

2

H

R

L

H/L

B (0) 0.8

T (44) 1.0

Gy (49) 0.8

Gy

(49)

0.

8

Gy (49) 0.8

B (1B) 0.8

R (1B) 0.8

R (1B) 0.8

B (0) 1.0

B (0

) 1

.0

B (0

) 1

.0

B (0

) 1

.0

B (0) 1.0

CABCABROOF

P (46) 0.8

O (19B) 0.8

R (1B) 0.8

R (1

B)

0.8

Gy

(49)

1.

0

Gy (49) 1.0 4

5

6

2

4

5

6

2

TO PLOTCONT. SW.ON SHEET 16

PULL CONNECTOR APARTFOR EUROPEAN MACHINESSHOWN FOR NAO

CAB POSITIVE STUD

CAB SWITCHED POWER

INSTRUMENT ILLUMINATION

CAB NEGATIVE STUD

P (4

6)

1.0

O/LB (64D) 0.8

SHEET 1 SHEET 2

T (44) 1.0

DBr/Y (45L) 1.0

O (1

9B)

0.8

DBr/LG (45R) 1.0

TO CLUSTER CAVITY 35ON SHEET 17


P (4

6)

1.0

TO SPLICE#4 ON

SHEET 8

TO BACK-UPALARM DIS.SWITCH ON

SHEET 12

TO RR WIPERMOTOR GROUND

ON SHEET 25

TO BACK-UP ALARMDISABLE SWITCHON SHEET 12

TO PILOTCONT. SW.ON SHT 16

SPLICE WITH TIMEDELAY GROUNDON SHEET 10

VIA RR FOR HT. SW. ON SHEET 4

VIA RR FOG LT. SW.ON SHEET 1

T (44) 0.8


TO HORN RELAY#5 ON SHEET 26

DBr/LG (45R) 0.8

CAB FLOORWELD STUD

DBr/Y (45L) 0.8

M

NO

NCC

1

2

3

(SWITCH IN TREADLEVALVE BELOW CAB

CLOSES WITH BRAKEPEDAL ANGLE)

CIRCUIT BREAKER B12 AMP

POWER IN

FLASHER OUT

GROUND

GROUND

N.C.

N.C.

R. TURN LIGHT OUT

L. TURN LIGHT OUT

RIGHT TURN SW.

LEFT TURN SW.

HAZARD SW.

OPPOSITE SIDE CONTROL

1

2

3

4

5

67

8

9

10

11

12

S CAB|FRONT

A B

TO FUSE B ON SHEET 8

42

23

85

4

13

13

21

1

94

2

68

66

64

62

4

4

XAC

CAB|FRONT

554241

PED|CAB

10128

CAB|REAR9

117

REAR|REAR LIGHT

7069

PED|CAB

13

TO INSTRUMENTCLUSTER CAVITY 13

ON SHEET 14

13

65

PED|CAB

6766

15

CAB|PED

1

3

2

4

1

3

2

4

O (19X) 1.0 30

31

32

33

34

35

36

96

97

98

99

100

1011

BEACONSWITCH

ROTATINGBEACON

STOP LAMPSWITCH

71HAZARDSWITCH

67

TURN SIGNAL,HI/LOW BEAM,

AND HORNSWITCH

FLASHERMODULE

4002-86


ELECTRICAL SCHEMATIC - SHEET 3A

BC00E096

4002-87


ELECTRICAL SCHEMATIC - SHEETS 3, 4, AND 5

BC00E080

DBr/LG (45R) 1.0

DBr/LG (45R) 1.0

O (18F) 1.0

SWITCHPOSITION

LIGHTS

PARKANDTAIL

DRIVE FLOODF & R

ILLUMINATION

1 OFF

2 ON

3 ON ON ON

4 ON ON ON ON

5 ON ON ON

O (18D) 1.0

DB

e(4

2C)

1.0

O (19U) 1.0

NAO

SHEET 3 SHEET 4 SHEET 5

REAR|CAB


DBe (42R) 0.8

Y (18G/42R) 1.0 TO CAB/PED CONN.CAVITY 12 ON SHEET 14

H/L RELAY REMOVED ANDCONNECTOR MATED FOR NAO(H/L SHOWN FOR EURO)

NAO

EURO

P(4

1F)

1.0

TO ENG. COMP. LIGHT ON PAGE 3 (EURO)

6/7/821C ONLY

VIA SPLICE #3

TO BEACON SWITCHON SHEET 1

VIA GROUNDSPLICE

TO RETURN TO TRAVELSWITCH, SHEET 19

TO BEACON SW.ON SHEET 1

TO L.H. RR.MARKS LT. ON SHEET 1(EURO)

P (41J) 2.0

P (18F) 1.0

P (18G) 1.0

T (44) 1.0

DBe (42C) 1.0

B (0) 1.0

B(O

)2.

0

TO R.H. RR MARK LT.ON SHEET 1 (EURO)

C B A

A B C

C B A

A B CFRONTLIGHTFRONT

D B A C C A B D

O

P

E

J

Q

G

F

FRONT|CAB

6

8

17

10

REAR LIGHT|REAR

4

6

1

830

5656b

3

S

56a

3 45

21

3 45

21

3 45

21

F3ILHD B1 F2F4TL B3F1 B2

FUSE X BEACON (7.5)

FUSE Y FOG LIGHTS (7.5)

FUSE Z FRNT. FLOOD LIGHTS AND ILLUM (10A)

FUSE A REAR FLOOD LIGHTS (10A)

FUSE B HIGH BEAM LEFT (5A)

FUSE C HIGH BEAM RIGHT (5A)

FUSE D LOW BEAM LEFT (5A)

FUSE E LOW BEAM RIGHT (5A)

FUSE F TAIL LIGHTS LEFT (5A)

FUSE G TAIL LIGHTS RIGHT (5A)

RIGHTFUSES

A B

A B

A B

A B

TO FUSE U ON SHEET 10

106 105

6 79 8

94

21

1

18

33

34 32

23 24

79 83 80

78

A B

77

7

9

5

2

REAR|CAB

TO INSTRUMENT CLUSTERCAVITY 15 SHEET 14

4

5

2

6

4

5

2

6

21

B (0) 1.0

B (

0)

1.0

B (

0)

1.0

DB

r (4

5)

1.0

O (

18G

) 1

.0

O (

18E

) 1

.0

DB

r (4

5)

1.0

B (

0)

1.0

DB

e (

42C

) 1

.0

O (

18D

) 1

.0

B (

0)

1.0

B (0) 1.0

O (

18F

) 1

.0

B (

0)

1.0

B (0) 1.0 B (0) 1.0

B (0) 2.0

DBr/Y (45L) 1.0

T (44) 1.0

DBr/Y (45L) 1.0

1

3

2

4

O (19X) 1.030

31

32

33

34

35

36

102 103 104 105

110

109108

107106

T (44) 1.0

TO R.H. RR.MARKS LT. ON SHEET 1(EURO)

B (0) 2.0

O (18E) 1.0

DBe (42C) 1.0

O (18G) 1.0

O (18G) 1.0

O (18C) 1.0

O (18B) 1.0

O (18F) 1.0

O (18C) 0.8

O (18B) 0.8

O (18F) 0.8

O (18E) 0.8

P (18G) 1.0

P (18F) 1.0

P (41F) 1.0

O (18G) 0.8

P (41F) 1.0

TO L.H. RR.MARK LT. ON

SHEET 3 (EURO)

Gy (49) 1.0

B (0) 2.0

B (

0)

2.0

O (

18D

) 0

.8

1

3

2

4

O (

18G

) 0

.8

Gy

(49)

0.

8

O (

18G

) 0

.8

O (

18F

) 0

.8

O (

19Z

)

1.0

O (

18A

) 2

.0

R (

19Y

)

1.0

P (

41T

) 1

.0

P (

41L)

2.

0

P (

41H

) 2

.0

P (

41L)

0.

8

O (18C) 0.8

R (

1)

3.

0

R (

1)

3.0

P (

41J)

0.

8

P (41J) 2.0

P (41T) 1.0

R (1) 3.0

Gy (49) 1.0

DBe (42C) 0.8

O (18G) 0.8

B (0) 1.0

B (

0)

1.0

B (0) 1.0

B (

0)

1.0

B (

0)

1.0

B (

0)

1.0

B (

0)

1.0

B (

0)

1.0

B (0) 1.0

B (0) 1.0

B (0) 0.8

DB

e (

42C

)

1.0

DB

e (4

2C)

1.0

DB

e (

42R

)

1.0

DB

e (

42R

)

1.0

DB

e (4

2C

)

1.0

B (0) 0.8DBe (42C) 1.0

DBe (42R) 1.0

DBe (42C) 1.0

DBe (42R) 1.0

B (

0)

1.0

DB

e (

42R

)

1.0

DB

e (4

2C)

1.0

B (

0)

1.0

B (

0)

1.0

Gy

(49)

0.

8

B (

0)

0.8

Gy

(49)

1

.0

CABROOF

CAB

CABROOF

CAB

O (19U) 0.8

O (19U) 1.0

DBe (42R) 0.8

Gy (49) 0.8

B (0) 1.0

B (

0)

1.0

B (

0)

1.0

111

112

114113 115 116

118

117

CAB POSITIVE STUD

CAB SWITCHED POWER


CAB NEGATIVE STUD

LEFTMARKER/TURN

SIGNAL

LEFTDRIVELAMP

LEFTFLOODLAMP

RIGHTFLOODLAMP

RIGHTDRIVELAMP

RIGHTMARKER/TURN

SIGNAL

LEFT BRAKE,TAIL, AND DIRECTIONAL

RIGHT BRAKE,TAIL, AND DIRECTIONAL

43FOG

LIGHTSWITCH

25

5 POSITIONROTARY

LAMPSWITCH

59

HIGH/LOWBEAM RELAY

LEFTFRONT

CABLAMP

LEFTREARCAB

LAMP

RIGHTFRONT

CABLAMP

RIGHTREARCAB

LAMPCOURTESY

LIGHT

84

CABDOMELIGHT

4002-88


NOTES

4002-89

INDEX

Symbols12 Volt Radio ..........................................................5024 Volt Radio ..........................................................495 Position Rotary Lamp Switch...............................59

AAccessory Relay #3................................................17Air Filter Restriction Switch.....................................23Alternator ................................................................12

BBack-up Alarm ........................................................20Back-up Alarm Disable Switch ...............................20Back-up Alarm Relay #7.........................................19Batteries .................................................................11Beacon Switch........................................................52Beacon, Rotating ....................................................53Blower Motor ..........................................................45

Resistor Board with Thermal Fuse.....................45Blower Switch .........................................................44Brake Warning Pressure Switch.............................22Bucket Control Valves Detent Electromagnets.......32Bucket Dump Pressure Switch ...............................37Bucket Rollback Pressure Switch...........................38Bulb

Cab Dome Lamp ................................................61Courtesy Light ....................................................61Engine Compartment Lamp

(European Models) ....................................... 67Left Brake Lamp (North American Models) ........57Left Directional Lamp

(North American Models) .............................. 57Left Drive Lamp (North American Models) .........56Left Flood Lamp (North American Models) ........56Left Front Cab Lamp ..........................................60Left Front Combination Lamp

(European Models) ....................................... 64Left Front Marker Lamp

(European Models) ....................................... 63Left Head Lamp (European Models) ..................66Left Marker (North American Models) ................56Left Rear Cab Lamp...........................................60Left Rear Combination Lamp

(European Models) ....................................... 65Left Rear Marker Lamp

(European Models) ....................................... 63Left Side Turn Lamp (Italy).................................64Left Tail Lamp (North American Models)............57Left Turn Signal (North American Models) .........56Rear License Lamp (European Models) ............67Right Brake Lamp (North American Models)......58Right Directional Lamp

(North American Models) .............................. 58Right Drive Lamp (North American Models).......57Right Flood Lamp (North American Models) ......56

BBulb (Continued)

Right Front Cab Lamp........................................60Right Front Combination Lamp

(European Models) ........................................65Right Front Marker Lamp

(European Models) ........................................63Right Marker (North American Models)..............57Right Rear Cab Lamp ........................................60Right Rear Combination Lamp

(European Models) ........................................66Right Rear Marker Lamp

(European Models) ........................................63Right Side Turn Lamp (Italy) ..............................64Right Tail Lamp (North American Models) .........58Right Turn Signal (North American Models) ......57Rotating Beacon ................................................53

CCab Dome Light .....................................................61Cigar Lighter...........................................................48Circuit Diagram Legend............................................9Cluster, Instrument ...........................................25, 26Cold Start Temperature Switch ..............................13Color Abbreviations ..................................................9Compressor Clutch.................................................46Compressor Clutch Lockout Relay.........................46Compressor, Seat ..................................................44Condenser

Fan Motor No. 1 .................................................47Fan Motor No. 2 .................................................47

Condenser Fan Relay ............................................46Connector, Diagnostic ............................................19Converter, Radio Power (24 volts to 12 volts) ........50Coolant Level Sender.............................................22Courtesy Light ........................................................61

DDeclutch Brake Switch ...........................................19Declutch Switch......................................................19Detent Switch .........................................................31Diagnostic Connector .............................................19

EEngin Speed Sensor ..............................................19Engine Automatic Shutdown Relay Socket #11 .....30Engine Compartment Lamp

(European Models).............................................67Engine Compartment Lamp Switch

(European Models).............................................67Engine Coolant Temperature Sender.....................23Engine Oil Pressure Sender...................................28Ether Solenoid........................................................14Ether Start Relay ....................................................14


4002-90

EEther Start Switch...................................................14

FFilter Maintenance Switch ......................................19Flasher Module.......................................................54Fog Light Switch .....................................................58Front Rotary Wiper and Washer Switch .................40Front Washer Pump Motor .....................................41Front Wiper Motor...................................................40Fuel Level Sender ..................................................22Fuel Relay ..............................................................13Fuel Shutoff Solenoid .............................................12

GGraphic Symbols ......................................................8

HHazard Switch ........................................................53Height Control Proximity Switch .............................33Hi/Low Beam Switch...............................................54High Pressure Switch (In Rear Chassis) ................45High/Low Beam Relay (European Models) ............59Hoist-up Pressure Switch .......................................37Horn........................................................................44Horn Relay..............................................................43Horn Switch ............................................................54How to Use this Section .........................................10Hydraulic Filter Restriction Switch ..........................23Hydraulic Oil Temperature Sender .........................23

IIgnition Relay #1.....................................................15Ignition Relay #2.....................................................16Ignition Switch ........................................................15Instrument Cluster ............................................25, 26Intermediate Speed Sensor....................................19

LLamp

Cab Dome ..........................................................61Courtesy.............................................................61Engine Compartment (European Models)..........67Left Brake (North American Models) ..................57Left Directional (North American Models) ..........57Left Drive (North American Models) ...................56Left Flood (North American Models) ..................56Left Front Cab ....................................................60Left Front Combination (European Models) .......64Left Front Marker (European Models) ................63Left Head (European Models) ............................66Left Marker (North American Models) ................56Left Rear Cab.....................................................60Left Rear Combination (European Models)........65Left Rear Marker (European Models).................63Left Side Turn (Italy)...........................................64Left Tail (North American Models) .....................57

LLamp (Continued)

Left Turn Signal (North American Models).........56Rear License (European Models) ......................67Right Brake (North American Models) ...............58Right Directional (North American Models)........58Right Drive (North American Models) ................57Right Flood (North American Models)................56Right Front Cab..................................................60Right Front Combination (European Models) ....65Right Front Marker (European Models) .............63Right Head (European Models) .........................66Right Marker (North American Models) .............57Right Rear Cab ..................................................60Right Rear Combination (European Models) .....66Right Rear Marker (European Models) ..............63Right Side Turn (Italy) ........................................64Right Tail (North American Models) ...................58Right Turn Signal (North American Models) ......57Switch, 5 Position Rotary ...................................59

Left Brake Lamp (North American Models) ............57Left Directional Lamp (North American Models) ....57Left Drive Lamp (North American Models) .............56Left Flood Lamp (North American Models) ............56Left Front Cab Lamp ..............................................60Left Front Combination Lamp (European Models) .64Left Front Marker Lamp (European Models) ..........63Left Head Lamp (European Models) ......................66Left Marker Lamp (North American Models) ..........56Left Rear Cab Lamp ...............................................60Left Rear Combination Lamp (European Models)..65Left Rear Marker Lamp (European Models)...........63Left Side Turn Lamp (Italy).....................................64Left Speaker ...........................................................50Left Tail Lamp (North American Models)................57Low Pressure Switch (In Cab)................................45

MMaster Disconnect Switch ......................................12Module

Flasher ...............................................................54Time Delay.........................................................17Transmission Electronic Control ........................19

Motor, Starter .........................................................13

NNeutral Start Relay .................................................14Notes ........................................................................9

OOutlet, Power..........................................................49Output Speed Sensor.............................................19

PPark Brake Switch ..................................................24Parking Brake Relay...............................................29Pilot Control Relay..................................................29


4002-91

PPilot Control Switch ................................................26Pilot Pressure Solenoid ..........................................29Pin Engage Solenoid ..............................................36Pin Engagement Switch .........................................36Power Converter (24 volt to 12 volt) .......................49Power Outlet...........................................................49Program Reset Switch............................................24

RRadio

12 volt.................................................................5024 volt.................................................................49Power Converter (24 volts to 12 volts) ...............50Remote...............................................................49

Rear License Lamp (European Models).................67Rear Rotary Wiper and Washer Switch..................41Rear Washer Pump Motor......................................41Rear Wiper Motor ...................................................42Redundant Brake Switches ....................................30Redundant Parking Brake Solenoids......................29Relay

Accessory, #3.....................................................17Backup Alarm, #7...............................................19Compressor Clutch Lockout ...............................46Condenser Fan ..................................................46Ether Start ..........................................................14Fuel ....................................................................13High/Low Beam (European Models) ..................59Horn ...................................................................43Ignition, #1..........................................................15Ignition, #2..........................................................16Neutral Start .......................................................14Parking Brake.....................................................29Pilot Control........................................................29Ride Control .......................................................37Secondary Steering with Lockout.......................35Socket #11, Engine Automatic Shutdown ..........30Start....................................................................13Voltmeter, #12....................................................17

Remote Radio.........................................................49Return-To-Dig Proximity Switch .............................32Return-To-Travel Proximity Switch.........................33Return-To-Travel/Float Switch................................32Ride Control Relay .................................................37Ride Control Switch ................................................37Ride Engage Solenoid............................................38Right Brake Lamp (North American Models) ..........58Right Directional Lamp

(North American Models) ...................................58Right Drive Lamp (North American Models) ...........57Right Flood Lamp (North American Models) ..........56Right Front Cab Lamp ............................................60Right Front Combination Lamp

(European Models).............................................65Right Front Marker Lamp (European Models) ........63Right Head Lamp (European Models) ....................66

RRight Marker Lamp (North American Models) ........57Right Rear Cab Lamp.............................................60Right Rear Combination Lamp

(European Models).............................................66Right Rear Marker Lamp (European Models) ........63Right Side Turn Lamp (Italy) ..................................64Right Speaker.........................................................51Right Tail Lamp (North American Models) .............58Right Turn Signal Lamp

(North American Models) ...................................57Rotating Beacon.....................................................53

SSeat Compressor and Switch.................................44Secondary Steering Pump/Motor ...........................36Secondary Steering Relay with Lockout.................35Secondary Steering Switch ....................................35Sender

Coolant Level .....................................................22Engine Coolant Temperature .............................23Engine Oil Pressure ...........................................28Fuel Level ..........................................................22Hydraulic Oil Temperature .................................23Torque Converter Output Temperature..............19

SensorEngine Speed ....................................................19Intermediate Speed............................................19Output Speed.....................................................19Transmission Solenoid Valve and

Temperature ..................................................19Turbine Speed ...................................................19

Shifter, Transmission..............................................19Shutoff, Fuel Solenoid ............................................12Solenoid

Ether ..................................................................14Fuel Shutoff........................................................12Pilot Pressure.....................................................29Pin Engage ........................................................36Redundant Parking Brake..................................29Ride Engage ......................................................38

SpeakerLeft .....................................................................50Right...................................................................51

Specifications ...........................................................7Start Relay..............................................................13Starter Motor ..........................................................13Stop Lamp Switch ..................................................53Switch.....................................................................46

5 Position Rotary Lamp......................................59Air Filter Restriction............................................23Back-up Alarm Disable.......................................20Beacon...............................................................52Blower ................................................................44Brake Warning Pressure ....................................22Bucket Dump Pressure ......................................37Bucket Rollback Pressure ..................................38


4002-92

SSwitch (Continued)

Cold Start Temperature......................................13Declutch .............................................................19Declutch Brake...................................................19Detent.................................................................31Engine Compartment Lamp

(European Models) ....................................... 67Ether Start ..........................................................14Filter Maintenance..............................................19Fog Light ............................................................58Front Rotary Wiper and Washer ........................40Hazard................................................................53Height Control Proximity ....................................33Hi/Lo Beam ........................................................54High Pressure (In Rear Chassis) .......................45Hoist-up Pressure ..............................................37Horn ...................................................................54Hydraulic Filter Restriction .................................23Ignition................................................................15Low Pressure (In Cab) .......................................45Master Disconnect .............................................12Park Brake .........................................................24Pilot Control Switch ............................................26Pin Engagement.................................................36Program Reset ...................................................24Rear Rotary Wiper and Washer .........................41Redundant Brake ...............................................30Return-To-Dig Proximity.....................................32Return-To-Travel Proximity ................................33Return-To-Travel/Float.......................................32Ride Control .......................................................37Seat Compressor ...............................................44Secondary Steering............................................35Stop Lamp..........................................................53Transmission Auto .............................................19Transmission Kick-down ....................................19Turn Signal.........................................................54Up/down Count ..................................................27

Symbols, Graphic .....................................................8

TThermostat .............................................................46Thermostat Switch..................................................46Time Delay Module ................................................17Torque Converter Output Temperature Sender .....19Transmission Auto Switch ......................................19Transmission Electronic Control Module................19Transmission Kick-down Switch.............................19Transmission Shifter...............................................19Transmission Solenoid Valve and

Temperature Sensors ........................................19Transmission Solenoid Valve and Temperature

Sensors .....................................................19Turbine Speed Sensor ...........................................19Turn Signal Lamp (North American Models) ..........56Turn Signal Switch .................................................54

UUp/down Count Switch ...........................................27

VVoltmeter Relay #12...............................................17

WWiper

Front Motor ........................................................40Front Rotary Switch ...........................................40Front Washer Pump Motor.................................41Front Washer Switch..........................................40Rear Motor .........................................................42Rear Rotary Switch ............................................41Rear Washer Pump Motor .................................41Rear Washer Switch ..........................................41


Section4005

4005




April, 2000

INFORMATION AND DIAGNOSTICS CENTER

NOTES

4005-3

TABLE OF CONTENTS

INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Stop Master Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Caution Master Indicator (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Beacon Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Pilot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Low Coolant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Brake Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Secondary Steering Indicator (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Air Conditioning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Air Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Hydraulic Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission Oil Filter Indicator (Not applicable to 621C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Service Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

WARNING DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Non-Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Transmission Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Transmission Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Requested Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Actual Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Transmission Mode (Automatic or Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SETTINGS, DIAGNOSTICS, AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Programming the Information Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Manual Scrolling Gauge Displays (01, 02, or 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Automatically Scrolling Gauge Displays (03 or 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Individual Function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Testing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Setting Display Center Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Voltmeter at Key ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


4005-4

Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Park Brake Information Center Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Pilot Lockout Information Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Hydraulic Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Air Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Work Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Fog Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Air Conditioning Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Transmission Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Requested Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Operational Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Actual Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Drive Line Shift Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Hourmeter Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Tachometer Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Service Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Movement Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Beacon Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Left Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Right Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Caution and Warning Master Indicator Lights Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Diagnostic Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Park Brake Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Redundant Brake Pressure Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Service Brake Foot Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Pilot Lockout Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Display Location 047 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Display Location Numbers (048 and 049) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Minimum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Maximum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Gear Range Read Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Display Location Number 054 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Reset Diagnostic Stack for Locations 071 through 090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Display Location Numbers (056 - 060) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Service Interval Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26ZF Transmission ECM Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27ZF Transmission ECM Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Information Center Software Revision Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27LED Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27LCD Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Internal Information Center Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Display Location Number 097 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Entry Code for Accessing Test Mode Locations 100 to 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Transmission Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Display Location Numbers 104 - 113 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Instrument Cluster (Information Center) Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Instrument Cluster (Information Center) Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Instrument Cluster (Information Center) Date Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Display Location Numbers 117 - 120 Reserved for Supplier Information . . . . . . . . . . . . . . . . . . . . . . . . . 29Display Location Numbers 121 -129 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Display Location Numbers 131 - 139 Reserved for Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . 30Display Location Numbers 140 - 170 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Temporary Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30


4005-5

Display Location Numbers 191 - 196 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Display Location Number 197 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Display Location Number 198 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Display Location Number 199 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DISPLAY LOCATION NUMBERS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43


4005-6


4005-7

INFORMATION AND DIAGNOSTIC CENTER The information and diagnostic center monitors a number of functions and can be tailored to fit the operator’spreferences, refer to Figure 1. The information center not only monitors machine functions, it warns the operatorwhen caution is needed due to a possible malfunction and when immediate action is needed due to a possiblecritical malfunction. When the machine is started, the information and diagnostic center will perform the followingself-test:

RD98K316

FIGURE 1. INFORMATION CENTER

Self-Test IMPORTANT: During operation, if the stop masterindicator (on the front console) flashes, and thewarning alarm is continuous, stop the machine, stopthe engine, and find the problem.

1. Turn the ignition (key) switch to the ON position.

2. The information center will automatically checkeach monitored system.

3. All LED’s (Light Emitting Diodes) will illuminatefor 2 - 3 seconds.

4. Six bar graphs will energize for 2 - 3 seconds.

5. The warning alarm will sound for 2 - 3 seconds.

6. If there is an open circuit between a sensor andthe information center, the LED will flash and thewarning alarm will sound for 5 seconds.

1. BEACON INDICATOR 11. HYDRAULIC OIL FILTER INDICATOR2. WORK LIGHT INDICATOR 12. AIR FILTER INDICATOR3. PILOT CONTROL INDICATOR 13. TRANSMISSION OIL FILTER INDICATOR4. LOW COOLANT INDICATOR 14. TRANSMISSION OIL TEMPERATURE GAUGE5. BRAKE PRESSURE INDICATOR 15. HYDRAULIC OIL TEMPERATURE GAUGE6. STOP MASTER INDICATOR 16. VOLTMETER GAUGE7. CAUTION MASTER INDICATOR 17. FUEL LEVEL GAUGE8. SECONDARY STEERING INDICATOR 18. ENGINE OIL PRESSURE9. PARKING BRAKE INDICATOR 19. ENGINE COOLANT TEMPERATURE GAUGE

10. AIR-CONDITIONING INDICATOR 20. SERVICE INDICATOR ICON

1

19

18

17

14

15

16

23

45 6 7 8 9 10

1112

13

20


4005-8

7. If there were no faults detected during the check,all monitored systems will return to normaloperation.

8. If only some of the LEDs illuminate, replace theinformation center.

9. If the LEDs illuminate, but the warning alarmdoes not sound, replace the information center.

10. If the warning alarm sounds but the LEDs do notilluminate, replace the information center.

11. If the warning alarm does not sound and theLEDs do not illuminate on the information center,do the following steps to test the power circuit:

Power Circuit Test A. Check the 7.5 amp fuse V. If the fuse is bad,

replace the fuse and repeat Self-Test steps 1through 7. If the fuse is good, do the next step.

B. Check wire 19V for continuity. Repair/replacethe wire as required. If continuity is found dothe next step.

C. Check wire 13V for continuity. Repair/replacethe wire as required. If continuity is found, dothe next step.

D. Check the voltmeter relay #12 for properoperation, see Section 4002. If voltmeteroperates properly, do the next step.

E. If no faults are found in Power Circuit Teststeps A through D, then remove and replacethe information center.

Indicators and Gauges Stop Master Indicator (Red)

IMPORTANT: Failure to follow these procedures mayresult in injury and/or damage to the machine.

When the stop master indicator illuminates:

1. Stop the machine immediately.

2. Turn OFF the engine.

3. The warning alarm sounds continuously and oneor more of the following conditions exist:

A. Low engine oil pressure.

B. Low brake pressure.

C. Low steering pressure.

D. Low engine coolant level.

E. High engine coolant temperature.

F. High hydraulic oil temperature.

G. High transmission oil temperature.

Caution Master Indicator (Yellow)

When the caution master indicator illuminates:

1. The warning alarm sounds for three seconds.

2. The indicator turns yellow and one or more of thefollowing conditions exist:

A. Parking brake engaged when shifting intoforward or reverse.

B. High engine coolant temperature.

C. High hydraulic oil temperature.

D. High transmission oil temperature.

E. Low engine oil pressure.

F. High or low air conditioning pressure.

G. Air filter restriction.

H. Transmission filter restriction (not applicablefor 621C model).

I. Hydraulic filter restriction.

J. Alternator malfunction.

K. Low fuel.

Beacon Indicator

The beacon indicator illuminates when the Beacon (ifequipped) is in the ON position.

Work Light Indicator

The work light indicator illuminates when the worklights are ON.

Pilot Control

The Pilot Control indicator illuminates when the pilotlockout is actuated.

Low Coolant Indicator

The low coolant indicator illuminates when theengine coolant is low.

1. The warning alarm sounds continuously.

2. The stop master indicator will be red.

3. Stop the engine and add coolant to the radiator.

Brake Pressure Indicator

The brake pressure indicator illuminates when thebrake system pressure is too low.



3. Stop the engine and correct the problem.


4005-9

Secondary Steering Indicator (If equipped)

The secondary steering indicator illuminates whenthe primary steering system pressure is too low.



3. Stop the engine and correct the problem.

Parking Brake Indicator

The parking brake indicator illuminates when theparking brake is applied. If the transmission is shiftedinto FORWARD or REVERSE when the parkingbrake is applied:

1. The warning alarm sounds for 3 seconds.

2. The caution master indicator turns yellow.

3. Disengage the parking brake before shifting themachine.

Air Conditioning Indicator

The air conditioning indicator illuminates when the airconditioner has stopped due to refrigerant pressuresthat are too high or too low.



3. Service the air-conditioning system, or theoutside air temperature is too cool for the systemto work.

Air Filter Indicator

The air filter indicator illuminates when the air filter isrestricted.



3. Replace or clean the air filter as required.

Hydraulic Oil Filter Indicator

The hydraulic oil filter indicator illuminates when thehydraulic filters are restricted.



3. Replace the hydraulic oil filters as required.

Transmission Oil Filter Indicator (Not applicable to 621C)

The transmission oil filter indicator illuminates whenthe transmission filter(s) are restricted.



3. Replace the transmission oil filters as required.

Transmission Oil Temperature Gauge

The transmission oil temperature gauge is shown asan indicator bar with a green, yellow or red zone.

Green Zone:

Indicates normal operating temperature, 20° to 120°C (68° to 248° F).

Yellow Zone:

1. Transmission oil temperature is too low, 20° C orbelow (68° F or below), or it has increased, 120°to 125° C (248° to 257° F).

2. The indicator bars flash.


4. The yellow caution master indicator turns on.

Red Zone:

NOTE: The machine must not be operated when thetemperature is in the red zone.

1. Transmission oil temperature continues toincrease,125° C and above (257° F and above).

2. The indicator bar flashes.


4. The red stop master indicator turns on.

5. Stop the machine.

6. Shift the transmission into NEUTRAL.

7. Run the engine at half throttle until thetransmission cools.

8. If the transmission oil temperature does notreturn to normal operating temperature, run theengine at idle speed and check the transmissionoil level.

9. Correct the problem before continuing to operatethe machine.

Hydraulic Oil Temperature Gauge

The hydraulic oil temperature gauge is shown as anindicator bar with a green, yellow, or red zone.

Green Zone:


Yellow Zone:

1. Hydraulic oil temperature has decreased, 20° Cor below (68° F or below), or it has increased105° to 110° C (221° to 230° F).


4005-10




Red Zone:


1. Hydraulic oil temperature continues to increase110° C and above (230° F and above).




5. Stop the machine and correct the problem.

Voltmeter Gauge

The voltmeter gauge is shown as an indicator barwith a green or yellow zone.

Green Zone:

Indicates normal operating range:

A. 26 to 32 volts above low idle = normaloperating range.

B. 18 to 24 volts stopped or at low idle = low tonormal battery charge.

C. 18 to 24 volts at above low idle = problem incharging system.

Yellow Zone:

Voltage has increased or decreased:

A. 0 to 18 volts stopped or at low idle = very lowbattery charge.

B. 32 volts and above = problem in chargingsystem (overcharging).





Fuel Level Gauge

The fuel level gauge is shown as an indicator bar witha green or yellow zone.

Green Zone:

Indicates normal operating range, 5 percent andabove.

Yellow Zone:

The tank is almost empty, 5 percent and below.




Engine Oil Pressure Gauge

The engine oil pressure gauge is shown as anindicator bar with a green, yellow, or red zone.

Green Zone:

Indicates normal operating pressure, 140 kPa (20psi) and above low idle.

Yellow Zone:

1. Engine oil pressure has decreased, 100 to 140kPa (15 to 20 psi).




Red Zone:

NOTE: The machine must not be operated when theoil pressure is in the red zone.

1. Engine oil pressure continues to decrease belowa safe operating pressure, 0 to 100 kPa (0 to 15psi).





Engine Coolant Temperature

The engine coolant temperature gauge is shown asan indicator bar with a green, yellow, or red zone.

Green Zone:


Yellow Zone:

1. Engine coolant temperature has decreased 20°C or below (68° or below), or increased 105° to110° C (221° to 230° F).




Red Zone:



4005-11

1. Engine coolant temperature continues toincrease, 110° C or above (230° F or above).





Service Indicator Icon When a fault code is written, the service indicatoricon (a manual with a wrench) will be displayed onthe information center.


4005-12

WARNING DISPLAYS

Critical Warning Displays

IMPORTANT: Failure to follow these procedures may result in injury and/or damage to the machine.

The following table is a listing of critical warning displays that may appear on the information center and thecorrective action required. When a fault occurs, a continuous warning alarm will sound, the STOP indicator will beRED, and the Display indicator will be illuminated. When this occurs bring the machine safely to a stop andshutdown the engine to help avoid expensive repairs.

DISPLAY DESCRIPTION CORRECTIVE ACTION

ENGINE OIL PRESSURE

Low engine oil pressure.

1. Check low idle specifications.2. Change engine oil and filter.3. Change operating procedures.

BRAKE PRESSURE Low brake pressure.1. Bring the machine to a safe stop and shut the engine

OFF immediately. 2. Check brake system for proper charging and leaks.

STEERING PRESSURE

Low steering pressure.

1. Bring the machine to a safe stop and shut the engineOFF immediately.

2. Check the hydraulic fluid level.3. Check hydraulic system and steering system for leaks.

COOLANT LEVEL Low coolant level.


2. Check the coolant level.3. Check the engine cooling system for leaks.

COOLANT TEMPERATURE

High engine coolant temperature.


2. Check the coolant levels after allowing the engine andcoolant to cool down.

3. Clean the radiator.

HYDRAULIC OIL TEMPERATURE

High hydraulic oil temperature.


2. Check the hydraulic fluid level.3. Clean the cooler.

TRANSMISSION OIL TEMPERATURE

High transmission oil temperature.


2. Check the transmission fluid level.3. Clean the cooler.4. Check transmission for leaks.5. Select lower gear.


4005-13

Non-Critical Warning Displays The following table is a listing of warning displays that may appear on the information center and the correctiveaction required. When a fault occurs, a warning alarm will sound for three seconds, the CAUTION indicator will beYELLOW, and the display indicator will be illuminated. When this occurs, do the corrective action and return themachine to service. If the noncritical warning display continues, shutdown the machine and perform repairs.

DISPLAY DESCRIPTION CORRECTIVE ACTION

PARKING BRAKEParking brake engaged and

shifts from Forward to Reverse.Release the parking brake and depress the service brake.

COOLANT TEMPERATURE

High engine coolant temperature.

1. Idle machine and monitor temperature.2. Clean radiator.

HYDRAULIC TEMPERATURE

High hydraulic temperature.1. Idle machine and monitor temperature.2. Clean the cooler.

TRANSMISSION TEMPERATURE

High transmission temperature.1. Idle machine and monitor temperature.2. Clean the cooler.3. Use a lower gear.

ENGINE OIL PRESSURE

Low engine oil pressure.1. Check low idle specifications.2. Change engine oil and filter.3. Change operating procedures.

AIR CONDITIONINGHigh or low air conditioning

pressure.

1. Turn air conditioning OFF.2. Low outside temperature.3. Servicing required.

AIR FILTER High air filter restriction.1. Clean air filter.2. Replace primary and secondary filters.

TRANSMISSION FILTER

Transmission filter restriction. Replace transmission filter.

HYDRAULIC FILTER Hydraulic filter restriction. Replace hydraulic filter.

ALTERNATOR Alternator malfunction.1. Check electrical system.2. Voltages are out of range.3. Change operating procedure.

FUEL Low fuel. Fill fuel tank within the next hour.


4005-14

INFORMATION AND DIAGNOSTIC CENTER Many of the machine functions can be displayed on the Programmable Information Center. It can be programmedto display all functions, or only the functions important to the operator. The following functions can be displayed onthe Information Center, refer to Figure 2:

RD98K316

FIGURE 2. INFORMATION CENTER AND TRANSMISSION DISPLAY

Hourmeter The hourmeter displays the accumulated runningtime of the engine in hours and tenths of an hour withan “hour glass” symbol.

Tachometer The tachometer displays the engine speed inrevolutions per minute along with a “r/min” symbol.

Speedometer The speedometer displays the ground speed in eitherkilometers per hour (km/h) or miles per hour (mph)along with either a “km/h” or “mph” symbol.

Engine Coolant Temperature Displays the engine coolant temperature in Celsiuswith the engine coolant temperature bar graphflashing. See page 10 for a detailed description of thebar graph function.

Engine Oil Pressure Displays the engine oil pressure in kilopascals (kPa)with the engine oil pressure bar graph flashing. Seepage 10 for a detailed description of the bar graphfunction.

Fuel Level Displays the fuel level in percent remaining in thetank with the fuel level bar graph flashing. See page10 for a detailed description of the bar graph function.

1. DIRECTION (F-N-R) 4. REQUESTED GEAR (1, 2, 3, 4)2. TRANSMISSION DISPLAY 5. ACTUAL GEAR BARS3. DISPLAY CENTER 6. TRANSMISSION MODE (A OR BLANK)

1

6

2

3

4

5


4005-15

Transmission Oil Temperature Displays the transmission oil temperature in Celsiuswith the transmission oil temperature bar graphflashing. See page 9 for a detailed description of thebar graph function.

Hydraulic Oil Temperature Displays the hydraulic oil temperature in Celsius withthe hydraulic oil temperature bar graph flashing. Seepage 9 for a detailed description of the bar graphfunction.

Voltmeter Displays the electrical system voltage level in voltswith the voltmeter bar graph flashing. See page 10for a detailed description of the bar graph function.

Transmission Display The Transmission Display shows the status of thetransmission control. The display center contains thefollowing information, refer to Figure 2:

Direction SelectedShown at the top of the display center:

Requested Gear The gear position on shift lever, shown in thecenter of the gear symbol:

Actual Gear

Shown with bars‘ to the right of the gear symbol. Thenumber of bars indicates the gear the transmission isactually in.

Transmission Mode (Automatic or Manual)

Shown in the lower left of the display center:

F Forward

N Neutral

R Reverse

F Flashing forward not engaged.

N Flashing set control lever to neutral position.

R Flashing reverse not engaged.

1 1st gear

2 2nd gear

3 3rd gear

4 4th gear

A Automatic Mode

No symbol will be displayed when transmission is in Manual Mode.


4005-16

SETTINGS, DIAGNOSTICS, AND FAULT CODES

RD98K316

FIGURE 3. INFORMATION CENTER

Programming the Information Center NOTE: The machine must be OFF prior toprogramming the information center.

Two switches are used during the programming ofthe information center: the up/down count switch andthe program/reset switch. These switches are locatedon the right hand side of the information center, referto Figure 3.

For an up count press the left side of the up/downcount switch. For a down count press the right side ofthe up/down count switch. The center position is OFFor NEUTRAL.

For programming press the le f t s ide o f theprogram/reset switch. For resetting press the rightside of the program/reset switch. The center positionis OFF or NEUTRAL.

To program the information center do the followingsteps:

1. Turn the machine OFF.

2. Turn the key to the RUN position.

3. Press the program/reset switch to program.

4. Press the up/down count switch to up countprogram location 010.

5. Center the program/reset switch to OFF.

6. Note the gauge display setting that is displayed,01, 02, 03, 04, or 05. If the desired setting hasalready been selected go to step 7.

7. Press the up/down count switch to up count tochoose one of the following gauge displaysettings:

1. INFORMATION CENTER 3. UP COUNT 5. PROGRAM2. DISPLAY CENTER 4. DOWN COUNT 6. RESET

3 4 5 6

1

2


4005-17

8. Press the program/reset switch to resetmomentarily.

9. If the Information Center does not functionproperly, do the programming steps again.

10. If the Information Center continues tomalfunction replace the instrument panel.

Manual Scrolling Gauge Displays (01, 02, or 05

If the Information Center has been programmed todisplay one of the manual scrolling displays (01, 02,or 05) press the up/down count switch to up countand scroll through the gauge displays.

1. Press the up count switch one time to display theTachometer.

2. Press the up count switch again to display theSpeedometer (km/h).

3. Press the up count switch again to display theHourmeter.

Automatically Scrolling Gauge Displays (03 or 04)

If the Information Center has been programmed withone of the automatic scrolling displays the gaugedisplay will automatically scroll through after startingthe machine. The up/down count switch has no effecton the display.

Individual Function Display

Do the following steps to display any individualfunction, at anytime, regardless of the gauge displaythat was programmed:


2. Press the up/down count switch to up count andselect one of the following individual functions:

3. Put the program/reset switch in the OFF (center)position.

4. If one of the individual functions (004 through009) is selected, the corresponding bar graph willflash indicating that this individual function isbeing displayed.

5. The individual function selected will be shown onthe information center.

Testing the Park Brake

Do the following steps to test the parking brake:

NOTE: The Transmission Control Module willdisconnect the transmission if any gear other than3rd is used.

1. Turn the machine ON.

2. Make sure the transmission is in the manual shiftmode, the gear selector is in 3rd neutral gear,and the park brake switch is ON.

3. Set the park brake calibration as follows:

A. Press the program/reset switch to program.

B. Press the up/down count switch to up countuntil the display reads 011.

C. Put the program/reset switch in the OFF(center) position.

01 Manually scrolls through Hourmeter, Tachometer, and Speedometer (km/h).

02 Manually scrolls through Hourmeter, Tachometer, and Speedometer (mph).

03

Automatically scrolls through Hourmeter (at start-up), Tachometer (in 1st and 3rd gears), and Speedometer (km/h in 4th gear).

04

Automatically scrolls through Hourmeter (at start-up), Tachometer (in 1st and 3rd gears), and Speedometer (mph in 4th gear).

05

Manually scrolls through Hourmeter, Tachometer, and Speedometer (mph), Speedometer (km/h), Engine Oil Temperature (Celsius), Engine Oil Pressure, Fuel Level, Transmission Oil Temperature (Celsius), Hydraulic Oil Temperature (Celsius), and Voltmeter.

NOTE: 05 is the factory installed setting.

000 Hourmeter

001 Tachometer

002 Speedometer (mph)

003 Speedometer (km/h)

004 Engine Oil Temperature

005 Engine Oil Pressure

006 Fuel Level

007 Transmission Oil Temperature

008 Hydraulic Oil Temperature

009 Voltmeter


4005-18

D. Press the up/down count switch to up countonce, so the display reads 01.

E. Shift the transmission selector into 3rd forwardand slowly increase the engine rpm.

F. The park brake should hold the machine at fullthrottle.

G. To exit the test mode, press the program/resetswitch to reset.

Transmission Clutch Calibration

Clutch Calibration ensures the most optimum shiftingof the transmission. Before doing the followingtransmission clutch calibration procedures make sureof the following:

1. The machine is running and the transmission oilis warm.

2. Engine low idle speed is correct.

3. The transmission is in neutral.

4. The park brake is applied.

5. If steps 1 through 4 have been accomplished,calibrate the transmission clutches as follows:

A. Put the transmission in the manual shift modeand the gear selector in 3rd gear neutral.

B. Press the program/reset switch to program.

C. Press the up/down count switch to up countuntil the display reads 011.

D. Put the program/reset switch in the OFF(center) position.

E. Press the up/down count switch to up counttwice, so the display reads 02.

F. 2 00 00 will begin to flash in the display center.

G. After one second, the Clutch Calibration MainCode status will be displayed in the 3rd and4th spaces (2 XX 00, the XX represents the3rd and 4th spaces).

H. The Modulation Cycle Number will bedisplayed in the 1st and 2nd spaces (2 00 XX,the XX represents the 1st and 2nd spaces).

I. During Clutch Calibration, the ClutchCalibration Main Code will change from 01 to07 as the process is completed. Code 07indicates that the calibration process iscomplete and the information center will returnto normal working status.

J. If any of the Clutch Calibration parameters areincorrect, the display center will stop flashingand display a code in the 1st, 2nd, 3rd, and4th spaces.

If this occurs, the code in the 3rd and 4thspaces will be a Clutch Calibration Main Code09 through 14 and indicate what process thecalibration was in when it was aborted

The 1st and 2nd spaces will produce theClutch Calibration Sub Code, which is thecode that informs the operator of the reasonthe process was aborted.

K. After completing the Clutch Calibrationprocedure, turn the machine OFF for 15seconds. This sets the calibration in thecontroller.

CLUTCH CALIBRATION MAIN CODES

Main Code Meaning

00Clutch Calibration Mode was not initiated because one of the requirements was not met.

01 Adjusting 1st gear.

02 Adjusting 2nd gear.

03 Adjusting 3rd gear.

04 Adjusting 4th gear.

05 Adjusting Forward gear.

06 Adjusting Reverse gear.

07 Clutch Calibration Completed.

08 Operator aborted calibration procedure.

09 Aborted while adjusting 1st gear.

10 Aborted while adjusting 2nd gear.

11 Aborted while adjusting 3rd gear.

12 Aborted while adjusting 4th gear.

13 Aborted while adjusting Forward gear.

14 Aborted while adjusting Reverse gear.

CLUTCH CALIBRATION SUB CODES

Sub Code Meaning

00 Calibration in process.

01 Fault present.

02 Shift lever not in neutral.


4005-19

Setting Display Center Lighting

Do the following procedures to set the brightnessof the display lighting:


2. Press the up/down count switch to up count untilthe display reads 012 (for working lights OFF) or013 (for working lights ON).

3. Place the program/reset switch in the OFF(center) position.

4. Increase the brightness by pressing the up/downcount switch to the up count position.

5. Decrease the brightness by pressing theup/down count switch to the down count position.

NOTE: The brightness can be varied between 001and 100, with 100 being the brightest. The factory setbrightness is 070 for working lights OFF and 020 forworking lights ON.

6. Press the program/reset switch to reset(momentar i ly, 0.25 seconds) to enter theselected brightness setting.

Voltmeter at Key ON Position

Do the following procedures to read the systemvoltage at the key ON position.


2. Press the up/down count switch to up count untilthe display reads 014.


4. The system voltage is displayed at the key ONposition.

5. Press the program/reset switch to reset to exitthe monitoring mode.

Alarm Check

Do the following procedures to check the audiblealarm system.



3. The alarm will begin to sound intermittently.


5. The Information Center will display 00 and soundthe alarm, when the machine is being checked,while all systems are normal. If there is a fault inthe system that would cause the alarm to sound,the Information Center will display 01 while thealarm is being checked. The alarm will soundintermittently.

Coolant Level Check

Do the following procedures to check the coolantlevel indicator light and the coolant level switch.



3. The coolant light will flash intermittently.


5. The Information Center will display 00, when themachine is being checked, if the coolant level isnormal. If the coolant level is low, the InformationCenter will display 01 while the coolant levelswitch is being checked. The coolant light willflash intermittently on the Information Center.

Brake Pressure

Do the following procedures to check the brakepressure indicator light and the brake pressureswitch.


2. Press the up/down count switch to up count untilthe display reads 017. The brake pressure lightwill flash intermittently.


4. The Information Center will display 01, when themachine is being checked, if the brake pressureis normal. If the brake pressure is low, theInformation Center will display 00 while the brakepressure switch is being checked. The brakepressure light will flash intermittently on theInformation Center.

03 Park brake not applied.

04 Output speed not 0 kph/mph.

05 Low transmission oil temperature.

06 High transmission oil temperature.

07 Low engine RPM.

08 High engine RPM.


4005-20

Secondary Steering Pressure Switch

Do the following procedures to check the secondarysteering pressure indicator light and the secondarysteering switch.


6. Press the up/down count switch to up count untilthe display reads 018. The secondary steeringpressure light will flash intermittently.


8. The Information Center will display 01, when themachine is being checked, if the secondarysteering switch is not activated. If the secondarysteering switch is activated, the InformationCenter will display 00 while the secondarysteering switch is being checked. The secondarysteering light will flash intermittently on theInformation Center.

Park Brake Information Center Output Check

Do the following procedures to check the park brakeindicator light and the status of the signal that theInformation Center is sending to the park brake relay(to engage or disengage).


2. Press the up/down count switch to up count untilthe display reads 019. The park brake light willflash intermittently.


4. The Information Center will display 00, when theInformation Center is not activating the parkbrake relay. The Information Center will display01 when it is activating the park brake relay. Thepark brake light will flash intermittently on theInformation Center.

Pilot Lockout Information Output Check

Do the following procedures to check the pilot lockoutindicator light and the status of the signal that theInformation Center is sending to the pilot lockoutrelay (to engage or disengage).


2. Press the up/down count switch to up count untilthe display reads 020. The pilot lockout light willflash intermittently.


4. The Information Center will display 00, when theInformation Center is not activating the pilotlockout relay. The Information Center will display01 when it is activating the pilot lockout relay. Thepilot lockout light will flash intermittently on theInformation Center.

Hydraulic Filter Restriction Switch Check

Do the following procedures to check the hydraulicfilter restriction indicator light and the hydraulic filterrestriction switch.


2. Press the up/down count switch to up count untilthe display reads 021. The hydraul ic f i l terrestriction indicator light will flash intermittently.


4. The Information Center will display 01, when themachine is being checked, if the hydraulic filterres t r ic t ion sw i tch is not act ivated. I f thehydraulic filter restriction switch is activated, theInformation Center will display 00 while thehydraul ic f i l ter restr ic t ion swi tch is beingchecked. The hydrau l ic f i l te r res t r ic t i onindicator light will flash intermittently on theInformation Center.

Air Filter Restriction Switch Check

Do the following procedures to check the air filterrestriction indicator light and the air filter restrictionswitch.


2. Press the up/down count switch to up count untilthe display reads 022. The air filter restrictionindicator light will flash intermittently.


4. The Information Center will display 01, when themachine is being checked, if the air f i l terrestriction switch is not activated. If the air filterrestriction switch is activated, the InformationCenter will display 00 while the air filter restrictionswitch is being checked. The air filter restrictionindicator light will flash intermittently on theInformation Center.

Work Lights Check

Do the following procedures to check the work lightsindicator light and the work light electrical signalcoming into the Information Center.



4005-21

2. Press the up/down count switch to up count untilthe display reads 023. The secondary work lightsindicator light will flash intermittently.


4. The Information Center will display 00 when thework lights are OFF and 01 when the work lightsare ON. The work l ights indicator l ight willcontinue to flash intermittently and the numberson the display will change in accordance with thestatus of the work lights.

Fog Lights Check

Do the following procedures to check the fog lightsindicator light and the fog light electrical signalcoming into the Information Center.


2. Press the up/down count switch to up count untilthe display reads 024. The fog lights indicatorlight will flash intermittently.


4. The Information Center will display 00 when thefog lights are OFF and 01 when the fog lights areON. The fog lights indicator light will continue toflash intermittently and the numbers on thedisplay will change in accordance with the statusof the fog lights.

Air Conditioning Switch Check

Do the fol lowing procedures to check the airconditioning indicator light and the air conditioninghigh/low pressure switch.


2. Press the up/down count switch to up count untilthe display reads 025. The air conditioningindicator light will flash intermittently.


4. The Information Center will display 00, when themachine is being checked, if the air conditioninghigh/low pressure switch is not activated. If theair conditioning high/low pressure switch isactivated, the Information Center will display 01while the air conditioning high/low pressureswitch is being checked. The air conditioningindicator light will flash intermittently on theInformation Center.

Transmission Filter Restriction Switch Check

Do the fo l l ow ing p rocedures to check thetransmission filter restriction indicator light and thetransmission filter restriction switch.


2. Press the up/down count switch to up count untilthe display reads 026. The transmission filterrestriction indicator light will flash intermittently.


4. The Information Center will display 00, when themachine is being checked, if the transmissionfilter restriction switch is not activated. If thetransmission filter restriction switch is activated,the Information Center will display 01 while thetransmission filter restriction switch is beingchecked. The transmission filter restr ictionindicator light will flash intermittently on theInformation Center.

Requested Gear Check

Do the following procedures to check that the gearbeing requested by the shifter is the same gear thatthe Information Center is reading.


2. Press the up/down count switch to up count untilthe display reads 028. The “F, N or R” indicator inthe transmission display will flash intermittently.


4. Place the gear shifter in all positions and verifythat the code in each position corresponds to thecodes in the table below

:

Operational Indicator Status

Do the following procedures to check the status ofthe operational indicator.


Forward 1-Code 101

Neutral 1-Code 201

Reverse 1-Code 301

Forward 2-Code 102

Neutral 2-Code 202

Reverse 2-Code 302

Forward 3-Code 103

Neutral 3-Code 203

Reverse 3-Code 303

Forward 4-Code 104

Neutral 4-Code 204


4005-22

2. Press the up/down count switch to up count untilthe display reads 029. The operational indicatorflashes intermittently.


4. The Information Center will read 00.

Actual Gear Check

Do the following procedures to check that the gearengaged in the transmission is the same gear thatthe Information Center is reading.

1. With the engine running put the transmission inmanual mode and release the parking brake.


3. Press the up/down count switch to up count untilthe display reads 030. The bars that outline thelarge gear in the transmission display will flashintermittently.


5. Place gear that the transmission is incorresponds to the codes in the table below.

:

Drive Line Shift Status

Do the following procedures to check the drive lineshift status.

1. With the engine running, release the parkingbrake.


3. Press the up/down count switch to up count untilthe display reads 031. The drive line shift statusbars flash intermittently.



6. Shift the shift lever.

7. The Information Center will read 001 when theshift is being made.

8. The Information Center will read will read 010 ifthe transmission does not engage the drive line.

9. The Information Center will read 110 if thetransmission is in Substitute Clutch ControlMode.

10. The Information Center will read 210 if thetransmission is in Limp Home Mode.

11. The Information Center will read 300 if thetransmission is in Shutdown Mode.

12. The Information Center will read 400 if thetransmission is in T.E.C.M. Shutdown Mode.

Hourmeter Indicator Status

Do the following procedures to check the status ofthe hourmeter indicator.


2. Press the up/down count switch to up count untilthe display reads 032. The hourmeter indicatorflashes intermittently.



Tachometer Indicator Status

Do the following procedures to check the status ofthe tachometer indicator.


2. Press the up/down count switch to up count untilthe display reads 033. The tachometer indicatorflashes intermittently.



Service Indicator Status

Do the following procedures to check the status ofthe service indicator.


2. Press the up/down count switch to up count untilthe display reads 034. The service indicatorflashes intermittently.


Forward 1-Code 101

Neutral 1-Code 201

Reverse 1-Code 301

Forward 2-Code 102

Neutral 2-Code 202

Reverse 2-Code 302

Forward 3-Code 103

Neutral 3-Code 203

Reverse 3-Code 303

Forward 4-Code 104

Neutral 4-Code 204

Limp HomeMode - 115

Limp HomeMode - 215

Limp HomeMode - 315


4005-23

4. The Information Center will read 00 if the serviceindicator is OFF or 01 if the service indicator isON.

Movement Indicator Status

Do the following procedures to check the status ofthe movement indicator.


2. Press the up/down count switch to up count untilthe display reads 035. The Kph and Mphindicators flash intermittently.



Beacon Status

Do the following procedures to check the status ofthe beacon.


2. Press the up/down count switch to up count untilthe display reads 036. The beacon indicatorflashes intermittently.


4. The Information Center will read 00 if the beaconis OFF or 01 if the beacon is ON.

Left Turn Indicator Status

Do the following procedures to check the status ofthe left turn indicator.


2. Press the up/down count switch to up count untilthe display reads 037. The left turn indicatorflashes intermittently.


4. The Information Center will read 00 if the leftturn indicator is OFF or 01 if the left turnindicator is ON.

Right Turn Indicator Status

Do the following procedures to check the status ofthe right turn indicator.


2. Press the up/down count switch to up count untilthe display reads 038. The right turn indicatorflashes intermittently.


4. The Information Center will read 00 if the rightturn indicator is OFF or 01 if the r ight turnindicator is ON.

Caution and Warning Master Indicator Lights Status

Do the following procedures to ensure that thecaution and warning lights are working correctly.


2. Press the up/down count switch to up count untilthe display reads 039 (Critical Master Light Red).


4. The Information Center will read 00 if theindicator is OFF under normal operation, or 01 ifthe indicator is ON under normal operation


6. Press the up/down count switch to up count untilthe display reads 041 (Caution Master LightYellow).


8. The Information Center will read 00 if theindicator is OFF under normal operation, or 01 ifthe indicator is ON under normal operation

Diagnostic Indicator Status

Do the following procedures to check the status ofthe diagnostic indicator.


2. Press the up/down count switch to up count untilthe display reads 040. The diagnostic indicatorflashes intermittently.



Master Reset

Do the following procedure to reset the InformationCenter to the values set at the factory for the GaugeDisplay, Information Center lighting for work lights offand on, minimum gear selection in automatic mode,and maximum gear selection.




4005-24


4. Press the up/down count switch to up count twiceto change the readings from 00 to 01.

5. Press the program/reset switch momentarily(0.25 second) to reset.

Park Brake Switch Check

Do the following procedures to check the park brakeswi tch and the s tatus o f the s igna l that theInformation Center is receiving from the park brakeswitch (to engage or disengage).




4. The Information Center will display 00, when theInformation Center is not receiving a signal fromthe park brake switch to engage the park brake.The Information Center will display 01 when it isreceiving a signal from the park brake switch toengage the park brake.

5. Cycle the park brake switch to ensure it isworking in both directions.

Redundant Brake Pressure Switch Check

Do the following procedures to check the redundantbrake pressure switch.


2. Press the up/down count switch to up count untilthe display reads 044. The brake light will flashintermittently.


4. The Information Center will display 00, when themachine is being checked, if the brake pressureis normal and there is nothing wrong with theci rcui t . I f the brake pressure is low, theInformation Center will display 01 while theredundant brake pressure switch is beingchecked. The brake light will flash intermittentlyon the Information Center.

Service Brake Foot Switch Check

Do the following procedures to check the servicebrake foot switch.


2. Press the up/down count switch to up count untilthe display reads 045. The park brake lightflashes intermittently.


4. The Information Center will read 00 when theswitch is open (service brakes are not applied)and 01 when the switch is closed (service brakesare applied).

Pilot Lockout Switch Check

Do the following procedures to check the pilot lockoutindicator light and the status of the signal that theInformation Center is receiving from the pilot lockoutswitch (to engage or disengage).




4. The Information Center will display 00, when theInformation Center is not receiving a signal fromthe switch to engage the pilot lockout. TheInformation Center will display 01 when it isreceiving a signal from the switch to disable theloader hydraulic controls.

5. Cycle the switch to ensure it is working in bothdirections.

Display Location 047

Do the following procedures to check display location047.


2. Press the up/down count switch to up count untilthe display reads 047. The pilot lockout lightflashes intermittently.


4. The Information Center will read 00 if the circuitis closed or 01 if there is a circuit malfunction.


4005-25

Display Location Numbers (048 and 049) Reserved for Future Use

Minimum Gear Selection

Do the fo l lowing procedures to program thetransmission for the lowest gear possible in theautomatic mode.

NOTE: The 1st or 2nd gear can be selected. Thegear that is selected will be the gear that thetransmission is in when the machine begins to move.The factory minimum gear setting is 1.




4. Read the number (1 or 2) shown on theInformation Center. If this is the desired gearselection, press the program/reset switch toeither program or reset.

5. If you want the other minimum gear selection,press the up/down count switch to up count.

6. Press the program/reset switch momentarily(0.25 seconds) to reset.

Maximum Gear Selection

Do the fo l lowing procedures to program thetransmission for the highest gear possible in theautomatic mode.

NOTE: The 2nd, 3rd, or 4th gear can be selected.The gear that is selected will be the highestattainable gear that the transmission will be able toreach. The factory maximum gear setting is 4.




4. Read the number (2, 3, or 4) shown on theInformation Center. If this is the desired gearselection, press the program/reset switch toeither program or reset.

5. If you want a different maximum gear selection,press the up/down count switch to up count untilthe desired number is displayed.

6. Press the program/reset switch momentarily(0.25 seconds) to reset.

Gear Range Read Only

Do the following procedures to read the gear range.


2. Press the up/down count switch to up count untilthe display reads 052. The operational indicatorwill flash intermittently.


4. The Information Center will read 1 or 2 (gears).


6. Press the up/down count switch to up count untilthe display reads 053. The operational indicatorwill flash intermittently.


8. The Information Center will read 2,3, or 4(gears).

Display Location Number 054 Reserved for Future Use

Reset Diagnostic Stack for Locations 071 through 090

Do the following procedure to remove all diagnosticcodes from field number locations 071 through 090.


2. Press the up/down count switch to up count untilthe display reads 055. The service indicator willflash intermittently.



5. Press the program/reset switch to reset. If thereare diagnostic codes in field number locations071 through 090 they will be removed, unless thecondition still exists.


4005-26

Display Location Numbers (056 - 060) Reserved for Future Use

Service Interval Hours

Field number locations 61 through 70 are serviceinterval hour settings. The service interval hoursaccumulate until they are reset. Once they are reset,they begin accumulating hours independent from themachine hours until they are reset again. Do thefollowing procedures to view or reset the serviceinterval hours.

NOTE: If the operator wanted location 061 toindicate when the engine oil should be changed,location 061 would be reset to begin accumulatinghours for the next oil change. The operator couldthen go into location 061 and monitor accumulatinghours. When location 061 reaches the engine oilchange interval, the operator would change the oiland reset location 061 again.

1. To view the service hour interval locations do thefollowing:


B. Press the up/down count switch to up countuntil the display reads the desired location(061 - 070).

C. Place the program/reset switch in the OFF(center) position.

D. Read the accumulated hours in the chosenlocation.

2. To reset the service interval hours do thefollowing:




D. Press the up/down count switch to down countand hold it for 3 seconds. The service intervalhours in the chosen location will reset to 0.

Fault Code Status

Field number locations 071 through 090 display faultcodes and the hours the faults occurred. TheInformation Center continuously monitors themachine’s condition and records any fault codes;however, it will only record a duplicate code onceevery hour. When a fault code is written, the serviceindicator icon (a manual with a wrench) will bedisplayed on the Information Center.

1. To view the fault codes and the hours theyoccurred do the following:




D. Read any fault codes in the chosen location.

NOTE: A complete list of fault codes can befound in the Fault Code Table in this section.

E. Press the program/reset switch to program.

F. Press the up/down count switch to up countone time to advance to the next location.

G. Place the program/reset switch in the OFF(center) position.

H. Read the hours that the previous fault codeoccurred at.

NOTE: The hour location will always follow the faultcode location.

NOTE: Example: Location 072 will display the hourson the machine when the fault code in location 071was written. Location 074 will display the hours onthe machine when the fault code in location 073 waswritten.

2. To monitor a particular location without going intothe programming mode do the following:


B. Press the up/down count switch to up countuntil the location to be monitored is displayed.


D. Press the program/reset switch to programand wait 5 seconds. The numbers on thedisplay will change.

E. Place the program/reset switch in the OFF(center) position.

F. Within 3 seconds, press the program/resetswitch to reset once.

G. With the machine is in normal operating modepress the program/reset switch to reset todisplay the hours accumulated in the selectedlocation. (Location 000 (hour meter) isprogrammed into the Information Center fromthe factory.


4005-27

H. To reset a programmed location back to 000(hour meter - factory sett ing), hold theprogram/reset switch to reset for 5 seconds.When it is reset, the operator can view thehour meter a t any t ime dur ing normaloperating conditions by pressing the resetswitch.

ZF Transmission ECM Part Number (1st part)

Do the following to display the first par t of thetransmission ECM ZF part number.




4. The Information Center will display the first partof the ZF Transmission ECM par t number(6009#, # is a digit from 0 to 9).

ZF Transmission ECM Part Number (2nd part)

Do the following to display the second part of thetransmission ECM ZF part number.




4. The Information Center will display the secondpart of the ZF Transmission ECM part number(#####, # is a digit from 0 to 9).

Information Center Software Revision Number

Do the following to display the Information Centersoftware revision number.




4. The Information Center will display the softwarerevision number.

LED Duty Cycle

Do the following to display the LED duty cycle.




4. The Information Center will display the LED dutycycle in units of 0.01 percent.

LCD Duty Cycle

Do the following to display the LCD duty cycle.




4. The Information Center will display the LCD dutycycle in units of 0.01 percent.

Internal Information Center Temperature

Do the following to display the internal temperature ofthe Information Center.




4. The Information Center’s internal temperaturewill be displayed in degrees Celsius.


Entry Code for Accessing Test Mode Locations 100 to 199

Do the following to access test mode locations from100 to 199.


2. Press the up/down count switch to down countuntil the display reads 098.




6. Press the up/down count switch one time so thatthe display reads 099.


4005-28




10. Press the up/down count switch to up count pastlocation 099.

NOTE: When locations 098 and 099 are reset at 21,the Information Center will scroll past location 099.Once location 100 or higher is reached, locations 098and 099 are automatically reset to 000. If only one ofthe locations is set at 21, and the user leaves therange of 098-099, locations 098 and 099 areautomatically reset to 000.

Transmission Identification Numbers

Do the following to view and change the transmissionidentification numbers.




4. Use the up/down count switch to change thedisplay to read 001




8. Use the up/down count switch to change thetransmission identification number.




12. Use the up/down count switch to change thetransmission identification number.







19. Place the program/reset switch in the OFF(center) position. When the transmission ECMhas been reprogrammed, 110 will be displayed.




23. Press the up/down count switch to down countuntil the display reads 000. Location 100 and 101are locked.

24. Press the reset button for one second.

25. Turn off and restart the machine.

Display Location Numbers 104 - 113 Reserved for Future Use

Instrument Cluster (Information Center) Part Number (1st part)

Do the fol lowing to enter the f irst par t of theinstrument cluster (Information Center) part number.


2. Press the up/down count switch to down countuntil the display reads 114. The service indicatorflashes intermittently.


4. Use the up/down count switch to enter the firstpart of the instrument cluster part number fromthe parts catalog.

Instrument Cluster (Information Center) Part Number (2nd part)

Do the following to enter the second part of theinstrument cluster (Information Center) part number.





4005-29

4. Use the up/down count switch to enter thesecond par t of the instrument cluster par tnumber from the parts catalog.

NOTE: The part number may contain the letter Afollowed by a number, to show revision level. Usingthe up/down count switch, enter the A as 0 (zero)followed by the number, (A1 = 01, A2 = 02).

Instrument Cluster (Information Center) Date Code

Do the following to display the instrument cluster datecode.




4. The Information center will display the date code.Read the date code as follows: the first twonumbers = year, next three numbers = day.

Display Location Numbers 117 - 120 Reserved for Supplier Information

Display Location Numbers 121 -129 Reserved for Future Use

Speedometer Calibration

Do the following to reset the speedometer calibration.

NOTE: If a dealer or customer changes tire sizes,the speedometer calibration will have to be changedto match the Information Center and transmissionECM to the new tire size.

NOTE: A calibration number is required to performthis function.

1. If your tire and calibration number are listed inthe table below go to step 3. Do the following tocalculate a calibration number:

A. Obtain the tire revolution/km (obtainable frommost manufacturers).

B. If the tire revolution/km is not available,measure the distance the tire travels (inmeters) in 10 revolutions. Divide that numberinto 1000. Multiply the answer by 10. This ishow many revolutions your tire makes in a km.

2. Multiply the tire revolution/km by the axle ratio.The answer wi l l be the new speedometercalibration number.




6. Use the up/down count switch to enter thecalibration number from the table.

MACHINE/TIRE AX

LE R

AT

IO

TIR

E R

EV

/KM

CA

LIB

RA

TIO

N N

UM

BE

R

621 w/ 17.5 x 25 L2 21.88 259 5667

621 w/ 17.5 x 25 XTLA/XHA

21.88 245 5361

621 w/ 20.5 x 25 L2 21.88 235 5142

621 w/ 20.5 x 25 XTLA/XHA

21.88 225 4923

721 w/ 17.5 x 25 L2 21.37 259 5535

721 w/ 17.5 x 25 XTLA/XHA

21.37 245 5236

721 w/ 20.5 x 25 L2 21.37 235 5022

721 w/ 20.5 x 25 XTLA/XHA

21.37 225 4808

821 w/ 20.5 x 25 L2 23.51 220 5172

821 w/ 20.5 x 25 XTLA/XHA

23.51 218 5125

821 w/ 23.5 x 25 L2 23.51 208 4890

821 w/ 23.5 x 25 XTLA/XHA

23.51 207 4867

921 w/ 26.5 x 25 L2 22.85 201 4593

921 w/ 26.5 x 25 XRD/XHA

22.85 193 4410


4005-30

Display Location Numbers 131 - 139 Reserved for Speedometer Calibration


Temporary Fault Code Status

Field number locations 171 through 190 displaytemporary fault codes and the hours the faultsoccurred. These temporar y fau l t codes wi l lautomatically be erased when the Information Centeris turned off. The Information Center monitors themachine’s condition and records any fault codes intothe short-term resettable memory once every 3minutes. This will enable a technician to quicklycheck conditions to verify if a problem was resolvedor still exists after maintenance. When a fault code iswritten, the service indicator icon (a manual with awrench) will be displayed on the Information Center.

1. To view the temporary fault codes and the hoursthey occurred do the following:




D. Read any fault codes in the chosen location.

NOTE: A complete list of fault codes can befound in the Fault Code Table in this section.

E. Press the program/reset switch to program.

F. Press the up/down count switch to up countone time to advance to the next location.

G. Place the program/reset switch in the OFF(center) position.

H. Read the hours that the previous fault codeoccurred at.

NOTE: The hour location will always follow the faultcode location.

NOTE: Example: Location 172 will display the hourson the machine when the fault code in location 171was written. Location 174 will display the hours onthe machine when the fault code in location 173 waswritten.

2. To monitor a particular location without going intothe programming mode do the following:


B. Press the up/down count switch to up countuntil the location to be monitored is displayed.


D. Press the program/reset switch to programand wait 5 seconds. The numbers on thedisplay will change.

E. Place the program/reset switch in the OFF(center) position.

F. Within 3 seconds, press the program/resetswitch to reset once.

G. With the machine is in normal operating modepress the program/reset switch to reset todisplay the hours accumulated in the selectedlocation. (Location 000 (hour meter) isprogrammed into the Information Center fromthe factory.

H. To reset a programmed location back to 000(hour meter - factory sett ing), hold theprogram/reset switch to reset for 5 seconds.When it is reset, the operator can view thehour meter a t any t ime dur ing normaloperating conditions by pressing the resetswitch.


Display Location Number 197 Reserved for Manufacturing Data


Display Location Number 199 Reserved for Manufacturing Data

NOTE: To exit the upper range of display locationnumbers (100-199) press the program/reset switch toreset.


4005-31

DISPLAY LOCATION NUMBERS AND DESCRIPTIONS

DISPLAY LOCATION NUMBER

DEFINITION STATUS

000 Engine Hours

001 Engine Tachometer

002 Speedometer in Miles Per Hour

003 Speedometer in Kilometers Per Hour

004 Engine Coolant Temperature in Degrees Celsius

005 Engine Oil Pressure in Kilopascals

006 Fuel Level in Percent of Fuel in Tank

007 Transmission Oil Temperature in Degrees Celsius

008 Hydraulic Oil Temperature in Degrees Celsius

009 Voltmeter Reading (Continuous)

010 Gauge Display Selection

011 Parking Brake Test / Clutch Calibration

012 Information Center Light Setting - Work Lights Off

013 Information Center Light Setting - Work Lights On

014 Voltmeter Reading at Key-on

015 Alarm Status 00 = Off, 01 = On

016 Coolant Level Status00 = Normal Level01 = Low Level

017 Brake Pressure Status00 = Switch Closed01 = Switch Opened(Open = Normal Pressure)

018 Steering Pressure Status00 = Switch Closed01 = Switch Opened(Open = Normal Pressure)

019 Present Park Brake Output from Information Center Status 00 = Off, 01 = On

020 Present Pilot Lockout Status Output from Information Center

00 = Off, 01 = On

021 Hydraulic Filter Restriction Switch Status00 = Switch Closed01 = Switch Opened(Open = Filter is OK)

022 Air Filter Restriction Switch Status00 = Switch Closed01 = Switch Opened(Open = Filter is OK)

023 Present Work Lights Status 00 = Off, 01 = On

024 Present Fog Lights Status (European Only) 00 = Off, 01 = On


4005-32

025 Air Conditioning High/Low Pressure Switch Status00 = Switch Open01 = Switch Closed(Open = Normal Pressure)

026 Transmission Filter Restriction Switch Status00 = Open01 = Closed(Open - Filter is OK)

027 Present Status Of High Beam Lights (European Only) 00 = Off, 01 = On

028 Requested Gear Status

101 = F1, 102 = F2, 103 = F3, 104 = F4, 201 = N1, 202 = N2, 203 = N3, 204 = N4, 301 = R1, 302 = R2, 303 = R3

029 Status of Transmission Operation Indicator - In Transmission Display

00 = Always

030 Actual Gear Status

101 = F1, 102 = F2, 103 = F3, 104 = F4, 115 = Limp Home, 201 = N1, 202 = N2, 203 = N3, 204 = N4, 215 = Limp Home, 301 = R1, 302 = R2, 303 = R3, 315 = Limp Home

031Shift StatusDriveline StatusOperational Mode

First Digit = 000 = Shift Not In Process001 = Shift In Process

Second Digit =001 = Driveline Not Engaged010 = Driveline Engaged

Third Digit = Mode Control010 = Normal110 = Substitute Clutch control210 = Limp Home Mode300 = Transmission Shutdown400 = T.E.C.M. Shutdown

032 Hourmeter Status 00 - Always

033 Tachometer Status 00 - Always

034 Current Status of Service Indicator for Normal Operating Mode (Book with the wrench)

00 = Off, 01 = On

035 Movement indicator Status 00 - Always

036 Beacon Status 00 = Off, 01 = On

037 Left Turn Indicator Status 00 = Off, 01 = On

038 Right Turn Indicator Status 00 = Off, 01 = On

039 Current Status Master Indicator (Red) 00 = Off, 01 = On

040 Current Status of Diagnostic Indicator (Book without the wrench - Operators Manual)

00 - Always


DEFINITION STATUS


4005-33

041 Current Status Master Indicator (Yellow) 00 = Off, 01 = On

042 Master Reset - Reset Information Center to Factory Setting

043 Park Brake Switch Status

00 = Switch Open01 = Switch Closed(Closed = engaged Parking Brake)

044 Redundant Brake Pressure Switch00 = Switch Closed01 = Switch Open(Closed = Normal Operation)

045 Service Brake Foot Switch Status00 = Switch Open01 = Switch Closed(Closed = Actuated)

046 Pilot Lockout Switch Status

00 = Switch Open01 = Switch Closed(Closed = Loader Controls Locked)

047 Seat Circuit01 = Circuit Closed02 = Circuit Malfunction

050 Minimum Gear Selection Range - 1st and 2nd gear

051 Maximum Gear Selection Range - 2nd, 3rd and 4th gear

052 Minimum Gear Read Only

053 Maximum Gear Read Only

055 Reset Diagnostic Stack, 071 to 090 to zero

Range = 0 to 99Default = 0Set to “21” and then exit this location 055 to reset diagnostic stack 071 -099 to zero

061 - 070 Service Hour interval Selection #1 - 10

071,073, 075,077, 079,081, 083,085, 087, 089

Fault Code #1 Through Fault Code #10

072,074,076,078,080,082,084,086,0

88,090

Hour Code #1 Through Hour Code #10. Hour Codes Follow Fault Codes Respectively.

I.e.: Hour Code #1 (072) Corresponds with Fault Code #1 (071)

091 1st Portion Of Transmission Electronic Control Module (ECM) Part Number (5 digits from 0-9)

ZF part number

092 2nd Portion Of Transmission ECM Part Number (5 digits from 0-9)

ZF part number

093 Cluster Software Revision Number


DEFINITION STATUS


4005-34

094 Light Emitting Diode (LED) Duty Cycle In units of 0.01%

095 Liquid Crystal Display (LCD) Duty Cycle In units of 0.01%

096 Internal Cluster Temperature In units of deg C

098 Entry Code for Accessing Test Mode Locations 100 to 199Set to “21” to enter Test Mode locations (Range = 0 to 99)

099 Entry Code for Accessing Test Mode Locations 100 to 199Set to “21” to enter Test Mode locations (Range = 0 to 99)

100 - 103 Transmission ID Number

114 Cluster Part Number

115 Cluster Part Number

116 Cluster Date Code

130 Speedometer Calibration

171 - 190 Temporary Fault Code Status


DEFINITION STATUS


4005-35

FAULT CODES

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

12900Engine coolant short circuit measuring less than 50 ohms to the engine coolant temperature sensor.

Troubleshoot electrical circuits.

12901

Engine coolant open circuit measuring greater than 10,000 ohms to the engine coolant temperature sensor with hydraulic oil temperature at 40° C (104° F) or more.

13000Low engine coolant level - This code will not be generated if the engine coolant temperature is below 20° C (68° F).

1. A critical stop function warning has occurred.2. Red stop indicator comes on and continuous

buzzer sounds.3. Stop machine and perform required service on

the critical area.

21100 Engine oil pressure is measured below 100 kPa (14.5 PSI)

21110 Engine coolant temperature is 110° C (230° F) or greater.

21900Engine oil pressure short circuit measuring less than 16 ohms to the engine oil pressure sensor.

Troubleshoot electrical circuits.

NOTE: Fault code 21900 is possible during coldengine start-up. After machine warm up, verifyproper operation.21901

Engine oil pressure open circuit measuring more than 270 ohms to the engine oil pressure sensor.

33900 Fuel level short circuit measuring less than 16 ohms to the fuel level sender.

Troubleshoot electrical circuits.33901 Fuel level open circuit measuring more than 270 ohms to the fuel level sender.

34000 Fuel solenoid output short circuit.

35000 High air filter restriction.

1. A caution level warning has occurred.2. Yellow caution indicator comes on and buzzer

sounds for 3 seconds.3. Perform required service on the cautioned area.

42125 Transmission temperature measured above 125° C (257° F)



the critical area.

45000 High transmission filter restriction when the transmission oil is above 20° C (68° F).



46017 Gear range fault error1. Check the cables from TCU to shift lever.2. Check signal combinations of shift lever

positions for gear range.

46018 Logical error at direction select signal1. Check the cables from TCU to shift lever.2. Check signal combinations of shift lever

positions F-N-R.


4005-36

46020 Logical fault at Park Brake Status1. Check the cables from the electronic boxes to

the status switches.2. Check signals of the status switches.

46037 Short circuit to battery voltage or Open circuit at temperature sensor input

1. Check the connectors.2. Check the temperature sensor.

46038 Short circuit to ground at temperature sensor input

1. Check the cables from TCU to the sensor.2. Check the connectors.3. Check the temperature sensor.

46039 Short circuit to battery voltage or open circuit at converter output temperature sensor input

46040 Short circuit to ground at converter output temperature sensor input

46049 Short circuit to battery voltage or Open circuit at engine speed input

1. Check the cables from TCU to the sensor.2. Check the connectors.3. Check the speed sensor.46050 Short circuit to ground at engine speed input

46051 Logical error at engine speed input

1. Check the cables from TCU to the sensor.2. Check the connectors.3. Check the speed sensor.4. Check the sensor gap.

NOTE: This fault code is reset after power up of theTCU. It is also reset if the signal is above zerospeed threshold.

46052 Short circuit to battery voltage or Open circuit at turbine speed input

1. Check the cables from TCU to the sensor.2. Check the connectors.3. Check the speed sensor.46053 Short circuit to ground at turbine speed input

46054 Logical error at turbine speed input


NOTE: This fault code is reset after power up of theTCU.

46055 Short circuit to battery voltage or Open circuit at intermediate speed input 1. Check the cables from TCU to the sensor.

2. Check the connectors.3. Check the speed sensor.46056 Short circuit to ground at intermediate speed

input

46057 Logical error at intermediate speed input



46058 Short circuit to battery voltage or Open circuit at output speed input

1. Check the cables from TCU to the sensor.2. Check the connectors.3. Check the speed sensor.46059 Short circuit to ground at output speed input



4005-37

46060 Logical error at output speed input



46062 Output speed zero, does not match other speeds.

1. Check the sensor signal of the output speedsensor.

2. Check the sensor gap of the output speedsensor.

3. Check the cable from the TCU to the sensor.


46064 Invalid gear range restriction (CAN)1. Check the cluster controller.2. Check wire of CAN-Bus.3. Check the cable to the cluster controller.

46065 Invalid declutch modulation selection (CAN)

46089 Invalid test mode signal (CAN) 1. Check the cluster controller.2. Check wire of CAN-Bus.3. Check the cable to the cluster controller.

46090 Invalid park brake status (CAN)

46091 Invalid shift quality selection (CAN)

46113 Short circuit to battery voltage at clutch K1

1. Check the cable from the TCU to the gearbox.2. Check the connectors from the TCU to the

gearbox.3. Check the regulator resistance.4. Check internal wire harness of the gearbox.

46114 Short circuit to ground at clutch K1

46115 Open circuit at clutch K1







46129 Short circuit to battery voltage a clutch K4



46132 Short circuit to battery voltage at clutch KV

46133 Short circuit to ground at clutch KV

46134 Open circuit at clutch KV

46135 Short circuit to battery voltage at clutch KR

46136 Short circuit to ground at clutch KR

46137 Open circuit at clutch KR



4005-38

46145 Short circuit to ground at reverse warning alarm relay 1. Check the cable from the TCU to the gearbox.

2. Check the connectors from the backup alarmdevice to TCU.

3. Check the resistance of backup alarm device.46146 Short circuit to battery voltage at reverse

warning alarm relay

46147 Open circuit at reverse warning alarm relay

46177 Slippage at clutch K1

1. Check pressure at clutch K1.2. Check main pressure in the system.3. Check sensor gap at internal speed sensor.4. Check sensor gap at output speed sensor.5. Check signal at internal speed sensor.6. Check signal at output speed sensor.7. Replace clutch.







46181 Slippage at clutch KV

1. Check pressure at clutch KV.2. Check main pressure in the system.3. Check sensor gap at internal speed sensor.4. Check sensor gap at output speed sensor.5. Check signal at internal speed sensor.6. Check signal at output speed sensor.7. Replace clutch.

46182 Slippage at clutch KR

1. Check pressure at clutch KR.2. Check main pressure in the system.3. Check sensor gap at internal speed sensor.4. Check sensor gap at output speed sensor.5. Check signal at internal speed sensor.6. Check signal at output speed sensor.7. Replace clutch.



4005-39

46183 Oil temperature at valve body is above limit 1. A critical stop function warning has occurred.2. Red stop indicator comes on and continuous


the critical area.4. Cool down machine.5. Check oil level.6. Check temperature sensor.

46184 Oil temperature at converter output is above limit

46186Differential pressure oil filter TCU measured a voltage at differential pressure switch out of the allowed range.

1. Check oil filter.2. Check wiring from TCU to differential pressure

switch.3. Check differential pressure switch (measure

resistance).

46209 Short circuit to battery voltage at power supply for sensors

1. Check cables and connectors to sensors, whichare supplied from AU1.

2. Check the power supply at the pin AU1. Itshould be approximately 5 volts.46210 Short circuit to ground at power supply for

sensors

46211 Low voltage at battery 1. Check power supply battery.2. Check cables from batteries to TCU.3. Check connectors from batteries to TCU.46212 High voltage at battery

46213 Error at switch 1 for solenoid power supply 1. Check fuse2. Check cables from gearbox to TCU.3. Check connectors from gearbox to TCU.4. Replace TCU.

46214 Error at switch 2 for solenoid power supply

46227 Short circuit to battery voltage at display output

1. Check the cable from TCU to the display.2. Check the connectors at the display.3. Change display.46228 Short circuit to ground at display output

46229 Error at communication on CAN1. Check the cluster controller.2. Check the wire of the CAN-Bus.3. Check cable to cluster controller.

46230 Undefined VIN request via CAN.

46241 General EEPROM fault Replace the TCU.

46242 Current ID not set or corruptReprogram the correct configuration for the vehicle.

46243 Application error (ZF internal) Replace the TCU.

46245 Clutch calibration fault Check the clutch.

46246 Clutch adjustment data lost Execute AEB.

47000 CAN interface failure where no signals are received over one second of time

1. Clear the codes.2. Restart the machine.3. Monitor machine operation and diagnostics.



4005-40

47001 Engine speed is missing 1. Verify corresponding function is displayed onthe information center and is working properly:

A. Engine rpm - run engine LI to HI and verifydisplay shows rpm.

B. Output shaft speed - drive unit with mph/kphdisplayed and ver i fy that i t is workingproperly.

C. Transmission oil temperature - displaytemperature values on information centerand run mach ine to ve r i fy tha t thetempera tu re changes w i th mach ineoperation.

4. If operation is satisfactory, clear fault codes andcontinue to monitor.

5. If there are problems during operation,troubleshoot the appropriate electrical circuits.

47002 Output shaft speed is missing

47011 Transmission oil temperature is missing

47012 Transmission filter restriction information is missing

1. Check the function/operation of thetransmission fi l ter restr iction by going toprogram count location 026.

2. Read filter restriction status: 00 = filteracceptable, 01 = filter restricted, 02 = filter fault.

3. If filter restricted, 01, replace filter.4. If 00 or 02, clear fault codes and monitor

machine performance and diagnostic codes.

47013 Current Transmission identification code is outside of the range

1. Reprogram transmission ID numbers.2. Verify program count location reads 110 or 100.3. Clear codes and monitor machine performance

and continue to operate.47014 Result code (11)

51000Low steering pressure has been detected after a normal operating pressure has been reached since start up.



the critical area.61000Low brake pressure (1700 PSI / 11721 kPa) has been detected after a normal operating pressure has been reached since start up.

619001700 PSI (11,721 kPa) Brake pressure switch has not cycled within 50 hours of operation time.

1. Turn machine off.2. Pump service brake 30 full strokes.3. Start machine and verify proper operation and

no diagnostic codes.4. Operate machine and monitor performance.61901

900 PSI (6250 kPa) Redundant brake pressure switch has not cycled within 100 hours of operation time.

64000 Park brake solenoid output short circuit. 1. Check park brake for proper operation.2. Do park brake test, see section 7008.3. Adjust/repair park brake as required.4. Clear diagnostic codes and monitor machine

performance.66900 Park brake switch has not cycled within 50

hours of operation time.



4005-41

66901 Service brake foot switch has not cycled within 50 hours of operation.

1. Verify full pedal actuation and return, make suredebris does not obstruct pedal travel.

2. Clear codes.3. Verify proper machine operation.4. If code reappears, check brake light switch and

troubleshoot electrical circuits.

72110 Hydraulic oil temperature is 110° C (230° F) or greater.



the critical area.

72900Hydraulic oil temperature short circuit measuring less than 50 ohms to the hydraulic oil temperature sensor.

Troubleshoot electrical circuits.72901

Hydraulic oil temperature open circuit measuring greater than 10,000 ohms to the hydraulic oil temperature sensor with the engine coolant temperature at 90° C (194° F) or more.

74000 Pilot pressure solenoid output short circuit.

75000 High hydraulic filter restriction when the hydraulic oil is above 20° C (68° F).



84018 System voltage is below 18 volts.

84032 System voltage is above 32 volts.

86010 Corrupt engine hours, data lost 1. Operate the machine to verify all functions andmonitoring systems are working properly (noyellow or red warnings, normal operation).

2. Monitor cluster performance during machineoperational check (no new diagnostic codes, noerratic behavior, flashing icons, etc.).

3. If all systems and operations are normal, cleard iagnost ic codes and cont inue machineoperation.

4. Monitor machine for recurrence of fault codes.5. Repeated codes may be an indication of a

pending cluster failure.

86011 Corrupt engine hours, data suspect

86012 Corrupt engine hours, data suspect

86020Corrupt tire calibration numbers, data lost – The calibration number will default back to the number used at cluster shipment

1. Reprogram correct tire calibration number forthe machine.

2. Verify proper machine operation and machinetravel speed to displayed speed.

3. Continue machine operation and monitor forrecurring fault codes.

86021 Corrupt tire calibration number, data suspect

86022 Corrupt tire calibration number, data suspect



4005-42

86030 Information Center memory error

1. Operate the machine to verify all functions andmonitoring systems are working properly (noyellow or red warnings, normal operation).

2. Monitor cluster performance during machineoperational check (no new diagnostic codes, noerratic behavior, flashing icons, etc.).

3. If all systems and operations are normal, cleard iagnost ic codes and cont inue machineoperation.

4. Monitor machine for recurrence of fault codes.5. Repeated codes may be an indication of a

pending cluster failure.

86040 Information Center program memory error

86050 Information Center RAM failure

86060

Information Center Reset – This code is generated if the Information Center Program “goes astray”. The Information Center is reset. This code will also be generated if there is a brief intermittent open between the time the engine is shut off and the Information Center shuts off.

86070 Open range setting

86071 Brightness setting

86072 Machine ID

86073 Machine info

86074 Cluster part number

86075 Cluster date code

86076 Cluster reserved

86077 Calibration number

86078 Shift quality

86079 Requested Gmin

86080 Requested Gmax

86081 Declutch modulation

86082 Creep setting

86083 Service hours

86084 Diagnostics stack pointer (internal to software)

86085 Diagnostics stack contents

86086 Digital input states (internal to software)

86087 Engine hour time stamps for digital input states (internal to software)

91000 Air Conditioning high or low pressure indication





4005-43

INDEX

AActual Gear Check ................................................22Air Conditioning Indicator ........................................9Air Conditioning Switch Check ..............................21Air Filter Indicator ....................................................9Air Filter Restriction Switch Check ........................20Alarm Check ..........................................................19Automatic Scrolling Gauge Displays .....................17

BBeacon Indicator ......................................................8Beacon Status .......................................................23Brake

Park, Information Center Output Check ............20Park, Testing ......................................................17Parking Brake Indicator .......................................9

Brake Pressure ......................................................19Brake Pressure Indicator .........................................8

CCalibration

Transmission Clutch ..........................................18Caution and Warning Master Indicator Lights .......23Caution Master Indicator (Yellow) ...........................8Check

Actual Gear .......................................................22Air Conditioning Switch .....................................21Alarm .................................................................19Coolant Level ....................................................19Fog Lights ..........................................................21Park Brake Switch .............................................24Requested Gear ................................................21Switch, Pilot Lockout .........................................24Switch, Redundant Brake Pressure ..................24Switch, Service Brake Foot ...............................24Work Lights .......................................................20

ClutchCalibration, Transmission ..................................18

Codes, Fault ..........................................................35Control

Pilot .....................................................................8Coolant

Engine Temperature ..........................................10Indicator, Low ......................................................8

Coolant Level Check .............................................19Critical Warning Displays .......................................12

DDiagnostic Center ....................................................7Diagnostic Indicator Status ....................................23Display Center

Lighting, Setting ................................................19Display Location

047 ....................................................................24

048 and 049 ......................................................25054 ....................................................................25056 through 060 ................................................26071 through 090 ................................................25097 ....................................................................27100 through 199 ................................................27104 through 113 ................................................28117 through 120 ................................................29121 through 129 ................................................29131 through 139 ................................................30140 through 170 ................................................30191 through 196 ................................................30197 ....................................................................30198 ....................................................................30199 ....................................................................30

Display Location Numbers and Descriptions .........31Displays

Gauge, Automatic Scrolling ...............................17Gauge, Manual Scrolling ...................................17Individual Function ............................................17

Drive Line Shift Status ...........................................22Duty Cycle, LCD ....................................................27Duty Cycle, LED ....................................................27

EEngine

Coolant Temperature .........................................10Oil Pressure Gauge ...........................................10

Engine Coolant Temperature ..........................10, 14Engine Oil Pressure ..............................................14Engine Oil Pressure Gauge ...................................10Entry Code

Test Mode Locations 100 to 199 .......................27

FFault Code Status ..................................................26Fault Codes ...........................................................35Filter

Indicator, Air Filter ...............................................9Indicator, Hydraulic Oil ........................................9Indicator, Transmission Oil ..................................9Restriction Switch, Air

Restriction Switch, Air Filter ..........................20Restriction Switch, Hydraulic .............................20Restriction Switch, Transmission .......................21

Fog Lights Check ..................................................21Fuel

Gauge, Level .....................................................10Fuel Level Gauge ..................................................10Fuel Lever .............................................................14

GGauge

Engine Oil Pressure ..........................................10Fuel Level ..........................................................10


4005-44

Hydraulic Oil Temperature ...................................9Transmission Oil Temperature .............................9Voltmeter ...........................................................10

Gauges and Indicators ............................................8Gear

Check, Actual ....................................................22Check, Requested .............................................21

Gear Range Read Only .........................................25Gear Selection

Maximum ...........................................................25Minimum ............................................................25

HHourmeter ..............................................................14Hourmeter Indicator Status ....................................22Hours

Service Interval .................................................26Hydraulic Filter Restriction Switch Check ..............20Hydraulic Oil Filter Indicator ....................................9Hydraulic Oil Temperature .....................................15Hydraulic Oil Temperature Gauge ...........................9

IIdentification Numbers

Transmission .....................................................28Indicator

Air Conditioning ...................................................9Air Filter ...............................................................9Beacon ................................................................8Brake Pressure ....................................................8Caution and Warning Master, Status Lights ......23Caution Master (Yellow) ......................................8Diagnostic, Status .............................................23Hourmeter, Status .............................................22Hydraulic Oil Filter ...............................................9Icon, Service .....................................................11Left Turn, Status ................................................23Low Coolant ........................................................8Movement, Status .............................................23Operational, Status ...........................................21Parking Brake ......................................................9Right Turn, Status ..............................................23Secondary Steering ............................................9Service, Status ..................................................22Stop Master (Red) ...............................................8Tachometer, Status ...........................................22Transmission Oil Filter .........................................9

Indicators and Gauges ............................................8Individual Function Display ....................................17Information and Diagnostic Center ....................7, 14Information Center

Internal Temperature .........................................27Software Revision Number ................................27

Instrument ClusterDate Code .........................................................29Part Number (1st part) ......................................28Part Number 2nd part) ......................................28

Internal Information Center Temperature ..............27

LLCD Duty Cycle .....................................................27LED Duty Cycle .....................................................27Left Turn Indicator Status ......................................23Level

Coolant, Check ..................................................19Lighting, Setting Display Center ............................19Lights

Fog ....................................................................21Work ..................................................................20

Low Coolant Indicator ..............................................8

MManual Scrolling Gauge Displays .........................17Master Reset .........................................................23Maximum Gear Selection ......................................25Minimum Gear Selection .......................................25Movement Indicator Status ....................................23

NNon-Critical Warning Displays ...............................13

OOil

Pressure Gauge, Engine ...................................10Operational Indicator Status ..................................21

PPark Brake

Information Center Output Check .....................20Testing ...............................................................17

Park Brake Switch Check ......................................24Parking Brake Indicator ...........................................9Pilot Control .............................................................8Pilot Lockout

Information Output Check .................................20Pilot Lockout Switch Check ...................................24Power Circuit Test ...................................................8Pressure

Brake Indicator ....................................................8Pressure, Brake .....................................................19Programming Information Center ..........................16Programming, Information Center .........................16

RRedundant Brake Pressure Switch Check ............24Requested Gear Check .........................................21Reset Diagnostic Stack for Display Locations .......25Reset, Master ........................................................23Right Turn Indicator Status ....................................23

SSecondary Steering Indicator ..................................9Secondary Steering Pressure Switch ....................20Self-Test ..................................................................7


4005-45

Service Brake Foot Switch Check .........................24Service Indicator Icon ............................................11Service Indicator Status .........................................22Service Interval Hours ...........................................26Setting Display Center Lighting .............................19Settings, Diagnostics, and Fault Codes .................16Software

Revision Number, Information Center ...............27Speedometer .........................................................14Speedometer Calibration .......................................29Status

Beacon ..............................................................23Caution and Warning Master Indicator Lights ...23Diagnostic Indicator ...........................................23Drive Line Shift ..................................................22Fault Code .........................................................26Fault Code, Temporary ......................................30Hourmeter Indicator ..........................................22Left Turn Indicator .............................................23Movement Indicator ...........................................23Right Turn Indicator ...........................................23Service Indicator ...............................................22Tachometer Indicator .........................................22

SteeringSecondary Indicator ............................................9Secondary Pressure Switch ..............................20

Stop Master Indicator (Red) ....................................8Switch

Park Brake, Check .............................................24Pilot Lockout ......................................................24Pressure, Secondary Steering ..........................20Redundant Brake Pressure ...............................24Restriction, Hydraulic Filter ...............................20Restriction,Transmission Filter ..........................21Service Brake Foot ............................................24

TTachometer ...........................................................14Tachometer Indicator Status .................................22Temperature

Engine Coolant ..................................................10Internal Information Center ...............................27

Temporary Fault Code Status ...............................30Test

Power Circuit .......................................................8Self-Test ..............................................................7

Test Mode Locations 100 to 199 ...........................27Testing Park Brake ................................................17Transmission

Identification Numbers ......................................28ZF Transmission

ECM Part Number (1st part) .........................27ECM Part Number (2nd part) ........................27

Transmission Clutch Calibration ............................18Transmission Display ............................................15Transmission Filter Restriction Switch Check .......21Transmission Oil Filter Indicator ..............................9

Transmission Oil Temperature ..............................15Transmission Oil Temperature Gauge ....................9

VVoltmeter ...............................................................15Voltmeter Gauge ...................................................10Voltmeter, Key ON ................................................19

WWarning Display ....................................................12Work Lights Check ................................................20

ZZF Transmission

See Transmission ..............................................27


4005-46

NOTES


0000-1SECTION INDEX - POWER TRAIN

Section Title

Section Number

Transmission Specifications, Pressure Checks, and Troubleshooting ............................................................................... 6002

Transmission .......................................................................................................................................................... 6003

Front and Rear Axle ................................................................................................................................................. 6004

Drive Shaft, Center Bearing, and Universal Joints ......................................................................................................... 6005

Wheels and Tires ..................................................................................................................................................... 6006

Transmission Control Valve .................................................................................................................................... 6007




April, 2000

Section6002 60

02




April, 2000

TRANSMISSION SPECIFICATIONS, SCHEMATIC,AND

TROUBLESHOOTING

6002-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CONSUMPTION TEST PROCEEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20TRANSMISSION ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6002-3

SPECIAL TOOLSCAS-1953A Transmission supplemental fitting kit.Includes: CAS-2324 special 90 degree adapter andCAS-2325 plug and cap set.

CAS-1804 Master pressure test kit

CAS-1808 Flowmeter kit

CAS-2702 Flowmeter adapter

CAS-2278 Flow test kit

SPECIFICATIONSMain pressure and clutch pressure ................................................................................16 to 18 bar (230 to 265 psi)Converter in pressure .................................................................................................8.5 to 10.5 bar (125 to 154 psi)Pressure reduction for solenoids ......................................................................................9 to 11 bar (130 to 160 psi)Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)Minimum pump output (at 2000 rpm)

621C...................................................................................................................................52 L/min (14 U.S. gpm)721C and 821C ..................................................................................................................80 L/min (21 U.S. gpm)

Transmission oil operating temperature..........................................................................80 to 120 °C (176 to 248 °F)Clutch KV..................................................................................................................................................16 to 18 barClutch KR .................................................................................................................................................16 to 18 barClutch K1 ..................................................................................................................................................16 to 18 barClutch K2 ..................................................................................................................................................16 to 18 barClutch K3 ..................................................................................................................................................16 to 18 barClutch K4 ..................................................................................................................................................16 to 18 bar


6002-4

GS99C607

FIGURE 1. COMPONENT LOCATIONS SYSTEMS

1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH7. TRANSMISSION 14. FILTER RESTRICTION SWITCH (721/821C MODELS ONLY)

1

2

34

5

6

7

8

9

10

14

12

13

11


6002-5

GS98K615

FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP2. POWER TAKE OFF 10. DRIVE SHAFT3. CLUTCH SHAFT KV 11. CONVERTER4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K46. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K18. OUTPUT SHAFT

1

14

13

9

7

6

5

4

3

8

12

11

2

10

15


6002-6

GS99C614

FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

1. LIFTING LUGS 4. OIL DRAIN PLUG2. TRANSMISSION SUSPENSION BORES 5. MODEL IDENTIFICATION PLATE3. OUTPUT FLANGE CONVERTER SIDE 6. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK

6 5 4

3

2

22

2

11


6002-7

GS99C608

FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

1. CONVERTER BELL HOUSING 4. FILTER HEAD 7. OIL DRAIN PLUG2. BREATHER 5. FILTER 8. OUTPUT FLANGE CONVERTER SIDE3. TRANSMISSION CASE COVER 6. OUTPUT FLANGE REAR 9. TRANSMISSION CASE

9

8

7

6

5

4

21 3


6002-8

GS98K609

FIGURE 5. COMPONENT LOCATIONS REAR VIEW

1. LIFTING LUGS 5. TRANSMISSION SUSPENSION BORES2. POWER TAKE OFF 6. OUTPUT FLANGE REAR3. TRANSMISSION CONTROL VALVE 7. FILTER4. OIL FILLER PIPE WITH OIL DIPSTICK 8. FILTER HEAD

8

7

6

5

4

3

211

5


6002-9

TRANSMISSION OPERATION

GeneralThe transmissions for the C series equipment isequipped with a Transmission ECM (ElectronicControl Module). This module controls modulationand shifting that were normally associated withhydraulically modulated transmissions, providingsmoother shifts and enhanced clutch life.

The Transmission ECM relies on signal from severalsolenoids that are incorporated into the design.These solenoids measure the speed of severalcomponents, as well as other sensors that measuretemperature. These solenoids and sensors arefurther defined in the following paragraphs.

In addi t ion, the transmission incorporates atwo-piece transmission case for ease of transmissionmaintenance, helical cut gears that help reducenoise, and all external hoses have been eliminated(all oil passages are internal).

Transmission ECMModulation and shift ing are control led by theTransmiss ion E lec t ron ic Con t ro l Modu le(Transmission ECM). This module replaces the oiland springs that are found in hydraulically modulatedtransmissions.

The Transmiss ion ECM cont ro ls the c lu tchengagement, provid ing smoother shi f ts andenhanced clutch life, whether the transmission is setto the automatic or manual shift mode.

The Transmission ECM also informs the InformationCenter, by the use of diagnostic codes, of anytransmission error and the hours of operation that theerror occurred.

Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation ofthe clutches, eliminating the need for a modulationvalve, and providing a smooth shift while maintainingconstant control over clutch engagement as follows:

A. A temperature sensor relays the oiltemperature to the Transmission ECM.

B. The Transmission ECM times the rate thesolenoid energizes and de-energizes.

C. As the transmission changes gears, there isreduced hesitation from one gear to the next.

Transmission ECM Tasks

The Transmission ECM performs a variety of tasks inthe overall system. The Transmission ECM:

A. Determines which clutches to engage in thetransmission.

B. Protect the engine and transmission turbinef rom ove rspeed cond i t i ons du r ingdownloading.

C. Receives speed information from the enginespeed sensor, the turbine speed sensor, theintermediate clutch speed sensor and thetransmission output speed sensor. Thesespeed sensors are checked to determine ifnormal sensor operation is present. The datais also used to control modulation duringshifting and to determine the appropriate shiftpatterns.

D. Detects system failures and determines theappropriate alternative actions.

E. Provides various diagnostic messages to theInformation Center.

F. Provides other information to the informationcenter, which in turn displays engine speed,wheel speed, gear shift selection, and actualgear selection.

G. Provides a method to calibrate thetransmission clutch control.

H. Establishes clutch modulation pressure duringtransmission shifts.

Transmission Sensor Data Collection.

The Transmission ECM collects and uses informationfrom four sensors to accurately shift the transmissionand determine if any clutches are slipping. Thesesensors are:

Engine (Speed) Sensor - monitors engine speed todetermine the load on the engine for shift points andsends the engine rpm to the Transmission ECM,which sends the information to the tachometer in theInformation Center.

Turbine (Speed) Sensor - assists the engine speedsensor in determining the load going into thetransmission and helps determine shift points.

Intermediate (Shaft Speed) Sensor - determinesdifferential gear speed in the transmission to checkfor clutch slippage.

Output (Speed) Sensor - monitors transmissionoutput shaft speed to help determine the load on thetransmission and to assist in determining shift points.Sends output shaft speed to Transmission ECMwhich sends the information to the speedometer inthe Information Center.


6002-10

The transmission ECM also reviews vol tageinformation from the shifter and transmissionsolenoids to determine if there are any short circuitsor open circuits in the system.

Automatic Problem Modes

If the Transmission ECM detects an error condition inthe transmission system, it will generate a servicecode in the Information Center and will enter one ofthree modes:

A. Clutch Modulation Substitute Mode

B. Limp-Home Mode

C. Transmission/Transmission ECM ShutdownMode

Clutch Modulation Substitute Mode

In this mode, the transmission clutch modulation istime dependant rather than load dependant. Thetransmission will go into the Clutch ModulationSubstitute Mode if any of the four speed sensors fail.

If the output speed sensor is working and thetransmission is in gear, the shift points in Automaticmode will be speed dependant but the modulationwill be a predetermined amount of time.

If the output speed sensor is not working and thetransmission is in gear, the shift points will still beload dependant but the modulat ion wi l l be apredetermined amount of time.

If the transmission is shifted from neutral into adirection in the Clutch Modulation Substitute Mode inautomatic, the transmission will shift into 4th gearand shift down until it gets the correct output speedfrom the turbine.

Limp-Home Mode

In this mode, the transmission will go into secondgear, forward or reverse, no matter what gear isselected. If second gear is not obtainable, theTransmission ECM selects a series of prioritizedgears un t i l an operable gear i s found. Thetransmission will go into the Limp Home Mode ifthere is a fault on one clutch, a fault on one clutchvalve, or a fault on more than one speed sensor.

Transmission/Transmission ECM Shutdown Mode

In this mode, the Transmission ECM has detected aseve re fa i l u re tha t d i sables con t ro l o f t hetransmission. The transmission will go into ShutdownMode if there is a fault on more than one clutch, afault on the solenoid power supply. or invalid voltage.In this mode, the transmission ECM will shut off allsolenoid valves and the power supply and thetransmission shifts into and stays in neutral.

If the Transmission ECM generates a code, thewrench over the serv ice manual icon wi l l bedisplayed on the Information Center.

Transmission Clutch CalibrationThe Transmission ECM has the capability to find theoptimal adjustment of the clutch filling parameters foreach individual transmission, providing the ability toindividually adjust the optimum fill time for theindividual transmission in the machine. Clutch FillingParameter Calibration is performed on each machineat the plant and should be repeated at the first 250hours of use and every 1000 hours thereafter

Gear SelectionsThe transmission in all C Series models provides 4forward and 3 reverse gear se lec t ions. Thetransmission ratios were designed to give optimizedspeed and torque for each gear selection. The torqueconverter is a single stage torque converter (onelocking unit in the torque converter).

Automatic/Manual ModesThe automatic/manual switch is located on the rightcontrol panel. The transmission is in automatic modewhen the top of the automatic/manual switch isdepressed. The Transmission Display Centerindicates when the machine is in the automaticmode.

RD98K308

FIGURE 6. AUTO/MANUAL TRANSMISSION SWITCH

Upshifting in Automatic Mode

Upshifting is determined by machine speed and thetorque on the transmission.

The transmission will shift from first or second gearup to the highest gear selected as the accelerator isdepressed, machine speed increases, and requiredtorque is reduced.


6002-11

If the machine speed is increasing, but the operatoris not depressing the accelerator (such as whengoing down a hill), the transmission will not upshift.

As the operator depresses the accelerator and thetorque on the t ransmiss ion is lowered, thetransmission will upshift.

Downshifting in Automatic Mode

Downshifting is determined directly by machinespeed and transmission torque. The transmission willdownshift to first or second gear as machine speeddecreases and transmission torque increases. Forexample, if the unit begins to climb a hill in forth gearand the machine speed decreases, as the torquerequirement increases, the transmission wi l ldownshift into third, then second, and down to firstgear, if necessary.

Upshifting in Manual Mode

In the manual mode, the transmission starts out inthe selected gear and stays in that gear until theoperator selects another gear or direction. Thetransmission can be upshifted without reducingengine speed or machine speed.

If the gear selected is two or more gears higher thanthe present gear, the transmission will shift upthrough the gears at 2.5 second intervals until theselected gear has been reached.

Downshifting in Manual Mode

The transmission can be downshifted in the manualmode without reducing engine speed or machinespeed.

If 1st gear is selected from 3rd or 4th gear, thetransmission will downshift into 2nd gear for 1.2seconds and then will shift into 1st gear.

Cold Start Protection System

The transmission has a cold start protection system.When the transmission sump temperature is minus10° C (14° F), the Transmission ECM will keep thetransmission in neutral.

When the transmission sump temperature warms upto minus 10° C (14°F) (within approximately oneminute), the machine will operate in all gears.

Downshift ButtonThe downshift button is located on top of the joystickcontrol lever in machines with a single leverconfiguration, and on top of the loader control lever inmachines with a two lever configuration.

With the number of different ways the downshiftbutton functions, the operator can tailor the use of themachine to the application at hand.

RD98K3061. DOWNSHIFT BUTTON/SINGLE LEVER CONFIGURATION

FIGURE 7

RD98K2731. DOWNSHIFT BUTTON/TWO LEVER CONFIGURATION

FIGURE 8

Automatic Mode

In the Automatic Mode, the downshift button onlyshifts down. The downshift button allows the operatorto downshift through the entire range of gears. This isuseful in long haul applications or roading.

Each time the button is pushed the transmission willinstantly downshift one gear from 4th to 3rd, thenfrom 3rd to 2nd, and then from 2nd to 1st.

The transmission will automatically downshift andthen upshift, as needed, to the last gear that wasselected with the downshift button.

EXAMPLE: If the downshift button was used to shiftfrom 4th to 3rd gear, the transmission willautomatically shift from 3rd down and the back up to3rd again. It will not shift into 4th until thetransmission has been returned to the full rangeautomatic mode.

1

1


6002-12

The transmission wil l return to the ful l rangeautomatic mode when:

A. Another gear is selected

B. The shifter is moved into neutral and then intoforward or reverse

C. The autoshift switch is recycled.

Manual Mode

In the manual mode, the downshift button togglesbetween 1st and 2nd gear. The manual mode isuseful in short haul operations. In this mode, thedownshift button function in two ways in 1st and 2ndgear.

When the operator is in 2nd gear and pushes thedownshift button, the transmission instantly shifts into1st gear. When the operator pushes the downshiftbutton again, the transmission upshifts into 2nd gear.

If the machine is in 2nd gear and the downshiftbutton is pushed, the transmission instantly shifts into1st gear. When the operator shuttles the shifter, thetransmission upshifts back into 2nd gear.

Brake Pedal Transmission DeclutchA transmission declutch feature concentrates moreengine power on the loader when digging in heavy ortough conditions, providing smother stops and starts.Total disconnection of the transmission from theengine is prevented. This feature will function in 1st,2nd, or 3rd gear only. It will not function in 4th gear.

RD98K308FIGURE 9. TRANSMISSION DECLUTCH SWITCH

When the transmission declutch switch is in the onposition and either brake pedal is pushed, theTransmission ECM reduces the pressure to thetransmission forward or reverse clutch.

The Transmiss ion ECM wi l l no t comple te lydisconnect the clutch from the engine, but graduallyreduces the forward or reverse clutch pressure downto a lower level.

When the brake pedal is released, the TransmissionECM gradually increases the forward or reverseclutch back up to system clutch pressure.

If the direction is changed while the transmission isdeclutched, the selected forward or revers clutch willbe filled and maintain a low pressure until the brakepedal is released. Then the selected forward orreverse clutch pressure will gradually increase up tosystem clutch pressure.


6002-13

NOTES


6002-14

TRANSMISSION PRESSURE TEST POINTS DIAGRAM

NOTE: See Figure 10 for Measuring Point, Transmitter, Sensor and Connection locations.

No. IDENTIFICATION/LOCATION CONNECTIONDESIGNATION ON

VALVE BLOCK

Measuring Points for Pressure Oil and Temperature51 Before the Converter - Opening Pressure 9 bar M10x1 H

52 Behind the Converter - Opening Pressure 3.5 bar M14x1.5

53 Clutch Forward 16+2 bar KV M10x1 B

55 Clutch Reverse 16+2 bar KR M10x1 E

56 Clutch 16+2 bar K1 M10x1 D

57 Clutch 16+2 bar K2 M10x1 A

58 Clutch 16+2 bar K3 M10x1 C

60 Clutch 16+2 bar K4 M10x1 F

63 Behind the Converter Temperature 100° C, Short Time 120° C M14x1/5

65 System Pressure 16+2 bar M10x1 K

Measuring Points for Delivery Rates15 Connection to the Heat Exchanger 1 5/16” - 12 UNF-2B

16 Connection from the Heat Exchanger 1 5/16” - 12 UNF-2B

Inductive Transmitter and Speed Sensor21 Inductive Transmitter n Turbine M18x1.5

34 Speed Sensor n Output and Speedometer47 Inductive Transmitter n Central Gear Train M18x1.5

48 Inductive Transmitter n Engine M18x1.5

Connections49 Plug Connection on the Hydraulic Control Unit68 System Pressure M16x1.5 G

69 Pilot Pressure M16x1.5 J


6002-15

BC00E065FIGURE 10. MEASURING POINTS AND CONNECTIONS


6002-16

CHART FOR RECORDING PRESSURE READINGSUse this chart to record the pressure readings.

P.I.N. Number: Date:

TEST POINTS

ShiftSpeed

P65

V53

R55

156

257

358

460

551

652

LP

1st F

2nd F

3rd F

4th F

1st R

2nd R

3rd R

Neut

P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE

V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN

R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT


6002-17

PRESSURE TEST RESULTS

All or Most Pressures Low and/or Flow Test LowPossible causes include:

1. Oil level not correct.

2. Oil type and grade not correct.

3. Oil operating temperature high.

4. Screen for suction tube plugged.

5. Suction tube or gaskets leak.

6. Main pressure valve, springs, or valve bore.

7. Reduction valve, springs, or valve bore.

8. Charge pump seals or gaskets leak.

9. Charge pump worn.

10. Oil supply flange not sealing correctly.

Some Pressures LowPossible causes include:

1. Circuit isolation does not correct low pressure.

A. Control valve or gasket.

B. Channel plate or gasket.

2. Circuit isolation corrects low pressure.

A. Clutch shaft or seals.

B. Clutch drum or piston.

Not Enough PowerPossible causes include:

1. Check Electrical Troubleshooting in this Sectionto verify actual gear selected.

2. Engine RPM below Stall Test specified RPM.

A. Check engine and fuel system for problem.

B. Check that torque converter installation iscorrect.

3. Engine RPM above Stall Test specified RPM.

A. Check converter pressures and flow.

B. Check that torque converter installation iscorrect.

Machine Stops or Hesitates While Shifting - IntermittentPossible causes include:

1. Check orifice and O-ring. (See Section 6007 forreplacing.)

2. Check for foreign material plugging orifices orsticking valves.

3. Check for reduced pressure at test pressurepoints.

4. See Electrical Troubleshooting this section forelectrical system problem.


6002-18

CONVERTER OUT PRESSURE CHECK

Test Equipment Required0 to 28 bar (400 psi) gauge with hose long enough totake readings in the cab and CAS-2324 SpecialAdapter.

Test Procedure1. Block the machine tires.

2. Apply the parking brakes.

3. Install the pressure gauge.

4. Heat the oil to an operating temperature of 80 to100° C (176 to 212° F).

5. While in the cab, put the transmission inNEUTRAL. Run the engine at full throttle. Recordthe reading in the char t on page 6002.16.Pressure must be 3.5 to 6.5 bar (51 to 96 psi).

LUBRICATION PRESSURE CHECK

Test Equipment Required0 to 7 bar (100 psi) gauge.

Test Procedure1. Block the machine tires.


3. Install the pressure gauge in the cooler returnline at the transmission.

4. Heat the oil to an operating temperature of 80 to100° C (176 to 212 ° F).

5. While in the cab, run the engine at full throttle.Put the transmission in each gear and record thereading in the chart on page 6002.16. Pressuremust be 0.2 to 1.2 bar (3 to 18 psi).

FLOWMETER TEST

Test Equipment RequiredCAS-1808 Flowmeter Kit; CAS-2702 FlowmeterAdapter.

Flowmeter Test Procedure1. Block the machine tires.


3. Heat the oil to an operating temperature of 80 to100° C (176 to 212° F).

4. Remove the filter and install the CAS-2702adapter.

5. Install the flowmeter between the adapter andthe filter.

6. While in the cab, run the engine at full throttle.Put the transmission in NEUTRAL and record theflow measurement. The correct flow for 621Cmachines is 52 L/min (14 U.S. gpm) at 2000 rpm.The correct flow for 721C and 821C machines is80 L/min (21 U.S. gpm) at 2000 rpm.

CONSUMPTION TEST PROCEEDURE1. Block the machine tires.


3. Heat the oil to an operating temperature of 80 to100° C (176 to 212 ° F).

4. Install the flowmeter to converter outlet line (lineto cooler) in series.

5. While in the cab, run the engine at full throttle.Put the transmission in NEUTRAL and record theflow measurement. The flow must be 9.1 L/min(2 U.S. gpm).

6. Repeat the procedure with the transmission inFORWARD in third gear. The flow must be 9.1L/min (2 U.S. gpm).

7. Repeat the procedure with the transmission inREVERSE in third gear. The flow must be 9.1L/min (2 U.S. gpm).


6002-19

TRANSMISSION OVERHEATING1. Operate machine in normal operating conditions and observe:

A. Verify actual oil temperature at test point. Normal operating temperature can be 56 degrees C (100 degreesF) above the ambient temperatures.

B. Use a stop watch to establish the exact length of time required to reach the overheating condition.

C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?

2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle(1250 to 1450 RPM).

A. Oil temperature returns to Normal - establish length of time.

1. Check oil level, type and grade is correct (See Section 1002).

2. Check operator’s gear selection is correct for conditions.

3. Make sure brakes are fully released.

4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).

B. Oil temperature remains overheated.

1. Check for dirty radiator - airflow restricted.

2. Check for engine overheating problem.

3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).

3. Perform all the pressure and flow tests.

4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits arenot within specifications.

5. Refer to Understanding Results to determine possible cause of any test results not within specifications.


6002-20

ERROR CODESIn case of possible errors in the system, a wrench appears on the display, combined with indication of the errornumber. See section 4005 for error code retrieval procedures and definitions. A transmission electrical schematichas been supplied in this section to assist in fault isolation, see figure 11.

TRANSMISSION SHIFTER LOGIC INFORMATION

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within theshifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. Inneutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is lowand B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter isengaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Function ShifterShifter Wire

ColorShifter Tower

ConnectorShifter Shroud

ConnectorHarness Wire #

Harnessped/cab #

Trans. ECM #

power B+ red/black A A 19A 43 45

forward V yellow - B 25F 44 43

reverse R pink - C 25R 45 64

neutral N gray - D 25T 46 67

gear2(3-4) B2 green B - 25W 48 65

gear1(1-4) B1 blue C - 25Z 49 63

downshift DS purple D - 25Y 50 22

Transmission ECM Function

Transmission ECM Pin #

Transmission Valve

Clutch #Transmission

Valve Pin #Wire #

Cab/engPin #

A1P1 56 Y1 K4 1 25K 16

A1P2 10 Y2 KR 2 25L 17

A1P3 32 Y3 K1 3 25M 18

A1P4 55 Y4 K3 4 25N 19

A1P5 9 Y5 KV 5 25P 20

A1P6 51 Y6 K2 6 25J 21

VPSI 12,13 all Y all K 7 25S 22

TEMP 39 TEMP none 8 36T 5

TEMP 46 TEMP none 9 36R 12


6002-21


TRANSMISSION ELECTRICAL SCHEMATICFIGURE 11

TRANSMISSIONKICK-DOWNSWITCH

TRANSMISSIONELECTRONICCONTROLMODULE

TURBINESPEEDSENSOR

INTERMEDIATESPEEDSENSOR

BACK-UPALARM

TORQUE CONVERTEROUTPUT TEMP SENDER

W (52P) 0.8

LBe (25K) 1.0

LBe (25L) 1.0

LBe (25M) 1.0

LBe (25N) 1.0

LBe (25P) 1.0

LBe (25J) 1.0

LBe (25S) 1.0

V (36T) 1.0V (36R) 1.0

CAB POSITIVE STUD

CAB SWITCHED POWER


B (0) 1.0LBe (25D) 1.0

B(0

)1.

0B

(0)

1.0

O (19A) 0.8

CAB NEGATIVE STUD

O (19T) 0.8O (19H) 1.0

VIA RIDE CONTROL SWITCHON SHEET 22

SHEET 11 SHEET 12 SHEET 13

O(1

9A)

0.8

O (19A) 0.8 TO FUSE AON SHEET 8

B (0) 0.8

VIA DETENT SWITCHON SHEET 19

VIA RIDE CONTROL SWITCHON SHEET 19

LBe (25Y) 0.8

LBe (25T) 0.8 TO NEUTRAL START RELAY #8ON SHEET 7

102A

921C

6/7/821C

NAO-JUMPER CONNECTEDEURO-JUMPER OPEN

SPARE

SPARE

TO FUSE A ON SHEET 8

VIA BEACON SWITCHON SHEET 1

VIA BEACON SWITCHON SHEET 1

TO RR WIPER SWITCHON SHEET 25

DETENT SWITCHON SHEET 5

B/R (50G) 0.5

TO PARKING BRAKE SWITCHON SHEET 15

V (37E) 0.8V (36G) 1.0

O (19A) 1.0

A

B

A

B

C29

28

10

7

11

9

8

16

17

18

19

20

21

22

5

12

ENG|CAB

31

25

24

13

B

A

B

A

6

1

2

3

4

5

9

7

8

445

10

3

12

51

42

41

67

56

32

55

9

19

66

62

21

39

13

68

26

23

27

25

46

65

63

22

43

64

29

7

1

2

15

17

18

49

A

B

C

D

TO ETHER SWITCHON SHEET 7

6

9

4

5

2

8

7

10

30

87

87a

85 86

NO

NCC

1

3

B

D

FRONT|CAB

21

LOCATED IN

HYD. CONTROLLER

TO FUSE T ON SHEET 10

TO FUSE T ON SHEET 10

TO FUSE HON SHEET 8

6

CAB |REAR

4

REAR|REARLIGHT

+-

TO MAIN CAB HARNESSON SHEET 17

TO PARKING BRAKE RELAY#9 ON SHEET 17

14

19

100

101

96

22

13 70

70

2194

20

41

38

95

102

53

108

48

49

50

43

44

45

46

CAB|PED B

C

D

94

15REARLIGHTREAR

A

B

31

6

1

234

5

9

7

8 118

1

2

3

4A

B

142



TO RR WIPER SWITCHON SHEET 25

TO PARKING BRAKE SWITCHON SHEET 15

TO ETHER SWITCHON SHEET 7

2

4

5

6

1

LBe (25G) 1.0

2

4

5

6

1

2

4

5

6

1

V (36R) 1.0

B (0) 1.0

LBe (25A) 1.0

LBe (25C) 1.0

LBe (25B) 1.0

V (36R) 1.0

Y (32F) 1.0

Y (32F) 0.8

O (19A) 0.8

B (0) 0.8

LBe (25D) 0.8

B (0) 0.8

LBe (25A) 0.8

LBe (25C) 0.8

LBe (25B) 0.8

V (36G) 1.0

B (0) 1.0B (0) 1.0

LBe (25K) 1.0

LBe (25L) 1.0

LBe (25M) 1.0LBe (25N) 1.0

LBe (25K) 0.8LBe (25L) 0.8

LBe (25M) 0.8

LBe (25N) 0.8

LBe (25P) 1.0

LBe (25J) 1.0

LBe (25S) 1.0

LBe (25P) 0.8

LBe (25J) 0.8

LBe (25S) 0.8

V (36T) 1.0

V (36R) 1.0

V (36R) 1.0Y (36R) 0.8Y (36T) 0.8

O (19T) 0.8

G (50L) 0.5

Y (50H) 0.5

Y (35R) 0.8

LBe (25W) 0.8

LBe (25Z) 0.8

LBe (25Y) 0.8

B (0) 1.0

Y (35R) 1.0

Gy (49) 1.0

B (

0)

0.8

B (

0)

0.8

B (

0)

1.0

Y (

35R

) 0

.8

Y (3

5A)

0.8

Gy

(49)

1.

0

Y (

35A

) 0

.8

Y (35C) 0.8

Y (3

5R)

1.0

B (

0)

1.0

B (

0)

1.0

LBe (25Y) 0.8

LBe (25F) 0.8

LBe (25R) 0.8

LBe (25T) 0.8 LBe (25T) 0.8

LBe (25T) 0.8

LBe (25W) 0.8

LBe (25Z) 0.8

LBe (25Y) 0.8

LBe (25F) 0.8

LBe (25R) 0.8

LBe (25T) 0.8

O (19A) 0.8

O (

19A

) 0

.8

O (19A) 1.0

LBe

(25G

) 0

.8

B (0

) 1

.0

B (0

) 1

.0

O (

19A

) 0

.8

LBe

(25H

) 0

.8

LBe (25G) 0.8

O (1

9A)

0.8

O (

19A

) 0

.8

Gy

(49)

1.

0

O (

19A

) 0

.8

Gy

(49)

1.

0

V (37D) 0.8

O (19A) 0.8

1

3

2

4

1

3

2

4

FILTER MAINTENANCESWITCH

OUTPUTSPEEDSENSOR

ENGINESPEEDSENSOR

TRANSMISSION SOLENOIDVALVE ANDTEMPERATURE SENSORS

TRANSMISSIONSHIFTER

BACKUP ALARMRELAY #7

BACK-UPALARMDISABLE

DIAGNOSTICCONNECTOR

TRANSMISSIONAUTO SWITCH

DECLUTCHSWITCH

DECLUTCHBRAKESWITCH

GM99C600

Section6003

6003




April, 2000

TRANSMISSION

6003-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6003-3

SPECIAL TOOLSAssembly car . . . . . . . . . . . . . . . . . . . . 5870 350 000Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . 5870 350 063Support . . . . . . . . . . . . . . . . . . . . . . . . 5870 350 090Adjusting screws M6 . . . . . . . . . . . . . . 5870 204 031Adjusting screws, universal . . . . . . . . . 5870 204 011Lifting device . . . . . . . . . . . . . . . . . . . . 5870 204 002Internal pliers . . . . . . . . . . . . . . . . . . . . 5870 900 013Separating device size 2 . . . . . . . . . . . 5870 300 024Two-leg puller . . . . . . . . . . . . . . . . . . . 5870 970 004Handles . . . . . . . . . . . . . . . . . . . . . . . . 5870 260 010Grab sleeve . . . . . . . . . . . . . . . . . . . . . 5873 001 057Grab sleeve . . . . . . . . . . . . . . . . . . . . . 5873 001 045Grab sleeve . . . . . . . . . . . . . . . . . . . . . 5873 001 059

Grab sleeve . . . . . . . . . . . . . . . . . . . . .5873 002 038Grab sleeve, K3 . . . . . . . . . . . . . . . . . 5873 001 058Basic set tool . . . . . . . . . . . . . . . . . . . 5873 001 000Rolling tool . . . . . . . . . . . . . . . . . . . . . .5870 600 007Rolling tool (suction tube). . . . . . . . . . 5870 600 003Rolling tool (pressure oil pipes) . . . . . 5870 600 004Rolling tool (Oil Pipes) . . . . . . . . . . . . 5870 600 005Assembly aid (K1, KV, KR) . . . . . . . . . 5870 345 086Assembly aid (K2, K3, K4) . . . . . . . . . 5870 345 085Dial indicator. . . . . . . . . . . . . . . . . . . . .5870 600 007Driver . . . . . . . . . . . . . . . . . . . . . . . . . 5870 057 011Handle, Driver. . . . . . . . . . . . . . . . . . . 5870 260 002

SPECIAL TORQUESOil pipes

Studs ............................................................................................................................... 9 Nm (80 pound-inches)Socket head screw ...................................................................................................... 23 Nm (194 pound-inches)Screw plug................................................................................................................... 51 Nm (451 pound-inches)

Clutch K1, K2, K3, K4.................................................................................................... 17 Nm (150 pounds-inches)

Plugs............................................................................................................................... 25 Nm (221 pounds-inches)

Output shaftOutput shaft screws..................................................................................................... 23 Nm (194 pound-inches)Housing cover screws ................................................................................................. 46 Nm (407 pound-inches)Output flange screws................................................................................................... 34 Nm (301 pound inches)

Oil feed housing and transmission pumpTransmission pump screws ......................................................................................... 46 Nm (407 pound-inches)Oil feed housing screws .............................................................................................. 23 Nm (194 pound-inches)

Engine connection and converterInput shaft screws ............................................................................................................ 115 Nm (82 pound-feet)Converter housing screws........................................................................................... 68 Nm (602 pound-inches)Cover............................................................................................................................ 23 Nm (194 pound-inches)Converter cover........................................................................................................... 46 Nm (407 pound-inches)Input flange .................................................................................................................. 34 Nm (301 pound-inches)

Duct plate Screws......................................................................................................................... 23 Nm (194 pound-inches)Screw plug................................................................................................................... 30 Nm (265 pound-inches)

Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound-inches)

Oil level tubeTube............................................................................................................................. 34 Nm (301 pound-inches)Cover housing screws ................................................................................................. 23 Nm (194 pound-inches)

Speed sensor and inductive transmitterSpeed sensor screw.................................................................................................... 23 Nm (194 pound-inches)Inductive transmitter .................................................................................................... 30 Nm (265 pound-inches)Cover plate .................................................................................................................. 12 Nm (194 pound-inches)Screw plug...................................................................................................................... 140 Nm (103 pound-feet)


6003-4

SPECIFICATIONSClutch KV and KR plate clearance ......................................................................................... 2.7 mm (0.106 inches)

Clutch K1 plate clearance....................................................................................................... 2.4 mm (0.094 inches)

Clutch K2, K3 plate clearance ................................................................................................. 1.8 mm (0.071 inches)

Clutch K4 Plate Clearance ..................................................................................................... 1.2 mm (0.047 inches)

NOTE: The J I Case Company reserves the right to make improvements in design or changes in specifications atany time without incurring any obligation to install them on units previously sold.


6003-5

DISASSEMBLY

STEP 1

BK00D037

Fasten the transmission on an assembly stand.

STEP 2

GD98M837

Remove the socket head screws, instal l twoalignment screws, and remove the control unit fromduct plate.

STEP 3

GD98M838

Remove both gaskets and the intermediate plate.

STEP 4

GD98M839

Remove the socket head screws, hex nuts, andremove the duct plate from transmission housing.Remove flat gasket.

STEP 5

GD98M851

Remove the inductive transmitter.

STEP 6

GD98M852

Remove the hex head screws and remove theconverter housing.


6003-6

STEP 7

GD98M853

Remove the socket head screws for removal of thetransmission pump.

STEP 8

GD98M854

Apply a bearing separator on the splines shoulder ofthe stator shaft and pull the pump out of the housingbores, using two-leg puller.

NOTE: If traces of wear should be encountered inthe pump housing or the cam disk, the completepump has to be replaced.

STEP 9

GD98M855

Separate the transmission pump from stator.Separate the cam plate from pump.

STEP 10

GD98M856

Remove the hex head screws and remove the oilfeed housing. Remove the flat gasket.

STEP 11

GD98M860

Remove the hex head screws, cover, and flat gasket.

STEP 12

GD98M861

Remove the lock plate, hex head screws, and pry theconverter side output flange from the shaft.

STEP 13Pry the shaft seal out of the housing bore.


6003-7

STEP 14Turn the transmission 180 degrees and remove therear output flange.

STEP 15

GD98M862

Remove the speed sensor and both inductivetransmitters.

STEP 16

GD98M863

Remove the hex nuts and the two covers..

STEP 17

GD98M864

Install guide rods.

NOTE: The following steps describe the commonremoval of all clutches.

STEP 18

BK00D029

Install clutch shaft retainer nuts. With clutch shaftretainer nuts attached to all clutches in the housingcover, ins ta l l eyebo l ts and l i f t ing dev ice totransmission cover.

STEP 19

BK00D028

Separate the cover along with clutches from thetransmission housing, using lifting device.

STEP 20

BK00D026

Place clutch disc carriers onto nesting table.


6003-8

STEP 21Remove clutch shaft retainer nuts and lift coverfree.

STEP 22

GD98M867

Remove the socket head screws and remove theoutput shaft and both oil baffle plates.

STEP 23

GD98M880

Pull tapered roller bearing from the shaft. Removethe opposite tapered roller bearing.

STEP 24

GD98M877

Remove the bearing outer race and pull output shaftout of the housing bore.

STEP 25

GD98M878

Squeeze the rectangular ring out and separate ballbearing from the shaft.

NOTE: The following steps are for the disassemblyof the clutch KV. The disassembly of the clutch KR issimilar.

STEP 26

GD98M979

Squeeze the sealing ring out.

STEP 27

GD98M881

Separate the clutch disc carrier from the shaft.


6003-9

STEP 28

GD98M882

Squeeze the snap ring out and remove the clutchdisc pack.

STEP 29

BK00D018

Preload compression spring using tool. (Tool inplace.)

STEP 30

BK00D020

Remove snap ring.

STEP 31

BK00D019

Remove the compression spring.

STEP 32

GD98M885

Remove the O-rings.

STEP 33

GD98M886

Squeeze the snap ring out.


6003-10

STEP 34

GD98M887

GD98M888

Press the idler gear from the shaft using a bearingseparator. Remove released needle bearing.

STEP 35

GD98M889

Squeeze the snap ring out and remove the ballbearing.

NOTE: The following steps are for the disassemblyof the clutch K3. The disassembly of the clutches K1and K2 are similar

STEP 36

GD98M890

Squeeze the rectangular ring out. Pull the taperedroller bearing from the shaft. Remove the oppositetapered roller bearing.

STEP 37

GD98M892

Remove the running disk, axial needle cage, andaxial washer.

STEP 38

GD98M893

Remove the idler gear.


6003-11

STEP 39

GD98M894

Remove the needle bearings and axial bearing.

STEP 40

GD98M895


STEP 41

BK00D018

Preload compression spring using tool. (Tool inplace.)

STEP 42

BKOOD020

Remove the snap ring.

STEP 43

BK00D019


STEP 44

BS00G001

Squeeze the sealing ring out. Remove bearing usingbearing puller. Tap assembly until piston drops out ofthe plate carrier.


6003-12

STEP 45

BK00D022

Remove the clutch disc carrier from the shaft.

NOTE: The following steps are for the disassemblyof the clutch K4.

STEP 46

GD98M800

Squeeze the snap ring out and separate the clutchdisc carrier from the shaft.

STEP 47

GD98M801


STEP 48

BK00D018

Preload compression spring using tool. (Tool inplace.

STEP 49

BK00D020

Remove the snap ring.

STEP 50

BK00D019



6003-13

ASSEMBLYNOTE: The following steps are for the reassembly ofthe oil pipes..

STEP 1

GD98M603

Insert suction tube (1), pressure pipes (2), andpressure pipe lubrication (3) into the housing.

STEP 2Fasten suction tube (1) and pressure pipes (2) withsocket head screw and hex nuts. Tighten to a torqueof 23 Nm (17 lb-ft)

STEP 3

GD98M605

Tilt the cover 180 degrees. Install the suction tubesand pressure pipes into the housing bores using arolling tool.

NOTE: Pipe end of the pressure pipes must beslightly below the housing plane face.

STEP 4

GD98M607

Install the screw plug with a new O-ring. Tighten thescrew plug to a torque of 140 Nm (103 lb-ft).

STEP 5

GD98M608

Insert all bearing outer races into the housing bore.

STEP 6

GD98M609

Install both oil pipes into the housing cover. Tilt thecover 180 degrees and install pipes into the housingbores using a rolling tool.

NOTE: The pipe end must be slightly below thehousing plane face.

1

3

2


6003-14

STEP 7

GD98M610

Install the studs. Tighten the studs to a torque of 9Nm (6.6 lb-ft).

NOTE: The following steps are for the assembly ofclutches KV and KR, starting with the pre-assemblyof the clutch disc carrier.

STEP 8

GD98M612

Insert both O-rings into the recesses of the pistonand apply oil. Check the function of the drain valve,clean as required.

STEP 9

GD98M613

Install the piston into the clutch disc carrier.

STEP 10

BK00D019

Preload the compression spring using tool.

STEP 11

BK00D018

Tool in place.

STEP 12

BK00D020

Install the snap ring.

NOTE: The following steps are for the KV and KRclutch disc packs. The disc stacking of clutches KVand KR is identical.


6003-15

STEP 13

225A

The above shows the installation position of theKV/KR components.

NOTE: Install the outer plate (3) with the steel facedside facing the piston.

NOTE: For the adjustment of the running clearancethere are snap rings of different thickness available.To ensure a proper measuring result, install clutchdiscs without oil.

STEP 14

GD98M616

Install the clutch disc pack.

STEP 15

GD98M617

Install the end shim and squeeze snap ring in.

STEP 16

GD98M618

Adjust the running clearance to 2.7 mm. Press theend shim on with approximately 10 kg (20 lb) andmeasure the dimension from the carrier face to theend shim, using depth gauge as shown. Exampledimension measurement, 7.25 mm (0.29 in).

1. PLATE CARRIER2. PISTON3. OUTER PLATE - ONE-SIDED COATED4. INNER PLATES5. OUTER PLATES - COATED ON BOTH SIDES6. SNAP RING7. END SHIM8. 2.5 mm +0.2 mm


6003-16

STEP 17

GD98M619

Use tools to lift the end shim against snap ring(upward) until contact is obtained and measure thedimension from the carrier face to the end shim,using depth gauge as shown. Example dimensionmeasurement, 4.55 mm (0.18 in). The differencebetween the dimension in the previous step and thisstep is the running clearance.

NOTE: In case of deviations from the required endshim clearance, use snap ring(s) of differentthickness for correct measurement.

STEP 18Remove the clutch disc pack, oil and reinstall theclutch disc pack.

STEP 19

GD98M620

Install the idler gear until all inner discs are engaged,then remove the idler gear.

STEP 20

GD98M621

Apply Loctite 243 to the stud. Tighten the stud to atorque of 17 Nm (12.5 lb-ft).

STEP 21

GD98M622

Insert ball bearing until contact is obtained andattach with a snap ring.

STEP 22

GD98M623

Install the needle bearing.


6003-17

STEP 23

GD98M624

Support the idler gear on the bearing inner race.Press the idler gear against the shoulder.

STEP 24

GD98M625

Attach the idler gear axially with a snap ring.

STEP 25

BK00D023

Use heat gun to heat clutch disc carrier.

STEP 26

BP00G020

Install gear and shaft into heated bore.

STEP 27

BK00D024

Heat bearing.

STEP 28

GD98M625

Place heated bearing on the shaft.

STEP 29Check the function of the clutch, using compressedair.

NOTE: The following steps are for the reassembly ofclutch K1, K2, and K3.


6003-18

STEP 30

GD98M630

Apply Loctite 243 to the stud and install the stud.Tighten the stud to a torque of 17 Nm (12.5 lb-ft).

STEP 31

GD98M631

Insert the clutch disc carrier until contact is obtained.

STEP 32

GD98M632

Check the function of the piston drain valve andclean as required. Inser t both O-rings into therecesses of the piston and apply oil.

STEP 33

GD98M633

Install the piston into the clutch disc carrier.

STEP 34

GD98M634

Install the compression spring and spring cup.BK00D023

STEP 35

BK00D019



6003-19

STEP 36

BK00D018

Tool in place.

STEP 37

BK00D020


NOTE: The following steps are for K1, K2 and K3clutches. The assembly of clutches K1, K2, and K3 isidentical.

STEP 38

232A

The above shows the installation position of the K1components.


STEP 39

232A

The above shows the installation position of the K2and K3 components.





6003-20

STEP 40

GD98M636


STEP 41

GD98M637

Install the end shim and squeeze the snap ring in.

STEP 42

GD98M638

Adjust the running clearance for K1 to 2.4 mm (0.09in). Adjust the running clearance for K2 and K3 to 1.8mm (0 .07 i n ) . P ress the end sh im on w i thapproximately 10 kg (20 lb) and measure thedimension from the carrier face to the end shim,using depth gauge as shown. Example dimensionmeasurement, 8.20 mm (0.32 in).

NOTE: For the adjustment of the end shimclearance there are snap rings of different thicknessavailable. To ensure a proper measuring result,install plates without oil.

STEP 43

GD98M639


NOTE: In case of deviations from the required endshim clearance, use snap ring(s) of differentthickness for correct measurement.

STEP 44Remove the clutch disc pack, oil and reinstall theclutch disc pack.


6003-21

STEP 45

GD98M640

Install the running disc (1), axial needle cage (2), andaxial washer (3).

NOTE: Install the running disc (1) with the chamferfacing the axial needle cage.

STEP 46

GD98M641

Install both the needle bearings.

STEP 47

GD98M642

Install the idler gear until all inner discs are engaged.

STEP 48

GD98M643

Install the axial washer (3), axial needle cage (2),and running disc (1). Install the running disc (1) withthe chamfer facing the axial needle cage.

NOTE: Ensure the running disc is overlapping withthe chaff collar to accommodate all the inner discs.

STEP 49

BK00D024

Heat bearing.

STEP 50

GD98M625


1

2

3

3

2

1


6003-22

STEP 51Check the function of the clutch, using compressedair.

NOTE: The following steps are for the reassemble ofclutch K4.

STEP 52

GD98M647

Heat the gear to about 120° C (248° F) and assembleuntil seated in position.

STEP 53

GD98M648

Install the gear shaft with the snap ring.

STEP 54

GD98M649

Install the stud. Tighten the stud to a torque of 17 Nm(12.5 lb-ft).

STEP 55

GD98M650

Check the function of the piston drain valve andclean as required. Insert both O-rings into the pistonrecesses and oil the O-rings.

STEP 56

GD98M651

Install the piston into the clutch disc carrier. Be surethe piston bottoms out.


6003-23

STEP 57

BK00D019


STEP 58

BK00D018

Tool in place.

STEP 59

BK00D020


NOTE: The following steps are for installing theclutch disc pack in clutch K4.

STEP 60

232A

The above shows the installation position of the K4components..


STEP 61

GD98M653




6003-24

STEP 62

GD98M654

Install the end shim and squeeze the snap ring in.

STEP 63

GD98M655

Press the end shim on with approximately 10 kg (20lb). Adjust the running clearance to 1.2 mm (0.05 in).Measure the dimension from the carrier face to theend shim, using depth gauge as shown. Exampledimension measurement, 7.25 mm (0.29 in).

NOTE: For the adjustment of the running clearancethere are snap rings of different thickness available.To ensure a proper measuring result, install plateswithout oil.

STEP 64

GD98M656


NOTE: In case of deviations from the required plateclearance, use snap ring(s) of different thickness forcorrect measurement.

STEP 65After the adjustment of the running clearance hasbeen done, remove the clutch disc pack, oil theclutch discs and reinstall.

STEP 66

GD98M657

Install the idler gear until all inner discs are engaged,then remove idler gear.


6003-25

STEP 67

GD98M658

Assemble both axial washers and the needle cage.

NOTE: Upper and lower axial washers have thesame thickness.

STEP 68

GD98M659

Install both needle bearings.

STEP 69

GD98M660

Install the idler gear.

STEP 70

GD98M661

Assemble axial washer (3), needle cage (2), andrunning disc (1). Install the running disc (1) with thechamfer facing the needle cage.

STEP 71

GD98M662

Assemble the pre-assembled clutch disc carrier untilall the inner discs are engaged.

STEP 72

GD98M663

Attach the clutch disc carrier with a snap ring.

3

2

1


6003-26

STEP 73

BK00D024

Heat bearing.

STEP 74

GD98M625


STEP 75Check the function of the clutch with compressed air.

NOTE: The following steps are for the reassembly ofthe input shaft.

STEP 76

GD98M666

Heat the gear to about 120° C (248° F) and assembleuntil contact is obtained.

STEP 77

GD98M667

Install the gear with the snap ring.

STEP 78

GD98M668

Install the snap ring into the recess of the turbineshaft.

STEP 79

GD98M669

Install the turbine shaft until the snap ring snaps intothe recess of the input shaft.


6003-27

STEP 80

BK00D024

Install bearings so inner races are against shoulder.Alternate method is to heat bearing and install onturbine shaft.

STEP 81

GD98M671

Squeeze the rectangular ring and hook the ring onthe output shaft.

STEP 82

GD98M672

Insert the output shaft into the housing bore untilcontact is obtained.

NOTE: The following steps are for the reassembly ofthe output shaft and clutches. All clutches have acommon installation.

STEP 83

GD98M673

Insert all the bearing outer races into the housingcover until contact is obtained.

STEP 84

BK00F003

Install the clutches onto the nesting table.

STEP 85

BK00D029

Use acceptable lifting equipment and install thehousing cover onto the clutches. Install clutch shaftretainer nuts.

ABK3

K1

K2

K4AN KR

KV


6003-28

STEP 86

GD98M679

The above shows the position of the single clutchesin the housing cover.

STEP 87

GD98M866

The above shows the position of the single clutchesand the input and output clutches.

STEP 88

GD98M681

Squeeze the sealing rings and insert rings in theirrespective grooves. Apply grease to the sealing ringsand align the rings centrally.

STEP 89

GD98M692

Insert both the O-rings into the annular groove of theoil pipes and apply grease.

STEP 90

Tilt the housing cover 180 degrees. Install the eyebolts for lifting.

STEP 91

GD98M683

Install output gear and shaft in transmission housing.Install alignment screws. Apply Loctite 574 to themounting face. Careful ly lower the cover andclutches into the gear box housing.

STEP 92Remove the clutch retaining nuts.

K3

K2

KV

KR

K4

K1

AB

K3

K2

KVAN

K1

K4

KR


6003-29

STEP 93

GD98M685

Separate the housing cover from the gearbox, usinga lifting device. Install output gear and output gearcover.

NOTE: The following steps are for the reassembly ofthe output shaft.

STEP 94

GD98M688

Position the screening plate.

STEP 95

GD98M689

Insert the output shaft. If bearing was removed, heatbearing bore and install.

STEP 96

GD98M690

Apply Loctite 243 to the socket head screws andinstall the screws. Tighten the screws to a torque of23 Nm (17 lb-ft).

STEP 97

GD98M695

Install the housing cover with the hex head screws.Tighten the screws to a torque of 46 Nm (34 lb-ft).

STEP 98

GD98M696

Install the shaft seal with the sealing lip facing the oilchamber. Apply grease to the sealing lip.


6003-30

STEP 99

GD98M697

Heat the output flange to about 90° C (194° F). ApplyLoctite 574 to the contact area and assemble theflange with the washers and hex head screws.Tighten the screws to a torque of 34 Nm (25 lb-ft).Apply lock plate to the hex head screws.

STEP 100

BK00D034

Install the output flange on the converter side using adriver tool.

NOTE: The following steps are for the assembly ofthe oil feed housing and transmission pump.

STEP 101

GD98M702

Install two alignment screws and mount the flatgasket.

STEP 102

GD98M703

Install the oil feed housing with washers and hexhead screws. Screw the hex head screws in only untilcontact is obtained, do not tighten.

STEP 103

GD98M704

Install the two alignment screws and insert the statorshaft.


6003-31

STEP 104

GD98M705

Apply oil and install the O-ring.

STEP 105

GD98M706

Insert the transmission pump.

STEP 106

GD98M707

Apply grease to the new O-rings. Install the O-ringson the socket head screws.

STEP 107

GD98M708

Install the transmission pump with the socket headscrews. Tighten the screws to a torque of 46 Nm (34lb-ft).

STEP 108

GD98M709

Install the oil feed housing with the hex head screwsand flat washers. Tighten the screws to a torque of25 Nm (18 lb-ft).

NOTE: The following steps are for the assembly ofthe engine connection and converter.


6003-32

STEP 109

GD98M712

Fit the flat gasket and install the cover with the hexhead screws. Tighten the screws to a torque of 23Nm (17 lb-ft).

STEP 110

GD98M724

Install new sealing rings and both plugs.

STEP 111

GD98M725

Install the gasket, place the duct plate againstshoulder and install the socket head screws and hexnuts. Tighten the screws to a torque of 25 Nm (18lb-ft).

NOTE: The following steps are for the assembly ofthe transmission control valve.

STEP 112

258

Mount the gasket (1), intermediate plate (2), andgasket (3).

STEP 113Install the screw plug with new O-ring. Tighten theplug to a torque of 30 Nm (22 lb-ft).

STEP 114

GD98M727

Install the control valve on the duct plate with thesocket head screws. Tighten the screws to a torqueof 9.5 Nm (7 lb-ft).

NOTE: The following steps are for the assembly ofthe filter.


6003-33

STEP 115

GD98M733

Install the two oil distribution covers on the housingwith hex nuts and flat washers. Tighten to a torque of25 Nm (18 lb-ft).

STEP 116

GD98M735

Apply grease to the new O-ring and install the speedsensor with the socket head screw. Tighten the screwto a torque of 23 Nm (17 lb-ft).

34 = Output and Speedometer Speed

STEP 117

GD98M736

With new O-rings, install the inductive transmitters.Tighten to a torque of 30 Nm (22 lb-ft).

STEP 118Install the breather.

STEP 119

GD98M737

Install the gasket and the cover plate. Tighten to atorque of 23 Nm (17 lb-ft).

STEP 120With a new O-ring, install the screw plug. Tighten to atorque of 140 Nm (103 lb-ft).

34


6003-34

NOTES


Section6006

6006




April, 2000

WHEELS AND TIRES

6006-2


TABLE OF CONTENTS

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6006-3

TIRE PRESSURE20.5 x 25 16 PR L2 ............................................................................................................................ 3.8 bar (55 psi)20.5 x 25 16 PR L3 ............................................................................................................................ 3.4 bar (50 psi)20.5 x R25 XHA TL .............................................................................. Front, 4.5 bar (65 psi), Rear, 2.8 bar (40 psi)20.5 x R25 XTLA TL ............................................................................ Front, 4.5 bar (65 psi), Rear, 2.8 bar (40 psi)23.5 x 25 12 PR L2 ............................................................................................................................ 3.1 bar (45 psi)23.5 x 25 12 PR L3 ............................................................................................................................ 2.8 bar (40 psi)23.5 x R25 XHA TL .............................................................................. Front, 4.5 bar (65 psi), Rear, 2.8 bar (40 psi)

CHANGING TIRES

48-44

1. Have a qualified tire mechanic service the splitrim wheels used on this machine.

2. The correct tire equipment, especially a tireinflation cage, is required. Using the wrongprocedure for a split rim wheel can result indeath.

IMPORTANT: When installing a Michelin tire,lubricate the tire with a tire mounting lubricant andinflate the tire to 551 kPa, 5.5 bar (80 psi) to makesure that the tire is seated on the rim. Then decreasethe pressure to the specified pressure.

INSTALLING A WHEEL1. Make sure the mounting surfaces of the rim and

axle flange are clean and free of dirt and grease.

2. Install the wheel, hardened washers and wheelnuts.

3. Use a hand wrench (not an impact) to tighten thewheel nuts to pul l the wheel against theplanetary housing. DO NOT use an impactwrench to tighten the wheel nuts.

4. Tighten the wheel nuts to 203 Nm (150pound-feet) in the sequence shown in Figure 1.Then t ighten the wheel nuts in the samesequence to 515 to 570 Nm (380 to 420pound-feet).

BC00F051

FIGURE 1. TORQUE SEQUENCE FOR WHEEL NUTS

WHEEL NUTSThe wheel nuts must be tightened after every 20hours of operation until the wheel nuts stay tight:

A. If the machine is new.

B. If a wheel has been removed and installed.

Torque SpecificationTighten the wheel nuts to 203 Nm (150 pound-feet) inthe sequence shown in Figure 1. Then a final torqueof 515 to 570 Nm (380 to 420 pound-feet) in thesame sequence.

WARNING: The split rim wheels used on this machine can be dangerous. When inflating a tire on themachine, use a self-locking nozzle and stand at the front or rear of the tire.

When inflating a tire off the machine, put the wheel in a tire inflation cage. The retaining ring and rim cancome off with enough force to result in death to a person in front of the rim.

11013

15

3

5

142

7

16

4

11

6 8

9

12


6006-4

NOTES


Section8002 80

02




April, 2000

HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

8002-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Problems in All Circuits - See the following pages for other circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Testing the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Test No. 1 - Primary Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Test No. 2 - Secondary Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Testing and Adjusting the Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Testing and Adjusting the Combination Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Testing the Control Pressure at the Ends of the Spools in the Loader Control Valve . . . . . . . . . . . . . . . . . . . 11Testing and Adjusting the Circuit Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Testing and Adjusting the Pressure for the Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14821C HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8002-3

SPECIFICATIONSPump Output

Primary Pump (toward engine) ......................................................................... 181 L/min at 2200 rpm at 138 bar(47.8 gpm at 2200 rpm at 2000 psi)

Secondary Pump (away from engine) ............................................................... 115 L/min at 2200 rpm at 138 bar(30.3 gpm at 2200 rpm at 2000 psi)

Main relief valve pressure setting ...........................................................................189 to 199 bar (2735 to 2885 psi)

Steering relief valve pressure setting.............................................................................................. See Section 5002

Hand pump pressure setting for circuit relief valve .........................................................................214 bar (3100 psi)

Accumulator pressure..................................................................................................................... See Section 7002

Combination valve pressure setting................................................................................40 to 43 bar (575 to 625 psi)

Pressure setting at unloader valve ............................................................... 145 to 158 bar (2100 to 2300 psi)


8002-4

SPECIAL TOOLS

633L95

CAS-1904 PRESSURE FITTING KIT

632L95


B785789M

CAS-10280 FLOWMETER

B877168V

CAS-1808 FLOWMETER FITTING KIT

B877895M

CAS-10090 HAND PUMP

B877558M



8002-5

TROUBLESHOOTING PROCEDURE

Visually check the machine for oil leakage anddamaged or missing parts. Repair or replaceany damaged or missing parts.

Check the oil level in the hydraulic reservoir. Is the oil level correct?.

NoFill the hydraulic reservoir with the hydraulicoil specified in Section 1002.

Yes

Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.

Problems in All Circuits - See the following pages for other circuits

Check and clean the one suction screen (twoif equipped with auxiliary steering) in thehydraulic reservoir.

Replace the two return line hydraulic filters.

See Section 2002. Do the stall test to see ifthe engine is good.

See Section 8003 and check for contaminated oil. Is the oil contaminated?

NoSee Page 7. Do the flowmeter tests of thehydraulic pump.

Yes

See Section 8003 and clean or replace the oil.

Problem in All Loader Circuits

See Page 9 and check the pressure setting ofthe main relief valve in the loader controlvalve. Is the pressure setting correct?

No Charge the accumulator.

Yes

See Page 8 and do the Secondary PumpOutput Test.

Problem in the Braking Circuit

See Section 7002 and check the braking circuit.


8002-6

Problem in a Single Loader Circuit

Star t and run the engine at full throttle.Operate the control for the bad circuit. Doesthe cylinder move in both directions?

NoSee Page 11. Check the pressure at bothends of the spool in the loader control valve. Isthe pressure correct at both ends?

Yes

Yes

No

The remote control valve isdamaged. See Section 8010and repair the remote controlvalve.

The loader control valve is damaged. SeeSection 8005 and repair the loader controlvalve

See Page 10. Check the pressure setting of the combination valve. Is the pressure setting correct?

NoSee Page 10 and adjust the combinationvalve.

Yes

Check the cylinder piston packing. Is the packing good?

No See Section 8006 and repair the cylinder.

Yes

See Page 12. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly?

NoSee Section 8005. Disassemble the loaderc o n t r o l va l ve a n d c h e ck fo r wo r n o rdamaged parts.

Yes

The problem is repaired.

Problem in the Steering Circuit

See Section 5002 and check the steeringcircuit. Is the steering circuit good? No Repair the component as necessary.

Yes

See Page 7. Do the Primary Pump OutputTest.


8002-7

Testing the Hydraulic Pump

Test No. 1 - Primary Pump Output Test

STEP 1Connect the flowmeter to the primary pressure hosefrom the hydraulic pump located toward the engine.

STEP 2Make sure the load control of the flowmeter is open.Make sure the hydraulic oil is 54 to 66°C (130 to150°F).

STEP 3Start and run the engine at 2000 r/min. Measure theflow at 0 kPa, 0 bar (0 psi). Record the flow.

STEP 4Slowly close the load valve on the flowmeter andmeasure the flow at 13 790 kPa, 138 bar (2000 psi).Make sure the engine is running at 2000 r/min withthe load applied. Record the flow.

STEP 5Divide the flow reading at 13 790 kPa, 138 bar (2000psi) by the reading at 0 kPa, 0 bar (0 psi). The answermultiplied by 100 is the percent efficiency of theprimary pump. If the efficiency is less than 75%repair or replace the pump.

GS98M898

1. CAS-10280 FLOWMETER 3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL)2. HYDRAULIC RESERVOIR 4. CONNECT TO PRIMARY PRESSURE PORT HOSE

12

3

4


8002-8

Test No. 2 - Secondary Pump Output Test

STEP 1Connect the flowmeter to the secondary pressurehose from the hydraulic pump located away from theengine.

STEP 2Make sure the load control of the flowmeter is open.Make sure the hydraulic oil is 54 to 66°C (130 to150°F).

STEP 3Start and run the engine at 2000 r/min. Measure theflow at 0 kPa, 0 bar (0 psi). Record the flow.

STEP 4Slowly close the load valve on the flowmeter andmeasure the flow at 13 790 kPa, 138 bar (2000 psi).Make sure the engine is running at 2000 r/min withthe load applied. Record the flow.

STEP 5Divide the flow reading at 13 790 kPa, 138 bar (2000psi) by the reading at 0 kPa, 0 bar (0 psi). The answermultiplied by 100 is the percent efficiency of theprimary pump. If the efficiency is less than 75%repair or replace the pump.

GS98M99

1. CAS-10280 FLOWMETER 3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL)2. HYDRAULIC RESERVOIR 4. CONNECT TO SECONDARY PRESSURE PORT HOSE

12

3

4


8002-9

Testing and Adjusting the Main Relief Valve

Pressure Check

STEP 1Engage the transport/service link.

STEP 2Lower the bucket to the floor. Stop the engine.

STEP 3Connect a 20 685 kPa, 207 bar (3000 psi) pressuregauge to the quick disconnect fitting at Test Port 1.This Test Port 1 is located on the opposite side of theprimary pressure port on the primary pump towardthe engine.

STEP 4Run the engine at full throttle. Heat the hydraulic oilto operating temperature.

STEP 5Hold the bucket control lever in the ROLLBACKposition.

STEP 6Read the pressure gauge. Compare the reading tothe specifications on Page 3.

STEP 7If the pressure is not correct, adjust the main reliefvalve.

Adjustment

STEP 1

GS98M8961. LOADER CONTROL VALVE2. MAIN RELIEF VALVE

Remove the cover at the front of the machine.

STEP 2Loosen the lock nut. Turn the adjustment screwc lockwise to i nc rease the p ressu re o rcounterclockwise to decrease the pressure.

STEP 3Check the pressure again. Repeat the adjustment asnecessary.

1

2


8002-10

Testing and Adjusting the Combination Valve

Pressure Check

STEP 1Before starting machine, pump the brakes repeatedlyto be sure the brake accumulators have no pressure.

STEP 2Connect a 6 895 kPa, 69 bar (1000 psi) pressuregauge to the quick disconnect fitting at the regulatingpressure test port.

GM98M4771. REGULATING PRESURE PORT2. COMBINATION VALVE

STEP 3Start and run the engine. Regulated pressure shouldbe 3 723 to 4 274 kPa, 37.2 to 42.7 bar (540 to 620psi).

STEP 4If the pressures are not correct, they must beadjusted.

Adjustment

STEP 1Remove the round plug from the regulator cartridgevalve.

STEP 2Use an Allen wrench to turn the adjusting screwc lockwise to i nc rease the p ressure o rcounterclockwise to decrease the pressure.

STEP 3Check the pressure setting again. Repeat theadjustment as necessary.

Leak Test

Test for internal leakage by raising the lift arms to thetop and shutting the engine off.

Repeatedly put the lift control lever into the “FLOAT”position and back to neutral. The system must allowa minimum of 10 actuations into float and still causethe lift arms to come down. If less than 10 fullactuations can be made and the checks in step 4 arecorrect, an internal hydraulic leak exists.

1

2


8002-11

Testing the Control Pressure at the Ends of the Spools in the Loader Control Valve

STEP 1Heat the hydraulic oil to operating temperature.


STEP 3Remove the cover at the front of the machine.

STEP 4Connect 6 896 kPa, 69 bar (1000 psi) pressuregauges to Test Ports 4 and 5 for the circuit which youare testing.

GS98M8971. LOADER CONTROL VALVE2. TEST PORT 4 (PRESSURE GAUGE)3. TEST PORT 5 (PRESSURE GAUGE)4. BUCKET SPOOL5. LIFT SPOOL6. AUXILIARY SPOOL

STEP 5Start and run the engine at low idle.

STEP 6Hold the control lever in a power position for thecircuit which you are testing. Read the pressuregauge. Record the pressure reading.

STEP 7Hold the control lever in the other power position.Read the other pressure gauge. Record the pressurereading.

STEP 8The pressure at each end of the spool must be 37 to43 bar (540 to 620 psi).

STEP 9If the pressure is not correct at both ends of thespool, check the pressure of the combination valve. Ifthe pressure is correct at one end of the spool but notat the other end, there is a problem in the remotecontrol valve. See Section 8010.

3

2

1 4 5 6


8002-12

Testing and Adjusting the Circuit Relief Valves

Pressure Check

STEP 1Circuit relief valves are located as shown below.

GS98M8961. CIRCUIT RELIEF VALVE2. MAIN RELIEF VALVE3. BUCKET SPOOL4. LIFT SPOOL5. AUXILIARY SPOOL

Remove the cover at the front of the machine.

STEP 2Lower the bucket to the floor. Stop the engine. Findan easy place to disconnect the line for the circuit tobe tested.

STEP 3Connect the hand pump to the disconnected line thatgoes to the loader control valve.

STEP 4Make sure that the hand pump is full of hydraulic oiland that the temperature of the oil is approximately21°C (70°F).

STEP 5Operate the handle of the hand pump and read thehighest pressure. Repeat this step several times tobe sure of the reading.

STEP 6Compare the reading to the specifications on Page 3.

STEP 7If the pressure is not correct, adjust the circuit reliefvalve.

Adjustment

STEP 1Loosen the lock nut. Turn the adjustment screwc lockwise to i nc rease the p ressure o rcounterclockwise to decrease the pressure.

STEP 2Check the pressure again. Repeat the adjustment asnecessary.

11

53 4

2

1 1


8002-13

Testing and Adjusting the Pressure for the Unloader Valve

Pressure Check

STEP 1Engage the transport/service link.


STEP 3Connect a 20 685 kPa, 207 bar (3000 psi) pressuregauge to the quick disconnect fitting at Test Port 6.This Test Port 6 is located on the face of the hydraulicpump on the secondary pump away from the engine.

STEP 4Start and run the engine at low idle.

STEP 5Heat the hydraulic oil to operating temperature.

STEP 6Put the bucket in the full ROLLBACK position.

STEP 7Run the engine at full throttle.

STEP 8Watch the pressure gauge as you slowly move thebucket control lever to the ROLLBACK position.When the gauge reading reaches 145 to 158 bar(2100 to 2300 psi), the gauge reading must drop to1 034 kPa, 10 bar (150 psi) or less.

Adjustment

STEP 1If the gauge reading did not drop according to thespecifications, remove the nut and turn the adjustingscrew until the setting is correct.

GS98M4741. NUT2. ADJUSTING SCREW3. UNLOADING VALVE

STEP 2Install the nut.

2

31


8002-14

HYDRAULIC COMPONENT LOCATIONS

BC00D096

1. AUXILIARY STEERING PUMP 13. DUAL PRESSURE ACCUMULATOR CHARGING VALVE2. PRIMARY/SECONDARY PUMP 14. BRAKE PUMP3. RESERVOIR 15. PRIORITY VALVE4. HYDRAULIC FILTERS 16. OIL COOLER5. STEERING CONTROL VALVE 17. TRANSMISSION DECLUTCH SWITCH6. LIFT CYLINDERS 18. FRONT BRAKE CYLINDERS7. BRAKE VALVE 19. COMBINATION VALVE8. LOADER CONTROL VALVES 20. BUCKET CYLINDER9. STEERING CYLINDERS 21. COUPLER LOCKING VALVE (OPTIONAL)

10. REMOTE CONTROL VALVES 22. COUPLER LOCKING CYLINDERS (OPTIONAL)11. REAR BRAKE CYLINDERS 23. RIDE CONTROL (OPTIONAL)12. BRAKE ACCUMULATORS 24. OIL COOLER BYPASS VALVE

25. UNLOADING VALVE

2425

6

620

7

23

4

9

10

185

11

1

16

1413

15 12

11

18

22

1917

9

23

218


8002-15


821C HYDRAULIC SCHEMATIC

HYDRAULICFILTERS

RESERVOIR

M

AUXILIARYSTEERING

PUMP

OIL COOLERBYPASS VALVE

SECONDARYPUMP

PRIMARYPUMP

PRESSURESWITCH

QUICKDISCONNECT

QUICKDISCONNECT

BREATHER

PRIORITYVALVE

T

P

LS

EF

CF

STEERINGCONTROL VALVE

P

LS

L

R

STEERINGCYLINDERS

RIGHT

LEFT

OPTIONALRIDE CONTROL

ACCUMULATOR

SLAVE VALVE

MASTER VALVE

BUCKETCYLINDER

LIFTCYLINDERS

OPTIONALAUXILIARYCYLINDERS

OPTIONALCOUPLERLOCKING

CYLINDERS

LOADER CONTROL VALVES

CIRCUITRELIEFVALVES

CIRCUITRELIEFVALVES

REGENERATIONVALVE

MAINRELIEFVALVE

OPTIONAL COUPLERLOCKING VALVE

ORIFICECHECKVALVES

AUXILIARY

LOADERLOWER &

FLOAT

LOADERRAISE

BUCKETDUMP

BUCKETROLLBACK

REMOTECONTROLVALVES

REAR BRAKECYLINDERS

FRONT BRAKECYLINDERS

PARKINGBRAKE

BRAKEVALVE

QUICKDISCONNECT

QUICKDISCONNECT

FB

ACF

PSIF

AUX

RB

PSIR

PPTPB

ACR

BRAKEACCUMULATOR

QUICKDISCONNECT

BRAKE PRESSURESWITCH

T

P

BRAKEPUMP

DUAL PRESSUREACCUMULATOR

CHARGING VALVE

AUXILIARY

AUXILIARY

AUXILIARY

UNLOADINGVALVE

P

S

T

OILCOOLER

COMBINATIONVALVE

BLEED SCREW

TRANS.DECLUTCH

SWITCH

BC00D061821C HYDRAULIC SCHEMATIC

1

5

12 7

19

17

1413

4

3

225

15

9

23

20

6

8

2221

10

11

18

2416

8002-16


NOTES

Section8004

8004




April, 2000

HYDRAULIC PUMP

8004-2


TABLE OF CONTENTS

SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8004-3

SPECIFICATIONManufacturer ................................................................................................................................................. Denison

Tandem vane hydraulic pump

Denison part number ................................................................................................................................ 014-70281

Case part number ..................................................................................................................................... 226568A1

SPECIAL TORQUESBolts for the shaft end cover on the hydraulic pump .......................................................... 187 Nm (138 pound-feet)

Bolts for the port end cover on the hydraulic pump ............................................................... 68 Nm (50 pound-feet)


8004-4

HYDRAULIC PUMP

DisassemblyNOTE: The hydraulic pump shown in Figure 1 is ageneral cross section view. Illustration may vary fromactual component parts.

1. Fasten the hydraulic pump in a vise with soft jawswith the shaft extended downward. Clamp thevise on the shaft end cover (2), not on thehousing (8), refer to Figure 1.

2. Loosen and remove the bolts (10) and the portend cover (1). Take note of the pressure portsposition to the suction port.

3. Remove and discard the seal (13) from the portend cover (1).

4. Firmly grasp the pump cartridge (3) and, whilerotating it, pull outward and remove the pumpcartridge (3) from the housing (8).

5. Remove and discard the seals (14 and 15) andbackup ring (16) from the pump cartridge (3).

6. Remove the hydraulic pump from the vise toreposition it with the shaft extended upward.Clamp the vise on the housing (8), not the shaftend cover (2).

7. Loosen and remove the bolts (11) from thehousing (8) and shaft end cover (2).

8. Slowly remove the shaft end cover (2) upwardand away from the housing (8).

NOTE: The shaft end cover (2) contains the pumpcartridge (4) and shaft (5).

9. Remove and discard the seal (17) from the shaftend cover (2).

10. Remove the housing (8) from the vise.

11. Fasten the shaft end cover (2) in the vise with thecoupling end of the shaft (5) downward.

12. Firmly grasp the pump cartridge (4) and, whilerotating it, pull outward and remove the pumpcartridge (4) from the shaft end cover (2).

13. Remove and discard the seals (19 and 20) andbackup ring (18) from the pump cartridge (4).

14. Remove the shaft end cover (2) from the viseand remove the retaining ring (9) from the shaftend cover (2).

15. Remove the shaft (5) from the shaft end cover (2)by gently tapping the coupling end of the shaft(5) with a plastic tipped hammer.

16. Remove and discard the seal (6) from the shaftend cover (2).

17. Loosen and remove the screws (22) from thepump cartridge (3).

18. Remove the plate (23) from the pump cartridge(3).

19. Loosen and remove the screws (12) from thepump cartridge (4).

20. Remove the plate (7) from the pump cartridge(4).

Inspection1. Clean all parts in cleaning solvent and allow all

parts to air dry or use a lint free cloth for dryingall parts thoroughly.

2. Inspect the port end cover (1), housing (8), shaftend cover (2) and the shaft (5) for wear marks,nicks and burrs. Replace the port end cover (1),housing (8), shaft end cover (2) or shaft (5) asrequired, refer to Figure 1.

3. Inspect the bearing on the shaft (5) for wear andcracks. If the bearing shows signs of wear or iscracked, a new shaft (5) is required.

4. Inspect the plates (7 and 23) for light scoring onthe wear surface. Replace the plate (7 or 23) witha new plate (7 or 23) if light scoring is found onthe wear surface.

5. Inspect the pump cartridges (3 and 4). Thevanes must move freely in the rotor slots and notbind or have excessive play. If the vanes do notmove freely in the rotor slots, or if they bind orhave excessive play, a new pump cartridge (3 or4) is required.

6. Make sure all ports in the pump cartridges (3 and4) are open and clean.


8004-5

GS98K862

FIGURE 1. HYDRAULIC PUMP - CROSS SECTION VIEW - REFERENCE ONLY

1. PORT END COVER 7. PLATE 13. SEAL 19. SEAL2. SHAFT END COVER 8. HOUSING 14. SEAL 20. SEAL3. PUMP CARTRIDGE 9. RETAINING RING 15. SEAL 21. GUIDE PIN4. PUMP CARTRIDGE 10. BOLT 16. BACKUP RING 22. SCREW5. SHAFT 11. BOLT 17. SEAL 23. PLATE6. SEAL 12. SCREW 18. BACKUP RING

20

5

1316

1

10

1718

19

9

3

8

11

2

4

14

6

7

2123

22

15

12

21


8004-6

Assembly1. Install a new backup ring (18) and new seals (19

and 20) onto the pump cartridge (4), refer toFigure 2.

2. If necessary, install a new plate (7) and screws(12) onto the pump cartridge (4).

3. Install a new backup ring (16) and new seals (14and 15) onto the pump cartridge (3).

4. If necessary, install a new plate (23) and screws(22) onto the pump cartridge (3).

5. Install a new seal (6) into the back side of theshaft end cover (2) with a shaft seal driver. Makecer tain that the open side of the seal (6) istoward the inside of the shaft end cover (2).

6. Lubricate the inside of the seal (6) with cleanhydraulic oil and install the shaft (5) into the shaftend cover (2).

7. Install the retaining ring (9) to secure the shaft (5)into the shaft end cover (2).

8. Fasten the shaft end cover (2) in a vise with softjaws with the coupling end of the shaft (5)downward.

9. Lubricate the seals (19 and 20) on the pumpcartridge (4) with clean hydraulic oil.

10. Install the pump cartridge (4) onto the shaft (5)and slide it down into the shaft end cover (2).

11. Lubricate and install a new seal (17) onto theshaft end cover (2).

12. Install the housing (8) over the pump cartridge(4) and, while rotating it, push the housing (8)downward until the housing (8) slips onto theguide pin (21) in the pump cartridge (4).

13. Install the bolts (11) through the shaft end cover(2) and into the housing (8).

14. Remove the hydraulic pump from the vise andplace it on a clean surface.

15. Tighten the bolts (11), refer to SPECIALTORQUES for the correct torque.

16. Fasten the hydraulic pump into the vise with theshaft extended downward. Clamp the vise on theshaft end cover (2), not the housing (8).

17. Install the pump cartridge (3) into the housing (8)and while rotating it, push the pump cartridge (3)downward until the pump cartridge (3) and guidepin (21) slips into the housing (8).

18. Lubricate the seals (14 and 15) on the pumpcartridge (3) with clean hydraulic oil.

19. Lubricate and install a new seal (13) onto theport end cover (1).

20. Install the port end cover (1) and bolts (10) ontothe housing (8).

21. Tighten the bolts (10), refer to SPECIALTORQUES for the correct torque.


8004-7

GS98K862

FIGURE 2. HYDRAULIC PUMP - CROSS SECTION VIEW - REFERENCE ONLY

1. PORT END COVER 7. PLATE 13. SEAL 19. SEAL2. SHAFT END COVER 8. HOUSING 14. SEAL 20. SEAL3. PUMP CARTRIDGE 9. RETAINING RING 15. SEAL 21. GUIDE PIN4. PUMP CARTRIDGE 10. BOLT 16. BACKUP RING 22. SCREW5. SHAFT 11. BOLT 17. SEAL 23. PLATE6. SEAL 12. SCREW 18. BACKUP RING

20

5

1316

1

10

1718

19

9

3

8

11

2

4

14

6

7

2123

22

15

12

21


8004-8

NOTES


Section8005

8005




April, 2000

LOADER CONTROL VALVE

8005-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SEPARATING THE VALVE SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BUCKET AND AUXILIARY SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

LIFT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REGENERATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CIRCUIT RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

CIRCUIT RELIEF AND ANTICAVITATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8005-3

SPECIFICATIONSManufacturer................................................................................................................................................... Gresen

Two Spool ValveGresen part number ................................................................................................................................ V70-338Case part number ................................................................................................................................... L126100

Three Spool ValveGresen part number ................................................................................................................................ V70-339Case part number ................................................................................................................................... L126101

Four Spool ValveGresen part number ................................................................................................................................ V70-340Case part number ................................................................................................................................... L126102

SPECIAL TORQUESNuts that fasten the valve sections .................................................................. 108 to 115 Nm (80 to 85 pound-feet)

Allen head screws for the spring caps .......................................................... 10 to 15 Nm (84 to 132 pound-inches)

Cap screws for the spools .......................................................................... 30 to 34 Nm (264 to 300 pound-inches)

Special screws for the spools ..................................................................... 30 to 34 Nm (264 to 300 pound-inches)

Spool extensions ......................................................................................... 30 to 34 Nm (264 to 300 pound-inches)

Plugs for load check valve ........................................................................... 12 to 15 Nm (108 to 132 pound-inches)

Main relief, circuit relief, circuit relief and anticavitation valves, and plugs .. 53 to 60 Nm (468 to 528 pound-inches)


8005-4

SEPARATING THE VALVE SECTIONS

DisassemblyNOTE: The four spool loader control valve was usedfor illustrating this procedure. Use this procedure as aguide for disassembling all loader control valves.

1. Clean the outside of the loader control valve.Write a number on each of the valve sections forcorrect assembly, refer to Figure 1.

2. Loosen the nuts (9) that fasten the valve sections(1, 2, 3 and 4) together.

3. Remove the nuts (9) and the end cover (5) fromthe studs (8).

4. Remove the studs (8) from the inlet and outletsection (1).

5. Separate the valve sections (1, 2, 3 and 4).

6. Remove and discard the O-rings (10 and 11)from the grooves in each valve section (1, 2, 3and 4) and the end cover (5).

Assembly1. Install new O-rings (10 and 11) in the grooves in

each valve sect ion (1, 2, 3 and 4). Applypetroleum jelly to the O-rings (10 and 11) to holdthe O-rings (10 and 11) in position, refer toFigure 1.

2. Put all of the valve sections (1, 2, 3 and 4) on thebench in the correct sequence for assembly.Install the studs (8) to align the valve sections (1,2, 3 and 4).

3. Pull the valve sections (1, 2, 3 and 4) together.

4. Install the end cover (5).

5. Install the nuts (9).

6. Tighten the nuts (9), refer to SPECIALTORQUES for the correct torque.


8005-5

GS98K834

FIGURE 1 - FOUR SPOOL LOADER CONTROL VALVE ASSEMBLY - EXPLODED VIEW

1. INLET AND OUTLET SECTION 5. END COVER 9. NUT2. BUCKET SECTION 6. PLUG 10. O-RING3. LIFT SECTION 7. O-RING 11. O-RING4. AUXILIARY SECTION 8. STUD

1

2

3

4

4

6

75

8

9

10

11

11


8005-6

BUCKET AND AUXILIARY SECTIONS

DisassemblyNOTE: The spool ports in the valve section areidentified as “A” or “B”. When removing parts fromthe spool ports, identify the parts according to theport they were removed from for correct installation.

1. Loosen and remove the Allen head screws (1)and lock washers (2), refer to Figure 2.

2. Remove the spring caps (3) from both ends ofthe valve section (11).

3. Remove the spool (4).

NOTE: The spool (4), when removed from the valvesection (11), contains a special screw (5), innerspring seat (6), inner spring (7), outer spring (8),outer spring seat (9), and special screw (10).

4. Remove and discard the O-ring (12) from bothends of the valve section (11).

5. Fasten the valve section (11) in a vise with softjaws and loosen and remove the plug (13).

6. Remove and discard the O-ring (14) from theplug (13).

7. Remove the spring (15) and the poppet (16).

8. Loosen and remove the circuit relief andanticavitation valve(s) (17) from both ends of thevalve section (11).

NOTE: If the auxiliary section is beingdisassembled, loosen and remove the circuit reliefand anticavitation valves (17) from both ends of thevalve section (11). If the bucket section is beingdisassembled, loosen and remove the circuit reliefvalve (17) from one end of the valve section (11), “B”port end of bucket section, and the circuit relief andanticavitation valve (17) from the other end of thevalve section (11), “A” port end of bucket section.

9. Fasten the spool (4) in a vise with soft jaws andloosen the special screw (5).

10. Remove the special screw (5), outer spring seat(9), outer spring (8), inner spring (7), and innerspring seat (6).

11. Loosen and remove the special screw (10) fromthe other end of the spool (4).

Inspection1. Clean all parts in cleaning solvent.

2. Inspect the spool (4) for wear and damage.

3. Inspect the inner and outer springs (7 and 8) fordamage.

4. Inspect the special screws (5 and 10) for damageto the threads and inspect the threads in theends of the spool (4) for damage.

5. Inspect the spool bores and all machinedsurfaces for wear and damage.

6. Inspect the poppet (16) and poppet seat for wearand damage.

7. Inspect the spring (15) for the poppet (16) forwear and damage.


8005-7

GS98K833

FIGURE 2 - BUCKET AND AUXILIARY SECTIONS - EXPLODED VIEW

1. ALLEN HEAD SCREW 6. INNER SPRING SEAT 11. VALVE SECTION 16. POPPET2. LOCK WASHER 7. INNER SPRING 12. O-RING 17. CIRCUIT RELIEF AND

ANTICAVITATION VALVE3. SPRING CAP 8. OUTER SPRING 13. PLUG4. SPOOL 9. OUTER SPRING SEAT 14. O-RING5. SPECIAL SCREW 10. SPECIAL SCREW 15. SPRING

1

23

1012

11

17

17

16

15

14

13

12

35

9

4

6

812

7


8005-8

Assembly1. Remove any oil from the threads on both ends of

the spool (4) and the threads on the specialscrews (5 or 10), refer to Figure 2.

2. Apply Loctite 271 to the threads on both ends ofthe spool (4).

3. Install the special screw (10) and tighten thespecial screw (10), refer to SPECIAL TORQUESfor the correct torque.

4. Install the special screw (5), outer spring seat(9), outer spring (8), inner spring (7), and innerspring seat (6).

5. Tighten the special screw (5), refer to SPECIALTORQUES for the correct torque.

6. Fasten the valve section (11) in a vise with softjaws. Lubricate the O-rings on the circuit reliefand anticavitation valve(s) (17), or the circuitrelief valve (17) with clean hydraulic oil.

7. Install and tighten the circuit relief valve or circuitrelief and anticavitation valve(s) (17), refer toSPECIAL TORQUES for the correct torque.

NOTE: If you are assembling a bucket section, installthe circuit relief valve (17) into “B” port of bucketsection and the circuit relief and anticavitation valve(17) into “A” port of bucket section.

8. Install the poppet (16).

9. Install the spring (15).

10. Install a new O-ring (14) on the plug (13) andlubricate the O-ring (14) with clean hydraulic oil.

11. Install and tighten the plug (13), refer toSPECIAL TORQUES for the correct torque.

12. Install a new O-ring (12). Apply petroleum jelly tothe O-ring (12) to hold the O-ring (12) in place inthe valve section (11). Repeat this procedure onthe opposite end of the valve section (11).

13. Lubricate the spool (4) and the spool bore withclean hydraulic oil.

14. Install the spool (4).

15. Install the spring caps (3), Allen head screws (1)and lock washers (2) on each end of the valvesection (11).

16. Tighten the Allen head screws (1), refer toSPECIAL TORQUES for the correct torque, onboth ends of the valve section (11).


8005-9

GS98K835.

FIGURE 3 - BUCKET SECTION AND AUXILIARY SECTIONS - CROSS SECTION VIEW

NOTE: Circuit relief valve without anticavitation shown, used in “B” port of bucket section only.

1. ALLEN HEAD SCREW 3. PLUG 5. POPPET 7. SPRING CAP2. CIRCUIT RELIEF AND ANTICAVITATION VALVE 4. SPRING 6. SPECIAL SCREW 8. SPOOL

67

87

2

45

1

2

3


8005-10

LIFT SECTION

DisassemblyNOTE: The spool ports in the valve section areidentified as “A” or “B”. When removing parts fromthe spool ports, identify the parts according to theport they were removed from for correct installation.

1. Loosen and remove the Allen head screws (1)and lock washers (2), refer to Figure 4.

2. Remove the spring caps (3) from both ends ofthe valve section (34).

3. Loosen the special screw (5).

4. Remove the special screw (5), outer spring seat(6), spacer (9), outer spring (8) and inner spring(7).

5. Remove the inner spring seat (12) and the largespacer (13).

6. Remove the sleeve (14).

7. Remove the backup ring (16) and O-ring (15).

8. Remove the spool (4) from the opposite end ofthe valve section (34).

NOTE: The spool (4), when removed from the valvesection (34), contains a special screw (25), outerspring seat (24), inner spring (23), outer spring (22),spool extension (21), inner spring seat (20), O-ring(19), small spacer (18) and an O-ring (17).

9. Remove the small spacer (18) from the spool (4).

10. Remove and discard the O-ring (11) from thelarge spacer (13). Install a new O-ring (11).

11. Remove and discard the O-ring (19) from thesmall spacer (18). Install a new O-ring (19).

12. Remove the O-ring (17) from the other end of thevalve section (34).

13. Fasten the spool (4) in a vise with soft jaws andloosen the special screw (25).

14. Remove the special screw (25), outer spring seat(24), outer spring (22), inner spring (23) andinner spring seat (20).

15. Remove the spool extensions (10 and 21) fromboth ends of the spool (4).

16. Fasten the valve section (34) in a vise with softjaws. Loosen and remove the plug (30). Repeatfor the opposite plug (30).

17. Loosen and remove the top plug (26).

18. Remove and discard the O-ring (27) from theplug (26).

19. Remove the spring (28).

20. Remove the poppet (29).

21. Remove and discard the O-rings (32 and 33) andbackup ring (31) from the plugs (30). Install newO-rings (32 and 33) and backup rings (31).


2. Inspect the spool (4) for wear and damage.

3. Inspect the inner and outer springs (7, 8, 22 and23) for damage.

4. Inspect the special screws (5 and 25) for damageto the threads and inspect the threads in theends of the spool (4) for damage.

5. Inspect the spool bores and all machinedsurfaces for wear and damage.

6. Inspect the poppet (29) and poppet seat for wearand damage.

7. Inspect the spring (28) for the poppet (29) forwear and damage.


8005-11

GS98K836

FIGURE 4 - LIFT SECTION - EXPLODED VIEW

1. ALLEN HEAD SCREW 8. OUTER SPRING 15. O-RING 22. OUTER SPRING 29. POPPET2. LOCK WASHER 9. SPACER 16. BACKUP RING 23. INNER SPRING 30. PLUG3. SPRING CAP 10. SPOOL EXTENSION 17. O-RING 24. OUTER SPRING SEAT 31. BACKUP RING4. SPOOL 11. O-RING 18. SMALL SPACER 25. SPECIAL SCREW 32. O-RING5. SPECIAL SCREW 12. INNER SPRING SEAT 19. O-RING 26. PLUG 33. O-RING6. OUTER SPRING SEAT 13. LARGE SPACER 20. INNER SPRING SEAT 27. O-RING 34. VALVE SECTION7. INNER SPRING 14. SLEEVE 21. SPOOL EXTENSION 28. SPRING

26

35

6

16

12

27

28

29

30

32

2524

23

22

2120

18

33

31

1

8

9

11

13

1415

3231

304

34

3332

17

19

12

710


8005-12

Assembly1. Install the poppet (29), refer to Figure 4.


3. Lubricate the O-ring (27) on the plug (26) withclean hydraulic oil.

4. Install and tighten the plug (26), refer toSPECIAL TORQUES for the correct torque.

5. Lubricate the O-rings (32 and 33) and backuprings (31) on the plugs (30) with clean hydraulicoil.

6. Install and tighten the plug (30), refer toSPECIAL TORQUES for the correct torque.Repeat for the opposite plug (30).

7. Remove any oil from the threads on both ends ofthe spool (4) and the threads on the spoolextensions (10 and 21).

8. Apply Loctite 271 to the threads in the spool (4).

9. Install the spool extensions (10 and 21) into theappropriate ends of the spool (4), refer toSPECIAL TORQUES for the correct torque.

10. Install the inner spring seat (20), inner spring(23), outer spring (22), outer spring seat (24) andthe special screw (25).


12. Install a new O-ring (17) into the valve section(34). Apply petroleum jelly to the O-ring (17) tohold the O-ring (17) in place in the valve section(34).

13. Install the small spacer (18) on the spool (4).

14. Lubricate the spool (4) and the spool bore withclean hydraulic oil.

15. Install a new O-ring (15) and backup ring (16)into the valve section (34). Apply petroleum jellyto the O-ring (15) to hold the O-ring (15) in placein the valve section (34).

16. Install the sleeve (14).

17. Install the large spacer (13).

18. Install the inner spring seat (12).

19. Install the inner spring (7), outer spring (8),spacer (9), outer spring seat (6) and specialscrew (5).


21. Install the spring cap (3) and Allen head screws(1) and lock washers (2).

22. Tighten the Allen head screws (1), refer toSPECIAL TORQUES for the correct torque.

23. Repeat procedure on opposite end of the valvesection for spring cap (3), Allen head screws (1)and lock washers (2).


8005-13

GS98K837

LIFT SECTION - CROSS SECTION VIEW

1. ALLEN HEAD SCREW 3. PLUG 5. POPPET 7. SPOOL2. PLUG 4. SPRING 6. SPRING CAP

54

1

7 66

1

2

3

2


8005-14

REGENERATION VALVE

Disassembly1. Fasten the inlet and outlet section in a vise with

soft jaws. Loosen and remove the regenerationvalve assembly (1), refer to Figure 6.

NOTE: The regeneration valve assembly (1)contains a body (2), plunger (3), valve (4), snap ring(5) and an O-ring (6).

2. Remove the snap ring (5) from the ID of the body(2).

3. Remove the valve (4).

4. Remove the plunger (3).

5. Remove and discard the O-ring (6) from the body(2). Install a new O-ring (6).


2. Inspect the body (2), plunger (3), valve (4), andsnap ring (5) for wear and damage. If the body(2) is damaged or worn, a new regenerationvalve assembly (1) must be used.

Assembly1. Lubricate the plunger (3) with clean hydraulic oil,

refer to Figure 6.

2. Install the plunger (3) into the body (2).

3. Lubricate the valve (4) with clean hydraulic oil.

4. Install the valve (4) into the body (2).

5. Install the snap ring (5).

6. Lubricate the O-ring (6) with clean hydraulic oil.

7. Install and tighten the regeneration valveassembly (2).


8005-15

GS98K838

FIGURE 6 - REGENERATION VALVE - EXPLODED VIEW

1. REGENERATION VALVE ASSEMBLY 3. PLUNGER 5. SNAP RING2. BODY 4. VALVE 6. O-RING

3

4

5

6

1

2


8005-16

MAIN RELIEF VALVE


soft jaws. Loosen and remove the main reliefvalve, refer to Figure 7.

2. Fasten the body (23) in a vise with soft jaws.Loosen and remove the adapter (7).

NOTE: The adapter (7) contains a lock nut (1),washer (2), adjusting screw (3), O-ring (4), spring(5), plunger (6), O-ring (8) and plunger seat (9).


4. Fasten the adapter (7) in a vise with soft jaws.Measure the distance to the top of the adjustingscrew (3). Make a record of the measurement foruse during assembly.

5. Loosen the lock nut (1).

6. Remove the adjusting screw (3).



9. Carefully push the poppet (20) and sleeve (15)out of the body (23).

10. Separate the poppet (20) and sleeve (15).Remove and discard the O-ring (16) and backupring (17) from the sleeve (15). Install a newO-ring (16) and backup ring (17).

11. Remove and discard the O-ring (18) and backupring (19) from the poppet (20). Install a newO-ring (18) and backup ring (19).

12. If necessary, remove the retaining ring (22) andscreen (21) from the poppet (20). Discard thescreen (21). Install a new screen (21) and installthe retaining ring (22).

13. Remove and discard the O-rings (25 and 26) andbackup ring (24) from the body (23). Install newO-rings (25 and 26) and a backup ring (24).

14. Remove and discard the O-rings (11 and 12) andbackup ring (10) from the adapter (7). Install newO-rings (11 and 12) and a backup ring (10).

15. Remove and discard the O-ring (4) from theadjusting screw (3). Install a new O-ring (4).


2. Inspect the poppet (20), screen (21), sleeve (15),and retaining ring (22) for wear and damage.

3. Inspect the plunger (6) and plunger seat (9) forwear and damage.

4. Inspect the springs (5 and 13) for damage.

5. Inspect all machined surfaces for wear anddamage.


8005-17

GS98K839

FIGURE 7 - MAIN RELIEF VALVE - EXPLODED VIEW

1. LOCK NUT 7. ADAPTER 13. SPRING 19. BACKUP RING 25. O-RING2. WASHER 8. O-RING 14. SPACER 20. POPPET 26. O-RING3. ADJUSTING SCREW 9. PLUNGER SEAT 15. SLEEVE 21. SCREEN4. O-RING 10. BACKUP RING 16. O-RING 22. RETAINING RING5. SPRING 11. O-RING 17. BACKUP RING 23. BODY6. PLUNGER 12. O-RING 18. O-RING 24. BACKUP RING

2625

24

23

2019

1817

1615

1413

6

12

34

78

9

5

1011

12

2221


8005-18

Assembly1. Lubricate the O-ring (18) on the poppet (20) with

clean hydraulic oil, refer to Figure 7.

2. Install the poppet (20) in the sleeve (15).

3. Lubricate the O-ring (16) and backup ring (17) onthe sleeve (15) with clean hydraulic oil.

4. Install the poppet (20), sleeve (15) and thespacer (14) into the body (23).


6. Lubricate the O-rings (11 and 12) and thebackup ring (10) on the adapter (7) with cleanhydraulic oil.

7. Install and tighten the adapter (7).

8. Install the plunger (6).


10. Lubricate the O-ring (4) on the adjusting screw(3) with clean hydraulic oil.

11. Turn the adjusting screw (3) into the adapter (7)to the same measurement made dur ingdisassembly.

12. Prevent the adjusting screw (3) from turning andtighten the lock nut (1).

13. See Figure 8. Lubricate the O-ring on the mainrelief valve (2) with clean hydraulic oil. Install andtighten the main relief valve (2), refer to SPECIALTORQUES for the correct torque.

GS98K8451. INLET AND OUTLET SECTION2. MAIN RELIEF VALVE

Figure 8. MAIN RELIEF VALVE INSTALLATION

The pressure setting of the main relief valve must bechecked after the loader control valve has beeninstalled. See Section 8002.

1

2


8005-19

GS98K840

FIGURE 9 - MAIN RELIEF VALVE - CROSS SECTION

1. ADJUSTING SCREW 6. O-RING 11. O-RING 16. BACKUP RING 21. SPRING2. WASHER 7. SLEEVE 12. SCREEN 17. O-RING 22. O-RING3. O-RING 8. O-RING 13. RETAINING RING 18. SPACER 23. PLUNGER4. ADAPTER 9. SPRING 14. POPPET 19. O-RING 24. LOCK NUT5. BACKUP RING 10. BACKUP RING 15. BACKUP RING 20. ADAPTER

22

23

241 2

3

4

5

6

7

8

9

10

11

1615

14

13

17

21

19

18

12

20


8005-20

CIRCUIT RELIEF VALVE

DisassemblyNOTE: Used on “B” port of the bucket section only.

1. Fasten the body (20) in a vise with soft jaws. Ifused, remove the cap (1) for the adjusting screw(4), refer to Figure 10.

2. Measure the distance to the top of the adjustingscrew (4). Make a record of the measurement foruse during assembly.





7. Loosen and remove the adapter (8).


9. Carefully push the poppet (17) out of the body(20).




13. Remove and discard the O-rings (12 and 13) andbackup ring (11) from the adapter (8). Install thenew O-rings (12 and 13) and a backup ring (11).



2. Inspect the poppet (17) and screen (18) for wearand damage.





8005-21

GS98K841

FIGURE 10 - CIRCUIT RELIEF VALVE - EXPLODED VIEW

1. CAP (IF USED) 6. SPRING 11. BACKUP RING 16. BACKUP RING 21. BACKUP RING2. LOCK NUT 7. PLUNGER 12. O-RING 17. POPPET 22. O-RING3. WASHER 8. ADAPTER 13. O-RING 18. SCREEN 23. O-RING4. ADJUSTING SCREW 9. O-RING 14. SPRING 19. RETAINING RING5. O-RING 10. PLUNGER SEAT 15. O-RING 20. BODY

23

13

45

67

8

910

1112

12

3

2221

20

19

1716

14

15

18


8005-22



2. Install the poppet (17) into the body (20).

3. Fasten the body (20) in a vise with soft jaws.Install the spring (14).







10. Prevent the adjusting screw (4) from turning andtighten the lock nut (2).

11. If used, install the cap (1).

The pressure setting of the circuit relief valve must bechecked with a hand pump according to instructionsin Section 8002.


8005-23

GS98K842

FIGURE 11 - CIRCUIT RELIEF VALVE - CROSS SECTION VIEW

1. CAP (IF USED) 5. BODY 9. SCREEN 13. O-RING 17. ADAPTER2. LOCK NUT 6. O-RING 10. O-RING 14. POPPET 18. O-RING3. PLUNGER 7. BACKUP RING 11. BACKUP RING 15. O-RING 19. WASHER4. O-RING 8. RETAINING RING 12. SPRING 16. BACKUP RING 20. ADJUSTING SCREW

18

19

20

5

4

2

17

6

16

7

15

14

13

12

11

10

9

1

8

3


8005-24

CIRCUIT RELIEF AND ANTICAVITATION VALVE


soft jaws. Loosen and remove the circuit reliefand anticavitation valve, refer to Figure 12.

2. Fasten the body (25) in a vise with soft jaws.Loosen and remove the adapter (8).

NOTE: The adapter (8) contains a lock nut (2),washer (3), adjusting screw (4), O-ring (5), spring (6),plunger (7), O-ring (9) and plunger seat (10).


4. Fasten the adapter (8) in a vise with soft jaws.Measure the distance to the top of the adjustingscrew (4). Make a record of the measurement foruse during assembly.





9. Carefully push the poppet (21) and sleeve (16)out of the body (25).

10. Remove the retaining ring (15).

11. Separate the poppet (21) and sleeve (16).

12. Remove and discard the O-ring (17) and backupring (18) from the sleeve (16). Install a newO-ring (17) and backup ring (18).




16. Remove and discard the O-rings (12 and 13) andbackup ring (11) from the adapter (8). Install newO-rings (12 and 13) and a backup ring (11).


Inspection

1. Clean all parts in cleaning solvent.

2. Inspect the poppet (21), screen (23), sleeve (16),and retaining rings (15 and 24) for wear anddamage.





8005-25

GS98K843

FIGURE 12 - CIRCUIT RELIEF AND ANTICAVITATION VALVE - EXPLODED VIEW

1. CAP (IF USED) 7. PLUNGER 13. O-RING 19. O-RING 25. BODY2. LOCK NUT 8. ADAPTER 14. SPRING 20. BACKUP RING 26. BACKUP RING3. WASHER 9. O-RING 15. RETAINING RING 21. POPPET 27. O-RING4. ADJUSTING SCREW 10. PLUNGER SEAT 16. SLEEVE 22. ROLL PIN 28. O-RING5. O-RING 11. BACKUP RING 17. O-RING 23. SCREEN6. SPRING 12. O-RING 18. BACKUP RING 24. RETAINING RING

28

13

45

67

89

10

1112

12

3 2726

21

19

1716

14

15

1820

25

2423

22


8005-26



2. Install the poppet (21) in the sleeve (16).

3. Install the retaining ring (15).

4. Lubricate the O-ring (17) and backup ring (18) onthe sleeve (16) with clean hydraulic oil.

5. Install the poppet (21) and sleeve (16) into thebody (25).








13. To prevent the adjusting screw (4) from turning,tighten the lock nut (2).

14. See Figure 13. Lubricate the O-ring on the circuitrelief and anticavitation valve (2) with cleanhydraulic oil. Install and tighten the circuit reliefand anticavitation valve (2), refer to SPECIALTORQUES for the correct torque.

GS98K8451. INLET AND OUTLET SECTION2. CIRCUITRELIEF AND ANTICAVITATION VALVE

FIGURE 13 - CIRCUIT RELIEF AND ANTICAVITATION VALVE INSTALLATION

The pressure setting of the main relief valve must bechecked wi th a hand pump according to theinstructions in Section 8002.

1

2


8005-27

GS98K844

FIGURE 14 - CIRCUIT RELIEF AND ANTICAVITATION VALVE - CROSS SECTION VIEW

1. ADJUSTING SCREW 7. SLEEVE 13. SCREEN 19. RETAINING RING 25. LOCK NUT2. WASHER 8. O-RING 14. RETAINING RING 20. O-RING 26. CAP (IF USED)3. O-RING 9. SPRING 15. POPPET 21. BODY4. ADAPTER 10. BACKUP RING 16. BACKUP RING 22. SPRING5. BACKUP RING 11. O-RING 17. BACKUP RING 23. O-RING6. O-RING 12. ROLL PIN 18. O-RING 24. PLUNGER

2

22

23

24

25 1

6

5

3

18

21

20

19

17

16

15

14

13

12

9

8

7

4

10

11

26


8005-28

NOTES


Section8013

8013




April, 2000

ACCUMULATOR FOR RIDE CONTROL

8013-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8013-3

SPECIFICATIONSAccumulator dry nitrogen pressure........................................................... 31 ±1.7 bar (450 ±25 psi) at 21° C (70° F)Accumulator fluid capacity....................................................................................................... 3785 ml (231 cu. inch)Accumulator maximum operating pressure ....................................................................................207 bar (3000 psi)

SPECIAL TORQUESAccumulator gas charging valve cap ....................................................................................13.6 Nm (10 pound-feet)Gas charging valve ..............................................................................................88 to 102 Nm (65 to 75 pound-feet)Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)Gland ............................................................................................................163 to 176 Nm (120 to 130 pound -feet)

SPECIAL TOOLS

94L95

CAS-10899 NITROGEN ACCUMULATOR CHARGING KITB786441M

CAS-1456 GLAND WRENCH


8013-4

CHARGING THE ACCUMULATOR WITH NITROGEN

GS98N801FIGURE 1. NITROGEN CHARGING KIT CAS-10899

M253A

M406

M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the NitrogenAccumulator Charging Kit to the machine or nitrogen, refer to Figure 1.

IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF duringhigh pressure (10 bar/150 psi and above) applications.

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause anexplosion.

WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 450 PSI(31 bar). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel theaccumulator at a dangerous rate of speed.

WARNING: Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulatorcontains nitrogen compressed to 450 PSI (31 bar). High heat will cause the safety plug to blow out of theaccumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.

VALVE “C”

VALVE “D”

VALVE “B”VALVE “A”

TONITROGENTANK

TOACCUMULATOR

!

!

!


8013-5

1. Close the shutoff valve A by turning it all the wayto the left (counterclockwise), refer to Figure 1.

2. Open valve B by turning it out all the way to theleft (counterclockwise).

3. Close valve C by turning it all the way to the right(clockwise).

4. Close the gauge valve D by turning it all the wayto the right (clockwise).

5. Connect the charging hose to the nitrogen supplytank.

6. SLOWLY turn valve A clockwise while watchingthe high pressure gauge. Stop turning valve Awhen the needle on the gauge reaches 31 bar(450 psi).

NOTE: If the needle goes over the needed pressure,quickly open and close valve D and check thepressure setting again.

The charging kit is now ready to be installed on theaccumulator.

7. Remove the two cap screws (14) and theprotection bracket (13) from the gas chargingvalve (11) on the accumulator, refer to Figure 2.

8. Remove the valve cap (12) from the gas chargingvalve (11) on the accumulator.

9. Back off the needle valve on the accumulator endo f the charg ing hose by tu r n ing i tcounterclockwise to the maximum amount. Thisprevents nitrogen from escaping from theaccumulator when the charging hose is attachedto the accumulator gas charging valve, refer toFigure 1.

10. Install the charging hose fitting onto theaccumulator gas charging valve (11), refer toFigure 2.

11. Tighten the needle valve by turning it clockwise.Slowly open the gauge valve D and observe thereading on the gauge. This reading is thenitrogen pressure level inside the accumulator,refer to Figure 1.

12. Open the shutoff valve A on the nitrogen supplytank. While observing the pressure on the gauge,s l i gh t l y open the need le va l ve on theaccumulator charge hose. By regulating theneedle valve, fill the accumulator to 31 bar (450psi). Close the needle valve. Close the shutoffvalve A on the nitrogen supply tank.

13. Close valve B by turning to the right (clockwise).After a few minutes, check the accumulator forleakage.

14. Back off the needle valve on the accumulator endo f the charg ing hose by tu r n ing i tcounterclockwise the maximum amount. This willprevent ni t rogen f rom escaping from theaccumulator as the hose is removed. Removethe charging hose from the accumulator gascharging valve (11), refer to Figure 2.

15. Install the valve cap (12) onto the gas chargingvalve (11) on the accumulator.

16. Install the protection bracket (13) over the gascharging valve (11) and secure it with cap screws(14).

17. Remove the charging hose from the nitrogensupply tank, refer to Figure 1.


8013-6

GS98K847

FIGURE 2. ACCUMULATOR - EXPLODED VIEW

1. TUBE 6. O-RING 11. GAS CHARGING VALVE2. WEAR RING 7. BACKUP RING 12. VALVE CAP3. WEAR RING 8. GLAND SEAL 13. PROTECTION BRACKET4. PISTON 9. GLAND 14. CAP SCREW5. BACKUP RING 10. O-RING

1

2

34

5

6

7

8

9 1011

13 14

12


8013-7

ACCUMULATOR

Disassembly1. Use a gland wrench to slowly loosen and remove

the gland (9) from the tube (1), refer to Figure 2.

2. Use a punch and push the piston (4) from thetube (1).

3. Remove the gland seal (8) from the gland (9).

4. Fasten the gland (9) in a vise with soft jaws. Becareful not to damage the gland (9).

5. Loosen and remove the gas charging valve (11)from the gland (9).

6. Remove and discard the O-ring (10) from the gascharging valve (11).

7. Remove and discard the wear rings (2 and 3)from the piston (4).

8. Remove and discard the O-ring (6) and backuprings (5 and 7) from the piston (4).


2. Inspect the inside of the tube (1) for grooves andother damage. If there is damage to the tube (1),a new tube (1) must be used.

3. Remove small scratches inside the tube (1) withemery cloth of medium grit. Use the emery clothwith a rotary motion.

4. Inspect the piston (4) for wear or damage thatcan cause nitrogen or oil leakage. Use a newpiston (4) as required.

5. Inspect the gland (9) for wear or damage that cancause nitrogen leakage. Use a new gland (9) asrequired.

6. Inspect the gas charging valve (11) for wear ordamage that can cause nitrogen leakage. Use anew gas charging valve (11) as required.

Assembly1. Install new backup rings (5 and 7) and a new O-

ring (6) on the piston (4), refer to Figure 2.

2. Install new wear rings (2 and 3) on the piston (4).

3. Lubricate the bore in the tube (1), the wear rings(2 and 3), and the O-ring (6) on the piston (4)with clean oil.

4. Push the piston (4) straight into the tube (1).

5. Install the valve cap (12) on the gas chargingvalve (11).

6. Install a new O-ring (10) on the gas chargingvalve (11).

7. Lubricate the O-ring (10) on the gas chargingvalve (11) with clean oil.

8. Install the gas charging valve (11) in the gland(9). Tighten the gas charging valve (11), refer toSPECIAL TORQUES for the correct torque.

9. Install a new gland seal (8) on the gland (9).

10. Lubricate the gland seal (8) on the gland (9) withclean oil. Apply antisieze compound to thethreads on the gland (9).

11. Use the gland wrench to install the gland (9) inthe tube (1). Tighten the gland (9), refer toSPECIAL TORQUES for the correct torque.

12. Charge the accumulator with nitrogen accordingto the instructions on page 3.

13. Install the protection bracket (13) in place on thegland (9). Install the cap screws (14) that fastenthe protection bracket (13) to the gland (9).Tighten the cap screws (14), refer to SPECIALTORQUES for the correct torque.


8013-8

NOTES


Documents

Manual de Servicio 821C