Manual De Servicio 821c p5b63

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1002

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Section 1002 FLUIDS AND LUBRICANTS

CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION 450 Sherman Avenue Hamilton, ON L8N 4C4 CANADA

Bur 7-13071

© 2000 Case Corporation Printed in U.S.A. April, 2000

Template Name: SM_2_col Template Date: 1994_04_05

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1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS ............................................................................................................................ 2 ENGINE OIL RECOMMENDATIONS....................................................................................................................... 3 DIESEL FUEL........................................................................................................................................................... 4 MAINTENANCE SCHEDULE ................................................................................................................................... 5

CAPACITIES AND LUBRICANTS Engine oil Capacity 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 system Capacity ................................................................................................................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 tank Capacity ........................................................................................................... 268 litres (70.8 U.S. gallons) Type of fuel....................................................................................... See diesel fuel specifications on page 4 Hydraulic system Hydraulic 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® Transmission Refill 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) Axles Capacity of center bowl Front ......................................................... 18.9 litres (20 quarts) 135H EP Plus 1.9 litres (4 pints) B91246 Rear .........................................................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 EP Rear ................................................................................................................ 5.5 litres (6 quarts) 135H EP Type of lubricant ........................................................................... Case (MS1316) 135H EP (SAE 85W-140) Limited slip additive .................................................................................................................. Case B91246 Brake system Type 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 damaged as a result of using an alternate oil.

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

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ENGINE OIL RECOMMENDATIONS Engine Oil Selection Case No. 1 Engine Oil is recommended for use in your Case engine. Case engine oil will lubricate your engine correctly under all operating conditions. If Case No. 1 Multi-Viscosity or Single Grade Engine Oil is not available, use only oil meeting API engine oil service category CE.

292L91 A2723

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 oil change intervals given in this manual are according to tests with Case lubricants.

Oil Viscosity / Temperature Ranges Temperature Fahrenheit −40°

−20° −30°

0° −10°

20° 10°

40° 30°

60° 50°

80° 70°

100° 90°

120° 110°

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 −34° −40°

−23° −29°

−12° −18°

−1° −7°

10° 4°

21° 16°

32° 27°

43° 38°

49°

Temperature Celsius NOTE: Use of an engine oil pan heater or an engine coolant heater is required when operating temperatures are in the shaded area. Bur 7-13071

Issued 4-00

Printed in U.S.A.



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 engine power and high fuel consumption. In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following Note. NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will restrict the fuel filter and 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 for Acceptable 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 storage container 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 .................................................................................................................................. 34 Flash point, minimum ..................................................................................................................140°F (60°C) Cloud point (wax appearance point), maximum .................................................. -5°F (-20°C) See Note above Pour point, maximum ........................................................................................ -15°F (-26°C) See Note above Distillation temperature, 90% point ...................................................................... 540 to 640°F (282 to 338°C) Viscosity, at 100°F (38°C) Centistokes .................................................................................................................................. 2.0 to 4.3 Saybolt 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. 2 Ash, by weight, maximum ............................................................................................................... 0.01 of 1%

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MAINTENANCE SCHEDULE Model 821C Instructions AS REQUIRED 22 SERVICE THE AIR CLEANER IF THE AIR CLEANER WARNING LAMP ILLUMINATES ........................... SEE OPERATORS MANUAL 37 SERVICE AIR CLEANER PRECLEANER.................................................................................................. SEE OPERATORS MANUAL 30 REPLACE THE TRANSMISSION FILTER IF THE TRANSMISSION FILTER RESTRICTION WARNING LAMP ILLUMINATES ................................................ USE CASE FILTER 19 CHECK THE RADIATOR COOLANT LEVEL IF THE WARNING LAMP ILLUMINATES .............................. SEE OPERATORS MANUAL 6.REPLACE THE HYDRAULIC FILTERS IF THE HYDRAULIC FILTER WARNING LAMP ILLUMINATES ................... USE CASE FILTERS 20 CHECK THE FAN BELT CONDITION ............................................................................................................REPLACE AS REQUIRED CHECK THE AIR CONDITIONING DRIVE TENSION (IF EQUIPPED) NOT SHOWN ...................................... ADJUST AS REQUIRED

EVERY 10 HOURS OF OPERATION OR EACH DAY- WHICHEVER OCCURS FIRST 16 CHECK THE ENGINE OIL LEVEL............................................................................................................. SEE OPERATORS MANUAL

EVERY 50 HOURS OF OPERATION 1.CHECK THE COOLANT RESERVOIR FLUID LEVEL........................................................................ ETHYLENE GLYCOL AND WATER 29 CHECK THE TRANSMISSION OIL LEVEL (ENGINE RUNNING AND OIL WARM) ................................... SEE OPERATORS MANUAL 5.CHECK THE HYDRAULIC RESERVOIR FLUID LEVEL .............................................................................. SEE OPERATORS MANUAL 15 LUBRICATE THE REAR AXLE TRUNNION PIVOTS (2 FITTINGS) .................................................. CASE MOLYDISULFIDE GREASE 27 LUBRICATE THE CENTER DRIVE SHAFT SLIP T (1 FITTING) ............................................... CASE MOLYDISULFIDE GREASE

EVERY 100 HOURS OF OPERATION 10 LUBRICATE THE BUCKET PIVOT POINTS (3 FITTINGS) ............................................................... CASE MOLYDISULFIDE GREASE 7.LUBRICATE THE STEERING CYLINDER PIVOTS - ROD AND CLOSED END (4 FITTINGS) ............ CASE MOLYDISULFIDE GREASE 9.LUBRICATE THE LOADER PIVOT POINTS (10 FITTINGS) ............................................................... CASE MOLYDISULFIDE GREASE 26 LUBRICATE THE FRONT DRIVE SHAFT SUPPPORT BEARING (1 FITTING) ................................ CASE MOLYDISULFIDE GREASE 32 LUBRICATE THE REAR DRIVE SHAFT SLIP T (1 FITTING) ................................................... CASE MOLYDISULFIDE GREASE 35 LUBRICATE THE REAR DRIVE SHAFT SLIP T (1) FITTING) .................................................. CASE MOLYDISULFIDE GREASE

EVERY 250 HOURS OF OPERATION 19 CHECK THE RADIATOR COOLANT LEVEL ................................................................................... ETHYLENE GLYCOL AND WATER 2.CHANGE THE ENGINE OIL AND REPLACE THE ENGINE OIL FILTER ..................................................... SEE OPERATORS MANUAL 34 CHECK THE BATTERY FLUID LEVEL ...................................................................................................... SEE OPERATORS MANUAL 36 CHECK THE TIRE CONDITION AND AIR PRESSURE ............................................................................. SEE OPERATORS MANUAL 12 CLEAN THE CAB AIR FILTERS (IF EQUIPPED)....................................................................................... SEE OPERATORS MANUAL 25 REPLACE ENGINE COOLING SYSTEM FILTER ................................................................................................... USE CASE FILTER

EVERY 500 HOURS OF OPERATION 3.REPLACE THE FUEL FILTERS .............................................................................................................................. USE CASE FILTERS 33 DRAIN WATER AND SEDIMENT FROM THE FUEL TANK ........................................................................ SEE OPERATORS MANUAL 14 REPLACE THE IN-LINE FUEL FILTER ................................................................................................................. USE CASE FILTERS

EVERY 1000 HOURS OF OPERATION 21 CHECK THE ENGINE VALVE CLEARANCES ................................................................................................. SEE SERVICE MANUAL 6.REPLACE THE HYDRAULIC FILTERS ................................................................................................................... USE CASE FILTERS 30 REPLACE THE TRANSMISSION OIL FILTER ....................................................................................................... USE CASE FILTERS 28 CHANGE THE TRANSMISSION OIL......................................................................................................... SEE OPERATORS MANUAL 23 CLEAN THE TRANSMISSION BREATHER ..................................................................................................... CLEAN WITH SOLVENT 24 LUBRICATE THE UPPER AND LOWER CHASSIS PIVOTS (2 FITTINGS) ....................................... CASE MOLYDISULFIDE GREASE 31 CHANGE THE FRONT/REAR AXLE DIFFERENTIAL AND PLANETARY OIL ............................................ SEE OPERATORS MANUAL

EVERY 2000 HOURS OF OPERATION OR EACH YEAR - WHICHEVER OCCURS FIRST 4.CHANGE THE HYDRAULIC OIL AND CLEAN THE SCREEN ..................................................................... SEE OPERATORS MANUAL 18 DRAIN, FLUSH AND REFILL THE ENGINE COOLING SYSTEM .................................................... ETHYLENE GLYCOL AND WATER 22 REPLACE THE AIR CLEANER ELEMENTS.......................................................................................................... USE CASE FILTERS

NOTE: When you drain, flush and refill the engine cooling system, add one container (0.5L) of Case cooling system treatment, and replace the cooling filter. Bur 7-13071

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Printed in U.S.A.



1002-6

MAINTENANCE SCHEDULE Model 821C

GS98J100

If you operate the machine in severe conditions, lubricate and service the machine more frequently. It is recommended that you see your Case dealer for information on the System Guard Lubrication Analysis System. See your Operators manual for maintenance of safety related items and for detailed information of the service items 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 in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

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SECTION INDEX - ELECTRICAL

0000-1

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


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4002

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Section 4002 ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING, AND SCHEMATICS

CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 South Service Road Hamilton, ON L7N 3M6 CANADA

Bur 7-12221

Copyright © 2000 Case Corporation Printed in U.S.A. April, 2000

Copyright © NOTES

Copyright © 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fuel Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cold Start Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Ether Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ether Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ether Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Ignition Relay #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Relay #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Relay #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter Relay #12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 16 17 17 17

TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Kick-down Switch (Located In Hydraulic Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Declutch Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-up Alarm Relay #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Bur 7-12221

Issued 4-00

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Copyright © 4002-4 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 23 23 24 24 25 26 27

TROUBLESHOOTING ENGINE OIL PRESSURE SENDER, PILOT CONTROL, PARKING BRAKE, ENGINE AUTOMATIC SHUTDOWN RELAY, AND REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant Parking Brake Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant Brake Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Automatic Shutdown Relay Socket #11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 28 29 29 29 29 30 30

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

31 31 32 32 32 33 33

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

34 35 35 35 36 36 36 37 37 37 37 38 38

TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Rotary Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 40 40 41 41 41 42

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

43 43 44 44 44 45 45 45 45 46 46

Bur 7-12221

Issued 4-00

Printed in U.S.A.

Copyright © 4002-5 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Fan Motor No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Fan Motor No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 46 46 47 47

TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET, RADIOS AND SPEAKERS . 48 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Power Converter (24 volt to 12 volt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Remote Radio or 24 Volt Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 12 Volt Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Radio Power Converter (24 volts to 12 volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH, TURN SIGNAL/HI/LOW BEAM/ HORN SWITCH, AND FLASHER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Turn Signal, Hi/Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS . . Left Marker/Turn Signal (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Drive Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Flood Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Flood Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Drive Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Marker and Turn Signal (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Brake, Tail, and Directional Lights (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Brake, Tail, and Directional Lights (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High/Low Beam Relay (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Front Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Rear Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Rear Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Front Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 56 56 56 56 57 57 57 58 58 59 59 60 60 60 60 61 61

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

62 63 63 63 63 64 64 64 65 65 66 66 66 67

Bur 7-12221

Issued 4-00

Printed in U.S.A.

Copyright © 4002-6 Engine Compartment Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Engine 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

Bur 7-12221

Issued 4-00

Printed in U.S.A.

Copyright © 4002-7

SPECIFICATIONS Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground System Voltage........................................................................................................................Approximately 24 volts Batteries The specifications are the same for the production battery and the replacement battery. Production Battery case P/N ............................................................................................... L51769 or BCM4DAW Replacement Battery Case P/N ..............................................................................................L13308 or BMC4DA Group Size ......................................................................................................................................................... 4D Reserve Capacity ................................................................................................................................ 310 minutes Cold Cranking Capacity: At -17°C (0°F)................................................................................................................................800 amperes At -29°C (-20°F) ...........................................................................................................................650 amperes Load of Capacity (Load) Test .............................................................................................................400 amperes Plates per Cell .....................................................................................................................................................23 Approximate weight with electrolyte ...................................................................................... 49.8 kg (110 pounds) Nonspill caps ............................................................................................................................................ Standard Alternator ..................................................................................................................................... 24 volt, 65 amperes Voltage Regulator ............................................................................................................. Solid State, Not Adjustable Starter................................................................................................................................ 24 volt, Solenoid Actuated Bucket Control Valves Detent Electromagnets .............................................................................................. 84 ohms Fuel Level Sender (E-F) .........................................................................................................................240-33 ohms Coolant and Hydraulic Temperature Sender 20°C (68°F).......................................................................... 3521ohms Coolant and Hydraulic Temperature Sender (Yellow Line) 105°C (221°F) ................................................. 154 ohms Coolant and Hydraulic Temperature Sender (Red Line) 110°C (230°F) .................................................. 133.9 ohms Hydraulic 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) s 2 to 3 of thermostat switch close at initial turn of the rotary switch. s 1 to 2 close with thermal setting. Engine Oil Pressure Sender. Reference Resistance vs. Pressure 1 Bar........................................................................................................................................................ 178 ohms 3 Bar.......................................................................................................................................................... 90 ohms 5.2 Bar....................................................................................................................................................... 38 ohms Fuel Solenoid Resistance (pull in) .............................................................................................................. 0.82 ohms Fuel Solenoid Resistance (hold in)............................................................................................................. 11.3 ohms

Bur 7-12221

Issued 4-00

Printed in U.S.A.

Copyright © 4002-8

GRAPHIC SYMBOLS

GM98M003

Bur 7-12221

Issued 4-00

Printed in U.S.A.

Copyright © 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 NOTE: Wires that continue, uninterrupted, to the next sheet are represented by this

symbol. symbol.

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.

Copyright © 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 as numbers in parenthesis,(17), found in the troubleshooting procedures, correspond to the circled numbers found on the Electrical and Hydraulic Schematic poster (rear pocket).

The schematic poster is color coded to assist in troubleshooting electrical circuits. Red denotes circuits that have constant power. Green denotes circuits that have power when the ignition switch in turned ON.

Items (90, Cigar Lighter) through (118, Cab Dome Light), Sheets 1 through 5 and 29 through 32, only appear on the foldout schematics in this section (see pages 67 through 97) and are not shown on the Electrical and Hydraulic Schematic poster (rear pocket).

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

GM98M004

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, COLD START, IGNITION SWITCH AND RELAYS 10 12

4 2

6 6A 1 8

3

9 11 13

5 7 GM98M005

1. 2. 3. 4. 5.

BATTERIES MASTER DISCONNECT SWITCH FUEL SHUTOFF SOLENOID ALTERNATOR STARTER MOTOR

6. 6A. 7. 8. 9.

START RELAY FUEL RELAY COLD START TEMPERATURE SWITCH ETHER SOLENOID ETHER START RELAY #6

10. 11. 12. 13.

ETHER START SWITCH NEUTRAL START RELAY #8 IGNITION SWITCH IGNITION RELAY #1

1 – Batteries NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests. NOTE: See Section 4003 and check the batteries.

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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 ). Put the master disconnect 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 ).

3 – Fuel Shutoff Solenoid Check Points Terminal for wire 0 to ground

Reading Continuity

Possible Cause of Bad Reading 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 Check Points Between housing of alternator and ground

Reading Continuity

Possible Cause of Bad Reading Bad ground connection.

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


5 – Starter Motor Check Points Between housing of starter and ground

Reading Continuity

Possible Cause of Bad Reading Bad ground connection.

NOTE: Put the master disconnect switch in the ON position. 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 Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position. Terminal 87 for red wire to ground

24 volts


NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal for wire 21C to ground

24 volts

Check neutral start relay (11), also check the circuit 21C.


24 volts

Bad start relay (6).

6A – Fuel Relay Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position. Terminal for wire 1 to ground

24 volts

Check circuit 1, also check circuit to batteries.

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

Reading


NOTE: The cold start temperature switch opens above 10 °C (50 °F). Terminal for wire 0 to ground

Continuity

Bad ground circuit.

NOTE: Disconnect the wires from the cold start temperature switch (7). Make sure the engine temperature is below 10 °C (50 °F). Between terminals A and B Bur 7-12221

Continuity

Bad cold start temperature switch (7). Issued 4-00

Printed in U.S.A.


8 – Ether Solenoid Check Points Terminal for wire 28T to ether start temperature switch

Reading Continuity

Possible Cause of Bad Reading Bad 28T circuit.

NOTE: Put the master disconnect switch and 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 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 Check Points Terminal for wire 0 to ground

Reading Continuity


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

Reading


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 Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


12 – Ignition Switch Check Points

Reading


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


NOTE: Hold the ignition switch (12) in the START position. Between Bat and Starter

Continuity


NOTE: Put the switch in the Acc position. Between Bat and Acc

Continuity


13 – Ignition Relay #1 Check Points Terminal for wire 0 to ground

Reading Continuity


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 13K to ground

24 volts

Check circuit 13K.


24 volts

Bad ignition relay #1 (13)

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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

17

14 15 16

GM98M006

14. IGNITION RELAY #2 15. ACCESSORY RELAY #3

16. VOLTMETER RELAY #12 17. TIME DELAY MODULE

14 – Ignition Relay #2 Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position. Terminal for wire 1 to ground

24 volts



24 volts

Check circuit 13K.

Terminal for wire 13R to ground

24 volts

Bad ignition relay #2 (14).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


15 – Accessory Relay #3 Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position. Terminal for wire 1 to ground

24 volts



24 volts

Check circuit 12K.


24 volts

Bad accessory relay (15), also check circuit 12P.

16 – Voltmeter Relay #12 Check Points Terminal for wire 0 to ground

Reading Continuity


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.


24 volts

Check circuit 13K.

Terminal for wire 13V to ground

24 volts

Bad voltmeter relay (16). Also check circuit 13V.

17 – Time Delay Module Check Points Terminal for wire 0 to ground

Reading Continuity


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.


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 time delay 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 volts Key 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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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

26 31 24

23 34

22 19 20 21

25

29

27 32

30

28

33

18 GM98M007

18. OUTPUT SPEED SENSOR 19. ENGINE SPEED SENSOR 20. INTERMEDIATE SPEED SENSOR 21. 22. 23. 24. 25. 26.

TURBINE SPEED SENSOR FILTER MAINTENANCE SWITCH TORQUE CONVERTER OUTPUT TEMPERATURE SENDER TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS TRANSMISSION ELECTRONIC CONTROL MODULE TRANSMISSION SHIFTER

Bur 7-12221

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 33. BACK-UP ALARM DISABLE SWITCH 34. BACK-UP ALARM

Issued 4-00

Printed in U.S.A.

Copyright © 4002-19 NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for Items 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 Check Points

Reading


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 brake to 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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


33 – Back-up Alarm Disable Switch Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF position. 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 Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF position. 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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH 39 41 38 36

40

42 43A

44 45

37 35 GM98M008

35. 36. 37. 38. 39. 40.

Bur 7-12221

BRAKE WARNING PRESSURE SWITCH COOLANT LEVEL SENDER FUEL LEVEL SENDER HYDRAULIC OIL TEMPERATURE SENDER HYDRAULIC FILTER RESTRICTION SWITCH ENGINE COOLANT TEMPERATURE SENDER

41. AIR FILTER RESTRICTION SWITCH 42. PROGRAM RESET SWITCH 43. PARK BRAKE SWITCH 43A.INSTRUMENT CLUSTER 44. PILOT CONTROL SWITCH 45. UP/DOWN COUNT SWITCH

Issued 4-00

Printed in U.S.A.


35 – Brake Warning Pressure Switch Check Points

Reading


NOTE: Brake pressure warning switch opens at 11 724 kPa (1700 psi). NOTE: Put the master disconnect switch and the ignition switch in the ON position. Continuity

Bad ground circuit.

Approximately 11.5 volts

Check circuit 33P.

Terminal B for wire 0 to ground Terminal A for wire 33P to ground

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).

No continuity

Bad brake warning pressure switch (35).

NOTE: Start and run the engine at idle. Between terminals A and B of the switch

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

36 – Coolant Level Sender Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 33P to ground

Approximately 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 Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36F to ground

Approximately 5 volts

Check the instrument cluster (43A).

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


38 – Hydraulic Oil Temperature Sender Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36H to ground



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

39 – Hydraulic Filter Restriction Switch Check Points

Reading


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.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 31H to ground.



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

40 – Engine Coolant Temperature Sender Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36C to ground



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

41 – Air Filter Restriction Switch Check Points

Reading


NOTE: Air filter restriction switch closes at 6.4 kPa (1 psi). Terminal for wire 0 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 31F to ground



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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


42 – Program Reset Switch Check Points Terminal for wire 0 to ground

Reading Continuity


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. 24 volts


Check instrument cluster (43A), also check circuit 37R.

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


24 volts

Bad program/ reset switch (42), also check circuit 1A.

43 – Park Brake Switch Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19A to ground

24 volts

Check fuse A, also check circuit 19A.

24 volts

Bad park brake switch (43).

NOTE: Apply parking brake switch (43). Terminal for wire 33U to ground


Bur 7-12221

24 volts

Bad park brake switch (43), also check circuit 49.

Issued 4-00

Printed in U.S.A.


43A – Instrument Cluster Check Points

Reading


Connector terminal 3 to ground

Continuity

Bad circuit 33P, also check the brake warning pressure switch (35).


Continuity

Bad circuit 31D, also check the coolant level sender (36).


39 to 225 ohms


Continuity


134 to 3521 ohms

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


134 to 3521 ohms

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


Continuity

Bad circuit 31F, also check the air filter restriction switch (41).


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).


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.


Continuity

Bad ground circuit.

Bur 7-12221

Bad circuit 36F, also check the fuel level sender (37). Bad circuit 35X, also check the secondary steering switch (61).

Issued 4-00

Printed in U.S.A.


43A – Instrument Cluster (Continued) Check Points

Reading


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 ground circuit.


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 Check Points Terminal for wire 0 to ground

Reading Continuity


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


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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


45 – Up/down Count Switch Check Points Terminal for wire 0 to ground

Reading Continuity


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


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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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

47 48 52 49 46

50 51 GM98M009

46. 47. 48. 49.

ENGINE OIL PRESSURE SENDER PILOT CONTROL RELAY #10 PARKING BRAKE RELAY #9 PARKING BRAKE SOLENOID

50. PILOT PRESSURE SOLENOID 51. REDUNDANT BRAKE SWITCHES 52. ENGINE AUTOMATIC SHUTDOWN RELAY #11

46 – Engine Oil Pressure Sender Check Points Between the engine oil pressure sender (46) and ground

Reading


Continuity

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

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 36P to ground


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

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


47 – Pilot Control Relay Check Points

Reading


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.


0 volts

Bad pilot control relay (47), also check circuit 53C and instrument cluster (43A).


24 volts

Bad circuit 53P.

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

48 – Parking Brake Relay Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the park brake switch (43) is OFF. Terminal for wire 19D to ground

24 volts

Bad fuse D, also check circuit 19D.


0 volts

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


24 volts

Bad circuit 52P.

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

49 – Redundant Parking Brake Solenoids Check Points

Reading



Continuity

Bad ground circuit.

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 Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


51 – Redundant Brake Switches Check Points

Reading


NOTE: Redundant brake switches close at 6200 kPa. Terminal for wire 0 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 33R to ground


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.

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING BUCKET CONTROLS 57 58 56

54

53 55 GM98M010

53. DETENT SWITCH 54. BUCKET CONTROL VALVES DETENT ELECTROMAGNETS 55. RETURN TO TRAVEL/FLOAT SWITCH

56. RETURN TO DIG PROXIMITY SWITCH 57. HEIGHT CONTROL PROXIMITY SWITCH 58. RETURN TO TRAVEL PROXIMITY SWITCH

53 – Detent Switch Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (44) in the OFF position. Terminal for wire 0 to ground

Continuity

Bad ground circuit.


24 volts

Bad pilot control relay (47), also check circuit 53P.


24 volts

Bad detent switch (53), also check circuit 56.


24 volts


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


54 – Bucket Control Valves Detent Electromagnets Check Points

Reading


NOTE: Disconnect the wires from the bucket control valve. Put the master disconnect switch and ignition switch in 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 Check Points Terminal for wire 0 to ground

Reading Continuity



24 volts


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 Check Points

Reading


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 return to dig proximity switch (56). Terminal B for wire 0 to ground

Continuity

Bad ground circuit.

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


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


57 – Height Control Proximity Switch Check Points

Reading


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 height control proximity switch (57). Terminal B for wire 0 to ground

Continuity

Bad ground circuit.


24 volts

Bad bucket control valve detent electromagnets pressure(54) or detent switch (53), also check circuit 54B.


24 volts


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

58 – Return-To-Travel Proximity Switch Check Points

Reading


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) in the RETURN TO TRAVEL position. Disconnect the connector from the return to travel proximity switch (58). Terminal B for wire 0 to ground

Continuity

Bad ground circuit.


24 volts

Bad return to travel/float switch (55), also check circuit 55B.


24 volts


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL 59 60 61 62

63 62A

62B

64 66 65

68

67

GM98M011

59. SECONDARY STEERING RELAY WITH LOCKOUT 60. SECONDARY STEERING RELAY WITH LOCKOUT 61. SECONDARY STEERING SWITCH 62. SECONDARY STEERING PUMP/MOTOR 62A.PIN ENGAGEMENT SWITCH 62B.PIN ENGAGE SOLENOID

Bur 7-12221

63. 64. 65. 66. 67. 68.

RIDE CONTROL SWITCH HOIST-UP PRESSURE SWITCH RIDE CONTROL RELAY #4 BUCKET DUMP PRESSURE SWITCH BUCKET ROLLBACK PRESSURE SWITCH RIDE ENGAGE SOLENOID

Issued 4-00

Printed in U.S.A.


59 – Secondary Steering Relay with Lockout 60 – Secondary Steering Relay with Lockout Check Points

Reading


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


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.

NOTE: Start and run the engine at idle. Terminal 2 of relay (59) to ground

0 volts

Bad relay (59), also check secondary steering switch (61).


0 volts

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


24 volts

Bad relay (59), also check instrument cluster (43A) and circuit 35X.


24 volts

Bad relay (60).


24 volts

Bad relay (59).


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 the ON position. Terminal 2 of relay (60) to ground

0 volts

Bad relay (60), also check circuit 19R and 19M.


24 volts

Bad relay (60), also check circuit 19R.

61 – Secondary Steering Switch Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 35X to ground

24 volts

Check the instrument cluster (43A), also check circuit 35X.

0 volts

Check the secondary steering relays (59 and 60), also check circuit 51P.

NOTE: Start and run the engine at idle. Terminal for wire 51P to ground

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


62 – Secondary Steering Pump/Motor Check Points Ground circuit to ground

Reading Continuity


NOTE: Start and run the engine for 2 minutes. Disconnect the wire from the fuel shutoff solenoid (3) to stop the engine. 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


Motor terminal of solenoid to ground

24 volts

Bad secondary steering pump/motor or solenoid (62).

Motor terminal of motor to ground

24 volts

Check 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 Check Points

Reading


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 lamp switch (112) in position 3 or higher and the pin engagement switch (62A) in the ON position. Disconnect the connector from the pin engagement switch (62A). Terminal for wire 49 to ground

24 volts


Continuity

Terminal for wire 19P to ground Between terminals for wires 19P and 57

24 volts Continuity

Check the 5 position rotary lamp switch (112), also check circuit 49. Bad ground circuit. Check fuse P, also check circuit 19P. Bad pin engagement switch (62A).

62B – Pin Engage Solenoid Check Points

Reading


NOTE: This solenoid 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 pin engagement switch (62A) in the ON position. Terminal for wire 0 to ground

Continuity


24 volts

Bad ground circuit. Bad pin engagement switch (62A), also check circuit 57.

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


63 – Ride Control Switch Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the 5 position rotary lamp switch (112) in position 3 or higher and the ride control switch in the ON position. Terminal for wire 49 to ground

24 volts


Continuity


24 volts

Check the 5 position rotary lamp switch (112), also check circuit 49. Bad ground circuit. 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 ON position. Between terminals for wires 19C and 58S

Continuity

Bad ride control switch (63).

64 – Hoist-up Pressure Switch Check Points Circuit 58H, point to point

Reading Continuity

Possible Cause of Bad Reading Bad circuit 58H.

NOTE: Put the master disconnect switch and ignition switch in the ON position. Start the engine. Push the ride control switch (63). Pull back on the loader lever until the green light under the ride control switch (63) is illuminated. Terminal for wire 58S to ground

24 volts

Bad hoist-up pressure switch (64), also check the ride control switch (63).

Reading


65 – Ride Control Relay Check Points Terminal for wire 0 to ground

Continuity

Bad ground circuit.

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

Circuit 58D, point to point

Reading

Continuity


Bad circuit 58D.

NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Push the ride control switch (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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


67 – Bucket Rollback Pressure Switch Check Points Circuit 58, point to point

Reading Continuity

Possible Cause of Bad Reading Bad circuit 58.

NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Push the ride control 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).


24 volts

Bad bucket rollback pressure switch (67).

68 – Ride Engage Solenoid Check Points

Reading


NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Put the ride control switch (63) and hoist-up pressure switch (64) in the ON position. Terminal for wire 0 to ground

Continuity


24 volts

Bad ground circuit. Bad circuit 58, also check bucket rollback pressure switch (67).

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING WIPER/WASHER

69

74

70 71

73

72

GM98M012

69. FRONT WIPER MOTOR 70. FRONT ROTARY WIPER AND WASHER SWITCH 71. FRONT WASHER PUMP MOTOR

Bur 7-12221

72. REAR WASHER PUMP MOTOR 73. REAR WIPER AND WASHER SWITCH 74. REAR WIPER MOTOR

Issued 4-00

Printed in U.S.A.


69 – Front Wiper Motor Check Points Terminal for wire 0 to ground

Reading Continuity


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).

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



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).


0 volts


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

70 – Front Rotary Wiper and Washer Switch Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the rotary wiper and washer switch (70) is in the OFF position. Terminal for wire 0 to ground Terminal for wire 19J to ground

Continuity 24 volts

Bad ground circuit. 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



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).


0 volts


Bur 7-12221

Issued 4-00

Printed in U.S.A.


71 – Front Washer Pump Motor Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front rotary wiper and washer switch (70) is in the OFF position. Terminal for wire 0 to ground

Continuity

Bad ground circuit.

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 Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the rear wiper and washer switch (73) is in the OFF position. Terminal for wire 0 to ground

Continuity

Bad ground circuit.

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 Check Points

Reading


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.


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

Bur 7-12221

24 volts

Bad rear wiper and washer switch (73), also check circuit 68W.

Issued 4-00

Printed in U.S.A.


74 – Rear Wiper Motor Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Make sure the rear wiper and washer switch (73) is in the OFF position. Between terminals for wires 68C and 68L

Continuity


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



0 volts


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND CONDENSER FANS 84 86 87 88 89

81 77

82 85

78

75

83 76

79 80 GM98013

75. 76. 77. 78. 79.

HORN RELAY #5 SEAT COMPRESSOR HORN BLOWER SWITCH RESISTOR BOARD

80. 81. 82. 83. 84.

BLOWER MOTOR LOW PRESSURE SWITCH (IN CAB) HIGH PRESSURE SWITCH (IN REAR CHASSIS) THERMOSTAT SWITCH COMPRESSOR CLUTCH LOCKOUT RELAY

85. 86. 87. 88. 89.

COMPRESSOR CLUTCH CONDENSER FAN RELAY NOT USED CONDENSER FAN #1 MOTOR CONDENSER FAN #2 MOTOR

75 – Horn Relay Check Points Terminal for wire 19U to ground

Reading 24 volts

64C to horn switch (100)

Possible Cause of Bad Reading Check fuse U, also check circuit 19U. 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

Bur 7-12221

24 volts

Check horn switch (100). If the horn switch (100) is good, replace the horn relay (75).

Issued 4-00

Printed in U.S.A.


76 – Seat Compressor and Switch Check Points

Reading


NOTE: This applies to models with air seat option only. Terminal for wire 0 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. 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 Check Points Terminal for wire 0 to ground

Reading Continuity


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 Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. 24 volts

Check fuse G, also check circuit 19G.

Terminals for wire 62L to ground

24 volts

Bad blower switch (78).

Terminals for wire 61T to ground

24 volts


Terminals for wire 19G to ground NOTE: Turn the blower switch to LOW.

NOTE: Turn the blower switch to MEDIUM. Terminals for wire 62M to ground

24 volts



24 volts


Terminals for wire 62H to ground

24 volts



24 volts


NOTE: Turn the blower switch to HIGH.

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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

Reading


NOTE: Disconnect the connector from the resistor board (79). Between terminals 1 and 2

Approximately 4.5 ohms

Bad resistor board (79).

Between terminals 2 and 3

Approximately 1.5 ohms

Bad resistor board (79).

80 – Blower Motor Check Points Terminals for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (78) to HIGH. 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 the blower switch (78) to LOW. If the blower motor (80) ran in HIGH but not in LOW or MEDIUM, check the resistor board (79).

81 – Low Pressure Switch (In Cab) Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the blower switch (78) to HIGH and the thermostat switch (83) to COLD. Terminal B for wire 61A to ground Circuit 61R, point to point

24 volts Continuity

Check the thermostat switch (83), also check circuit 61A. 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) Check Points

Reading


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

Bur 7-12221

Open

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

Issued 4-00

Printed in U.S.A.


83 – Thermostat Switch Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the blower switch (78) to HIGH. 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 Check Points Terminals for wire 0 to ground

Reading Continuity


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

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the blower switch (78) to HIGH and the thermostat switch (83) to COLD. Terminals for wire 61C to ground

24 volts

Check the compressor clutch lockout relay (84), also check circuit 61C.

86 – Condenser Fan Relay Check Points

Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminals for wire 0 to ground

Continuity

Terminals for wire 1 to ground

24 volts

Bad ground circuit. 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.

Bur 7-12221

Issued 4-00

Printed in U.S.A.


88 – Condenser Fan Motor No. 1 Check Points Terminals for wire 0 to ground

Reading Continuity


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


Reading Continuity


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


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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET, RADIOS AND SPEAKERS 94 95

93 93A

91 92

93B

90

GM98M014

90. CIGAR LIGHTER 91. POWER CONVERTER 92. POWER OUTLET

93. REMOTE OR 24 VOLT RADIO 93A.12 VOLT RADIO 93B.RADIO POWER CONVERTER

94. LEFT SPEAKER 95. RIGHT SPEAKER

90 – Cigar Lighter Check Points Terminal for wire 19W to ground Terminal for wire 0 to ground

Reading 24 volts Continuity

Possible Cause of Bad Reading Check fuse W, also check circuit 19W. Bad ground circuit.

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


91 – Power Converter (24 volt to 12 volt) Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19L to ground

24 volts

Bad fuse L, also check circuit 19L.


24 volts

Check circuit 1.


24 volts

Bad power converter (91).

92 – Power Outlet Check Points Terminal for wire 0 to ground Terminal for wire 12V to ground

Reading Continuity 12 volts

Possible Cause of Bad Reading Bad ground circuit. 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 Check Points

Reading

Terminal in radio connector for wire 0 to ground

Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on. Put the balance 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 and 95). 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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


93A – 12 Volt Radio Check Points

Reading

Terminal in radio connector for wire 0 to ground

Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on. Rotate the balance 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 and 95). 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) Check Points Terminal for wire 0 to ground

Reading Continuity


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).

Reading


94 – Left Speaker Check Points

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


95 – Right Speaker Check Points

Reading


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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER MODULE 97 99

98

96

100

101

GM98M015

96. BEACON SWITCH 97. ROTATING BEACON

98. STOP LAMP SWITCH 99. HAZARD SWITCH

100. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH 101. FLASHER MODULE

96 – Beacon Switch Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position and the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground

24 volts

Check the 5 position rotary lamp switch (112), also check circuit 49.

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

Bur 7-12221

24 volts

Bad beacon switch (96).

Issued 4-00

Printed in U.S.A.


97 – Rotating Beacon Check Points

Reading


Bulb

Continuity

Bad bulb.


Continuity

Bad ground circuit.

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 Check Points

Reading


NOTE: The stop lamp switch is located in the treadle valve below the cab. It closes with brake pedal angle. NOTE: Put the master disconnect switch in the ON position. 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 Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position. Make sure the hazard switch (99) is OFF. Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground

24 volts

Check circuit 49.

Terminal for wire 1B to ground

24 volts

Check Circuit Breaker B, also check circuit 1B.

24 volts

Bad hazard switch (99).

NOTE: Turn the hazard switch (99) ON Terminal for wire 45H to ground

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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

Reading Continuity



NOTE: Put the master disconnect switch and the ignition switch in the ON position. 24 volts


Check fuse B, also check circuit 19B.

NOTE: Move the turn signal lever for right turn. 24 volts


Bad turn signal switch (100).

NOTE: Move the turn signal lever for left turn. 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 Check Points

Reading


NOTE: Jumper circuit 45N must be connected for North American Machines and disconnected for European machines. Terminal for wire 0 to ground

Continuity

Bad ground circuit.

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


Intermittent 24 volts

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



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

Bad circuit 45H, also check hazard switch (99).

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).



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



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

Continuity

Bur 7-12221

Bad circuit 45A, also check turn signal lever (100). Bad flasher module (101), also check circuit 45L.

Bad 45N circuit.

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS 118

113

116 117

114

102 103 104

110 111 112

115

105 106 107

108

109 GM98M016

102. 103. 104. 105. 106. 107. 108. 109. 110.

LEFT MARKER/TURN SIGNAL LEFT DRIVE LAMP LEFT FLOOD LAMP RIGHT FLOOD LAMP RIGHT DRIVE LAMP RIGHT MARKER/TURN SIGNAL LEFT BRAKE, TAIL AND DIRECTIONAL RIGHT BRAKE, TAIL AND DIRECTIONAL FOG LIGHT SWITCH

111. HIGH/LOW BEAM RELAY (ON EUROPEAN MODELS ONLY) 112. 5 POSITION ROTARY LAMP SWITCH 113. LEFT FRONT CAB LAMP 114. LEFT REAR CAB LAMP 115. RIGHT REAR CAB LAMP 116. RIGHT FRONT CAB LAMP 117. COURTESY LIGHT 118.CAB DOME LIGHT

NOTE: Item numbers 102 through 109 are applicable to external lighting and signals for the North American Models. 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.

Bur 7-12221

Issued 4-00

Printed in U.S.A.


102 – Left Marker/Turn Signal (North American Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Continuity

Bad bulb.

Bulb (Turn signal)

Continuity

Bad bulb.

Terminal for wire 45 to ground Terminal for wire 18F to ground


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

24 volts

Check fuse F´, lamp switch (112), and also check circuit 18F.

103 – Left Drive Lamp (North American Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 18D to ground

24 volts

Bad bulb. 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) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 42C to ground

24 volts

Bad bulb. Check 5 position rotary lamp switch (112), also check circuit 42C.

105 – Right Flood Lamp (North American Models) Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in the flood lamp ON position. Bulb Terminal for wire 42C to ground

Bur 7-12221

Continuity 24 volts

Bad bulb. Check the 5 position rotary lamp switch (112), also check circuit 42C.

Issued 4-00

Printed in U.S.A.


106 – Right Drive Lamp (North American Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 18E to ground

24 volts

Bad bulb. 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) Check Points Terminal for wire 0 to ground

Reading Continuity


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 position 2 or higher. Bulb (Marker)

Continuity

Bad bulb.

Bulb (Turn signal)

Continuity

Bad bulb.



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

24 volts

Check fuse G´, check the 5 position rotary lamp switch (112), and check circuit 18G.

NOTE: Turn on the marker lights. Terminal for wire 18G to ground

108 – Left Brake, Tail, and Directional Lights (North American Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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.



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

24 volts

Check fuse F´, check the 5 position rotary lamp switch (112), and check circuit 18F.

NOTE: Turn on the tail marker lights. Terminal for wire 18F to ground


Bur 7-12221

24 volts

Check the stop lamp switch (98), also check circuit 44.

Issued 4-00

Printed in U.S.A.


109 – Right Brake, Tail, and Directional Lights (North American Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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.



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

24 volts

Check fuse G´, check the 5 position rotary lamp switch (112), and check circuit 18G.

NOTE: Turn on the tail marker lights. Terminal for wire 18G to ground


24 volts


110 – Fog Light Switch Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the fog light switch in the ON position. Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground

24 volts

Check circuit 49.

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).

Bur 7-12221

Issued 4-00

Printed in U.S.A.


111 – High/Low Beam Relay (European Models) Check Points

Reading


NOTE: This relay is for use in European models only. In North American models the relay is removed. Jumper 41L and 41J is connected. Put the master disconnect switch in the ON position. Terminal for wire 1 to ground

24 volts

Check circuit 1.

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).

24 volts

Bad hi/low beam relay (111), also check that jumper 41L and 41J is disconnected.

24 volts

Bad high/low beam relay (111).

NOTE: Put the low beams ON. Terminal for wire 41L to ground NOTE: Put the high beams ON. Terminal for wire 41H to ground

112 – 5 Position Rotary Lamp Switch Check Points

Reading


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

NOTE: Put the 5 position rotary lamp switch (112) in position 2 or higher. Terminal for wire 41T

24 volts

Bad 5 position rotary lamp switch (112).


24 volts


NOTE: Put the 5 position rotary lamp switch (112) in position 3 or 4. Terminal for wire 41J

24 volts


NOTE: Put the 5 position rotary lamp switch (112) in position 4 or 5. Terminal for wire 42C

24 volts


Terminal for wire 42R

24 volts


Bur 7-12221

Issued 4-00

Printed in U.S.A.


113 – Left Front Cab Lamp Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 42C to ground

Bad bulb.

24 volts

Check the circuit 42C, also check 5 position rotary lamp switch (112).

Reading


114 – Left Rear Cab Lamp Check Points Terminal for wire 0 to ground

Continuity

Bad ground circuit.


Bulb Terminal for wire 42R to ground

Bad bulb.

24 volts

Check the circuit 42R, also check 5 position rotary lamp switch (112).

Reading


115 – Right Rear Cab Lamp Check Points Terminal for wire 0 to ground

Continuity

Bad ground circuit.


Bulb Terminal for wire 42R to ground

Bad bulb.

24 volts

Check the circuit 42R, also check 5 position rotary lamp switch (112).

Reading


116 – Right Front Cab Lamp Check Points Terminal for wire 0 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in position 4 or 5. Bulb Terminal for wire 42C to ground

Bur 7-12221

Continuity 24 volts

Bad bulb. Check the circuit 42C, also check 5 position rotary lamp switch (112).

Issued 4-00

Printed in U.S.A.


117 – Courtesy Light Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 49 to ground

Bad bulb.

24 volts

Check the circuit 49, also check 5 position rotary lamp switch (112).

Reading


118 – Cab Dome Light Check Points Terminal for wire 0 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Put the cab dome light switch (118) in either ON position. Bulb Terminal for wire 19U to ground

Continuity 24 volts

Bad bulb. Check the fuse U, also check the circuit 19U.

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN MODELS 119 123 125 129

120 124 126 130

121 131

122

132

127 128

GM98M017

119. 120. 121. 122. 123.

LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP LEFT REAR MARKER LAMP RIGHT REAR MARKER LAMP LEFT SIDE TURN (ITALY)

124. 125. 126. 127. 128.

RIGHT SIDE TURN (ITALY) LEFT FRONT COMBINATION LAMP RIGHT FRONT COMBINATION LAMP LEFT REAR COMBINATION LAMP RIGHT REAR COMBINATION LAMP

129. LEFT HEAD LAMP 130. RIGHT HEAD LAMP 131. REAR LICENSE LAMP 132. ENGINE COMPARTMENT LAMP

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


119 – Left Front Marker Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity



Bulb Terminal for wire 18F to ground

24 volts

Bad bulb. Check fuse F´, also check circuit 18F and 5 position rotary lamp switch (112).

120 – Right Front Marker Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity



Bulb Terminal for wire 18G to ground

24 volts

Bad bulb. Check fuse G´, also check circuit 18G and 5 position rotary lamp switch (112).

121 – Left Rear Marker Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity



Bulb Terminal for wire 18G to ground

24 volts


122 – Right Rear Marker Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Continuity

Bad bulb.

Terminal for wire 18G to ground

24 volts

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

Bur 7-12221

Issued 4-00

Printed in U.S.A.


123 – Left Side Turn (Italy) Check Points Terminal for wire 0 to ground

Reading Continuity


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


Bad bulb.


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

Reading


124 – Right Side Turn (Italy) Check Points Terminal for wire 0 to ground

Continuity

Bad ground circuit.

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



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

125 – Left Front Combination Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Continuity

Bad bulb.

Bulb (Turn signal)

Continuity

Bad bulb.



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

NOTE: Put the 5 position rotary lamp switch (112) in position 2 or higher. Terminal for wire 18F to ground

Bur 7-12221

24 volts

Check fuse F´, also check circuit 18F. Bad 5 position rotary lamp switch (112).

Issued 4-00

Printed in U.S.A.


126 – Right Front Combination Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Continuity

Bad bulb.

Bulb (Turn signal)

Continuity

Bad bulb.



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

NOTE: Put the 5 position rotary lamp switch (112) in position 2 or higher. 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) Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch is OFF. Move the turn signal lever (100) for a left turn. Bulbs Terminal for wire 45 to ground

Continuity Intermittent 24 volts

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

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

24 volts

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

NOTE: Put the fog lights ON. Terminal for wire 41TF and 41F to ground


Bur 7-12221

24 volts


Issued 4-00

Printed in U.S.A.


128 – Right Rear Combination Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulbs Terminal for wire 45 to ground


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

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

24 volts

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

NOTE: Put the fog lights ON. Terminal for wire 41TF and 41F to ground


24 volts


129 – Left Head Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 18D to ground

24 volts

Bad bulb. 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) Check Points Terminal for wire 0 to ground

Reading Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the low beams ON. Bulb Terminal for wire 18E to ground

Continuity 24 volts

Bad bulb. 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 Bur 7-12221

24 volts

Check fuse C´, also check circuit 18C and hi/low beam relay (111). Issued 4-00

Printed in U.S.A.


131 – Rear License Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for wire 18F to ground

24 volts


132 – Engine Compartment Lamp (European Models) Check Points Terminal for wire 0 to ground

Reading Continuity


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

Bulb Terminal for red wire to ground

24 volts

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

133 – Engine Compartment Lamp Switch (European Models) Check Points

Reading


NOTE: Put the master disconnect switch in the ON position. Open the right side engine compartment door to close switch. Remove both switch harness connections to check continuity. Terminal A on connector 135 to terminal a on connector 137

Bur 7-12221

Continuity

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

Issued 4-00

Printed in U.S.A.


CONNECTORS

GM98M018

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M019

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M020

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M021

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M022

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M023

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M024

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M025

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M026

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M027

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M028

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M029

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M030

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M031

Bur 7-12221

Issued 4-00

Printed in U.S.A.


GM98M032

Bur 7-12221

Issued 4-00

Printed in U.S.A.


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

1

1

CAB POSITIVE STUD

TO FUSE "L"

TO FUSE "L"

TO FUSE "L"

TO FUSE "L"

SHT 2

SHT 2

SHT 2

SHT 2

SHT 2

RADIO

RADIO HARNESS

A

O/W (65C) 0.8

BLOCK "C6",

B

B (0) 0.8

109

114

A B

O/W (65C) 0.8 B (0) 0.8

O (19L) 1.0

4

RADIO

93B

RADIO HARNESS

114

A B

109

B (0) 0.8

B (0) 0.8

O/W (65R) 0.8

B (0) 0.8

HARN

6

RADIO

3

1

2

5

4

24V

12V

A B

RADIO HARN

HARNESS O/W (65C) 0.8 B (0) 0.8

110

114

A B

112

112

LEFT SPEAKER

A B

94 111

B (0) 1.0

95 RIGHT SPEAKER

LEFT SPEAKER

A B

94 111

95

B (0) 1.0

94

POWER OUTLET

RIGHT SPEAKER

LEFT SPEAKER

SHEET 30

A B

111

95 RIGHT SPEAKER 4

CAB NEGATIVE STUD

SHEET 29

O/W (65L) 0.8

O/W (65C) 0.8

B (0) 0.8

B (0) 0.8

O/W (65R) 0.8

5

A B

112

92

B (0) 3.0

B (0) 5.0

B (0) 3.0

2

110 A B

4

1

HARN

109

110 116

O/W (65L) 0.8

B (0) 0.8

3

B (0) 0.8

6

B (0) 0.8

RADIO HARN

JUMPER

O/W (65R) 0.8

4

HARN

RADIO POWER CONVERTER

O/W (65L) 0.8

5

O/W (65C) 0.8

B (0) 0.8

B (0) 0.8

2

"C5"

B (0) 1.0

R (12V) 3.0

1

TO 12V RADIO

BLOCK

O (19L) 1.0

3

93A

FUSE

JUMPER

HARNESS FUSE

"C18"

BLOCK "C5"

B (0) 0.8

6

TO 24V RADIO

FUSE

JUMPER HARN

"C12",

CIGAR LIGHTER

8 10 12 13

B (0) 0.8

90

7

O/W (65R) 0.8

115

6

12 VOLT RADIO

93

O/W (65L) 0.8

R (12V) 5.0

3

O (19L) 1.0

12V

1

B (0) 0.8

POWER CONVERTER

B (0) 0.8

GND

IGN

O (19L) 1.0

24V

2

O/W (65R) 0.8

"C5"

9

O/W (65R) 0.8

O (19W) 3.0

BLOCK

B (0) 0.8

FUSE

91

14 5 11 4

O/W (65L) 0.8

REMOTE RADIO

O/W (65L) 0.8

O (19L) 1.0

"C16"

R (1) 5.0

"C11"

93

O/W (65C) 0.8

BLOCK

O (19L) 1.0

REMOTE RADIO FUSE

FUSE BLOCK

24 VOLT RADIO

113 O (19L) 1.0

O (19W) 1.0

O (19L) 1.0

TO FUSE "W"

SHEET 31

SHEET 32

BC00E078

Bur 7-12221

Issued 4-00

Printed in U.S.A.


NOTES

Bur 7-12221

Issued 4-00

Printed in U.S.A.


ELECTRICAL SCHEMATIC - SHEETS 1 AND 2

1 2

CAB POSITIVE STUD

1

CAB SWITCHED POWER

2

VIA RR FOR HT. SW. ON SHEET 4

3

3

R (1B) 0.8

INSTRUMENT ILLUMINATION

30

O (19X) 1.0 TO FUSE B ON SHEET 8

CIRCUIT BREAKER B 12 AMP

SPLICE WITH TIME DELAY GROUND ON SHEET 10

O (19B) 0.8 R (1B) 0.8

1

PED|CAB

13

CAB|FRONT Gy (49) 1.0

1

POWER IN

2

FLASHER OUT

B (0) 1.0

3

GROUND

B (0) 1.0

4

GROUND

5

N.C.

6

N.C.

DBr/LG (45R) 0.8

7

R. TURN LIGHT OUT

DBr/Y (45L) 0.8

8

L. TURN LIGHT OUT

DBr/LG (45B) 0.8

9

RIGHT TURN SW.

DBr/Y (45A) 0.8

10

LEFT TURN SW.

67

DBr (45H) 0.8

11

HAZARD SW.

66

DBr (45N) 0.8

12

OPPOSITE SIDE CONTROL

R (1B) 0.8

S

R (1B) 0.8

CAB|PED Gy (49) 0.8

BEACON SWITCH

96

15

R (1B) 0.8 TO BACK-UP ALARM DISABLE SWITCH ON SHEET 12

B (0) 1.0 2

6 5

2

DBr (45H) 0.8

Gy (49) 0.8 6

4

42

P (46) 0.8

TO PLOT CONT. SW. ON SHEET 16

P (46) 1.0

Gy (49) 1.0

5

71 2

TO INSTRUMENT CLUSTER CAVITY 13 ON SHEET 14

HAZARD SWITCH

4 CAB CAB ROOF

23

NC

3

99

4

PULL CONNECTOR APART FOR EUROPEAN MACHINES SHOWN FOR NAO

13

T (44) 1.0

4

1 2

PED|CAB DBr/LG (45B) 0.8

98

TO CLUSTER CAVITY 35 ON SHEET 17

70

T (44) 0.8

DBr/Y (45L) 0.8

69

DBr/Y (45A) 0.8

(SWITCH IN TREADLE VALVE BELOW CAB CLOSES WITH BRAKE PEDAL ANGLE)

45

B

B (0) 0.8

31

X

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

A

DBr/Y (45L) 1.0

31

C

DBr/LG (45R) 1.0

32

REAR|REAR LIGHT

10

DBr/LG (45L) 1.0

9

DBr/Y (45L) 1.0

33

12

DBr/LG (45R) 1.0

11

DBr/LG (45R) 1.0

34

T (44) 1.0

8

7

35

94

21

DBr/LG (45R) 0.8

T (44) 1.0

R


54

L

PED|CAB A

H/L

68

B (0) 1.0

T (44) 0.8

O/LB (64D) 0.8

55

DBr/Y (45L) 0.8

42

67


41 O/LB (64D) 0.8

66

97

13

B (0) 0.8 O/LB (64C) 0.8

CAB FLOOR WELD STUD

B (0) 0.8

ROTATING BEACON

B (0) 1.0

1

H

O (19B) 0.8

13

2

M

T (44) 0.8

CAB|REAR

STOP LAMP SWITCH

B (0) 1.0

P (46) 1.0

85

1 CAB|FRONT

B (0) 1.0

A B

62

64

C

NO

B (0) 1.0

TO PILOT CONT. SW. ON SHT 16

B (0) 0.8 4

B (0) 1.0

TO BACK-UP ALARM DIS. SWITCH ON SHEET 12

TO RR WIPER MOTOR GROUND ON SHEET 25

R (1B) 0.8 DBr (45N) 0.8

65

B (1B) 0.8

Gy (49) 0.8

TO SPLICE #4 ON SHEET 8

FLASHER MODULE

101

B (0) 1.0

O/LB (64C) 0.8

TO HORN RELAY #5 ON SHEET 26

36

4

CAB NEGATIVE STUD VIA RR FOG LT. SW. ON SHEET 1

100

SHEET 1

TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH

4

SHEET 2

BC00E079

Bur 7-12221

Issued 4-00

Printed in U.S.A.


ELECTRICAL SCHEMATIC - SHEET 3A

BC00E096

Bur 7-12221

Issued 4-00

Printed in U.S.A.


ELECTRICAL SCHEMATIC - SHEETS 3, 4, AND 5

VIA SPLICE #3

1

CAB POSITIVE STUD

1

2

CAB SWITCHED POWER

2

3

3

FUSE F

TAIL LIGHTS LEFT (5A)

FUSE G

TAIL LIGHTS RIGHT (5A)

B (0) 2.0 T (44) 1.0 B (0) 2.0

O (18C) 0.8

G

O (18B) 0.8

O (18F) 1.0

F

O (18F) 0.8

T (44) 1.0

105

C A B D

3

NAO

8

9 P (18F) 1.0

5

10

P (41F) 1.0

2

P (18F) 1.0 2

B (0) 2.0

TO FUSE U ON SHEET 10

R (1) 3.0

23

CAB ROOF CAB


O (19U) 1.0

43 FOG LIGHT SWITCH

110

B (0) 1.0 Gy (49) 0.8 LIGHTS

Gy (49) 1.0

B (0) 1.0 4

DBe (42R) 0.8

33 34

25

TO RETURN TO TRAVEL SWITCH, SHEET 19

5

P (41T) 1.0

HD

5 POSITION ROTARY LAMP SWITCH

112

1

2

TL F4 B1

3

4

5

IL

1

2

TO BEACON SWITCH ON SHEET 1

F1

3

4

B3

5

32 F3 F2

1

2 3

4

B2

5

SWITCH POSITION

PARK AND TAIL

DRIVE

1

FLOOD F&R

ILLUMINATION

OFF

2

ON

3

ON

ON

4

ON

ON

5

ON

ON ON

ON

ON

ON

CAB NEGATIVE STUD

NAO

77

24

DBe (42C) 1.0

P (41J) 2.0

6

4

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

CAB ROOF CAB

O (19U) 0.8

Gy (49) 1.0

36

118

DBe (42C) 0.8

REAR|CAB

TO BEACON SW. ON SHEET 1

P (41J) 2.0

DBe (42R) 0.8

P (41F) 1.0

TO L.H. RR. MARK LT. ON SHEET 3 (EURO)

LEFT BRAKE, TAIL, AND DIRECTIONAL

O (19U) 1.0

CAB DOME LIGHT

A B

B (0) 0.8

84

TO CAB/PED CONN. CAVITY 12 ON SHEET 14

Y (18G/42R) 1.0

O (18G) 0.8

O (18G) 0.8

B (0) 2.0

109

1

S

EURO

17

RIGHT BRAKE, TAIL, AND DIRECTIONAL

REAR|CAB B (0) 0.8

21

94

108

56

DBe (42C) 1.0

7

8

56b

6

P (18G) 1.0

REAR LIGHT|REAR

B(O) 2.0

106

D B A C

Q

1.0

T (44) 1.0

6

B (0) 1.0 DBe (42R) 1.0 B (0) 1.0

DBe (42R) 1.0

B (0) 1.0

O (18G) 1.0

DBr/LG (45R) 1.0

35

O (18C) 1.0 O (18B) 1.0

P (18G) 1.0

O (18F) 1.0

B (0) 1.0

21

56a

4

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

DBr/Y (45L) 1.0

34

J

B (0) 1.0

DBr/LG (45R) 1.0

33

E

P(41F)

B (0) 1.0

O (18G) 1.0 DBe (42C) 1.0

80

83

59 30

O (18E) 0.8

B (0) 1.0

DBr/Y (45L) 1.0

P

111

A B

DBe (42C) 1.0

HIGH/LOW BEAM RELAY

O O (18E) 1.0

A B

A B

FRONT|CAB O (18D) 1.0

32

A B

78

79

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

DBe (42C) 1.0

31

TO ENG. COMP. LIGHT ON PAGE 3 (EURO) 6/7/821C ONLY

COURTESY LIGHT

B (0) 0.8

LOW BEAM RIGHT (5A)

117

Gy (49) 0.8

LOW BEAM LEFT (5A)

FUSE E

B (0) 1.0

HIGH BEAM RIGHT (5A)

FUSE D

DBe (42C) 1.0

FUSE C

RIGHT FRONT CAB LAMP

B (0) 1.0

HIGH BEAM LEFT (5A)

RIGHT REAR CAB LAMP

DBe (42C) 1.0

REAR FLOOD LIGHTS (10A)

FUSE B

LEFT REAR CAB LAMP

B (0) 1.0

P (41T) 1.0

R (19Y) 1.0

O (19Z) 1.0

O (18A) 2.0

1

O (18F) 0.8

C B A

O (18G) 0.8

8

Gy (49) 0.8

9

A B C

FRONT A B C LIGHT FRONT

O (18G) 0.8

B (0) 1.0 O (18D) 0.8

7

FRNT. FLOOD LIGHTS AND ILLUM (10A)

FUSE A

P (41L) 2.0

B (0) 1.0

C B A

FUSE Z

LEFT FRONT CAB LAMP

18

B (0) 1.0

6

FOG LIGHTS (7.5)

Gy (49) 1.0

B (0) 1.0

O (18G) 1.0

DBr (45) 1.0

B (0) 1.0

O (18E) 1.0

1.0 DBe (42C)

B (0) 1.0

DBe (42C) 1.0

O (18D) 1.0

B (0) 1.0

O (18F) 1.0

DBr (45) 1.0

B (0) 1.0

RIGHT MARKER/TURN SIGNAL

BEACON (7.5)

FUSE Y

B (0) 1.0

107

FUSE X

B (0) 1.0

DRIVE LAMP

B (0) 1.0

106

DBe (42R) 1.0

RIGHT FLOOD LAMP

B (0) 1.0

105

116

DBe (42R) 1.0 B (0) 1.0

LEFT FLOOD LAMP

115

DBe (42R) 1.0

104

114

B (0) 1.0

LEFT DRIVE LAMP

113

DBe (42C) 1.0

103

P (41J) 0.8

LEFT MARKER/TURN SIGNAL

O (18C) 0.8

P (41L) 0.8

102

TO INSTRUMENT CLUSTER CAVITY 15 SHEET 14 RIGHT

R (1) 3.0

RIGHT FUSES

O (19X) 1.0

P (41H) 2.0

30

R (1) 3.0


4

VIA GROUND SPLICE

SHEET 4

SHEET 3

SHEET 5

BC00E080

Bur 7-12221

Issued 4-00

Printed in U.S.A.


NOTES

Bur 7-12221

Issued 4-00

Printed in U.S.A.


INDEX Symbols

B

12 Volt Radio ..........................................................50 24 Volt Radio ..........................................................49 5 Position Rotary Lamp Switch...............................59

Bulb (Continued) Right Front Cab Lamp........................................60 Right Front Combination Lamp (European Models) ........................................65 Right Front Marker Lamp (European Models) ........................................63 Right Marker (North American Models)..............57 Right Rear Cab Lamp ........................................60 Right Rear Combination Lamp (European Models) ........................................66 Right Rear Marker Lamp (European Models) ........................................63 Right Side Turn Lamp (Italy) ..............................64 Right Tail Lamp (North American Models) .........58 Right Turn Signal (North American Models) ......57 Rotating Beacon ................................................53

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

B Back-up Alarm ........................................................20 Back-up Alarm Disable Switch ...............................20 Back-up Alarm Relay #7.........................................19 Batteries ................................................................. 11 Beacon Switch........................................................52 Beacon, Rotating ....................................................53 Blower Motor ..........................................................45 Resistor Board with Thermal Fuse .....................45 Blower Switch .........................................................44 Brake Warning Pressure Switch.............................22 Bucket Control Valves Detent Electromagnets.......32 Bucket Dump Pressure Switch ...............................37 Bucket Rollback Pressure Switch...........................38 Bulb Cab Dome Lamp ................................................61 Courtesy Light ....................................................61 Engine Compartment Lamp (European Models) ....................................... 67 Left Brake Lamp (North American Models) ........57 Left Directional Lamp (North American Models) .............................. 57 Left Drive Lamp (North American Models) .........56 Left Flood Lamp (North American Models) ........56 Left Front Cab Lamp ..........................................60 Left Front Combination Lamp (European Models) ....................................... 64 Left Front Marker Lamp (European Models) ....................................... 63 Left Head Lamp (European Models) ..................66 Left Marker (North American Models) ................56 Left Rear Cab Lamp ...........................................60 Left Rear Combination Lamp (European Models) ....................................... 65 Left Rear Marker Lamp (European Models) ....................................... 63 Left Side Turn Lamp (Italy).................................64 Left Tail Lamp (North American Models)............57 Left Turn Signal (North American Models) .........56 Rear License Lamp (European Models) ............67 Right Brake Lamp (North American Models)......58 Right Directional Lamp (North American Models) .............................. 58 Right Drive Lamp (North American Models).......57 Right Flood Lamp (North American Models) ......56 Bur 7-12221

C Cab Dome Light .....................................................61 Cigar Lighter...........................................................48 Circuit Diagram Legend............................................9 Cluster, Instrument ...........................................25, 26 Cold Start Temperature Switch ..............................13 Color Abbreviations ..................................................9 Compressor Clutch.................................................46 Compressor Clutch Lockout Relay.........................46 Compressor, Seat ..................................................44 Condenser Fan Motor No. 1 .................................................47 Fan Motor No. 2 .................................................47 Condenser Fan Relay ............................................46 Connector, Diagnostic ............................................19 Converter, Radio Power (24 volts to 12 volts) ........50 Coolant Level Sender.............................................22 Courtesy Light ........................................................61

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

E Engin Speed Sensor ..............................................19 Engine Automatic Shutdown Relay Socket #11 .....30 Engine Compartment Lamp (European Models).............................................67 Engine Compartment Lamp Switch (European Models).............................................67 Engine Coolant Temperature Sender.....................23 Engine Oil Pressure Sender ...................................28 Ether Solenoid........................................................14 Ether Start Relay ....................................................14 Issued 4-00

Printed in U.S.A.


E

L

Ether Start Switch...................................................14

Lamp (Continued) Left Turn Signal (North American Models).........56 Rear License (European Models) ......................67 Right Brake (North American Models) ...............58 Right Directional (North American Models)........58 Right Drive (North American Models) ................57 Right Flood (North American Models)................56 Right Front Cab..................................................60 Right Front Combination (European Models) ....65 Right Front Marker (European Models) .............63 Right Head (European Models) .........................66 Right Marker (North American Models) .............57 Right Rear Cab ..................................................60 Right Rear Combination (European Models) .....66 Right Rear Marker (European Models) ..............63 Right Side Turn (Italy) ........................................64 Right Tail (North American Models) ...................58 Right Turn Signal (North American Models) ......57 Switch, 5 Position Rotary ...................................59 Left Brake Lamp (North American Models) ............57 Left Directional Lamp (North American Models) ....57 Left Drive Lamp (North American Models) .............56 Left Flood Lamp (North American Models) ............56 Left Front Cab Lamp ..............................................60 Left Front Combination Lamp (European Models) .64 Left Front Marker Lamp (European Models) ..........63 Left Head Lamp (European Models) ......................66 Left Marker Lamp (North American Models) ..........56 Left Rear Cab Lamp ...............................................60 Left Rear Combination Lamp (European Models)..65 Left Rear Marker Lamp (European Models)...........63 Left Side Turn Lamp (Italy).....................................64 Left Speaker ...........................................................50 Left Tail Lamp (North American Models)................57 Low Pressure Switch (In Cab)................................45

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

G Graphic Symbols ......................................................8

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

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

L Lamp Cab Dome ..........................................................61 Courtesy .............................................................61 Engine Compartment (European Models)..........67 Left Brake (North American Models) ..................57 Left Directional (North American Models) ..........57 Left Drive (North American Models) ...................56 Left Flood (North American Models) ..................56 Left Front Cab ....................................................60 Left Front Combination (European Models) .......64 Left Front Marker (European Models) ................63 Left Head (European Models) ............................66 Left Marker (North American Models) ................56 Left Rear Cab.....................................................60 Left Rear Combination (European Models)........65 Left Rear Marker (European Models).................63 Left Side Turn (Italy)...........................................64 Left Tail (North American Models) .....................57 Bur 7-12221

M Master Disconnect Switch ......................................12 Module Flasher ...............................................................54 Time Delay .........................................................17 Transmission Electronic Control ........................19 Motor, Starter .........................................................13

N Neutral Start Relay .................................................14 Notes ........................................................................ 9

O Outlet, Power..........................................................49 Output Speed Sensor.............................................19

P Park Brake Switch ..................................................24 Parking Brake Relay...............................................29 Pilot Control Relay..................................................29 Issued 4-00

Printed in U.S.A.


P

R

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

Right Marker Lamp (North American Models) ........57 Right Rear Cab Lamp.............................................60 Right Rear Combination Lamp (European Models).............................................66 Right Rear Marker Lamp (European Models) ........63 Right Side Turn Lamp (Italy) ..................................64 Right Speaker.........................................................51 Right Tail Lamp (North American Models) .............58 Right Turn Signal Lamp (North American Models) ...................................57 Rotating Beacon.....................................................53

R Radio 12 volt.................................................................50 24 volt.................................................................49 Power Converter (24 volts to 12 volts) ...............50 Remote...............................................................49 Rear License Lamp (European Models).................67 Rear Rotary Wiper and Washer Switch..................41 Rear Washer Pump Motor......................................41 Rear Wiper Motor ...................................................42 Redundant Brake Switches ....................................30 Redundant Parking Brake Solenoids......................29 Relay Accessory, #3.....................................................17 Backup Alarm, #7 ...............................................19 Compressor Clutch Lockout ...............................46 Condenser Fan ..................................................46 Ether Start ..........................................................14 Fuel ....................................................................13 High/Low Beam (European Models) ..................59 Horn ...................................................................43 Ignition, #1..........................................................15 Ignition, #2..........................................................16 Neutral Start .......................................................14 Parking Brake.....................................................29 Pilot Control........................................................29 Ride Control .......................................................37 Secondary Steering with Lockout.......................35 Socket #11, Engine Automatic Shutdown ..........30 Start....................................................................13 Voltmeter, #12 ....................................................17 Remote Radio.........................................................49 Return-To-Dig Proximity Switch .............................32 Return-To-Travel Proximity Switch.........................33 Return-To-Travel/Float Switch................................32 Ride Control Relay .................................................37 Ride Control Switch ................................................37 Ride Engage Solenoid............................................38 Right Brake Lamp (North American Models) ..........58 Right Directional Lamp (North American Models) ...................................58 Right Drive Lamp (North American Models) ...........57 Right Flood Lamp (North American Models) ..........56 Right Front Cab Lamp ............................................60 Right Front Combination Lamp (European Models).............................................65 Right Front Marker Lamp (European Models) ........63 Right Head Lamp (European Models) ....................66 Bur 7-12221

S Seat Compressor and Switch.................................44 Secondary Steering Pump/Motor ...........................36 Secondary Steering Relay with Lockout.................35 Secondary Steering Switch ....................................35 Sender Coolant Level .....................................................22 Engine Coolant Temperature .............................23 Engine Oil Pressure ...........................................28 Fuel Level ..........................................................22 Hydraulic Oil Temperature .................................23 Torque Converter Output Temperature..............19 Sensor Engine Speed ....................................................19 Intermediate Speed............................................19 Output Speed .....................................................19 Transmission Solenoid Valve and Temperature ..................................................19 Turbine Speed ...................................................19 Shifter, Transmission..............................................19 Shutoff, Fuel Solenoid ............................................12 Solenoid Ether ..................................................................14 Fuel Shutoff........................................................12 Pilot Pressure.....................................................29 Pin Engage ........................................................36 Redundant Parking Brake ..................................29 Ride Engage ......................................................38 Speaker Left .....................................................................50 Right...................................................................51 Specifications ...........................................................7 Start Relay..............................................................13 Starter Motor ..........................................................13 Stop Lamp Switch ..................................................53 Switch.....................................................................46 5 Position Rotary Lamp......................................59 Air Filter Restriction............................................23 Back-up Alarm Disable.......................................20 Beacon ...............................................................52 Blower ................................................................44 Brake Warning Pressure ....................................22 Bucket Dump Pressure ......................................37 Bucket Rollback Pressure ..................................38 Issued 4-00

Printed in U.S.A.


S

T

Switch (Continued) Cold Start Temperature......................................13 Declutch .............................................................19 Declutch Brake...................................................19 Detent.................................................................31 Engine Compartment Lamp (European Models) ....................................... 67 Ether Start ..........................................................14 Filter Maintenance..............................................19 Fog Light ............................................................58 Front Rotary Wiper and Washer ........................40 Hazard................................................................53 Height Control Proximity ....................................33 Hi/Lo Beam ........................................................54 High Pressure (In Rear Chassis) .......................45 Hoist-up Pressure ..............................................37 Horn ...................................................................54 Hydraulic Filter Restriction .................................23 Ignition................................................................15 Low Pressure (In Cab) .......................................45 Master Disconnect .............................................12 Park Brake .........................................................24 Pilot Control Switch ............................................26 Pin Engagement.................................................36 Program Reset ...................................................24 Rear Rotary Wiper and Washer .........................41 Redundant Brake ...............................................30 Return-To-Dig Proximity.....................................32 Return-To-Travel Proximity ................................33 Return-To-Travel/Float.......................................32 Ride Control .......................................................37 Seat Compressor ...............................................44 Secondary Steering............................................35 Stop Lamp..........................................................53 Transmission Auto .............................................19 Transmission Kick-down ....................................19 Turn Signal.........................................................54 Up/down Count ..................................................27 Symbols, Graphic .....................................................8

Thermostat .............................................................46 Thermostat Switch..................................................46 Time Delay Module ................................................17 Torque Converter Output Temperature Sender .....19 Transmission Auto Switch ......................................19 Transmission Electronic Control Module................19 Transmission Kick-down Switch.............................19 Transmission Shifter...............................................19 Transmission Solenoid Valve and Temperature Sensors ........................................19 Transmission Solenoid Valve and Temperature Sensors .....................................................19 Turbine Speed Sensor ...........................................19 Turn Signal Lamp (North American Models) ..........56 Turn Signal Switch .................................................54

Bur 7-12221

U Up/down Count Switch ...........................................27

V Voltmeter Relay #12...............................................17

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

Issued 4-00

Printed in U.S.A.

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Copyright ©

Section 4005

4005

INFORMATION AND DIAGNOSTICS CENTER


Bur 7-12251


Copyright © NOTES

Copyright © 4005-3

TABLE OF CONTENTS INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Stop Master Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Caution Master Indicator (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Beacon Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pilot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Low Coolant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brake Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Secondary Steering Indicator (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Air Conditioning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Air Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Transmission Oil Filter Indicator (Not applicable to 621C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Service Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WARNING DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Non-Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requested Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actual Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Mode (Automatic or Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 14 14 14 14 14 14 15 15 15 15 15 15 15 15

SETTINGS, DIAGNOSTICS, AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming the Information Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Scrolling Gauge Displays (01, 02, or 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatically Scrolling Gauge Displays (03 or 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Display Center Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter at Key ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 16 17 17 17 17 18 19 19 19 19

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-4 Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park Brake Information Center Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Lockout Information Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requested Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actual Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Line Shift Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hourmeter Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tachometer Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movement Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beacon Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caution and Warning Master Indicator Lights Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park Brake Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant Brake Pressure Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Brake Foot Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Lockout Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location 047 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Numbers (048 and 049) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Range Read Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Number 054 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset Diagnostic Stack for Locations 071 through 090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Numbers (056 - 060) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Interval Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission ECM Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Transmission ECM Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Information Center Software Revision Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Information Center Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Number 097 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entry Code for Accessing Test Mode Locations 100 to 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Numbers 104 - 113 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster (Information Center) Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster (Information Center) Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster (Information Center) Date Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Numbers 117 - 120 Reserved for Supplier Information . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Numbers 121 -129 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Numbers 131 - 139 Reserved for Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . Display Location Numbers 140 - 170 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bur 7-12251

Issued 4-00

19 20 20 20 20 20 20 21 21 21 21 21 22 22 22 22 22 23 23 23 23 23 23 23 24 24 24 24 24 25 25 25 25 25 25 26 26 26 27 27 27 27 27 27 27 27 28 28 28 28 29 29 29 29 30 30 30

Printed in U.S.A.

Copyright © 4005-5 Display Location Numbers 191 - 196 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Number 197 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Number 198 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Location Number 199 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPLAY LOCATION NUMBERS AND DESCRIPTIONS

30 30 30 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-6

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-7

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

3

4

5

6

7

8

9

10

11

2

12 13

1 20 14

19

15 18

16

17

RD98K316

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

BEACON INDICATOR WORK LIGHT INDICATOR PILOT CONTROL INDICATOR LOW COOLANT INDICATOR BRAKE PRESSURE INDICATOR STOP MASTER INDICATOR CAUTION MASTER INDICATOR SECONDARY STEERING INDICATOR PARKING BRAKE INDICATOR AIR-CONDITIONING INDICATOR

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

HYDRAULIC OIL FILTER INDICATOR AIR FILTER INDICATOR TRANSMISSION OIL FILTER INDICATOR TRANSMISSION OIL TEMPERATURE GAUGE HYDRAULIC OIL TEMPERATURE GAUGE VOLTMETER GAUGE FUEL LEVEL GAUGE ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE GAUGE SERVICE INDICATOR ICON

FIGURE 1. INFORMATION CENTER

Self-Test IMPORTANT: During operation, if the stop master indicator (on the front console) flashes, and the warning alarm is continuous, stop the machine, stop the engine, and find the problem. 1. Turn the ignition (key) switch to the ON position. 2. The information center will automatically check each monitored system.

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3. All LED’s (Light Emitting Diodes) will illuminate for 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 and the information center, the LED will flash and the warning alarm will sound for 5 seconds.

Issued 4-00

Printed in U.S.A.

Copyright © 4005-8 7. If there were no faults detected during the check, all monitored systems will return to normal operation. 8. If only some of the LEDs illuminate, replace the information center. 9. If the LEDs illuminate, but the warning alarm does not sound, replace the information center. 10. If the warning alarm sounds but the LEDs do not illuminate, replace the information center.

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 the following conditions exist: A. Parking brake engaged when shifting into forward or reverse. B. High engine coolant temperature.

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

C. High hydraulic oil temperature.

Power Circuit Test

F. High or low air conditioning pressure.

A. Check the 7.5 amp fuse V. If the fuse is bad, replace the fuse and repeat Self-Test steps 1 through 7. If the fuse is good, do the next step. B. Check wire 19V for continuity. Repair/replace the wire as required. If continuity is found do the next step. C. Check wire 13V for continuity. Repair/replace the wire as required. If continuity is found, do the next step. D. Check the voltmeter relay #12 for proper operation, see Section 4002. If voltmeter operates properly, do the next step. E. If no faults are found in Power Circuit Test steps A through D, then remove and replace the information center.

D. High transmission oil temperature. E. Low engine oil pressure. G. Air filter restriction. H. Transmission filter restriction (not applicable for 621C model). I. Hydraulic filter restriction. J. Alternator malfunction. K. Low fuel.

Beacon Indicator The beacon indicator illuminates when the Beacon (if equipped) is in the ON position. Work Light Indicator The work light indicator illuminates when the work lights are ON.

Pilot Control

Indicators and Gauges

The Pilot Control indicator illuminates when the pilot lockout is actuated.

Stop Master Indicator (Red)

Low Coolant Indicator

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

The low coolant indicator illuminates when the engine coolant is low.

When the stop master indicator illuminates:

1. The warning alarm sounds continuously.

1. Stop the machine immediately.

2. The stop master indicator will be red.

2. Turn OFF the engine.

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

3. The warning alarm sounds continuously and one or more of the following conditions exist: A. Low engine oil pressure. B. Low brake pressure. C. Low steering pressure.

Brake Pressure Indicator The brake pressure indicator illuminates when the brake system pressure is too low. 1. The warning alarm sounds continuously.

D. Low engine coolant level.


E. High engine coolant temperature.

3. Stop the engine and correct the problem.

F. High hydraulic oil temperature. G. High transmission oil temperature.

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-9

Secondary Steering Indicator (If equipped) The secondary steering indicator illuminates when the primary steering system pressure is too low.

2. The caution master indicator turns yellow. 3. Replace the transmission oil filters as required.

Transmission Oil Temperature Gauge


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


Green Zone:

3. Stop the engine and correct the problem.

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

Parking Brake Indicator The parking brake indicator illuminates when the parking brake is applied. If the transmission is shifted into FORWARD or REVERSE when the parking brake is applied:

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

1. The warning alarm sounds for 3 seconds.

2. The indicator bars flash.

2. The caution master indicator turns yellow.


3. Disengage the parking brake before shifting the machine.

4. The yellow caution master indicator turns on.

Air Conditioning Indicator The air conditioning indicator illuminates when the air conditioner has stopped due to refrigerant pressures that are too high or too low.

Red Zone: NOTE: The machine must not be operated when the temperature is in the red zone. 1. Transmission oil temperature continues to increase,125° C and above (257° F and above).


2. The indicator bar flashes.



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

4. The red stop master indicator turns on.

Air Filter Indicator The air filter indicator illuminates when the air filter is restricted. 1. The warning alarm sounds for 3 seconds. 2. The caution master indicator turns yellow. 3. Replace or clean the air filter as required.

Hydraulic Oil Filter Indicator The hydraulic oil filter indicator illuminates when the hydraulic filters are restricted.

5. Stop the machine. 6. Shift the transmission into NEUTRAL. 7. Run the engine at half throttle until the transmission cools. 8. If the transmission oil temperature does not return to normal operating temperature, run the engine at idle speed and check the transmission oil level. 9. Correct the problem before continuing to operate the machine.

Hydraulic Oil Temperature Gauge


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


Green Zone:

3. Replace the hydraulic oil filters as required.


Transmission Oil Filter Indicator (Not applicable to 621C) The transmission oil filter indicator illuminates when the transmission filter(s) are restricted. 1. The warning alarm sounds for 3 seconds. Bur 7-12251

Yellow Zone: 1. Hydraulic oil temperature has decreased, 20° C or below (68 ° F or below), or it has increased 105° to 110° C (221° to 230° F). Issued 4-00

Printed in U.S.A.

Copyright © 4005-10 2. The indicator bars flash.

1. The indicator bars flash.





Red Zone:

Engine Oil Pressure Gauge

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

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

1. Hydraulic oil temperature continues to increase 110° C and above (230° F and above).

Green Zone:

2. The indicator bar flashes.

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


Yellow Zone:

4. The red stop master indicator turns on. 5. Stop the machine and correct the problem.

Voltmeter Gauge The voltmeter gauge is shown as an indicator bar with a green or yellow zone.

1. Engine oil pressure has decreased, 100 to 140 kPa (15 to 20 psi). 2. The indicator bars flash. 3. The warning alarm sounds for 3 seconds. 4. The yellow caution master indicator turns on.

Green Zone:

Red Zone:

Indicates normal operating range:

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

A. 26 to 32 volts above low idle = normal operating range. B. 18 to 24 volts stopped or at low idle = low to normal battery charge. C. 18 to 24 volts at above low idle = problem in charging system.

1. Engine oil pressure continues to decrease below a safe operating pressure, 0 to 100 kPa (0 to 15 psi). 2. The indicator bar flashes. 3. The warning alarm sounds continuously.

Yellow Zone:

4. The red stop master indicator turns on.

Voltage has increased or decreased:

5. Stop the machine and correct the problem.

A. 0 to 18 volts stopped or at low idle = very low battery charge. B. 32 volts and above = problem in charging system (overcharging). 1. The indicator bars flash.

Engine Coolant Temperature The engine coolant temperature gauge is shown as an indicator bar with a green, yellow, or red zone. Green Zone:




Yellow Zone:

4. Stop the machine and correct the problem.

Fuel Level Gauge The fuel level gauge is shown as an indicator bar with a green or yellow zone. Green Zone:

1. Engine coolant temperature has decreased 20° C or below (68° or below), or increased 105° to 110° C (221° to 230° F). 2. The indicator bars flash. 3. The warning alarm sounds for 3 seconds. 4. The yellow caution master indicator turns on.

Indicates normal operating range, 5 percent and above.

Red Zone:

Yellow Zone:

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

The tank is almost empty, 5 percent and below. Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-11 1. Engine coolant temperature continues to increase, 110° C or above (230° F or above). 2. The indicator bar flashes. 3. The warning alarm sounds continuously.

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

4. The red stop master indicator turns on. 5. Stop the machine and correct the problem.

Bur 7-12251

Issued 4-00

Printed in U.S.A.


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 the corrective action required. When a fault occurs, a continuous warning alarm will sound, the STOP indicator will be RED, and the Display indicator will be illuminated. When this occurs bring the machine safely to a stop and shutdown the engine to help avoid expensive repairs .

DISPLAY

DESCRIPTION

ENGINE OIL PRESSURE

Low engine oil pressure.

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.

Low steering pressure.

1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check the hydraulic fluid level. 3. Check hydraulic system and steering system for leaks.

Low coolant level.

1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check the coolant level. 3. Check the engine cooling system for leaks.

COOLANT TEMPERATURE

High engine coolant temperature.

1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check the coolant levels after allowing the engine and coolant to cool down. 3. Clean the radiator.

HYDRAULIC OIL TEMPERATURE

High hydraulic oil temperature.

1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check the hydraulic fluid level. 3. Clean the cooler.

High transmission oil temperature.

1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check the transmission fluid level. 3. Clean the cooler. 4. Check transmission for leaks. 5. Select lower gear.

STEERING PRESSURE

COOLANT LEVEL

TRANSMISSION OIL TEMPERATURE

Bur 7-12251

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

Issued 4-00

Printed in U.S.A.


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

DESCRIPTION

CORRECTIVE ACTION

PARKING BRAKE

Parking brake engaged and shifts from Forward to Reverse.

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.

AIR CONDITIONING

High or low air conditioning pressure.

AIR FILTER

High air filter restriction.

TRANSMISSION FILTER

Transmission filter restriction.

HYDRAULIC FILTER

Hydraulic filter restriction.

Release the parking brake and depress the service brake.

1. Check low idle specifications. 2. Change engine oil and filter. 3. Change operating procedures. 1. Turn air conditioning OFF. 2. Low outside temperature. 3. Servicing required. 1. Clean air filter. 2. Replace primary and secondary filters. Replace transmission filter. 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.

Bur 7-12251

Issued 4-00

Printed in U.S.A.


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

3

2 4

1

5

6 RD98K316

1. DIRECTION (F-N-R) 2. TRANSMISSION DISPLAY 3. DISPLAY CENTER

4. REQUESTED GEAR (1, 2, 3, 4) 5. ACTUAL GEAR BARS 6. TRANSMISSION MODE (A OR BLANK)

FIGURE 2. INFORMATION CENTER AND TRANSMISSION DISPLAY

Hourmeter

Engine Coolant Temperature

The hourmeter displays the accumulated running time of the engine in hours and tenths of an hour with an “hour glass” symbol.

Displays the engine coolant temperature in Celsius with the engine coolant temperature bar graph flashing. See page 10 for a detailed description of the bar graph function.

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

Speedometer The speedometer displays the ground speed in either kilometers per hour (km/h) or miles per hour (mph) along with either a “km/h” or “mph” symbol.

Engine Oil Pressure Displays the engine oil pressure in kilopascals (kPa) with the engine oil pressure bar graph flashing. See page 10 for a detailed description of the bar graph function.

Fuel Level Displays the fuel level in percent remaining in the tank with the fuel level bar graph flashing. See page 10 for a detailed description of the bar graph function.

Bur 7-12251

Issued 4-00

Printed in U.S.A.


Transmission Oil Temperature

Transmission Display

Displays the transmission oil temperature in Celsius with the transmission oil temperature bar graph flashing. See page 9 for a detailed description of the bar graph function.

The Transmission Display shows the status of the transmission control. The display center contains the following information, refer to Figure 2:

Hydraulic Oil Temperature

Shown at the top of the display center:

Direction Selected F

Forward

N

Neutral

R

Reverse

Voltmeter

F

Flashing forward not engaged.

Displays the electrical system voltage level in volts with the voltmeter bar graph flashing. See page 10 for a detailed description of the bar graph function.

N

Flashing set control lever to neutral position.

R

Flashing reverse not engaged.

Displays the hydraulic oil temperature in Celsius with the hydraulic oil temperature bar graph flashing. See page 9 for a detailed description of the bar graph function.

Requested Gear The gear position on shift lever, shown in the center of the gear symbol: 1

1st gear

2

2nd gear

3

3rd gear

4

4th gear

Actual Gear Shown with bars‘ to the right of the gear symbol. The number of bars indicates the gear the transmission is actually in.

Transmission Mode (Automatic or Manual) Shown in the lower left of the display center: A

Automatic Mode No symbol will be displayed when transmission is in Manual Mode.

Bur 7-12251

Issued 4-00

Printed in U.S.A.


SETTINGS, DIAGNOSTICS, AND FAULT CODES

3

4

5

6

2 1

RD98K316

1. INFORMATION CENTER 2. DISPLAY CENTER

3. UP COUNT 4. DOWN COUNT

5. PROGRAM 6. RESET

FIGURE 3. INFORMATION CENTER

Programming the Information Center NOTE: The machine must be OFF programming the information center.

prior

1. Turn the machine OFF. 2. Turn the key to the RUN position. to

Two switches are used during the programming of the information center: the up/down count switch and the program/reset switch. These switches are located on the right hand side of the information center, refer to Figure 3. For an up count press the left side of the up/down count switch. For a down count press the right side of the up/down count switch. The center position is OFF or NEUTRAL.

3. Press the program/reset switch to program. 4. Press the up/down count switch to up count program 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 has already been selected go to step 7. 7. Press the up/down count switch to up count to choose one of the following gauge display settings:

Fo r p r o g r a m m i n g p r e s s t h e l e f t s i d e o f t h e program/reset switch. For resetting press the right side of the program/reset switch. The center position is OFF or NEUTRAL. To program the information center do the following steps: Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-17 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

Individual Function Display Do the following steps to display any individual function, at anytime, regardless of the gauge display that was programmed: 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count and select one of the following individual functions:

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.

8. Press the program/reset momentarily.

switch

to

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

reset

9. If the Information Center does not function properly, do the programming steps again. 10. If the Information Center continues malfunction replace the instrument .

to

Manual Scrolling Gauge Displays (01, 02, or 05 If the Information Center has been programmed to display one of the manual scrolling displays (01, 02, or 05) press the up/down count switch to up count and scroll through the gauge displays. 1. Press the up count switch one time to display the Tachometer. 2. Press the up count switch again to display the Speedometer (km/h). 3. Press the up count switch again to display the Hourmeter.

Automatically Scrolling Gauge Displays (03 or 04) If the Information Center has been programmed with one of the automatic scrolling displays the gauge display will automatically scroll through after starting the machine. The up/down count switch has no effect on the display.

Bur 7-12251

000

3. Put the program/reset switch in the OFF (center) position. 4. If one of the individual functions (004 through 009) is selected, the corresponding bar graph will flash indicating that this individual function is being displayed. 5. The individual function selected will be shown on the information center.

Testing the Park Brake Do the following steps to test the parking brake: NOTE: The Transmission Control Module will disconnect the transmission if any gear other than 3rd is used. 1. Turn the machine ON. 2. Make sure the transmission is in the manual shift mode, 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 count until the display reads 011. C. Put the program/reset switch in the OFF (center) position.

Issued 4-00

Printed in U.S.A.

Copyright © 4005-18 D. Press the up/down count switch to up count once, so the display reads 01. E. Shift the transmission selector into 3rd forward and slowly increase the engine rpm. F. The park brake should hold the machine at full throttle. G. To exit the test mode, press the program/reset switch to reset.

Transmission Clutch Calibration Clutch Calibration ensures the most optimum shifting of the transmission. Before doing the following transmission clutch calibration procedures make sure of the following: 1. The machine is running and the transmission oil is warm. 2. Engine low idle speed is correct.

If this occurs, the code in the 3rd and 4th spaces will be a Clutch Calibration Main Code 09 through 14 and indicate what process the calibration was in when it was aborted The 1st and 2nd spaces will produce the Clutch Calibration Sub Code, which is the code that informs the operator of the reason the process was aborted. K. After completing the Clutch Calibration procedure, turn the machine OFF for 15 seconds. This sets the calibration in the controller. CLUTCH CALIBRATION MAIN CODES Main Code 00

Clutch 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.

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 mode and the gear selector in 3rd gear neutral. B. Press the program/reset switch to program. C. Press the up/down count switch to up count until the display reads 011. D. Put the program/reset switch in the OFF (center) position. E. Press the up/down count switch to up count twice, so the display reads 02. F. 2 00 00 will begin to flash in the display center. G. After one second, the Clutch Calibration Main Code status will be displayed in the 3rd and 4th spaces (2 XX 00, the XX represents the 3rd and 4th spaces). H. The Modulation Cycle Number will be displayed in the 1st and 2nd spaces (2 00 XX, the XX represents the 1st and 2nd spaces). I. During Clutch Calibration, the Clutch Calibration Main Code will change from 01 to 07 as the process is completed. Code 07 indicates that the calibration process is complete and the information center will return to normal working status. J. If any of the Clutch Calibration parameters are incorrect, the display center will stop flashing and display a code in the 1st, 2nd, 3rd, and 4th spaces. Bur 7-12251

Meaning

CLUTCH CALIBRATION SUB CODES Sub Code

Meaning

00

Calibration in process.

01

Fault present.

02

Shift lever not in neutral.

Issued 4-00

Printed in U.S.A.

Copyright © 4005-19 03

Park brake not applied.

2. Press the up/down count switch to up count until the display reads 015.

04

Output speed not 0 kph/mph.

3. The alarm will begin to sound intermittently.

05

Low transmission oil temperature.

06

High transmission oil temperature.

4. Place the program/reset switch in the OFF (center) position.

07

Low engine RPM.

08

High engine RPM.

Setting Display Center Lighting Do the following procedures to set the brightness of the display lighting: 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 012 (for working lights OFF) or 013 (for working lights ON).

5. The Information Center will display 00 and sound the alarm, when the machine is being checked, while all systems are normal. If there is a fault in the system that would cause the alarm to sound, the Information Center will display 01 while the alarm is being checked. The alarm will sound intermittently.

Coolant Level Check Do the following procedures to check the coolant level indicator light and the coolant level switch. 1. Press the program/reset switch to program.



4. Increase the brightness by pressing the up/down count switch to the up count position.

3. The coolant light will flash intermittently.

5. Decrease the brightness by pressing the up/down count switch to the down count position. NOTE: The brightness can be varied between 001 and 100, with 100 being the brightest. The factory set brightness is 070 for working lights OFF and 020 for working lights ON. 6. Press the program/reset switch to reset (momentar ily, 0.25 s econds ) to enter the selected brightness setting.

Voltmeter at Key ON Position Do the following procedures to read the system voltage at the key ON position. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 014. 3. Place the program/reset switch in the OFF (center) position. 4. The system voltage is displayed at the key ON position. 5. Press the program/reset switch to reset to exit the monitoring mode.

Alarm Check

4. Place the program/reset switch in the OFF (center) position. 5. The Information Center will display 00, when the machine is being checked, if the coolant level is normal. If the coolant level is low, the Information Center will display 01 while the coolant level switch is being checked. The coolant light will flash intermittently on the Information Center.

Brake Pressure Do the following procedures to check the brake pressure indicator light and the brake pressure switch. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 017. The brake pressure light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 01, when the machine is being checked, if the brake pressure is normal. If the brake pressure is low, the Information Center will display 00 while the brake pressure switch is being checked. The brake pressure light will flash intermittently on the Information Center.

Do the following procedures to check the audible alarm system. 1. Press the program/reset switch to program. Bur 7-12251

Issued 4-00

Printed in U.S.A.


Secondary Steering Pressure Switch Do the following procedures to check the secondary steering pressure indicator light and the secondary steering switch. 5. Press the program/reset switch to program. 6. Press the up/down count switch to up count until the display reads 018. The secondary steering pressure light will flash intermittently. 7. Place the program/reset switch in the OFF (center) position. 8. The Information Center will display 01, when the machine is being checked, if the secondary steering switch is not activated. If the secondary steering switch is activated, the Information Center will display 00 while the secondar y steering switch is being checked. The secondary steering light will flash intermittently on the Information Center.

Park Brake Information Center Output Check Do the following procedures to check the park brake indicator light and the status of the signal that the Information Center is sending to the park brake relay (to engage or disengage). 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 019. The park brake light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 00, when the Information Center is not activating the park brake relay. The Information Center will display 01 when it is activating the park brake relay. The park brake light will flash intermittently on the Information Center.

Pilot Lockout Information Output Check Do the following procedures to check the pilot lockout indicator light and the status of the signal that the Information Center is sending to the pilot lockout relay (to engage or disengage). 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 020. The pilot lockout light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position.

4. The Information Center will display 00, when the Information Center is not activating the pilot lockout relay. The Information Center will display 01 when it is activating the pilot lockout relay. The pilot lockout light will flash intermittently on the Information Center.

Hydraulic Filter Restriction Switch Check Do the following procedures to check the hydraulic filter restriction indicator light and the hydraulic filter restriction switch. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 021. The hydraulic filter restriction indicator light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 01, when the machine is being checked, if the hydraulic filter r e s t r i c t i o n sw i t c h is n ot a cti va ted. If th e hydraulic filter restriction switch is activated, the Information Center will display 00 while the hyd ra ul ic fi lte r r es tr ic ti on swi tch is being c he cke d. Th e hy d r a u l i c f i l t e r r e s t r i c t i o n indicator light will flash intermittently on the Information Center.

Air Filter Restriction Switch Check Do the following procedures to check the air filter restriction indicator light and the air filter restriction switch. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 022. The air filter restriction indicator light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 01, when the machine is being checked, if the air filter restriction switch is not activated. If the air filter restriction switch is activated, the Information Center will display 00 while the air filter restriction switch is being checked. The air filter restriction indicator light will flash intermittently on the Information Center.

Work Lights Check Do the following procedures to check the work lights indicator light and the work light electrical signal coming into the Information Center. 1. Press the program/reset switch to program.

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-21 2. Press the up/down count switch to up count until the display reads 023. The secondary work lights indicator light will flash intermittently.

Transmission Filter Restriction Switch Check


D o t h e fo l l o w i n g p r o c e d u r e s t o c h e c k t h e transmission filter restriction indicator light and the transmission filter restriction switch.

4. The Information Center will display 00 when the work lights are OFF and 01 when the work lights are ON. The work lights indicator light will continue to flash intermittently and the numbers on the display will change in accordance with the status of the work lights.

1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 026. The transmission filter restriction indicator light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position.

Fog Lights Check

4. The Information Center will display 00, when the machine is being checked, if the transmission filter restriction switch is not activated. If the transmission filter restriction switch is activated, the Information Center will display 01 while the transmission filter restriction switch is being checked. The transmission filter restriction indicator light will flash intermittently on the Information Center.

Do the following procedures to check the fog lights indicator light and the fog light electrical signal coming into the Information Center. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 024. The fog lights indicator light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 00 when the fog lights are OFF and 01 when the fog lights are ON. The fog lights indicator light will continue to flash intermittently and the numbers on the display will change in accordance with the status of the fog lights.

Requested Gear Check Do the following procedures to check that the gear being requested by the shifter is the same gear that the Information Center is reading. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 028. The “F, N or R” indicator in the transmission display will flash intermittently.

Air Conditioning Switch Check


Do the following procedures to check the air conditioning indicator light and the air conditioning high/low pressure switch.

4. Place the gear shifter in all positions and that the code in each position corresponds to the codes in the table below

1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 025. The air conditioning indicator light will flash intermittently.

:

Forward 1Code 101

Neutral 1Code 201

Reverse 1Code 301


Forward 2Code 102

Neutral 2Code 202

Reverse 2Code 302

4. The Information Center will display 00, when the machine is being checked, if the air conditioning high/low pressure switch is not activated. If the air conditioning high/low pressure switch is activated, the Information Center will display 01 while the air conditioning high/low pressure switch is being checked. The air conditioning indicator light will flash intermittently on the Information Center.

Forward 3Code 103

Neutral 3Code 203

Reverse 3Code 303

Forward 4Code 104

Neutral 4Code 204

Operational Indicator Status Do the following procedures to check the status of the operational indicator. 1. Press the program/reset switch to program.

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-22 2. Press the up/down count switch to up count until the display reads 029. The operational indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00.

Actual Gear Check Do the following procedures to check that the gear engaged in the transmission is the same gear that the Information Center is reading. 1. With the engine running put the transmission in manual mode and release the parking brake.

7. The Information Center will read 001 when the shift is being made. 8. The Information Center will read will read 010 if the transmission does not engage the drive line. 9. The Information Center will read 110 if the transmission is in Substitute Clutch Control Mode. 10. The Information Center will read 210 if the transmission is in Limp Home Mode. 11. The Information Center will read 300 if the transmission is in Shutdown Mode. 12. The Information Center will read 400 if the transmission is in T.E.C.M. Shutdown Mode.

2. Press the program/reset switch to program. 3. Press the up/down count switch to up count until the display reads 030. The bars that outline the large gear in the transmission display will flash intermittently. 4. Place the program/reset switch in the OFF (center) position. 5. Place gear that the transmission is corresponds to the codes in the table below.

in

:

Forward 1Code 101

Neutral 1Code 201

Reverse 1Code 301

Forward 2Code 102

Neutral 2Code 202

Reverse 2Code 302

Forward 3Code 103

Neutral 3Code 203

Reverse 3Code 303

Forward 4Code 104

Neutral 4Code 204

Limp Home Mode - 115


Hourmeter Indicator Status Do the following procedures to check the status of the hourmeter indicator. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 032. The hourmeter indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00.

Tachometer Indicator Status Do the following procedures to check the status of the tachometer indicator. 1. Press the program/reset switch to program.


Drive Line Shift Status Do the following procedures to check the drive line shift status. 1. With the engine running, release the parking brake. 2. Press the program/reset switch to program. 3. Press the up/down count switch to up count until the display reads 031. The drive line shift status bars flash intermittently. 4. Place the program/reset switch in the OFF (center) position.

2. Press the up/down count switch to up count until the display reads 033. The tachometer indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00.

Service Indicator Status Do the following procedures to check the status of the service indicator. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 034. The service indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position.

5. The Information Center will read 00. 6. Shift the shift lever. Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-23 4. The Information Center will read 00 if the service indicator is OFF or 01 if the service indicator is ON.

Movement Indicator Status Do the following procedures to check the status of the movement indicator. 1. Press the program/reset switch to program.

3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00 if the right tur n indicator is OFF or 01 if the r ight tur n indicator is ON.

Caution and Warning Master Indicator Lights Status

2. Press the up/down count switch to up count until the dis play r eads 035. The K ph and Mp h indicators flash intermittently.

Do the following procedures to ensure that the caution and warning lights are working correctly.


2. Press the up/down count switch to up count until the display reads 039 (Critical Master Light Red).

4. The Information Center will read 00.


Beacon Status Do the following procedures to check the status of the beacon.

1. Press the program/reset switch to program.

4. The Information Center will read 00 if the indicator is OFF under normal operation, or 01 if the indicator is ON under normal operation



2. Press the up/down count switch to up count until the display reads 036. The beacon indicator flashes intermittently.

6. Press the up/down count switch to up count until the display reads 041 (Caution Master Light Yellow).



4. The Information Center will read 00 if the beacon is OFF or 01 if the beacon is ON.

8. The Information Center will read 00 if the indicator is OFF under normal operation, or 01 if the indicator is ON under normal operation

Left Turn Indicator Status Do the following procedures to check the status of the left turn indicator. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 037. The left turn indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00 if the left tur n indi cator is OFF or 01 if the left tur n indicator is ON.

Diagnostic Indicator Status Do the following procedures to check the status of the diagnostic indicator. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 040. The diagnostic indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00.

Master Reset Right Turn Indicator Status Do the following procedures to check the status of the right turn indicator. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 038. The right turn indicator flashes intermittently. Bur 7-12251

Do the following procedure to reset the Information Center to the values set at the factory for the Gauge Display, Information Center lighting for work lights off and on, minimum gear selection in automatic mode, and maximum gear selection. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 042. Issued 4-00

Printed in U.S.A.

Copyright © 4005-24 3. Place the program/reset switch in the OFF (center) position. 4. Press the up/down count switch to up count twice to 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 brake sw i t c h a n d t h e s t a t u s o f t h e s i g n a l t h a t t h e Information Center is receiving from the park brake switch (to engage or disengage). 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 043. The park brake light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 00, when the Information Center is not receiving a signal from the park brake switch to engage the park brake. The Information Center will display 01 when it is receiving a signal from the park brake switch to engage the park brake. 5. Cycle the park brake switch to ensure it is working in both directions.

Redundant Brake Pressure Switch Check Do the following procedures to check the redundant brake pressure switch. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 044. The brake light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 00, when the machine is being checked, if the brake pressure is normal and there is nothing wrong with the c i r c u i t . I f t h e b r a ke p r e s s u r e i s l ow, t h e Information Center will display 01 while the redundant brake pressure switch is being checked. The brake light will flash intermittently on the Information Center.

2. Press the up/down count switch to up count until the display reads 045. The park brake light flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00 when the switch is open (service brakes are not applied) and 01 when the switch is closed (service brakes are applied).

Pilot Lockout Switch Check Do the following procedures to check the pilot lockout indicator light and the status of the signal that the Information Center is receiving from the pilot lockout switch (to engage or disengage). 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 046. The park brake light will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display 00, when the Information Center is not receiving a signal from the switch to engage the pilot lockout. The Information Center will display 01 when it is receiving a signal from the switch to disable the loader hydraulic controls. 5. Cycle the switch to ensure it is working in both directions.

Display Location 047 Do the following procedures to check display location 047. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 047. The pilot lockout light flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00 if the circuit is closed or 01 if there is a circuit malfunction.

Service Brake Foot Switch Check Do the following procedures to check the service brake foot switch. 1. Press the program/reset switch to program. Bur 7-12251

Issued 4-00

Printed in U.S.A.


Display Location Numbers (048 and 049) Reserved for Future Use

Gear Range Read Only Do the following procedures to read the gear range.

Minimum Gear Selection


Do th e fo ll owi n g p r o c e d ur e s t o p r o gra m t h e transmission for the lowest gear possible in the automatic mode.

2. Press the up/down count switch to up count until the display reads 052. The operational indicator will flash intermittently.

NOTE: The 1st or 2nd gear can be selected. The gear that is selected will be the gear that the transmission is in when the machine begins to move. The factory minimum gear setting is 1.



4. The Information Center will read 1 or 2 (gears). 5. Press the program/reset switch to program.


6. Press the up/down count switch to up count until the display reads 053. The operational indicator will flash intermittently.



4. Read the number (1 or 2) shown on the Information Center. If this is the desired gear selection, press the program/reset switch to either program or reset.

8. The Information Center will read 2,3, or 4 (gears).

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 th e fo ll owi n g p r o c e d ur e s t o p r o gra m t h e transmission for the highest gear possible in the automatic mode. NOTE: The 2nd, 3rd, or 4th gear can be selected. The gear that is selected will be the highest attainable gear that the transmission will be able to reach. The factory maximum gear setting is 4. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 051. 3. Place the program/reset switch in the OFF (center) position.

Display Location Number 054 Reserved for Future Use Reset Diagnostic Stack for Locations 071 through 090 Do the following procedure to remove all diagnostic codes from field number locations 071 through 090. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 055. The service indicator will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. Press the up/down count switch to up count until the display reads 21. 5. Press the program/reset switch to reset. If there are diagnostic codes in field number locations 071 through 090 they will be removed, unless the condition still exists.

4. Read the number (2, 3, or 4) shown on the Information Center. If this is the desired gear selection, press the program/reset switch to either program or reset. 5. If you want a different maximum gear selection, press the up/down count switch to up count until the desired number is displayed. 6. Press the program/reset switch momentarily (0.25 seconds) to reset.

Bur 7-12251

Issued 4-00

Printed in U.S.A.


Display Location Numbers (056 - 060) Reserved for Future Use

1. To view the fault codes and the hours they occurred do the following: A. Press the program/reset switch to program.

Service Interval Hours Field number locations 61 through 70 are service interval hour settings. The service interval hours accumulate until they are reset. Once they are reset, they begin accumulating hours independent from the machine hours until they are reset again. Do the following procedures to view or reset the service interval hours. NOTE: If the operator wanted location 061 to indicate when the engine oil should be changed, location 061 would be reset to begin accumulating hours for the next oil change. The operator could then go into location 061 and monitor accumulating hours. When location 061 reaches the engine oil change interval, the operator would change the oil and reset location 061 again. 1. To view the service hour interval locations do the following: A. Press the program/reset switch to program. B. Press the up/down count switch to up count until the display reads the desired location (061 - 070).

B. Press the up/down count switch to up count until the display reads the desired location (071 - 090). C. Place the program/reset switch in the OFF (center) position. D. Read any fault codes in the chosen location. NOTE: A complete list of fault codes can be found 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 count one 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 code occurred at. NOTE: The hour location will always follow the fault code location.

C. Place the program/reset switch in the OFF (center) position.

NOTE: Example: Location 072 will display the hours on the machine when the fault code in location 071 was written. Location 074 will display the hours on the machine when the fault code in location 073 was written.

D. Read the accumulated hours in the chosen location.

2. To monitor a particular location without going into the programming mode do the following:

2. To reset the service interval hours do the following: A. Press the program/reset switch to program. B. Press the up/down count switch to up count until the display reads the desired location (061 - 070). C. Place the program/reset switch in the OFF (center) position. D. Press the up/down count switch to down count and hold it for 3 seconds. The service interval hours in the chosen location will reset to 0.

Fault Code Status Field number locations 071 through 090 display fault codes and the hours the faults occurred. The Infor mation Center continuously monitors the machine’s condition and records any fault codes; however, it will only record a duplicate code once every hour. When a fault code is written, the service indicator icon (a manual with a wrench) will be displayed on the Information Center. Bur 7-12251

A. Press the program/reset switch to program. B. Press the up/down count switch to up count until the location to be monitored is displayed. C. Place the program/reset switch in the OFF (center) position. D. Press the program/reset switch to program and wait 5 seconds. The numbers on the display will change. E. Place the program/reset switch in the OFF (center) position. F. Within 3 seconds, press the program/reset switch to reset once. G. With the machine is in normal operating mode press the program/reset switch to reset to display the hours accumulated in the selected location. (Location 000 (hour meter) is programmed into the Information Center from the factory.

Issued 4-00

Printed in U.S.A.

Copyright © 4005-27 H. To reset a programmed location back to 000 (hour meter - factor y setting), hold the program/reset switch to reset for 5 seconds. When it is reset, the operator can view the h o u r m e t e r a t a ny t i m e d u r i n g n o r m a l operating conditions by pressing the reset switch.

ZF Transmission ECM Part Number (1st part) Do the following to display the first par t of the transmission ECM ZF part number. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 091. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display the first part of 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 the transmission ECM ZF part number.

1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 094. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display the LED duty cycle in units of 0.01 percent.

LCD Duty Cycle Do the following to display the LCD duty cycle. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 095. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display the LCD duty cycle in units of 0.01 percent.

Internal Information Center Temperature Do the following to display the internal temperature of the Information Center. 1. Press the program/reset switch to program.






4. The Information Center’s internal temperature will be displayed in degrees Celsius.

4. The Information Center will display the second part 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 Center software revision number. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 093. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display the software revision number.

Display Location Number 097 Reserved for Future Use Entry Code for Accessing Test Mode Locations 100 to 199 Do the following to access test mode locations from 100 to 199. 1. Press the program/reset switch to program. 2. Press the up/down count switch to down count until the display reads 098. 3. Place the program/reset switch in the OFF (center) position. 4. Press the up/down count switch to up count until the display reads 21. 5. Press the program/reset switch to program.

LED Duty Cycle Do the following to display the LED duty cycle. Bur 7-12251

6. Press the up/down count switch one time so that the display reads 099. Issued 4-00

Printed in U.S.A.

Copyright © 4005-28 7. Place the program/reset switch in the OFF (center) position. 8. Press the up/down count switch to up count until the display reads 21. 9. Press the program/reset switch to program. 10. Press the up/down count switch to up count past location 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 098 and 099 are automatically reset to 000. If only one of the locations is set at 21, and the leaves the range of 098-099, locations 098 and 099 are automatically reset to 000.

Transmission Identification Numbers Do the following to view and change the transmission identification numbers. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 102. 3. Place the program/reset switch in the OFF (center) position. 4. Use the up/down count switch to change the display to read 001 5. Press the program/reset switch to program. 6. Press the up/down count switch to up count until the display reads 101. 7. Place the program/reset switch in the OFF (center) position. 8. Use the up/down count switch to change the transmission identification number. 9. Place the program/reset switch in the OFF (center) position.

17. Press the program/reset switch to program. 18. Press the up/down count switch to up count until the display reads 103. 19. Place the program/reset switch in the OFF (center) position. When the transmission ECM has been reprogrammed, 110 will be displayed. 20. Press the program/reset switch to program. 21. Press the up/down count switch to down count until the display reads 102. 22. Place the program/reset switch in the OFF (center) position. 23. Press the up/down count switch to down count until the display reads 000. Location 100 and 101 are 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 following to enter the first par t of the instrument cluster (Information Center) part number. 1. Press the program/reset switch to program. 2. Press the up/down count switch to down count until the display reads 114. The service indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. Use the up/down count switch to enter the first part of the instrument cluster part number from the parts catalog.

10. Press the up/down count switch to down count until the display reads 100.

Instrument Cluster (Information Center) Part Number (2nd part)


Do the following to enter the second part of the instrument cluster (Information Center) part number.

12. Use the up/down count switch to change the transmission identification number. 13. Press the program/reset switch to program. 14. Press the up/down count switch to up count until the display reads 102. 15. Place the program/reset switch in the OFF (center) position.

1. Press the program/reset switch to program. 2. Press the up/down count switch to down count until the display reads 115. The service indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position.

16. Press the up/down count switch to up count until the display reads 010. Bur 7-12251

Issued 4-00

Printed in U.S.A.


AXLE RATIO

TIRE REV/KM

CALIBRATION NUMBER

4. Use the up/down count switch to enter the second par t of the instr ument cluster par t number from the parts catalog.

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

Speedometer Calibration

821 w/ 23.5 x 25 L2

23.51

208

4890

Do the following to reset the speedometer calibration.

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

NOTE: The part number may contain the letter A followed by a number, to show revision level. Using the up/down count switch, enter the A as 0 (zero) followed by the number, (A1 = 01, A2 = 02).

MACHINE/TIRE

Instrument Cluster (Information Center) Date Code Do the following to display the instrument cluster date code. 1. Press the program/reset switch to program. 2. Press the up/down count switch to down count until the display reads 116. The service indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information center will display the date code. Read the date code as follows: the first two numbers = year, next three numbers = day.

Display Location Numbers 117 - 120 Reserved for Supplier Information Display Location Numbers 121 -129 Reserved for Future Use

NOTE: If a dealer or customer changes tire sizes, the speedometer calibration will have to be changed to match the Information Center and transmission ECM to the new tire size. NOTE: A calibration number is required to perform this function. 1. If your tire and calibration number are listed in the table below go to step 3. Do the following to calculate a calibration number: A. Obtain the tire revolution/km (obtainable from most manufacturers). B. If the tire revolution/km is not available, measure the distance the tire travels (in meters) in 10 revolutions. Divide that number into 1000. Multiply the answer by 10. This is how many revolutions your tire makes in a km.

3. Press the program/reset switch to program. 4. Press the up/down count switch to up count until the display reads 130. 5. Place the program/reset switch in the OFF (center) position. 6. Use the up/down count switch to enter the calibration number from the table.

2. Multiply the tire revolution/km by the axle ratio. The answer will be the new speedometer calibration number. Bur 7-12251

Issued 4-00

Printed in U.S.A.


Display Location Numbers 131 - 139 Reserved for Speedometer Calibration

C. Place the program/reset switch in the OFF (center) position.

Display Location Numbers 140 - 170 Reserved for Future Use

D. Press the program/reset switch to program and wait 5 seconds. The numbers on the display will change.

Temporary Fault Code Status

E. Place the program/reset switch in the OFF (center) position.

Field number locations 171 through 190 display temporar y fault codes and the hours the faults o c c u r r e d . T h e s e t e m p o r a r y fa u l t c o d e s w i l l automatically be erased when the Information Center is turned off. The Information Center monitors the machine’s condition and records any fault codes into the shor t-term resettable memory once every 3 minutes. This will enable a technician to quickly check conditions to if a problem was resolved or still exists after maintenance. When a fault code is written, the service indicator icon (a manual with a wrench) will be displayed on the Information Center. 1. To view the temporary fault codes and the hours they occurred do the following: A. Press the program/reset switch to program. B. Press the up/down count switch to up count until the display reads the desired location (171 - 190). C. Place the program/reset switch in the OFF (center) position. D. Read any fault codes in the chosen location. NOTE: A complete list of fault codes can be found 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 count one time to advance to the next location. G. Place the program/reset switch in the OFF (center) position.

F. Within 3 seconds, press the program/reset switch to reset once. G. With the machine is in normal operating mode press the program/reset switch to reset to display the hours accumulated in the selected location. (Location 000 (hour meter) is programmed into the Information Center from the factory. H. To reset a programmed location back to 000 (hour meter - fac tor y setting), hold the program/reset switch to reset for 5 seconds. When it is reset, the operator can view the h o u r m e t e r a t a ny t i m e d u r i n g n o r m a l operating conditions by pressing the reset switch.

Display Location Numbers 191 - 196 Reserved for Future Use Display Location Number 197 Reserved for Manufacturing Data Display Location Number 198 Reserved for Future Use Display Location Number 199 Reserved for Manufacturing Data NOTE: To exit the upper range of display location numbers (100-199) press the program/reset switch to reset.

H. Read the hours that the previous fault code occurred at. NOTE: The hour location will always follow the fault code location. NOTE: Example: Location 172 will display the hours on the machine when the fault code in location 171 was written. Location 174 will display the hours on the machine when the fault code in location 173 was written. 2. To monitor a particular location without going into the programming mode do the following: A. Press the program/reset switch to program. B. Press the up/down count switch to up count until the location to be monitored is displayed. Bur 7-12251

Issued 4-00

Printed in U.S.A.


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 Status

00 = Normal Level 01 = Low Level

017

Brake Pressure Status

00 = Switch Closed 01 = Switch Opened (Open = Normal Pressure)

018

Steering Pressure Status

00 = Switch Closed 01 = 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 Status

00 = Switch Closed 01 = Switch Opened (Open = Filter is OK)

022

Air Filter Restriction Switch Status

00 = Switch Closed 01 = 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

Bur 7-12251

Issued 4-00

Printed in U.S.A.

Copyright © 4005-32 DISPLAY LOCATION NUMBER

DEFINITION

STATUS

025

Air Conditioning High/Low Pressure Switch Status

00 = Switch Open 01 = Switch Closed (Open = Normal Pressure)

026

Transmission Filter Restriction Switch Status

00 = Open 01 = Closed (Open - Filter is OK)

027

Present Status Of High Beam Lights (European Only)

00 = Off, 01 = On

028

Requested Gear Status

101 104 203 302

029

Status of Transmission Operation Indicator - In Transmission Display

00 = Always

030

Actual Gear Status

101 104 201 204 301 315

031

Shift Status Driveline Status Operational Mode

First Digit = 000 = Shift Not In Process 001 = Shift In Process

= = = =

= = = = = =

F1, 102 = F2, 103 = F3, F4, 201 = N1, 202 = N2, N3, 204 = N4, 301 = R1, R2, 303 = R3

F1, 102 = F2, 103 = F3, F4, 115 = Limp Home, N1, 202 = N2, 203 = N3, N4, 215 = Limp Home, R1, 302 = R2, 303 = R3, Limp Home

Second Digit = 001 = Driveline Not Engaged 010 = Driveline Engaged Third Digit = Mode Control 010 = Normal 110 = Substitute Clutch control 210 = Limp Home Mode 300 = Transmission Shutdown 400 = 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

Bur 7-12251

Issued 4-00

Printed in U.S.A.


DEFINITION

041

Current Status Master Indicator (Yellow)

042

Master Reset - Reset Information Center to Factory Setting

STATUS 00 = Off, 01 = On

043

Park Brake Switch Status

00 = Switch Open 01 = Switch Closed (Closed = engaged Parking Brake)

044

Redundant Brake Pressure Switch

00 = Switch Closed 01 = Switch Open (Closed = Normal Operation)

045

Service Brake Foot Switch Status

00 = Switch Open 01 = Switch Closed (Closed = Actuated)

046

Pilot Lockout Switch Status

00 = Switch Open 01 = Switch Closed (Closed = Loader Controls Locked)

047

Seat Circuit

01 = Circuit Closed 02 = 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

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 ,078,080,08 2,084,086,0 88,090

Range = 0 to 99 Default = 0 Set to “21” and then exit this location 055 to reset diagnostic stack 071 -099 to zero

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

Bur 7-12251

Issued 4-00

Printed in U.S.A.


DEFINITION

STATUS

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 199

Set to “21” to enter Test Mode locations (Range = 0 to 99)

099

Entry Code for Accessing Test Mode Locations 100 to 199

Set 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

Bur 7-12251

Temporary Fault Code Status

Issued 4-00

Printed in U.S.A.


FAULT CODES CODE

DEFINITION

12900

Engine coolant short circuit measuring less than 50 ohms to the engine coolant temperature sensor.

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.

13000

Low engine coolant level - This code will not be generated if the engine coolant temperature is below 20° C (68° F).

21100

Engine oil pressure is measured below 100 kPa (14.5 PSI)

21110

Engine coolant temperature is 110° C (230° F) or greater.

21900

Engine oil pressure short circuit measuring less than 16 ohms to the engine oil pressure sensor.

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.

33901

Fuel level open circuit measuring more than 270 ohms to the fuel level sender.

34000

Fuel solenoid output short circuit.

35000

42125

45000

46017

46018

Bur 7-12251

POSSIBLE STEPS FOR REPAIR

Troubleshoot electrical circuits.

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.

Troubleshoot electrical circuits. NOTE: Fault code 21900 is possible during cold engine start-up. After machine warm up, proper operation.


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.

Transmission temperature measured above 125° C (257° F)


High transmission filter restriction when the transmission oil is above 20° C (68° F).


Gear range fault error

1. Check the cables from TCU to shift lever. 2. Check signal combinations of shift lever positions for gear range.

Logical error at direction select signal

1. Check the cables from TCU to shift lever. 2. Check signal combinations of shift lever positions F-N-R. Issued 4-00

Printed in U.S.A.

Copyright © 4005-36 CODE

DEFINITION


46020

Logical fault at Park Brake Status

1. 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

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

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 temperature sensor.

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. 2. 3. 4.

Check the cables from TCU to the sensor. Check the connectors. Check the speed sensor. Check the sensor gap.

NOTE: This fault code is reset after power up of the TCU. It is also reset if the signal is above zero speed threshold. 46052

Short circuit to battery voltage or Open circuit at turbine speed input

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 the TCU. 46055

Short circuit to battery voltage or Open circuit at intermediate speed input

46056

Short circuit to ground at intermediate speed input

46057

Logical error at intermediate speed input



NOTE: This fault code is reset after power up of the TCU. 46058

Short circuit to battery voltage or Open circuit at output speed input

46059

Short circuit to ground at output speed input

Bur 7-12251

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.

Issued 4-00

Printed in U.S.A.


46060

DEFINITION

Logical error at output speed input

POSSIBLE STEPS FOR REPAIR 1. 2. 3. 4.


NOTE: This fault code is reset after power up of the TCU.

46062

Output speed zero, does not match other speeds.

1. Check the sensor signal of the output speed sensor. 2. Check the sensor gap of the output speed sensor. 3. Check the cable from the TCU to the sensor. NOTE: This fault code is reset after power up of the TCU.

46064

Invalid gear range restriction (CAN)

46065

Invalid declutch modulation selection (CAN)

46089

Invalid test mode signal (CAN)

46090

Invalid park brake status (CAN)

46091

Invalid shift quality selection (CAN)

46113

Short circuit to battery voltage at clutch K1

46114

Short circuit to ground at clutch K1

46115

Open circuit at clutch K1

46116


46117


46118


46119


46120


46121


46129

Short circuit to battery voltage a clutch K4

46130


46131


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

Bur 7-12251

1. Check the cluster controller. 2. Check wire of CAN-Bus. 3. Check the cable to the cluster controller.

1. Check the cluster controller. 2. Check wire of CAN-Bus. 3. Check the cable to the cluster controller.

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.

Issued 4-00

Printed in U.S.A.


DEFINITION

46145

Short circuit to ground at reverse warning alarm relay

46146

Short circuit to battery voltage at reverse warning alarm relay

46147

Open circuit at reverse warning alarm relay

46177

46178

46179

46180

46181

46182

Bur 7-12251


1. Check the cable from the TCU to the gearbox. 2. Check the connectors from the backup alarm device to TCU. 3. Check the resistance of backup alarm device.

Slippage at clutch K1

1. 2. 3. 4. 5. 6. 7.

Check pressure at clutch K1. Check main pressure in the system. Check sensor gap at internal speed sensor. Check sensor gap at output speed sensor. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.


1. 2. 3. 4. 5. 6. 7.



1. 2. 3. 4. 5. 6. 7.



1. 2. 3. 4. 5. 6. 7.


Slippage at clutch KV

1. 2. 3. 4. 5. 6. 7.

Check pressure at clutch KV. Check main pressure in the system. Check sensor gap at internal speed sensor. Check sensor gap at output speed sensor. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch KR

1. 2. 3. 4. 5. 6. 7.

Check pressure at clutch KR. Check main pressure in the system. Check sensor gap at internal speed sensor. Check sensor gap at output speed sensor. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Issued 4-00

Printed in U.S.A.


DEFINITION

46183

Oil temperature at valve body is above limit

46184

Oil temperature at converter output is above limit

46186

Differential pressure oil filter TCU measured a voltage at differential pressure switch out of the allowed range.

46209

Short circuit to battery voltage at power supply for sensors

46210

Short circuit to ground at power supply for sensors

46211

Low voltage at battery

46212

High voltage at battery

46213

Error at switch 1 for solenoid power supply

46214

Error at switch 2 for solenoid power supply

46227

Short circuit to battery voltage at display output

46228

Short circuit to ground at display output

POSSIBLE STEPS FOR REPAIR 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. 4. Cool down machine. 5. Check oil level. 6. Check temperature sensor. 1. Check oil filter. 2. Check wiring from TCU to differential pressure switch. 3. Check differential pressure switch (measure resistance). 1. Check cables and connectors to sensors, which are supplied from AU1. 2. Check the power supply at the pin AU1. It should be approximately 5 volts. 1. Check power supply battery. 2. Check cables from batteries to TCU. 3. Check connectors from batteries to TCU. 1. 2. 3. 4.

Check fuse Check cables from gearbox to TCU. Check connectors from gearbox to TCU. Replace TCU.

1. Check the cable from TCU to the display. 2. Check the connectors at the display. 3. Change display. 1. Check the cluster controller. 2. Check the wire of the CAN-Bus. 3. Check cable to cluster controller.

46229

Error at communication on CAN

46230

Undefined VIN request via CAN.

46241

General EEPROM fault

Replace the TCU.

46242

Current ID not set or corrupt

Reprogram 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

Bur 7-12251

1. Clear the codes. 2. Restart the machine. 3. Monitor machine operation and diagnostics.

Issued 4-00

Printed in U.S.A.


DEFINITION

47001

Engine speed is missing

47002

Output shaft speed is missing

POSSIBLE STEPS FOR REPAIR 1. corresponding function is displayed on the information center and is working properly: A. Engine rpm - run engine LI to HI and display shows rpm. B. Output shaft speed - drive unit with mph/kph dis played and ver ify that it is wor king properly.

47011

Transmission oil temperature is missing

47012

Transmission filter restriction information is missing

47013

Current Transmission identification code is outside of the range

47014

Result code (11)

51000

Low steering pressure has been detected after a normal operating pressure has been reached since start up.

61000

Low brake pressure (1700 PSI / 11721 kPa) has been detected after a normal operating pressure has been reached since start up.

61900

1700 PSI (11,721 kPa) Brake pressure switch has not cycled within 50 hours of operation time.

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.

66900

Park brake switch has not cycled within 50 hours of operation time.

Bur 7-12251

C. Transmission oil temperature - display temperature values on information center a n d r u n m a c h i n e t o ve r i f y t h a t t h e temperature changes with machine operation. 4. If operation is satisfactory, clear fault codes and continue to monitor. 5. If there are problems during operation, troubleshoot the appropriate electrical circuits. 1. Check the function/operation of the transmission filter restr iction by going to program count location 026. 2. Read filter restriction status: 00 = filter acceptable, 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. 1. Reprogram transmission ID numbers. 2. program count location reads 110 or 100. 3. Clear codes and monitor machine performance and continue to operate. 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.

1. Turn machine off. 2. Pump service brake 30 full strokes. 3. Start machine and proper operation and no diagnostic codes. 4. Operate machine and monitor performance. 1. 2. 3. 4.

Check park brake for proper operation. Do park brake test, see section 7008. Adjust/repair park brake as required. Clear diagnostic codes and monitor machine performance.

Issued 4-00

Printed in U.S.A.


DEFINITION


Service brake foot switch has not cycled within 50 hours of operation.

1. full pedal actuation and return, make sure debris does not obstruct pedal travel. 2. Clear codes. 3. 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.


72900

Hydraulic oil temperature short circuit measuring less than 50 ohms to the hydraulic oil temperature sensor.

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

86011

Corrupt engine hours, data suspect

86012

Corrupt engine hours, data suspect

86020

Corrupt tire calibration numbers, data lost – The calibration number will default back to the number used at cluster shipment

86021

Corrupt tire calibration number, data suspect

86022

Corrupt tire calibration number, data suspect

66901

Bur 7-12251


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. 1. Operate the machine to all functions and monitoring systems are working properly (no yellow or red warnings, normal operation). 2. Monitor cluster performance during machine operational check (no new diagnostic codes, no erratic behavior, flashing icons, etc.). 3. If all systems and operations are normal, clear d ia gno s tic co de s an d c ont inue m ac hi ne operation. 4. Monitor machine for recurrence of fault codes. 5. Repeated codes may be an indication of a pending cluster failure. 1. Reprogram correct tire calibration number for the machine. 2. proper machine operation and machine travel speed to displayed speed. 3. Continue machine operation and monitor for recurring fault codes.

Issued 4-00

Printed in U.S.A.


DEFINITION

86030

Information Center memory error

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

Bur 7-12251


1. Operate the machine to all functions and monitoring systems are working properly (no yellow or red warnings, normal operation). 2. Monitor cluster performance during machine operational check (no new diagnostic codes, no erratic behavior, flashing icons, etc.). 3. If all systems and operations are normal, clear d ia gno s tic co de s an d c ont inue m ac hi ne operation. 4. Monitor machine for recurrence of fault codes. 5. Repeated codes may be an indication of a pending cluster failure.


Issued 4-00

Printed in U.S.A.


INDEX A Actual Gear Check ................................................22 Air Conditioning Indicator ........................................9 Air Conditioning Switch Check ..............................21 Air Filter Indicator ....................................................9 Air Filter Restriction Switch Check ........................20 Alarm Check ..........................................................19 Automatic Scrolling Gauge Displays .....................17

B Beacon Indicator ......................................................8 Beacon Status .......................................................23 Brake Park, Information Center Output Check ............20 Park, Testing ......................................................17 Parking Brake Indicator .......................................9 Brake Pressure ......................................................19 Brake Pressure Indicator .........................................8

C Calibration Transmission Clutch ..........................................18 Caution and Warning Master Indicator Lights .......23 Caution Master Indicator (Yellow) ...........................8 Check Actual Gear .......................................................22 Air Conditioning Switch .....................................21 Alarm .................................................................19 Coolant Level ....................................................19 Fog Lights ..........................................................21 Park Brake Switch .............................................24 Requested Gear ................................................21 Switch, Pilot Lockout .........................................24 Switch, Redundant Brake Pressure ..................24 Switch, Service Brake Foot ...............................24 Work Lights .......................................................20 Clutch Calibration, Transmission ..................................18 Codes, Fault ..........................................................35 Control Pilot .....................................................................8 Coolant Engine Temperature ..........................................10 Indicator, Low ......................................................8 Coolant Level Check .............................................19 Critical Warning Displays .......................................12

D Diagnostic Center ....................................................7 Diagnostic Indicator Status ....................................23 Display Center Lighting, Setting ................................................19 Display Location 047 ....................................................................24 Bur 7-12251

048 and 049 ......................................................25 054 ....................................................................25 056 through 060 ................................................26 071 through 090 ................................................25 097 ....................................................................27 100 through 199 ................................................27 104 through 113 ................................................28 117 through 120 ................................................29 121 through 129 ................................................29 131 through 139 ................................................30 140 through 170 ................................................30 191 through 196 ................................................30 197 ....................................................................30 198 ....................................................................30 199 ....................................................................30 Display Location Numbers and Descriptions .........31 Displays Gauge, Automatic Scrolling ...............................17 Gauge, Manual Scrolling ...................................17 Individual Function ............................................17 Drive Line Shift Status ...........................................22 Duty Cycle, LCD ....................................................27 Duty Cycle, LED ....................................................27

E Engine Coolant Temperature .........................................10 Oil Pressure Gauge ...........................................10 Engine Coolant Temperature ..........................10, 14 Engine Oil Pressure ..............................................14 Engine Oil Pressure Gauge ...................................10 Entry Code Test Mode Locations 100 to 199 .......................27

F Fault Code Status ..................................................26 Fault Codes ...........................................................35 Filter Indicator, Air Filter ...............................................9 Indicator, Hydraulic Oil ........................................9 Indicator, Transmission Oil ..................................9 Restriction Switch, Air Restriction Switch, Air Filter ..........................20 Restriction Switch, Hydraulic .............................20 Restriction Switch, Transmission .......................21 Fog Lights Check ..................................................21 Fuel Gauge, Level .....................................................10 Fuel Level Gauge ..................................................10 Fuel Lever .............................................................14

G Gauge Engine Oil Pressure ..........................................10 Fuel Level ..........................................................10 Issued 4-00

Printed in U.S.A.

Copyright © 4005-44 Hydraulic Oil Temperature ...................................9 Transmission Oil Temperature .............................9 Voltmeter ...........................................................10 Gauges and Indicators ............................................8 Gear Check, Actual ....................................................22 Check, Requested .............................................21 Gear Range Read Only .........................................25 Gear Selection Maximum ...........................................................25 Minimum ............................................................25

H Hourmeter ..............................................................14 Hourmeter Indicator Status ....................................22 Hours Service Interval .................................................26 Hydraulic Filter Restriction Switch Check ..............20 Hydraulic Oil Filter Indicator ....................................9 Hydraulic Oil Temperature .....................................15 Hydraulic Oil Temperature Gauge ...........................9

Internal Information Center Temperature ..............27

L LCD Duty Cycle .....................................................27 LED Duty Cycle .....................................................27 Left Turn Indicator Status ......................................23 Level Coolant, Check ..................................................19 Lighting, Setting Display Center ............................19 Lights Fog ....................................................................21 Work ..................................................................20 Low Coolant Indicator ..............................................8

M Manual Scrolling Gauge Displays .........................17 Master Reset .........................................................23 Maximum Gear Selection ......................................25 Minimum Gear Selection .......................................25 Movement Indicator Status ....................................23

N I Identification Numbers Transmission .....................................................28 Indicator Air Conditioning ...................................................9 Air Filter ...............................................................9 Beacon ................................................................8 Brake Pressure ....................................................8 Caution and Warning Master, Status Lights ......23 Caution Master (Yellow) ......................................8 Diagnostic, Status .............................................23 Hourmeter, Status .............................................22 Hydraulic Oil Filter ...............................................9 Icon, Service .....................................................11 Left Turn, Status ................................................23 Low Coolant ........................................................8 Movement, Status .............................................23 Operational, Status ...........................................21 Parking Brake ......................................................9 Right Turn, Status ..............................................23 Secondary Steering ............................................9 Service, Status ..................................................22 Stop Master (Red) ...............................................8 Tachometer, Status ...........................................22 Transmission Oil Filter .........................................9 Indicators and Gauges ............................................8 Individual Function Display ....................................17 Information and Diagnostic Center ....................7, 14 Information Center Internal Temperature .........................................27 Software Revision Number ................................27 Instrument Cluster Date Code .........................................................29 Part Number (1st part) ......................................28 Part Number 2nd part) ......................................28 Bur 7-12251

Non-Critical Warning Displays ...............................13

O Oil Pressure Gauge, Engine ...................................10 Operational Indicator Status ..................................21

P Park Brake Information Center Output Check .....................20 Testing ...............................................................17 Park Brake Switch Check ......................................24 Parking Brake Indicator ........................................... 9 Pilot Control ............................................................. 8 Pilot Lockout Information Output Check .................................20 Pilot Lockout Switch Check ...................................24 Power Circuit Test ................................................... 8 Pressure Brake Indicator ....................................................8 Pressure, Brake .....................................................19 Programming Information Center ..........................16 Programming, Information Center .........................16

R Redundant Brake Pressure Switch Check ............24 Requested Gear Check .........................................21 Reset Diagnostic Stack for Display Locations .......25 Reset, Master ........................................................23 Right Turn Indicator Status ....................................23

S Secondary Steering Indicator .................................. 9 Secondary Steering Pressure Switch ....................20 Self-Test .................................................................. 7 Issued 4-00

Printed in U.S.A.

Copyright © 4005-45 Service Brake Foot Switch Check .........................24 Service Indicator Icon ............................................11 Service Indicator Status .........................................22 Service Interval Hours ...........................................26 Setting Display Center Lighting .............................19 Settings, Diagnostics, and Fault Codes .................16 Software Revision Number, Information Center ...............27 Speedometer .........................................................14 Speedometer Calibration .......................................29 Status Beacon ..............................................................23 Caution and Warning Master Indicator Lights ...23 Diagnostic Indicator ...........................................23 Drive Line Shift ..................................................22 Fault Code .........................................................26 Fault Code, Temporary ......................................30 Hourmeter Indicator ..........................................22 Left Turn Indicator .............................................23 Movement Indicator ...........................................23 Right Turn Indicator ...........................................23 Service Indicator ...............................................22 Tachometer Indicator .........................................22 Steering Secondary Indicator ............................................9 Secondary Pressure Switch ..............................20 Stop Master Indicator (Red) ....................................8 Switch Park Brake, Check .............................................24 Pilot Lockout ......................................................24 Pressure, Secondary Steering ..........................20 Redundant Brake Pressure ...............................24 Restriction, Hydraulic Filter ...............................20 Restriction,Transmission Filter ..........................21 Service Brake Foot ............................................24

Transmission Oil Temperature ..............................15 Transmission Oil Temperature Gauge ....................9

V Voltmeter ...............................................................15 Voltmeter Gauge ...................................................10 Voltmeter, Key ON ................................................19

W Warning Display ....................................................12 Work Lights Check ................................................20

Z ZF Transmission See Transmission ..............................................27

T Tachometer ...........................................................14 Tachometer Indicator Status .................................22 Temperature Engine Coolant ..................................................10 Internal Information Center ...............................27 Temporary Fault Code Status ...............................30 Test Power Circuit .......................................................8 Self-Test ..............................................................7 Test Mode Locations 100 to 199 ...........................27 Testing Park Brake ................................................17 Transmission Identification Numbers ......................................28 ZF Transmission ECM Part Number (1st part) .........................27 ECM Part Number (2nd part) ........................27 Transmission Clutch Calibration ............................18 Transmission Display ............................................15 Transmission Filter Restriction Switch Check .......21 Transmission Oil Filter Indicator ..............................9 Bur 7-12251

Issued 4-00

Printed in U.S.A.


NOTES

Bur 7-12251

Issued 4-00

Printed in U.S.A.

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SECTION INDEX - POWER TRAIN

0000-1

Section Title Section Number Transmission Specifications, Pressure Checks, and Troubleshooting ............................................................................... 6002 Transmission .......................................................................................................................................................... 6003 Front and Rear Axle ................................................................................................................................................. 6004 Drive Shaft, Center Bearing, and Universal ts ......................................................................................................... 6005 Wheels and Tires ..................................................................................................................................................... 6006 Transmission Control Valve .................................................................................................................................... 6007


Bur 7-13231


Copyright ©

6002

Copyright ©

Section 6002 TRANSMISSION SPECIFICATIONS, SCHEMATIC, AND TROUBLESHOOTING


Bur 7-12391


Copyright © 6002-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSUMPTION TEST PROCEEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 3 9 9 9 10 10 10 11 12 14 16 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 19 20 20 20 21

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Copyright © 6002-3

SPECIAL TOOLS CAS-1953A Transmission supplemental fitting kit. Includes: CAS-2324 special 90 degree adapter and CAS-2325 plug and cap set. CAS-1804 Master pressure test kit

CAS-1808 Flowmeter kit CAS-2702 Flowmeter adapter CAS-2278 Flow test kit

SPECIFICATIONS Main 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 bar Clutch KR .................................................................................................................................................16 to 18 bar Clutch K1 ..................................................................................................................................................16 to 18 bar Clutch K2 ..................................................................................................................................................16 to 18 bar Clutch K3 ..................................................................................................................................................16 to 18 bar Clutch K4 ..................................................................................................................................................16 to 18 bar

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Copyright © 6002-4

4

1

3 2

5

12

9

6

8 14 11

13 7

10

GS99C607

1. 2. 3. 4. 5. 6. 7.

TRANSMISSION ELECTRONIC CONTROL MODULE DOWNSHIFT BUTTON DECLUTCH ROCKER SWITCH MANUAL/AUTOMATIC ROCKER SWITCH SHIFTER SUPPLY SYSTEM CONNECTIONS B+ AND RETURN TRANSMISSION

8. 9. 10. 11. 12. 13. 14.

INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR HALL SENSOR - OUTPUT SPEED SENSOR TRANSMISSION CONTROL VALVE CABLE DECLUTCH LIMIT SWITCH FILTER RESTRICTION SWITCH (721/821C MODELS ONLY)

FIGURE 1. COMPONENT LOCATIONS SYSTEMS

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Copyright © 6002-5

12 1

11

2

3

10

4

9

15

5

14 8

7 6 13 GS98K615

1. 2. 3. 4. 5. 6. 7. 8.

CLUTCH SHAFT KR POWER TAKE OFF CLUTCH SHAFT KV CLUTCH SHAFT K2 CLUTCH SHAFT K3 OUTPUT FLANGE REAR OUTPUT FLANGE CONVERTER SIDE OUTPUT SHAFT

9. 10. 11. 12. 13. 14. 15.

TRANSMISSION PUMP DRIVE SHAFT CONVERTER INDUCTIVE TRANSMITTER FOR ENGINE SPEED CLUTCH SHAFT K4 CONVERTER RELIEF VALVE CLUTCH SHAFT K1

FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

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Copyright © 6002-6

1

1

2

2

2

2

3 6

5

4 GS99C614

1. LIFTING LUGS 2. TRANSMISSION SUSPENSION BORES 3. OUTPUT FLANGE CONVERTER SIDE

4. OIL DRAIN PLUG 5. MODEL IDENTIFICATION PLATE 6. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK

FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

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Copyright © 6002-7

2

1

3

4

5

9 6

8 7 GS99C608

1. CONVERTER BELL HOUSING 2. BREATHER 3. TRANSMISSION CASE COVER

4. FILTER HEAD 5. FILTER 6. OUTPUT FLANGE REAR

7. OIL DRAIN PLUG 8. OUTPUT FLANGE CONVERTER SIDE 9. TRANSMISSION CASE

FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

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1

2

1

3 8

7 4

6 5 5

GS98K609

1. 2. 3. 4.

LIFTING LUGS POWER TAKE OFF TRANSMISSION CONTROL VALVE OIL FILLER PIPE WITH OIL DIPSTICK

5. 6. 7. 8.

TRANSMISSION SUSPENSION BORES OUTPUT FLANGE REAR FILTER FILTER HEAD

FIGURE 5. COMPONENT LOCATIONS REAR VIEW

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Copyright © 6002-9

TRANSMISSION OPERATION General

A. Determines which clutches to engage in the transmission.

The transmissions for the C series equipment is equipped with a Transmission ECM (Electronic Control Module). This module controls modulation and shifting that were normally associated with hydraulically modulated transmissions, providing smoother shifts and enhanced clutch life. The Transmission ECM relies on signal from several solenoids that are incorporated into the design. These solenoids measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. In a ddi ti on , th e tran s mi ss i on i nc o r po rat es a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise, and all external hoses have been eliminated (all oil ages are internal).

Transmission ECM Modulation and shifting are controlled by the Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e (Transmission ECM). This module replaces the oil and springs that are found in hydraulically modulated transmissions. T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h e n g a ge m e n t , p r ov i d i n g s m o o t h e r s h i f ts a n d enhanced clutch life, whether the transmission is set to the automatic or manual shift mode. The Transmission ECM also informs the Information Center, by the use of diagnostic codes, of any transmission error and the hours of operation that the error occurred.

Electrical Shift Solenoids Electrical Shift Solenoids control the modulation of the clutches, eliminating the need for a modulation valve, and providing a smooth shift while maintaining constant control over clutch engagement as follows: A. A temperature sensor relays the temperature to the Transmission ECM.

oil

B. The Transmission ECM times the rate the solenoid energizes and de-energizes. C. As the transmission changes gears, there is reduced hesitation from one gear to the next.

Transmission ECM Tasks The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM: Bur 7-12391

B. Protect the engine and transmission turbine fr om overspeed conditions dur ing ing. C. Receives speed information from the engine speed sensor, the turbine speed sensor, the intermediate clutch speed sensor and the transmission output speed sensor. These speed sensors are checked to determine if normal sensor operation is present. The data is also used to control modulation during shifting and to determine the appropriate shift patterns. D. Detects system failures and determines the appropriate alternative actions. E. Provides various diagnostic messages to the Information Center. F. Provides other information to the information center, which in turn displays engine speed, wheel speed, gear shift selection, and actual gear selection. G. Provides a method to transmission clutch control.

calibrate

the

H. Establishes clutch modulation pressure during transmission shifts.

Transmission Sensor Data Collection. The Transmission ECM collects and uses information from four sensors to accurately shift the transmission and determine if any clutches are slipping. These sensors are: Engine (Speed) Sensor - monitors engine speed to determine the load on the engine for shift points and sends the engine rpm to the Transmission ECM, which sends the information to the tachometer in the Information Center. Turbine (Speed) Sensor - assists the engine speed sensor in deter mining the load going into the transmission and helps determine shift points. Intermediate (Shaft Speed) Sensor - determines differential gear speed in the transmission to check for clutch slippage. Output (Speed) Sensor - monitors transmission output shaft speed to help determine the load on the transmission and to assist in determining shift points. Sends output shaft speed to Transmission ECM which sends the information to the speedometer in the Information Center.

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Copyright © 6002-10 T he tra ns m i s s io n E CM al s o r ev i ews vol ta g e infor mation from the shifter and transmission solenoids to determine if there are any short circuits or open circuits in the system.

Automatic Problem Modes If the Transmission ECM detects an error condition in the transmission system, it will generate a service code in the Information Center and will enter one of three modes: A. Clutch Modulation Substitute Mode B. Limp-Home Mode C. Transmission/Transmission ECM Shutdown Mode Clutch Modulation Substitute Mode In this mode, the transmission clutch modulation is time dependant rather than load dependant. The transmission will go into the Clutch Modulation Substitute Mode if any of the four speed sensors fail. If the output speed sensor is working and the transmission is in gear, the shift points in Automatic mode will be speed dependant but the modulation will be a predetermined amount of time. If the output speed sensor is not working and the transmission is in gear, the shift points will still be load depen dant but the modul ation will be a predetermined amount of time. If the transmission is shifted from neutral into a direction in the Clutch Modulation Substitute Mode in automatic, the transmission will shift into 4th gear and shift down until it gets the correct output speed from the turbine.

If the Transmission ECM generates a code, the wre nch over the ser v ic e manual ic on wil l b e displayed on the Information Center.

Transmission Clutch Calibration The Transmission ECM has the capability to find the optimal adjustment of the clutch filling parameters for each individual transmission, providing the ability to individually adjust the optimum fill time for the individual transmission in the machine. Clutch Filling Parameter Calibration is performed on each machine at the plant and should be repeated at the first 250 hours of use and every 1000 hours thereafter

Gear Selections The transmission in all C Series models provides 4 fo r wa r d a n d 3 r eve r s e g e a r s e l e c t i o n s. Th e transmission ratios were designed to give optimized speed and torque for each gear selection. The torque converter is a single stage torque converter (one locking unit in the torque converter).

Automatic/Manual Modes The automatic/manual switch is located on the right control . The transmission is in automatic mode when the top of the automatic/manual switch is depressed. The Transmission Display Center indicates when the machine is in the automatic mode.

Limp-Home Mode In this mode, the transmission will go into second gear, forward or reverse, no matter what gear is selected. If second gear is not obtainable, the Transmission ECM selects a series of prioritized g e a r s u n t i l a n o p e r a bl e g e a r i s fo u n d . T h e transmission will go into the Limp Home Mode if there is a fault on one clutch, a fault on one clutch valve, or a fault on more than one speed sensor. Transmission/Transmission ECM Shutdown Mode In this mode, the Transmission ECM has detected a s ev e r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e transmission. The transmission will go into Shutdown Mode if there is a fault on more than one clutch, a fault on the solenoid power supply. or invalid voltage. In this mode, the transmission ECM will shut off all solenoid valves and the power supply and the transmission shifts into and stays in neutral. Bur 7-12391

RD98K308

FIGURE 6. AUTO/MANUAL TRANSMISSION SWITCH

Upshifting in Automatic Mode Upshifting is determined by machine speed and the torque on the transmission. The transmission will shift from first or second gear up to the highest gear selected as the accelerator is depressed, machine speed increases, and required torque is reduced.

Issued 4-00

Printed in U.S.A.

Copyright © 6002-11 If the machine speed is increasing, but the operator is not depressing the accelerator (such as when going down a hill), the transmission will not upshift.

With the number of different ways the downshift button functions, the operator can tailor the use of the machine to the application at hand.

As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.

1

Downshifting in Automatic Mode Downshifting is determined directly by machine speed and transmission torque. The transmission will downshift to first or second gear as machine speed decreases and transmission torque increases. For example, if the unit begins to climb a hill in forth gear and the machine speed decreases, as the torque requirement incr eases, the trans mission will downshift into third, then second, and down to first gear, if necessary.

RD98K306

1. DOWNSHIFT BUTTON/SINGLE LEVER CONFIGURATION

Upshifting in Manual Mode

FIGURE 7

In the manual mode, the transmission starts out in the selected gear and stays in that gear until the operator selects another gear or direction. The transmission can be upshifted without reducing engine speed or machine speed. If the gear selected is two or more gears higher than the present gear, the transmission will shift up through the gears at 2.5 second intervals until the selected gear has been reached.

1

Downshifting in Manual Mode The transmission can be downshifted in the manual mode without reducing engine speed or machine speed. If 1st gear is selected from 3rd or 4th gear, the transmission will downshift into 2nd gear for 1.2 seconds 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 minus 10° C (14° F), the Transmission ECM will keep the transmission in neutral. When the transmission sump temperature warms up to minus 10° C (14°F) (within approximately one minute), the machine will operate in all gears.

Downshift Button The downshift button is located on top of the joystick control l ever in machines with a single lever configuration, and on top of the loader control lever in machines with a two lever configuration.

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RD98K273

1. DOWNSHIFT BUTTON/TWO LEVER CONFIGURATION FIGURE 8

Automatic Mode In the Automatic Mode, the downshift button only shifts down. The downshift button allows the operator to downshift through the entire range of gears. This is useful in long haul applications or roading. Each time the button is pushed the transmission will instantly downshift one gear from 4th to 3rd, then from 3rd to 2nd, and then from 2nd to 1st. The transmission will automatically downshift and then upshift, as needed, to the last gear that was selected with the downshift button. EXAMPLE: If the downshift button was used to shift from 4th to 3rd gear, the transmission will automatically shift from 3rd down and the back up to 3rd again. It will not shift into 4th until the transmission has been returned to the full range automatic mode.

Issued 4-00

Printed in U.S.A.

Copyright © 6002-12 The transmission will retur n to the full range automatic mode when: A. Another gear is selected B. The shifter is moved into neutral and then into forward or reverse C. The autoshift switch is recycled.

Manual Mode In the manual mode, the downshift button toggles between 1st and 2nd gear. The manual mode is useful in short haul operations. In this mode, the downshift button function in two ways in 1st and 2nd gear.

When the brake pedal is released, the Transmission ECM gradually increases the forward or reverse clutch back up to system clutch pressure. If the direction is changed while the transmission is declutched, the selected forward or revers clutch will be filled and maintain a low pressure until the brake pedal is released. Then the selected forward or reverse clutch pressure will gradually increase up to system clutch pressure.

When the operator is in 2nd gear and pushes the downshift button, the transmission instantly shifts into 1st gear. When the operator pushes the downshift button again, the transmission upshifts into 2nd gear. If the machine is in 2nd gear and the downshift button is pushed, the transmission instantly shifts into 1st gear. When the operator shuttles the shifter, the transmission upshifts back into 2nd gear.

Brake Pedal Transmission Declutch A transmission declutch feature concentrates more engine power on the loader when digging in heavy or tough conditions, providing smother stops and starts. Total disconnection of the transmission from the engine is prevented. This feature will function in 1st, 2nd, or 3rd gear only. It will not function in 4th gear.

RD98K308

FIGURE 9. TRANSMISSION DECLUTCH SWITCH

When the transmission declutch switch is in the on position and either brake pedal is pushed, the Transmission ECM reduces the pressure to the transmission forward or reverse clutch. T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y disconnect the clutch from the engine, but gradually reduces the forward or reverse clutch pressure down to a lower level. Bur 7-12391

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NOTES

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TRANSMISSION PRESSURE TEST POINTS DIAGRAM No.

IDENTIFICATION/LOCATION

CONNECTION

DESIGNATION ON VALVE BLOCK

M10x1

H

Measuring Points for Pressure Oil and Temperature 51

Before the Converter - Opening Pressure 9 bar

52

Behind the Converter - Opening Pressure 3.5 bar

53

M14x1.5

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 Rates 15

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 Sensor 21

Inductive Transmitter n Turbine

34

M18x1.5

Speed Sensor n Output and Speedometer

47

Inductive Transmitter n Central Gear Train

M18x1.5

48

Inductive Transmitter n Engine

M18x1.5

Connections 49

Plug Connection on the Hydraulic Control Unit

68

System Pressure

M16x1.5

G

69

Pilot Pressure

M16x1.5

J

NOTE: See Figure 10 for Measuring Point, Transmitter, Sensor and Connection locations.

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BC00E065

FIGURE 10. MEASURING POINTS AND CONNECTIONS

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CHART FOR RECORDING PRESSURE READINGS Use this chart to record the pressure readings. P.I.N. Number:

Date: TEST POINTS

Shift Speed

P 65

V 53

R 55

1 56

2 57

3 58

4 60

5 51

6 52

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

V= FORWARD CLUTCH

2= SECOND GEAR CLUTCH

5= CONVERTER IN

R= REVERSE CLUTCH

3= THIRD GEAR CLUTCH

6= CONVERTER OUT

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LP= LUBE PRESSURE

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PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low Possible causes include:

Not Enough Power Possible causes include:

1. Oil level not correct.

1. Check Electrical Troubleshooting in this Section to actual gear selected.

2. Oil type and grade not correct.

2. Engine RPM below Stall Test specified RPM.

3. Oil operating temperature high.

A. Check engine and fuel system for problem.

4. Screen for suction tube plugged.

B. Check that torque converter installation is correct.

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.

3. Engine RPM above Stall Test specified RPM. A. Check converter pressures and flow. B. Check that torque converter installation is correct.

10. Oil supply flange not sealing correctly.

Machine Stops or Hesitates While Shifting - Intermittent

Some Pressures Low

Possible causes include:

Possible 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.

1. Check orifice and O-ring. (See Section 6007 for replacing.) 2. Check for foreign material plugging orifices or sticking valves. 3. Check for reduced pressure at test pressure points. 4. See Electrical Troubleshooting this section for electrical system problem.

B. Clutch drum or piston.

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CONVERTER OUT PRESSURE CHECK Test Equipment Required

2. Apply the parking brakes.

0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and CAS-2324 Special Adapter.

3. Install the pressure gauge.

Test Procedure

5. While in the cab, put the transmission in NEUTRAL. Run the engine at full throttle. Record the reading in the char t on page 6002.16. Pressure must be 3.5 to 6.5 bar (51 to 96 psi).

1. Block the machine tires.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F).

LUBRICATION PRESSURE CHECK Test Equipment Required

3. Install the pressure gauge in the cooler return line at the transmission.

0 to 7 bar (100 psi) gauge.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F).

Test Procedure

5. While in the cab, run the engine at full throttle. Put the transmission in each gear and record the reading in the chart on page 6002.16. Pressure must be 0.2 to 1.2 bar (3 to 18 psi).

1. Block the machine tires. 2. Apply the parking brakes.

FLOWMETER TEST Test Equipment Required CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter Adapter.

Flowmeter Test Procedure 1. Block the machine tires. 2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F).

4. Remove the filter and install the CAS-2702 adapter. 5. Install the flowmeter between the adapter and the filter. 6. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The correct flow for 621C machines is 52 L/min (14 U.S. gpm) at 2000 rpm. The correct flow for 721C and 821C machines is 80 L/min (21 U.S. gpm) at 2000 rpm.

CONSUMPTION TEST PROCEEDURE 1. Block the machine tires. 2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F). 4. Install the flowmeter to converter outlet line (line to cooler) in series.

6. Repeat the procedure with the transmission in FORWARD in third gear. The flow must be 9.1 L/min (2 U.S. gpm). 7. Repeat the procedure with the transmission in REVERSE in third gear. The flow must be 9.1 L/min (2 U.S. gpm).

5. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The flow must be 9.1 L/min (2 U.S. gpm).

Bur 7-12391

Issued 4-00

Printed in U.S.A.


TRANSMISSION OVERHEATING 1. Operate machine in normal operating conditions and observe: A. actual oil temperature at test point. Normal operating temperature can be 56 degrees C (100 degrees F) 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 are not within specifications. 5. Refer to Understanding Results to determine possible cause of any test results not within specifications.

Bur 7-12391

Issued 4-00

Printed in U.S.A.


ERROR CODES In case of possible errors in the system, a wrench appears on the display, combined with indication of the error number. See section 4005 for error code retrieval procedures and definitions. A transmission electrical schematic has been supplied in this section to assist in fault isolation, see figure 11.

TRANSMISSION SHIFTER LOGIC INFORMATION Function

Shifter

Shifter Wire Color

Shifter Tower Connector

Shifter Shroud Connector

Harness Wire #

Harness ped/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

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral 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 low and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is engaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES Transmission ECM Function

Transmission ECM Pin #

Transmission Valve

Clutch #

Transmission Valve Pin #

Wire #

Cab/eng Pin #

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

Bur 7-12391

Issued 4-00

Printed in U.S.A.


TRANSMISSION ELECTRICAL SCHEMATIC FIGURE 11

1 TO FUSE A ON SHEET 8

CAB SWITCHED POWER

3

Y (32F) 0.8

17

66

29

O (19A) 0.8

15

28

B (0) 0.8

A

B (0) 1.0 LBe (25D) 1.0

45 4

10

LBe (25A) 1.0

7

LBe (25D) 0.8 LBe (25A) 0.8

62

B

B (0) 1.0

11

B (0) 0.8

3

TO PARKING BRAKE SWITCH ON SHEET 15

TO PARKING BRAKE SWITCH ON SHEET 15

1

19

LBe (25C) 1.0

9

LBe (25C) 0.8

42

LBe (25B) 1.0

8

LBe (25B) 0.8

41

13

V (36G) 1.0

49

A

2

18

6

O (19A) 0.8

13

TRANSMISSION SHIFTER

70

B

9

CAB|PED

B(0) 1.0

B

LBe (25W) 0.8

B

65

LBe (25W) 0.8

48

LBe (25Z) 0.8

C

7

63

LBe (25Z) 0.8

49

LBe (25Y) 0.8

D

10

22

LBe (25Y) 0.8

43

O (19A) 0.8

A

2

43

LBe (25F) 0.8

44

LBe (25F) 0.8

B

4

64 67

LBe (25R) 0.8

45

LBe (25R) 0.8

C

6

46

LBe (25T) 0.8

D

5

LBe (25Y) 0.8

B(0) 1.0

LBe (25T) 0.8

LBe (25T) 0.8

B LBe (25T) 0.8

A B (0) 1.0 B (0) 1.0

24

SPARE

25

SPARE

LBe (25K) 1.0

16

56

2

LBe (25L) 1.0

17

LBe (25K) 0.8 LBe (25L) 0.8

3

LBe (25M) 1.0 LBe (25N) 1.0

18

LBe (25M) 0.8

32

19

LBe (25N) 0.8

55

5 6

LBe (25P) 1.0

20

LBe (25P) 0.8

9

LBe (25J) 1.0

21

LBe (25J) 0.8

51

7

LBe (25S) 1.0

22

LBe (25S) 0.8

12

8 9

V (36T) 1.0

5

1

4

V (36R) 1.0

TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS

V (36R) 1.0

12

ENG|CAB

TO ETHER SWITCH ON SHEET 7

TO ETHER SWITCH ON SHEET 7

10

LBe (25Y)

0.8 1

LBe (25T)

TO NEUTRAL START RELAY #8 ON SHEET 7

0.8

LBe (25K) 1.0

2 3 4

LBe (25L) 1.0 LBe (25M) 1.0

2

LOCATED IN HYD. CONTROLLER

LBe (25G) 0.8

13 Y (36T) 0.8 Y (36R) 0.8

39 46

29 87

TO FUSE T ON SHEET 10

O (19T) 0.8

23 TO FUSE T ON SHEET 10

O (19T) 0.8

O (19H) 1.0

TO FUSE H ON SHEET 8

O (19A) 0.8

TO FUSE A ON SHEET 8

87a

68

Y (35C) 0.8

85

86

2 1 6 5

LBe (25S) 1.0

8 9

V (36R) 1.0

7

LBe (25J) 1.0 V (36T) 1.0

1 TO PARKING BRAKE RELAY #9 ON SHEET 17

W (52P) 0.8

21

2

BACKUP ALARM RELAY #7

118

26

Y (50H) 0.5

25

TO RR WIPER SWITCH ON SHEET 25

1

TO MAIN CAB HARNESS ON SHEET 17

C

NC

4 1

Y (35R) 0.8

4

BACK-UP ALARM DISABLE

6

Y (35R) 1.0

CAB |REAR B (0) 1.0


94

5

Y (35R) 0.8

TRANSMISSION ELECTRONIC 19 CONTROL MODULE

Y (35A) 0.8


B (0) 0.8

B/R (50G) 0.5

B (0) 0.8

6

21 94 NAO-JUMPER CONNECTED EURO-JUMPER OPEN

NO

4

REAR|REAR LIGHT

DECLUTCH SWITCH

+ -

2 B (0) 1.0

38

BACK-UP ALARM

TO RR WIPER SWITCH ON SHEET 25

Gy (49) 1.0

27 G (50L) 0.5

4

53

B (0) 1.0

7

Y (35R) 1.0

LBe (25P) 1.0

REAR 15 LIGHT REAR

1 LBe (25G) 1.0

3

B

O (19A) 1.0

D

FRONT|CAB

DECLUTCH BRAKE SWITCH

B (0) 1.0

5 6

Gy (49) 1.0

LBe (25N) 1.0 Y (35A) 0.8

102A

1

TRANSMISSION KICK-DOWN SWITCH 20

70

30

6/7/821C

41

50

A

96

8

4

O (19A) 0.8

INTERMEDIATE SPEED 95 SENSOR

102

5

LBe (25H) 0.8

101

TRANSMISSION AUTO SWITCH

Gy (49) 1.0

C

921C

108

4

O (19A) 0.8

31 O (19A) 1.0

142

TURBINE SPEED SENSOR

3

V (36R) 1.0

B

ENGINE SPEED SENSOR

2

B (0) 0.8 V (37E) 0.8

VIA DETENT SWITCH ON SHEET 19

CAB NEGATIVE STUD

4

SHEET 11

VIA BEACON SWITCH ON SHEET 1

SHEET 12

B (0) 1.0

A

OUTPUT SPEED 100 SENSOR

22

1

V (37D) 0.8

B (0) 1.0

V (36G) 1.0

O (19A) 0.8

LBe (25G) 0.8

TORQUE CONVERTER OUTPUT TEMP SENDER

DIAGNOSTIC CONNECTOR Gy (49) 1.0

V (36R) 1.0

O (19A) 0.8

B

VIA BEACON SWITCH ON SHEET 1

0.8

Y (32F) 1.0

VIA RIDE CONTROL SWITCH ON SHEET 22

O(19A)

A

3


O (19A) 0.8

31

2

DETENT SWITCH ON SHEET 5

O (19A) 0.8

2

1

CAB POSITIVE STUD

FILTER MAINTENANCE SWITCH

4

SHEET 13

VIA RIDE CONTROL SWITCH ON SHEET 19

GM99C600

Bur 7-12391

Issued 4-00

Printed in U.S.A.

Copyright ©

Copyright ©

6003

Section 6003 TRANSMISSION


Bur 7-13271


Copyright © 6003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-13271

Issued 4-00

3 3 4 5 16

Printed in U.S.A.

Copyright © 6003-3

SPECIAL TOOLS Assembly car . . . . . . . . . . . . . . . . . . . . Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting screws M6 . . . . . . . . . . . . . . Adjusting screws, universal . . . . . . . . . Lifting device . . . . . . . . . . . . . . . . . . . . Internal pliers . . . . . . . . . . . . . . . . . . . . Separating device size 2 . . . . . . . . . . . Two-leg puller . . . . . . . . . . . . . . . . . . . Handles . . . . . . . . . . . . . . . . . . . . . . . . Grab sleeve . . . . . . . . . . . . . . . . . . . . . Grab sleeve . . . . . . . . . . . . . . . . . . . . . Grab sleeve . . . . . . . . . . . . . . . . . . . . .

5870 350 000 5870 350 063 5870 350 090 5870 204 031 5870 204 011 5870 204 002 5870 900 013 5870 300 024 5870 970 004 5870 260 010 5873 001 057 5873 001 045 5873 001 059

Grab sleeve . . . . . . . . . . . . . . . . . . . . .5873 002 038 Grab sleeve, K3 . . . . . . . . . . . . . . . . . 5873 001 058 Basic set tool . . . . . . . . . . . . . . . . . . . 5873 001 000 Rolling tool . . . . . . . . . . . . . . . . . . . . . .5870 600 007 Rolling tool (suction tube). . . . . . . . . . 5870 600 003 Rolling tool (pressure oil pipes) . . . . . 5870 600 004 Rolling tool (Oil Pipes) . . . . . . . . . . . . 5870 600 005 Assembly aid (K1, KV, KR) . . . . . . . . . 5870 345 086 Assembly aid (K2, K3, K4) . . . . . . . . . 5870 345 085 Dial indicator. . . . . . . . . . . . . . . . . . . . .5870 600 007 Driver . . . . . . . . . . . . . . . . . . . . . . . . . 5870 057 011 Handle, Driver. . . . . . . . . . . . . . . . . . . 5870 260 002

SPECIAL TORQUES Oil 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 shaft Output 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 pump Transmission pump screws ......................................................................................... 46 Nm (407 pound-inches) Oil feed housing screws .............................................................................................. 23 Nm (194 pound-inches) Engine connection and converter Input 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 tube Tube............................................................................................................................. 34 Nm (301 pound-inches) Cover housing screws ................................................................................................. 23 Nm (194 pound-inches) Speed sensor and inductive transmitter Speed 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)

Bur 7-13271

Issued 4-00

Printed in U.S.A.

Copyright © 6003-4

SPECIFICATIONS Clutch 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 at any time without incurring any obligation to install them on units previously sold.

Bur 7-13271

Issued 4-00

Printed in U.S.A.

Copyright © 6003-5

DISASSEMBLY STEP 1

STEP 4

BK00D037

Fasten the transmission on an assembly stand.

STEP 2

GD98M839

Remove the socket head screws, hex nuts, and remove the duct plate from transmission housing. Remove flat gasket.

STEP 5

GD98M837

Rem ove the s ocke t h ea d sc r ews, i ns tal l two alignment screws, and remove the control unit from duct plate.

Remove the inductive transmitter.

STEP 3

STEP 6

GD98M851

GD98M838

Remove both gaskets and the intermediate plate.

Bur 7-13271

GD98M852

Remove the hex head screws and remove the converter housing.

Issued 4-00

Printed in U.S.A.

Copyright © 6003-6

STEP 7

STEP 10

GD98M853

GD98M856

Remove the socket head screws for removal of the transmission pump.

Remove the hex head screws and remove the oil feed housing. Remove the flat gasket.

STEP 8

STEP 11

GD98M854

GD98M860

Apply a bearing separator on the splines shoulder of the stator shaft and pull the pump out of the housing bores, using two-leg puller.

Remove the hex head screws, cover, and flat gasket.

STEP 12

NOTE: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced.

STEP 9

GD98M861

Remove the lock plate, hex head screws, and pry the converter side output flange from the shaft.

STEP 13 GD98M855

Pry the shaft seal out of the housing bore.

Separate the transmission pump from stator. Separate the cam plate from pump. Bur 7-13271

Issued 4-00

Printed in U.S.A.

Copyright © 6003-7

STEP 14

STEP 18

Turn the transmission 180 degrees and remove the rear output flange.

STEP 15

BK00D029

GD98M862

Remove the speed sensor and both inductive transmitters.

Install clutch shaft retainer nuts. With clutch shaft retainer nuts attached to all clutches in the housing c o ve r, i n s t a l l ey e b o l t s a n d l i f t i n g d ev i c e t o transmission cover.

STEP 19

STEP 16

BK00D028

GD98M863

Remove the hex nuts and the two covers..

Separate the cover along with clutches from the transmission housing, using lifting device.

STEP 20

STEP 17

BK00D026 GD98M864

Place clutch disc carriers onto nesting table.

Install guide rods. NOTE: The following steps describe the common removal of all clutches. Bur 7-13271

Issued 4-00

Printed in U.S.A.

Copyright © 6003-8

STEP 21

STEP 25

Remove clutch shaft retainer nuts and lift cover free.

STEP 22

GD98M878

Squeeze the rectangular ring out and separate ball bearing from the shaft. GD98M867

Remove the socket head screws and remove the output shaft and both oil baffle plates.

NOTE: The following steps are for the disassembly of the clutch KV. The disassembly of the clutch KR is similar.

STEP 26

STEP 23

GD98M979 GD98M880

Pull tapered roller bearing from the shaft. Remove the opposite tapered roller bearing.

Squeeze the sealing ring out.

STEP 27

STEP 24

GD98M881

GD98M877

Remove the bearing outer race and pull output shaft out of the housing bore. Bur 7-13271

Separate the clutch disc carrier from the shaft.

Issued 4-00

Printed in U.S.A.

Copyright © 6003-9

STEP 28

STEP 31

GD98M882

Squeeze the snap ring out and remove the clutch disc pack.

BK00D019

Remove the compression spring.

STEP 32

STEP 29

GD98M885

Remove the O-rings. BK00D018

Preload compression spring using tool. (Tool in place.)

STEP 33

STEP 30

GD98M886

Squeeze the snap ring out. BK00D020

Remove snap ring.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 34

STEP 36

GD98M887

GD98M890

Squeeze the rectangular ring out. Pull the tapered roller bearing from the shaft. Remove the opposite tapered roller bearing.

STEP 37

GD98M888

Press the idler gear from the shaft using a bearing separator. Remove released needle bearing.

STEP 35 GD98M892

Remove the running disk, axial needle cage, and axial washer.

STEP 38

GD98M889

Squeeze the snap ring out and remove the ball bearing. NOTE: The following steps are for the disassembly of the clutch K3. The disassembly of the clutches K1 and K2 are similar

Bur 7-13271

GD98M893

Remove the idler gear.

Issued 4-00

Printed in U.S.A.


STEP 39

STEP 42

GD98M894

BKOOD020

Remove the needle bearings and axial bearing.

Remove the snap ring.

STEP 40

STEP 43

GD98M895


BK00D019

Remove the compression spring.

STEP 44

STEP 41

BS00G001 BK00D018

Preload compression spring using tool. (Tool in place.)

Bur 7-13271

Squeeze the sealing ring out. Remove bearing using bearing puller. Tap assembly until piston drops out of the plate carrier.

Issued 4-00

Printed in U.S.A.


STEP 45

STEP 48

BK00D022

Remove the clutch disc carrier from the shaft. NOTE: The following steps are for the disassembly of the clutch K4.

BK00D018

Preload compression spring using tool. (Tool in place.

STEP 49

STEP 46

BK00D020 GD98M800

Squeeze the snap ring out and separate the clutch disc carrier from the shaft.

Remove the snap ring.

STEP 50

STEP 47

BK00D019

Remove the compression spring. GD98M801


Bur 7-13271

Issued 4-00

Printed in U.S.A.


ASSEMBLY NOTE: The following steps are for the reassembly of the oil pipes..

STEP 4

STEP 1

2 GD98M607

3

Install the screw plug with a new O-ring. Tighten the screw plug to a torque of 140 Nm (103 lb-ft).

1

STEP 5

GD98M603

Inser t suction tube (1), pressure pipes (2), and pressure pipe lubrication (3) into the housing.

STEP 2 Fasten suction tube (1) and pressure pipes (2) with socket head screw and hex nuts. Tighten to a torque of 23 Nm (17 lb-ft)

STEP 3 GD98M608

Insert all bearing outer races into the housing bore.

STEP 6

GD98M605

Tilt the cover 180 degrees. Install the suction tubes and pressure pipes into the housing bores using a rolling tool. NOTE: Pipe end of the pressure pipes must be slightly below the housing plane face.

GD98M609

Install both oil pipes into the housing cover. Tilt the cover 180 degrees and install pipes into the housing bores using a rolling tool. NOTE: The pipe end must be slightly below the housing plane face.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 7

STEP 10

GD98M610

Install the studs. Tighten the studs to a torque of 9 Nm (6.6 lb-ft). NOTE: The following steps are for the assembly of clutches KV and KR, starting with the pre-assembly of the clutch disc carrier.

BK00D019

Preload the compression spring using tool.

STEP 11

STEP 8

BK00D018

Tool in place.

STEP 12 GD98M612

Insert both O-rings into the recesses of the piston and apply oil. Check the function of the drain valve, clean as required.

STEP 9

BK00D020

Install the snap ring. NOTE: The following steps are for the KV and KR clutch disc packs. The disc stacking of clutches KV and KR is identical. GD98M613

Install the piston into the clutch disc carrier. Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 13

STEP 15

GD98M617 225A

1. 2. 3. 4. 5. 6. 7. 8.

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM 2.5 mm +0.2 mm

Install the end shim and squeeze snap ring in.

STEP 16

The above shows the installation position of the KV/KR components. NOTE: Install the outer plate (3) with the steel faced side facing the piston. NOTE: For the adjustment of the running clearance there are snap rings of different thickness available. To ensure a proper measuring result, install clutch discs without oil.

STEP 14

GD98M618

Adjust the running clearance to 2.7 mm. Press the end shim on with approximately 10 kg (20 lb) and measure the dimension from the carrier face to the end shim, using depth gauge as shown. Example dimension measurement, 7.25 mm (0.29 in).

GD98M616

Install the clutch disc pack.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 17

STEP 20

GD98M619

GD98M621

Use tools to lift the end shim against snap ring (upward) until is obtained and measure the dimension from the carrier face to the end shim, using depth gauge as shown. Example dimension measurement, 4.55 mm (0.18 in). The difference between the dimension in the previous step and this step is the running clearance.

Apply Loctite 243 to the stud. Tighten the stud to a torque of 17 Nm (12.5 lb-ft).

STEP 21

NOTE: In case of deviations from the required end shim clearance, use snap ring(s) of different thickness for correct measurement.

STEP 18 Remove the clutch disc pack, oil and reinstall the clutch disc pack.

STEP 19 GD98M622

Insert ball bearing until is obtained and attach with a snap ring.

STEP 22

GD98M620

Install the idler gear until all inner discs are engaged, then remove the idler gear.

GD98M623

Install the needle bearing.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 23

STEP 26

GD98M624

the idler gear on the bearing inner race. Press the idler gear against the shoulder.

BP00G020

Install gear and shaft into heated bore.

STEP 27

STEP 24

BK00D024 GD98M625

Attach the idler gear axially with a snap ring.

Heat bearing.

STEP 28

STEP 25

GD98M625 BK00D023

Use heat gun to heat clutch disc carrier.

Place heated bearing on the shaft.

STEP 29 Check the function of the clutch, using compressed air. NOTE: The following steps are for the reassembly of clutch K1, K2, and K3.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 30

STEP 33

GD98M630

Apply Loctite 243 to the stud and install the stud. Tighten the stud to a torque of 17 Nm (12.5 lb-ft).

GD98M633

Install the piston into the clutch disc carrier.

STEP 34

STEP 31

GD98M634 GD98M631

Install the compression spring and spring cup.

Insert the clutch disc carrier until is obtained.

BK00D023

STEP 35

STEP 32

BK00D019

GD98M632

Check the function of the piston drain valve and clean as required. Inser t both O-rings into the recesses of the piston and apply oil.

Bur 7-13271


Issued 4-00

Printed in U.S.A.


STEP 36

STEP 38

232A

BK00D018

1. 2. 3. 4. 5. 6. 7. 8.

Tool in place.

STEP 37


The above shows the installation position of the K1 components. NOTE: Install the outer plate (3) with the steel faced side facing the piston.

STEP 39

BK00D020

Install the snap ring. NOTE: The following steps are for K1, K2 and K3 clutches. The assembly of clutches K1, K2, and K3 is identical.

232A

1. 2. 3. 4. 5. 6. 7. 8.


The above shows the installation position of the K2 and K3 components. NOTE: Install the outer plate (3) with the steel faced side facing the piston.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 40

STEP 42

GD98M636


GD98M638

Adjust the running clearance for K1 to 2.4 mm (0.09 in). Adjust the running clearance for K2 and K3 to 1.8 mm (0.07 in). Press the end shim on with approximately 10 kg (20 lb) and measure the dimension from the carrier face to the end shim, using depth gauge as shown. Example dimension measurement, 8.20 mm (0.32 in).

STEP 41

NOTE: For the adjustment of the end shim clearance there are snap rings of different thickness available. To ensure a proper measuring result, install plates without oil.

STEP 43

GD98M637

Install the end shim and squeeze the snap ring in.

GD98M639

Use tools to lift the end shim against snap ring (upward) until is obtained and measure the dimension from the carrier face to the end shim, using depth gauge as shown. Example dimension measurement, 5.80 mm (0.23 in). The difference between the dimension in the previous step and this step is the running clearance. NOTE: In case of deviations from the required end shim clearance, use snap ring(s) of different thickness for correct measurement.

STEP 44 Remove the clutch disc pack, oil and reinstall the clutch disc pack. Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 45

STEP 48 3

1

2

2

1

3

GD98M640

GD98M643

Install the running disc (1), axial needle cage (2), and axial washer (3).

Install the axial washer (3), axial needle cage (2), and running disc (1). Install the running disc (1) with the chamfer facing the axial needle cage.

NOTE: Install the running disc (1) with the chamfer facing the axial needle cage.

STEP 46

NOTE: Ensure the running disc is overlapping with the chaff collar to accommodate all the inner discs.

STEP 49

GD98M641

Install both the needle bearings.

BK00D024

Heat bearing.

STEP 47

STEP 50

GD98M642

Install the idler gear until all inner discs are engaged.

GD98M625


Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 51

STEP 54

Check the function of the clutch, using compressed air. NOTE: The following steps are for the reassemble of clutch K4.

STEP 52

GD98M649

Install the stud. Tighten the stud to a torque of 17 Nm (12.5 lb-ft).

STEP 55 GD98M647

Heat the gear to about 120° C (248° F) and assemble until seated in position.

STEP 53

GD98M650

Check the function of the piston drain valve and clean as required. Insert both O-rings into the piston recesses and oil the O-rings.

STEP 56 GD98M648

Install the gear shaft with the snap ring.

GD98M651

Install the piston into the clutch disc carrier. Be sure the piston bottoms out.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 57

STEP 60

BK00D019

232A

1. 2. 3. 4. 5. 6. 7. 8.


STEP 58


The above shows the installation position of the K4 components.. NOTE: Install the outer plate (3) with the steel faced side facing the piston.

STEP 61

BK00D018

Tool in place.

STEP 59

GD98M653


BK00D020

Install the snap ring.

NOTE: The following steps are for installing the clutch disc pack in clutch K4.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 62

STEP 64

GD98M654

Install the end shim and squeeze the snap ring in.

STEP 63

GD98M656

Use tools to lift the end shim against snap ring (upward) until is obtained and measure the dimension from the carrier face to the end shim, using depth gauge as shown. Example dimension measurement, 6.05 mm (0.24 in). The difference between the dimension in the previous step and this step is the running clearance. NOTE: In case of deviations from the required plate clearance, use snap ring(s) of different thickness for correct measurement.

STEP 65 After the adjustment of the running clearance has been done, remove the clutch disc pack, oil the clutch discs and reinstall. GD98M655

Press the end shim on with approximately 10 kg (20 lb). Adjust the running clearance to 1.2 mm (0.05 in). Measure the dimension from the carrier face to the end shim, using depth gauge as shown. Example dimension measurement, 7.25 mm (0.29 in).

STEP 66

NOTE: For the adjustment of the running clearance there are snap rings of different thickness available. To ensure a proper measuring result, install plates without oil.

GD98M657

Install the idler gear until all inner discs are engaged, then remove idler gear.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 67

STEP 70 1 2 3

GD98M658

Assemble both axial washers and the needle cage. NOTE: Upper and lower axial washers have the same thickness.

GD98M661

Assemble axial washer (3), needle cage (2), and running disc (1). Install the running disc (1) with the chamfer facing the needle cage.

STEP 71

STEP 68

GD98M662 GD98M659

Assemble the pre-assembled clutch disc carrier until all the inner discs are engaged.

Install both needle bearings.

STEP 69

STEP 72

GD98M660 GD98M663

Install the idler gear.

Bur 7-13271

Attach the clutch disc carrier with a snap ring.

Issued 4-00

Printed in U.S.A.


STEP 73

STEP 77

BK00D024

GD98M667

Heat bearing.

Install the gear with the snap ring.

STEP 74

STEP 78

GD98M625


GD98M668

Install the snap ring into the recess of the turbine shaft.

STEP 75 Check the function of the clutch with compressed air.

STEP 79

NOTE: The following steps are for the reassembly of the input shaft.

STEP 76

GD98M669

Install the turbine shaft until the snap ring snaps into the recess of the input shaft. GD98M666

Heat the gear to about 120° C (248° F) and assemble until is obtained. Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 80

STEP 83 K1 AB

K3

K4

KR

AN

K2 KV

BK00D024

GD98M673

Install bearings so inner races are against shoulder. Alternate method is to heat bearing and install on turbine shaft.

Insert all the bearing outer races into the housing cover until is obtained.

STEP 84

STEP 81

BK00F003 GD98M671

Squeeze the rectangular ring and hook the ring on the output shaft.

Install the clutches onto the nesting table.

STEP 85

STEP 82

BK00D029

GD98M672

Insert the output shaft into the housing bore until is obtained.

Use acceptable lifting equipment and install the housing cover onto the clutches. Install clutch shaft retainer nuts.

NOTE: The following steps are for the reassembly of the output shaft and clutches. All clutches have a common installation. Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 86

STEP 89

KR KV K4

K2

K3

K1

GD98M679

GD98M692

The above shows the position of the single clutches in the housing cover.

Insert both the O-rings into the annular groove of the oil pipes and apply grease.

STEP 87

STEP 90 AN

KV K2

KR K4

Tilt the housing cover 180 degrees. Install the eye bolts for lifting.

STEP 91

K1

K3

AB

GD98M866

The above shows the position of the single clutches and the input and output clutches.

STEP 88 GD98M683

Install output gear and shaft in transmission housing. Install alignment screws. Apply Loctite 574 to the mounting face. Carefully lower the cover and clutches into the gear box housing.

STEP 92 Remove the clutch retaining nuts.

GD98M681

Squeeze the sealing rings and insert rings in their respective grooves. Apply grease to the sealing rings and align the rings centrally.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 93

STEP 96

GD98M685

GD98M690

Separate the housing cover from the gearbox, using a lifting device. Install output gear and output gear cover.

Apply Loctite 243 to the socket head screws and install the screws. Tighten the screws to a torque of 23 Nm (17 lb-ft).

NOTE: The following steps are for the reassembly of the output shaft.

STEP 97

STEP 94

GD98M695

GD98M688

Position the screening plate.

Install the housing cover with the hex head screws. Tighten the screws to a torque of 46 Nm (34 lb-ft).

STEP 98

STEP 95

GD98M696 GD98M689

Insert the output shaft. If bearing was removed, heat bearing bore and install.

Bur 7-13271

Install the shaft seal with the sealing lip facing the oil chamber. Apply grease to the sealing lip.

Issued 4-00

Printed in U.S.A.


STEP 99

STEP 101

GD98M697

GD98M702

Heat the output flange to about 90° C (194° F). Apply Loctite 574 to the area and assemble the flange 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.

Install two alignment screws and mount the flat gasket.

STEP 102

STEP 100

GD98M703

BK00D034

Install the output flange on the converter side using a driver tool.

Install the oil feed housing with washers and hex head screws. Screw the hex head screws in only until is obtained, do not tighten.

STEP 103

NOTE: The following steps are for the assembly of the oil feed housing and transmission pump.

GD98M704

Install the two alignment screws and insert the stator shaft.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 104

STEP 107

GD98M705

Apply oil and install the O-ring.

GD98M708

Install the transmission pump with the socket head screws. Tighten the screws to a torque of 46 Nm (34 lb-ft).

STEP 105

STEP 108

GD98M706

Insert the transmission pump. GD98M709

STEP 106

Install the oil feed housing with the hex head screws and flat washers. Tighten the screws to a torque of 25 Nm (18 lb-ft). NOTE: The following steps are for the assembly of the engine connection and converter.

GD98M707

Apply grease to the new O-rings. Install the O-rings on the socket head screws.

Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 109

STEP 112

GD98M712

258

Fit the flat gasket and install the cover with the hex head screws. Tighten the screws to a torque of 23 Nm (17 lb-ft).

Mount the gasket (1), intermediate plate (2), and gasket (3).

STEP 110

Install the screw plug with new O-ring. Tighten the plug to a torque of 30 Nm (22 lb-ft).

STEP 113

STEP 114

GD98M724

Install new sealing rings and both plugs.

STEP 111

GD98M727

Install the control valve on the duct plate with the socket head screws. Tighten the screws to a torque of 9.5 Nm (7 lb-ft). NOTE: The following steps are for the assembly of the filter.

GD98M725

Install the gasket, place the duct plate against shoulder and install the socket head screws and hex nuts. Tighten the screws to a torque of 25 Nm (18 lb-ft). NOTE: The following steps are for the assembly of the transmission control valve. Bur 7-13271

Issued 4-00

Printed in U.S.A.


STEP 115

STEP 118 Install the breather.

STEP 119

GD98M733

Install the two oil distribution covers on the housing with hex nuts and flat washers. Tighten to a torque of 25 Nm (18 lb-ft).

GD98M737

Install the gasket and the cover plate. Tighten to a torque of 23 Nm (17 lb-ft).

STEP 116

STEP 120 With a new O-ring, install the screw plug. Tighten to a torque of 140 Nm (103 lb-ft).

34

GD98M735

Apply grease to the new O-ring and install the speed sensor with the socket head screw. Tighten the screw to 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). Bur 7-13271

Issued 4-00

Printed in U.S.A.


NOTES

Bur 7-13271

Issued 4-00

Printed in U.S.A.

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Section 6006

6006

WHEELS AND TIRES


Bur 7-13301


Copyright © 6006-2

TABLE OF CONTENTS TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-13301

Issued 4-00

3 3 3 3 3

Printed in U.S.A.

Copyright © 6006-3

TIRE PRESSURE 20.5 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 WARNING: The split rim wheels used on this machine can be dangerous. When inflating a tire on the machine, 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 can come off with enough force to result in death to a person in front of the rim. 48-44

1. Have a qualified tire mechanic service the split rim wheels used on this machine. 2. The correct tire equipment, especially a tire inflation cage, is required. Using the wrong procedure for a split rim wheel can result in death.

IMPORTANT: When installing a Michelin tire, lubricate the tire with a tire mounting lubricant and inflate the tire to 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated on the rim. Then decrease the pressure to the specified pressure.

INSTALLING A WHEEL 1. Make sure the mounting surfaces of the rim and axle flange are clean and free of dirt and grease. 13

2. Install the wheel, hardened washers and wheel nuts.

1

10

6

3. Use a hand wrench (not an impact) to tighten the wh e e l nut s t o p u l l t he w h ee l a g a i ns t t h e planetar y housing. DO NOT use an impact wrench to tighten the wheel nuts.

8

11

15

4

4. Tighten the wheel nuts to 203 Nm (150 pound-feet) in the sequence shown in Figure 1. The n tig ht en th e whe el nuts in th e s am e s e q u e n c e t o 5 1 5 t o 5 7 0 Nm ( 3 8 0 t o 4 2 0 pound-feet).

3

16

12 7

5 9

2

14

BC00F051

FIGURE 1. TORQUE SEQUENCE FOR WHEEL NUTS

WHEEL NUTS The wheel nuts must be tightened after every 20 hours of operation until the wheel nuts stay tight: A. If the machine is new. B. If a wheel has been removed and installed.

Bur 7-13301

Torque Specification Tighten the wheel nuts to 203 Nm (150 pound-feet) in the sequence shown in Figure 1. Then a final torque of 515 to 570 Nm (380 to 420 pound-feet) in the same sequence.

Issued 4-00

Printed in U.S.A.

Copyright © 6006-4

NOTES

Bur 7-13301

Issued 4-00

Printed in U.S.A.

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8002

Copyright ©

Section 8002 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS


Bur 7-13371


Copyright © 8002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems in All Circuits - See the following pages for other circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1 - Primary Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 2 - Secondary Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing and Adjusting the Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing and Adjusting the Combination Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Control Pressure at the Ends of the Spools in the Loader Control Valve . . . . . . . . . . . . . . . . . . . Testing and Adjusting the Circuit Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing and Adjusting the Pressure for the Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821C HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-13371

Issued 4-00

3 4 5 5 5 5 6 6 7 7 8 9 9 9 10 10 10 10 11 12 12 12 13 13 13 14 15

Printed in U.S.A.

Copyright © 8002-3

SPECIFICATIONS Pump 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)

Bur 7-13371

Issued 4-00

Printed in U.S.A.

Copyright © 8002-4

SPECIAL TOOLS

B877168V

633L95

CAS-1808 FLOWMETER FITTING KIT

CAS-1904 PRESSURE FITTING KIT

B877895M

632L95

CAS-10090 HAND PUMP


B877558M

B785789M

CAS-10280 FLOWMETER

Bur 7-13371


Issued 4-00

Printed in U.S.A.

Copyright © 8002-5

TROUBLESHOOTING PROCEDURE Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts. Check the oil level in the hydraulic reservoir. Is the oil level correct?.

No

Fill the hydraulic reservoir with the hydraulic oil 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 (two if equipped with auxiliar y steering) in the hydraulic reservoir. Replace the two return line hydraulic filters. See Section 2002. Do the stall test to see if the engine is good. See Section 8003 and check for contaminated oil. Is the oil contaminated?

No

See Page 7. Do the flowmeter tests of the hydraulic pump.

No

Charge the accumulator.

Yes See Section 8003 and clean or replace the oil.

Problem in All Loader Circuits See Page 9 and check the pressure setting of the main relief valve in the loader control valve. Is the pressure setting correct? Yes See Page 8 and do the Secondar y Pump Output Test.

Problem in the Braking Circuit See Section 7002 and check the braking circuit.

Bur 7-13371

Issued 4-00

Printed in U.S.A.

Copyright © 8002-6

Problem in a Single Loader Circuit Star t and run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

No

See Page 11. Check the pressure at both ends of the spool in the loader control valve. Is the pressure correct at both ends? No

Yes

The remote control valve is damaged. See Section 8010 and repair the remote control valve.

Yes The loader control valve is damaged. See Section 8005 and repair the loader control valve

See Page 10. Check the pressure setting of the combination valve. Is the pressure setting correct?

No

See Page 10 and adjust the combination valve.

No

See Section 8006 and repair the cylinder.

No

See Section 8005. Disassemble the loader c o n t r o l va l ve a n d c h e ck fo r wo r n o r damaged parts.

No

Repair the component as necessary.

Yes Check the cylinder piston packing. Is the packing good? Yes See Page 12. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly? Yes The problem is repaired.

Problem in the Steering Circuit See Section 5002 and check the steering circuit. Is the steering circuit good? Yes See Page 7. Do the Primary Pump Output Test.

Bur 7-13371

Issued 4-00

Printed in U.S.A.

Copyright © 8002-7

Testing the Hydraulic Pump

STEP 4

STEP 1

Slowly close the load valve on the flowmeter and measure the flow at 13 790 kPa, 138 bar (2000 psi). Make sure the engine is running at 2000 r/min with the load applied. Record the flow.

Connect the flowmeter to the primary pressure hose from the hydraulic pump located toward the engine.

STEP 5

Test No. 1 - Primary Pump Output Test

STEP 2 Make sure the load control of the flowmeter is open. Make sure the hydraulic oil is 54 to 66°C (130 to 150°F).

Divide the flow reading at 13 790 kPa, 138 bar (2000 psi) by the reading at 0 kPa, 0 bar (0 psi). The answer multiplied by 100 is the percent efficiency of the primary pump. If the efficiency is less than 75% repair or replace the pump.

STEP 3 Start and run the engine at 2000 r/min. Measure the flow at 0 kPa, 0 bar (0 psi). Record the flow.

3

1

2

4

GS98M898

1. CAS-10280 FLOWMETER 2. HYDRAULIC RESERVOIR

Bur 7-13371

3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL) 4. CONNECT TO PRIMARY PRESSURE PORT HOSE

Issued 4-00

Printed in U.S.A.

Copyright © 8002-8

Test No. 2 - Secondary Pump Output Test STEP 1 Connect the flowmeter to the secondary pressure hose from the hydraulic pump located away from the engine.

STEP 4 Slowly close the load valve on the flowmeter and measure the flow at 13 790 kPa, 138 bar (2000 psi). Make sure the engine is running at 2000 r/min with the load applied. Record the flow.

STEP 5 STEP 2 Make sure the load control of the flowmeter is open. Make sure the hydraulic oil is 54 to 66°C (130 to 150°F).

Divide the flow reading at 13 790 kPa, 138 bar (2000 psi) by the reading at 0 kPa, 0 bar (0 psi). The answer multiplied by 100 is the percent efficiency of the primary pump. If the efficiency is less than 75% repair or replace the pump.

STEP 3 Start and run the engine at 2000 r/min. Measure the flow at 0 kPa, 0 bar (0 psi). Record the flow.

3

2 1

4

GS98M99

1. CAS-10280 FLOWMETER 2. HYDRAULIC RESERVOIR

Bur 7-13371

3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL) 4. CONNECT TO SECONDARY PRESSURE PORT HOSE

Issued 4-00

Printed in U.S.A.

Copyright © 8002-9

Testing and Adjusting the Main Relief Valve

Adjustment STEP 1

Pressure Check STEP 1 Engage the transport/service link.

1

STEP 2 Lower the bucket to the floor. Stop the engine.

STEP 3 Connect a 20 685 kPa, 207 bar (3000 psi) pressure gauge to the quick disconnect fitting at Test Port 1. This Test Port 1 is located on the opposite side of the primary pressure port on the primary pump toward the engine.

STEP 4 Run the engine at full throttle. Heat the hydraulic oil to operating temperature.

2 GS98M896

STEP 5 Hold the bucket control lever in the ROLLBACK position.

STEP 6 Read the pressure gauge. Compare the reading to the specifications on Page 3.

STEP 7 If the pressure is not correct, adjust the main relief valve.

1. LOADER CONTROL VALVE 2. MAIN RELIEF VALVE

Remove the cover at the front of the machine.

STEP 2 Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure.

STEP 3 Check the pressure again. Repeat the adjustment as necessary.

Bur 7-13371

Issued 4-00

Printed in U.S.A.


Testing and Adjusting the Combination Valve Pressure Check

Adjustment

STEP 1

STEP 1

Before starting machine, pump the brakes repeatedly to be sure the brake accumulators have no pressure.

Remove the round plug from the regulator cartridge valve.

STEP 2

STEP 2

Connect a 6 895 kPa, 69 bar (1000 psi) pressure gauge to the quick disconnect fitting at the regulating pressure test port.

Use an Allen wrench to turn the adjusting screw clockwise to increas e the pressure or counterclockwise to decrease the pressure.

STEP 3

1

Check the pressure setting again. Repeat the adjustment as necessary.

Leak Test 2

Test for internal leakage by raising the lift arms to the top and shutting the engine off. Repeatedly put the lift control lever into the “FLOAT” position and back to neutral. The system must allow a minimum of 10 actuations into float and still cause the lift ar ms to come down. If less than 10 full actuations can be made and the checks in step 4 are correct, an internal hydraulic leak exists.

GM98M477

1. REGULATING PRESURE PORT 2. COMBINATION VALVE

STEP 3 Start and run the engine. Regulated pressure should be 3 723 to 4 274 kPa, 37.2 to 42.7 bar (540 to 620 psi).

STEP 4 If the pressures are not correct, they must be adjusted.

Bur 7-13371

Issued 4-00

Printed in U.S.A.


Testing the Control Pressure at the Ends of the Spools in the Loader Control Valve

STEP 7

STEP 1

STEP 8

Heat the hydraulic oil to operating temperature.

The pressure at each end of the spool must be 37 to 43 bar (540 to 620 psi).

STEP 2

Hold the control lever in the other power position. Read the other pressure gauge. Record the pressure reading.

STEP 9

Lower the bucket to the floor. Stop the engine.

If the pressure is not correct at both ends of the spool, check the pressure of the combination valve. If the pressure is correct at one end of the spool but not at the other end, there is a problem in the remote control valve. See Section 8010.

STEP 3 Remove the cover at the front of the machine.

STEP 4 Connect 6 896 kPa, 69 bar (1000 psi) pressure gauges to Test Ports 4 and 5 for the circuit which you are testing.

3

2

1

4

5

6 GS98M897

1. 2. 3. 4. 5. 6.

LOADER CONTROL VALVE TEST PORT 4 (PRESSURE GAUGE) TEST PORT 5 (PRESSURE GAUGE) BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL

STEP 5 Start and run the engine at low idle.

STEP 6 Hold the control lever in a power position for the circuit which you are testing. Read the pressure gauge. Record the pressure reading.

Bur 7-13371

Issued 4-00

Printed in U.S.A.


Testing and Adjusting the Circuit Relief Valves

STEP 3 Connect the hand pump to the disconnected line that goes to the loader control valve.

Pressure Check STEP 4 STEP 1 Circuit relief valves are located as shown below.

3

4

5

1

Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).

STEP 5 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

1

STEP 6 Compare the reading to the specifications on Page 3.

STEP 7 If the pressure is not correct, adjust the circuit relief valve.

Adjustment STEP 1 Loosen the lock nut. Turn the adjustment screw clockwise to increas e the pressure or counterclockwise to decrease the pressure.

2 1

1

STEP 2 GS98M896

1. 2. 3. 4. 5.

CIRCUIT RELIEF VALVE MAIN RELIEF VALVE BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL

Check the pressure again. Repeat the adjustment as necessary.

Remove the cover at the front of the machine.

STEP 2 Lower the bucket to the floor. Stop the engine. Find an easy place to disconnect the line for the circuit to be tested.

Bur 7-13371

Issued 4-00

Printed in U.S.A.


Testing and Adjusting the Pressure for the Unloader Valve

Adjustment

Pressure Check

If the gauge reading did not drop according to the specifications, remove the nut and turn the adjusting screw until the setting is correct

STEP 1 Engage the transport/service link.

STEP 1

.

2 STEP 2 Lower the bucket to the floor. Stop the engine.

1

3

STEP 3 Connect a 20 685 kPa, 207 bar (3000 psi) pressure gauge to the quick disconnect fitting at Test Port 6. This Test Port 6 is located on the face of the hydraulic pump on the secondary pump away from the engine.

STEP 4 Start and run the engine at low idle.

STEP 5 Heat the hydraulic oil to operating temperature.

STEP 6 Put the bucket in the full ROLLBACK position.

STEP 7 Run the engine at full throttle.

STEP 8 Watch the pressure gauge as you slowly move the bucket control lever to the ROLLBACK position. When the gauge reading reaches 145 to 158 bar (2100 to 2300 psi), the gauge reading must drop to 1 034 kPa, 10 bar (150 psi) or less.

Bur 7-13371

GS98M474

1. NUT 2. ADJUSTING SCREW 3. UNLOADING VALVE

STEP 2 Install the nut.

Issued 4-00

Printed in U.S.A.


HYDRAULIC COMPONENT LOCATIONS 5 18 6 9

20 10 7

4 3 24

6

2

25

22

11

1 18 21 8 16

23 14

9

13 15

17

12

19 11 BC00D096

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

Bur 7-13371

AUXILIARY STEERING PUMP PRIMARY/SECONDARY PUMP RESERVOIR HYDRAULIC FILTERS STEERING CONTROL VALVE LIFT CYLINDERS BRAKE VALVE LOADER CONTROL VALVES STEERING CYLINDERS REMOTE CONTROL VALVES REAR BRAKE CYLINDERS BRAKE ACCUMULATORS

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

DUAL PRESSURE ACCUMULATOR CHARGING VALVE BRAKE PUMP PRIORITY VALVE OIL COOLER TRANSMISSION DECLUTCH SWITCH FRONT BRAKE CYLINDERS COMBINATION VALVE BUCKET CYLINDER COUPLER LOCKING VALVE (OPTIONAL) COUPLER LOCKING CYLINDERS (OPTIONAL) RIDE CONTROL (OPTIONAL) OIL COOLER BY VALVE UNLOADING VALVE

Issued 4-00

Printed in U.S.A.


821C HYDRAULIC SCHEMATIC OPTIONAL COUPLER 21 LOCKING VALVE

QUICK DISCONNECT

OPTIONAL COUPLER 22 LOCKING CYLINDERS

PARKING BRAKE

12

BLEED SCREW PB

T

AUX

PP

BRAKE ACCUMULATOR

FRONT BRAKE CYLINDERS

7 BRAKE VALVE

AUXILIARY

LOADER CONTROL VALVES 8

AUXILIARY

18

CIRCUIT RELIEF VALVES

AUXILIARY QUICK DISCONNECT

RB

10

ACR

FB

COMBINATION VALVE

11

ACF

QUICK DISCONNECT

PSIF

AUXILIARY

REMOTE CONTROL VALVES

PSIR

19

OPTIONAL AUXILIARY CYLINDERS

ORIFICE CHECK VALVES

CIRCUIT RELIEF VALVES

6

LOADER LOWER & FLOAT

REAR BRAKE CYLINDERS

LIFT CYLINDERS

LOADER RAISE BUCKET DUMP

17

BUCKET ROLLBACK

TRANS. DECLUTCH SWITCH

BUCKET CYLINDER MAIN RELIEF VALVE

BRAKE PRESSURE SWITCH

20

REGENERATION VALVE

MASTER VALVE

T

UNLOADING VALVE

S

QUICK DISCONNECT

T

25 2 P

PRIMARY PUMP

BRAKE PUMP

P

PRIORITY 15 VALVE P

LS EF CF

DUAL PRESSURE 13 ACCUMULATOR CHARGING VALVE

SLAVE VALVE

14 SECONDARY PUMP M

HYDRAULIC 4 FILTERS

QUICK DISCONNECT

ACCUMULATOR T

PRESSURE SWITCH

OPTIONAL 23 RIDE CONTROL

5

BREATHER

STEERING CONTROL VALVE

AUXILIARY 1 STEERING PUMP

RIGHT L

P

RESERVOIR 3

OIL COOLER BY VALVE 24

OIL COOLER 16

STEERING CYLINDERS

LS

9

R

LEFT 821C HYDRAULIC SCHEMATIC Bur 7-13371

BC00D061

Issued 4-00

Printed in U.S.A.


NOTES

Bur 7-13371

Issued 4-00

Printed in U.S.A.

Copyright ©

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8004

Section 8004 HYDRAULIC PUMP


Bur 7-13381


Copyright © 8004-2

TABLE OF CONTENTS SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 3 4 4 4 6

Printed in U.S.A.

Copyright © 8004-3

SPECIFICATION Manufacturer ................................................................................................................................................. Denison Tandem vane hydraulic pump Denison part number ................................................................................................................................ 014-70281 Case part number ..................................................................................................................................... 226568A1

SPECIAL TORQUES Bolts 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)

Bur 7-13381

Issued 4-00

Printed in U.S.A.

Copyright © 8004-4

HYDRAULIC PUMP Disassembly

17. Loosen and remove the screws (22) from the pump cartridge (3).

NOTE: The hydraulic pump shown in Figure 1 is a general cross section view. Illustration may vary from actual component parts.

18. Remove the plate (23) from the pump cartridge (3).

1. Fasten the hydraulic pump in a vise with soft jaws with the shaft extended downward. Clamp the vise on the shaft end cover (2), not on the housing (8), refer to Figure 1. 2. Loosen and remove the bolts (10) and the port end cover (1). Take note of the pressure ports position to the suction port. 3. Remove and discard the seal (13) from the port end cover (1). 4. Firmly grasp the pump cartridge (3) and, while rotating it, pull outward and remove the pump cartridge (3) from the housing (8). 5. Remove and discard the seals (14 and 15) and backup ring (16) from the pump cartridge (3). 6. Remove the hydraulic pump from the vise to reposition it with the shaft extended upward. Clamp the vise on the housing (8), not the shaft end cover (2). 7. Loosen and remove the bolts (11) from the housing (8) and shaft end cover (2). 8. Slowly remove the shaft end cover (2) upward and away from the housing (8). NOTE: The shaft end cover (2) contains the pump cartridge (4) and shaft (5). 9. Remove and discard the seal (17) from the shaft end cover (2). 10. Remove the housing (8) from the vise.

19. Loosen and remove the screws (12) from the pump cartridge (4). 20. Remove the plate (7) from the pump cartridge (4).

Inspection 1. Clean all parts in cleaning solvent and allow all parts to air dry or use a lint free cloth for drying all parts thoroughly. 2. Inspect the port end cover (1), housing (8), shaft end 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) as required, refer to Figure 1. 3. Inspect the bearing on the shaft (5) for wear and cracks. If the bearing shows signs of wear or is cracked, a new shaft (5) is required. 4. Inspect the plates (7 and 23) for light scoring on the wear surface. Replace the plate (7 or 23) with a new plate (7 or 23) if light scoring is found on the wear surface. 5. Inspect the pump cartridges (3 and 4). The vanes must move freely in the rotor slots and not bind or have excessive play. If the vanes do not move freely in the rotor slots, or if they bind or have excessive play, a new pump cartridge (3 or 4) is required. 6. Make sure all ports in the pump cartridges (3 and 4) are open and clean.

11. Fasten the shaft end cover (2) in the vise with the coupling end of the shaft (5) downward. 12. Firmly grasp the pump cartridge (4) and, while rotating it, pull outward and remove the pump cartridge (4) from the shaft end cover (2). 13. Remove and discard the seals (19 and 20) and backup ring (18) from the pump cartridge (4). 14. Remove the shaft end cover (2) from the vise and remove the retaining ring (9) from the shaft end 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 shaft end cover (2). Bur 7-13381

Issued 4-00

Printed in U.S.A.

Copyright © 8004-5

15

16

18

13

17

9 19

14

1 5

10

20 7

3 23

4

21

21

6

2

11

12

22 8

GS98K862

1. 2. 3. 4. 5. 6.

PORT END COVER SHAFT END COVER PUMP CARTRIDGE PUMP CARTRIDGE SHAFT SEAL

7. 8. 9. 10. 11. 12.

PLATE HOUSING RETAINING RING BOLT BOLT SCREW

13. 14. 15. 16. 17. 18.

SEAL SEAL SEAL BACKUP RING SEAL BACKUP RING

19. 20. 21. 22. 23.

SEAL SEAL GUIDE PIN SCREW PLATE

FIGURE 1. HYDRAULIC PUMP - CROSS SECTION VIEW - REFERENCE ONLY

Bur 7-13381

Issued 4-00

Printed in U.S.A.

Copyright © 8004-6

Assembly 1. Install a new backup ring (18) and new seals (19 and 20) onto the pump cartridge (4), refer to Figure 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 (14 and 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 the shaft end cover (2) with a shaft seal driver. Make cer tain that the open side of the seal (6) is toward the inside of the shaft end cover (2). 6. Lubricate the inside of the seal (6) with clean hydraulic oil and install the shaft (5) into the shaft end 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 soft jaws with the coupling end of the shaft (5) downward. 9. Lubricate the seals (19 and 20) on the pump cartridge (4) with clean hydraulic oil.

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 the guide 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 and place it on a clean surface. 15. Tighten the bolts (11), refer to SPECIAL TORQUES for the correct torque. 16. Fasten the hydraulic pump into the vise with the shaft extended downward. Clamp the vise on the shaft 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 guide pin (21) slips into the housing (8). 18. Lubricate the seals (14 and 15) on the pump cartridge (3) with clean hydraulic oil. 19. Lubricate and install a new seal (13) onto the port end cover (1). 20. Install the port end cover (1) and bolts (10) onto the housing (8). 21. Tighten the bolts (10), refer to SPECIAL TORQUES for the correct torque.

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 the shaft end cover (2).

Bur 7-13381

Issued 4-00

Printed in U.S.A.

Copyright © 8004-7

15

16

18

13

17

9 19

14

1 5

10

20 7

3 23

4

21

21

6

2

11

12

22 8

GS98K862

1. 2. 3. 4. 5. 6.

PORT END COVER SHAFT END COVER PUMP CARTRIDGE PUMP CARTRIDGE SHAFT SEAL

7. 8. 9. 10. 11. 12.

PLATE HOUSING RETAINING RING BOLT BOLT SCREW

13. 14. 15. 16. 17. 18.

SEAL SEAL SEAL BACKUP RING SEAL BACKUP RING

19. 20. 21. 22. 23.

SEAL SEAL GUIDE PIN SCREW PLATE

FIGURE 2. HYDRAULIC PUMP - CROSS SECTION VIEW - REFERENCE ONLY

Bur 7-13381

Issued 4-00

Printed in U.S.A.

Copyright © 8004-8

NOTES

Bur 7-13381

Issued 4-00

Printed in U.S.A.

Copyright ©

Section 8005

8005

LOADER CONTROL VALVE


Bur 7-13391


Copyright © 8005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEPARATING THE VALVE SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET AND AUXILIARY SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REGENERATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT RELIEF AND ANTICAVITATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-13391

Issued 4-00

3 3 4 4 4 6 6 6 8 10 10 10 12 14 14 14 14 16 16 16 18 20 20 20 22 24 24 24 26

Printed in U.S.A.

Copyright © 8005-3

SPECIFICATIONS Manufacturer................................................................................................................................................... Gresen Two Spool Valve Gresen part number ................................................................................................................................ V70-338 Case part number ................................................................................................................................... L126100 Three Spool Valve Gresen part number ................................................................................................................................ V70-339 Case part number ................................................................................................................................... L126101 Four Spool Valve Gresen part number ................................................................................................................................ V70-340 Case part number ................................................................................................................................... L126102

SPECIAL TORQUES Nuts 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)

Bur 7-13391

Issued 4-00

Printed in U.S.A.

Copyright © 8005-4

SEPARATING THE VALVE SECTIONS Disassembly NOTE: The four spool loader control valve was used for illustrating this procedure. Use this procedure as a guide for disassembling all loader control valves. 1. Clean the outside of the loader control valve. Write a number on each of the valve sections for correct 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) from the studs (8). 4. Remove the studs (8) from the inlet and outlet section (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, 3 and 4) and the end cover (5).

Bur 7-13391

Assembly 1. Install new O-rings (10 and 11) in the grooves in each valve section (1, 2, 3 and 4). Apply petroleum jelly to the O-rings (10 and 11) to hold the O-rings (10 and 11) in position, refer to Figure 1. 2. Put all of the valve sections (1, 2, 3 and 4) on the bench 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 TORQUES for the correct torque.

Issued 4-00

SPECIAL

Printed in U.S.A.

Copyright © 8005-5

1

2 3

4 4

6 7

5

10 11 11 8 9

GS98K834

1. 2. 3. 4.

INLET AND OUTLET SECTION BUCKET SECTION LIFT SECTION AUXILIARY SECTION

5. 6. 7. 8.

END COVER PLUG O-RING STUD

9. NUT 10. O-RING 11. O-RING

FIGURE 1 - FOUR SPOOL LOADER CONTROL VALVE ASSEMBLY - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.

Copyright © 8005-6

BUCKET AND AUXILIARY SECTIONS Disassembly NOTE: The spool ports in the valve section are identified as “A” or “B”. When removing parts from the spool ports, identify the parts according to the port 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 of the valve section (11). 3. Remove the spool (4). NOTE: The spool (4), when removed from the valve section (11), contains a special screw (5), inner spring 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 both ends of the valve section (11).

Inspection 1. 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) for damage. 4. Inspect the special screws (5 and 10) for damage to the threads and inspect the threads in the ends of the spool (4) for damage. 5. Inspect the spool bores and all machined surfaces for wear and damage. 6. Inspect the poppet (16) and poppet seat for wear and damage. 7. Inspect the spring (15) for the poppet (16) for wear and damage.

5. Fasten the valve section (11) in a vise with soft jaws and loosen and remove the plug (13). 6. Remove and discard the O-ring (14) from the plug (13). 7. Remove the spring (15) and the poppet (16). 8. Loosen and remove the circuit relief and anticavitation valve(s) (17) from both ends of the valve section (11). NOTE: If the auxiliary section is being disassembled, loosen and remove the circuit relief and anticavitation valves (17) from both ends of the valve section (11). If the bucket section is being disassembled, loosen and remove the circuit relief valve (17) from one end of the valve section (11), “B” port end of bucket section, and the circuit relief and anticavitation valve (17) from the other end of the valve section (11), “A” port end of bucket section. 9. Fasten the spool (4) in a vise with soft jaws and loosen the special screw (5). 10. Remove the special screw (5), outer spring seat (9), outer spring (8), inner spring (7), and inner spring seat (6). 11. Loosen and remove the special screw (10) from the other end of the spool (4).

Bur 7-13391

Issued 4-00

Printed in U.S.A.

Copyright © 8005-7

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6

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3

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12

13 4 14 9

17

15 16

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17

12 10 1 2

3 GS98K833

1. 2. 3. 4. 5.

ALLEN HEAD SCREW LOCK WASHER SPRING CAP SPOOL SPECIAL SCREW

6. 7. 8. 9. 10.

INNER SPRING SEAT INNER SPRING OUTER SPRING OUTER SPRING SEAT SPECIAL SCREW

11. 12. 13. 14. 15.

VALVE SECTION O-RING PLUG O-RING SPRING

16. POPPET 17. CIRCUIT RELIEF AND ANTICAVITATION VALVE

FIGURE 2 - BUCKET AND AUXILIARY SECTIONS - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.

Copyright © 8005-8

Assembly

8. Install the poppet (16). 9. Install the spring (15).

1. Remove any oil from the threads on both ends of the spool (4) and the threads on the special screws (5 or 10), refer to Figure 2.

10. Install a new O-ring (14) on the plug (13) and lubricate the O-ring (14) with clean hydraulic oil.

2. Apply Loctite 271 to the threads on both ends of the spool (4).

11. Install and tighten the plug (13), refer to SPECIAL TORQUES for the correct torque.

3. Install the special screw (10) and tighten the special screw (10), refer to SPECIAL TORQUES for the correct torque.

12. Install a new O-ring (12). Apply petroleum jelly to the O-ring (12) to hold the O-ring (12) in place in the valve section (11). Repeat this procedure on the opposite end of the valve section (11).

4. Install the special screw (5), outer spring seat (9), outer spring (8), inner spring (7), and inner spring seat (6). 5. Tighten the special screw (5), refer to SPECIAL TORQUES for the correct torque. 6. Fasten the valve section (11) in a vise with soft jaws. Lubricate the O-rings on the circuit relief and anticavitation valve(s) (17), or the circuit relief valve (17) with clean hydraulic oil. 7. Install and tighten the circuit relief valve or circuit relief and anticavitation valve(s) (17), refer to SPECIAL TORQUES for the correct torque.

13. Lubricate the spool (4) and the spool bore with clean 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 valve section (11). 16. Tighten the Allen head screws (1), refer to SPECIAL TORQUES for the correct torque, on both ends of the valve section (11).

NOTE: If you are assembling a bucket section, install the circuit relief valve (17) into “B” port of bucket section and the circuit relief and anticavitation valve (17) into “A” port of bucket section.

Bur 7-13391

Issued 4-00

Printed in U.S.A.

Copyright © 8005-9

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6

8

7

GS98K835

.

1. ALLEN HEAD SCREW 2. CIRCUIT RELIEF AND ANTICAVITATION VALVE

3. PLUG 4. SPRING

5. POPPET 6. SPECIAL SCREW

7. SPRING CAP 8. SPOOL

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.

Bur 7-13391

Issued 4-00

Printed in U.S.A.


LIFT SECTION Disassembly

19. Remove the spring (28).

NOTE: The spool ports in the valve section are identified as “A” or “B”. When removing parts from the spool ports, identify the parts according to the port they were removed from for correct installation.

20. Remove the poppet (29).

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 of the 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 large spacer (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 of the valve section (34). NOTE: The spool (4), when removed from the valve section (34), contains a special screw (25), outer spring 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).

21. Remove and discard the O-rings (32 and 33) and backup ring (31) from the plugs (30). Install new O-rings (32 and 33) and backup rings (31).

Inspection 1. Clean all parts in cleaning solvent. 2. Inspect the spool (4) for wear and damage. 3. Inspect the inner and outer springs (7, 8, 22 and 23) for damage. 4. Inspect the special screws (5 and 25) for damage to the threads and inspect the threads in the ends of the spool (4) for damage. 5. Inspect the spool bores and all machined surfaces for wear and damage. 6. Inspect the poppet (29) and poppet seat for wear and damage. 7. Inspect the spring (28) for the poppet (29) for wear and damage.

9. Remove the small spacer (18) from the spool (4). 10. Remove and discard the O-ring (11) from the large spacer (13). Install a new O-ring (11). 11. Remove and discard the O-ring (19) from the small spacer (18). Install a new O-ring (19). 12. Remove the O-ring (17) from the other end of the valve section (34). 13. Fasten the spool (4) in a vise with soft jaws and loosen the special screw (25). 14. Remove the special screw (25), outer spring seat (24), outer spring (22), inner spring (23) and inner spring seat (20). 15. Remove the spool extensions (10 and 21) from both ends of the spool (4). 16. Fasten the valve section (34) in a vise with soft jaws. Loosen and remove the plug (30). Repeat for the opposite plug (30). 17. Loosen and remove the top plug (26). 18. Remove and discard the O-ring (27) from the plug (26). Bur 7-13391

Issued 4-00

Printed in U.S.A.


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14

30 27 12

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29 33 17 34

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33 18

32 31

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22 23 30

24 25

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3 GS98K836

1. 2. 3. 4. 5. 6. 7.

ALLEN HEAD SCREW LOCK WASHER SPRING CAP SPOOL SPECIAL SCREW OUTER SPRING SEAT INNER SPRING

8. 9. 10. 11. 12. 13. 14.

OUTER SPRING SPACER SPOOL EXTENSION O-RING INNER SPRING SEAT LARGE SPACER SLEEVE

15. 16. 17. 18. 19. 20. 21.

O-RING BACKUP RING O-RING SMALL SPACER O-RING INNER SPRING SEAT SPOOL EXTENSION

22. 23. 24. 25. 26. 27. 28.

OUTER SPRING INNER SPRING OUTER SPRING SEAT SPECIAL SCREW PLUG O-RING SPRING

29. 30. 31. 32. 33. 34.

POPPET PLUG BACKUP RING O-RING O-RING VALVE SECTION

FIGURE 4 - LIFT SECTION - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


Assembly 1. Install the poppet (29), refer to Figure 4. 2. Install the spring (28). 3. Lubricate the O-ring (27) on the plug (26) with clean hydraulic oil. 4. Install and tighten the plug (26), refer to SPECIAL TORQUES for the correct torque. 5. Lubricate the O-rings (32 and 33) and backup rings (31) on the plugs (30) with clean hydraulic oil. 6. Install and tighten the plug (30), refer to SPECIAL TORQUES for the correct torque. Repeat for the opposite plug (30). 7. Remove any oil from the threads on both ends of the spool (4) and the threads on the spool extensions (10 and 21). 8. Apply Loctite 271 to the threads in the spool (4). 9. Install the spool extensions (10 and 21) into the appropriate ends of the spool (4), refer to SPECIAL TORQUES for the correct torque.

12. Install a new O-ring (17) into the valve section (34). Apply petroleum jelly to the O-ring (17) to hold 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 with clean hydraulic oil. 15. Install a new O-ring (15) and backup ring (16) into the valve section (34). Apply petroleum jelly to the O-ring (15) to hold the O-ring (15) in place in 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 special screw (5). 20. Tighten the special screw (5), refer to SPECIAL TORQUES for the correct torque. 21. Install the spring cap (3) and Allen head screws (1) and lock washers (2).

10. Install the inner spring seat (20), inner spring (23), outer spring (22), outer spring seat (24) and the special screw (25).

22. Tighten the Allen head screws (1), refer to SPECIAL TORQUES for the correct torque.

11. Tighten the special screw (25), refer to SPECIAL TORQUES for the correct torque.

23. Repeat procedure on opposite end of the valve section for spring cap (3), Allen head screws (1) and lock washers (2).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


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7

GS98K837

1. ALLEN HEAD SCREW 2. PLUG

3. PLUG 4. SPRING

5. POPPET 6. SPRING CAP

7. SPOOL

LIFT SECTION - CROSS SECTION VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


REGENERATION VALVE Disassembly 1. Fasten the inlet and outlet section in a vise with soft jaws. Loosen and remove the regeneration valve 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).

Assembly 1. 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 assembly (2).

the

regeneration

valve

5. Remove and discard the O-ring (6) from the body (2). Install a new O-ring (6).

Inspection 1. Clean all parts in cleaning solvent. 2. Inspect the body (2), plunger (3), valve (4), and snap ring (5) for wear and damage. If the body (2) is damaged or worn, a new regeneration valve assembly (1) must be used.

Bur 7-13391

Issued 4-00

Printed in U.S.A.


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1

3

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5 6

GS98K838

1. REGENERATION VALVE ASSEMBLY 2. BODY

3. PLUNGER 4. VALVE

5. SNAP RING 6. O-RING

FIGURE 6 - REGENERATION VALVE - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


MAIN RELIEF VALVE Disassembly 1. Fasten the inlet and outlet section in a vise with soft jaws. Loosen and remove the main relief valve, 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). 3. Remove the spring (13).

Inspection 1. Clean all parts in cleaning solvent. 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) for wear and damage. 4. Inspect the springs (5 and 13) for damage. 5. Inspect all machined surfaces for wear and damage.

4. Fasten the adapter (7) in a vise with soft jaws. Measure the distance to the top of the adjusting screw (3). Make a record of the measurement for use during assembly. 5. Loosen the lock nut (1). 6. Remove the adjusting screw (3). 7. Remove the spring (5). 8. Remove the plunger (6). 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 backup ring (17) from the sleeve (15). Install a new O-ring (16) and backup ring (17). 11. Remove and discard the O-ring (18) and backup ring (19) from the poppet (20). Install a new O-ring (18) and backup ring (19). 12. If necessary, remove the retaining ring (22) and screen (21) from the poppet (20). Discard the screen (21). Install a new screen (21) and install the retaining ring (22). 13. Remove and discard the O-rings (25 and 26) and backup ring (24) from the body (23). Install new O-rings (25 and 26) and a backup ring (24). 14. Remove and discard the O-rings (11 and 12) and backup ring (10) from the adapter (7). Install new O-rings (11 and 12) and a backup ring (10). 15. Remove and discard the O-ring (4) from the adjusting screw (3). Install a new O-ring (4).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


12 11 10 9 8 7 6 5

4 3

25

2

26

24

1 23 22 21 20 18

19

17 15 13

16

14 GS98K839

1. 2. 3. 4. 5. 6.

LOCK NUT WASHER ADJUSTING SCREW O-RING SPRING PLUNGER

7. 8. 9. 10. 11. 12.

ADAPTER O-RING PLUNGER SEAT BACKUP RING O-RING O-RING

13. 14. 15. 16. 17. 18.

SPRING SPACER SLEEVE O-RING BACKUP RING O-RING

19. 20. 21. 22. 23. 24.

BACKUP RING POPPET SCREEN RETAINING RING BODY BACKUP RING

25. O-RING 26. O-RING

FIGURE 7 - MAIN RELIEF VALVE - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


Assembly 1. Lubricate the O-ring (18) on the poppet (20) with clean hydraulic oil, refer to Figure 7.

13. See Figure 8. Lubricate the O-ring on the main relief valve (2) with clean hydraulic oil. Install and tighten the main relief valve (2), refer to SPECIAL TORQUES for the correct torque.

2. Install the poppet (20) in the sleeve (15). 3. Lubricate the O-ring (16) and backup ring (17) on the sleeve (15) with clean hydraulic oil. 4. Install the poppet (20), sleeve (15) and the spacer (14) into the body (23).

1 2

5. Install the spring (13). 6. Lubricate the O-rings (11 and 12) and the backup ring (10) on the adapter (7) with clean hydraulic oil. 7. Install and tighten the adapter (7). 8. Install the plunger (6). 9. Install the spring (5). 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 during disassembly.

GS98K845

1. INLET AND OUTLET SECTION 2. MAIN RELIEF VALVE

Figure 8. MAIN RELIEF VALVE INSTALLATION The pressure setting of the main relief valve must be checked after the loader control valve has been installed. See Section 8002.

12. Prevent the adjusting screw (3) from turning and tighten the lock nut (1).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


1 24

2

23

3 4

22

21 20 5

19

6 18 7

17

8

16 15

9 10

14

11 13 12 GS98K840

1. 2. 3. 4. 5.

ADJUSTING SCREW WASHER O-RING ADAPTER BACKUP RING

6. 7. 8. 9. 10.

O-RING SLEEVE O-RING SPRING BACKUP RING

11. 12. 13. 14. 15.

O-RING SCREEN RETAINING RING POPPET BACKUP RING

16. 17. 18. 19. 20.

BACKUP RING O-RING SPACER O-RING ADAPTER

21. 22. 23. 24.

SPRING O-RING PLUNGER LOCK NUT

FIGURE 9 - MAIN RELIEF VALVE - CROSS SECTION

Bur 7-13391

Issued 4-00

Printed in U.S.A.


CIRCUIT RELIEF VALVE Disassembly NOTE: Used on “B” port of the bucket section only. 1. Fasten the body (20) in a vise with soft jaws. If used, remove the cap (1) for the adjusting screw (4), refer to Figure 10. 2. Measure the distance to the top of the adjusting screw (4). Make a record of the measurement for use during assembly. 3. Loosen the lock nut (2).

Inspection 1. Clean all parts in cleaning solvent. 2. Inspect the poppet (17) and screen (18) for wear and damage. 3. Inspect the plunger (7) and plunger seat (10) for wear and damage. 4. Inspect the springs (6 and 14) for damage. 5. Inspect all machined surfaces for wear and damage.

4. Remove the adjusting screw (4). 5. Remove the spring (6). 6. Remove the plunger (7). 7. Loosen and remove the adapter (8). 8. Remove the spring (14). 9. Carefully push the poppet (17) out of the body (20). 10. Remove and discard the O-ring (15) and backup ring (16) from the poppet (17). Install a new O-ring (15) and backup ring (16). 11. If necessary, remove the retaining ring (19) and screen (18) from the poppet (17). Discard the screen (18). Install a new screen (18) and install the retaining ring (19). 12. Remove and discard the O-rings (22 and 23) and backup ring (21) from the body (20). Install new O-rings (22 and 23) and a backup ring (21). 13. Remove and discard the O-rings (12 and 13) and backup ring (11) from the adapter (8). Install the new O-rings (12 and 13) and a backup ring (11). 14. Remove and discard the O-ring (5) from the adjusting screw (4). Install a new O-ring (5).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


13 12 11 10 9 8

7 6

5 4 2

3

1

23 22

18

21

15

20 19 17 16 14

GS98K841

1. 2. 3. 4. 5.

CAP (IF USED) LOCK NUT WASHER ADJUSTING SCREW O-RING

6. 7. 8. 9. 10.

SPRING PLUNGER ADAPTER O-RING PLUNGER SEAT

11. 12. 13. 14. 15.

BACKUP RING O-RING O-RING SPRING O-RING

16. 17. 18. 19. 20.

BACKUP RING POPPET SCREEN RETAINING RING BODY

21. BACKUP RING 22. O-RING 23. O-RING

FIGURE 10 - CIRCUIT RELIEF VALVE - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


Assembly 1. Lubricate the O-ring (15) on the poppet (17) with clean hydraulic oil, refer to Figure 10. 2. Install the poppet (17) into the body (20).

8. Lubricate the O-ring (5) on the adjusting screw (4) with clean hydraulic oil. 9. Turn the adjusting screw (4) into the adapter (8) to the same measurement made during disassembly.

3. Fasten the body (20) in a vise with soft jaws. Install the spring (14).

10. Prevent the adjusting screw (4) from turning and tighten the lock nut (2).

4. Lubricate the O-rings (12 and 13) and the backup ring (11) on the adapter (8) with clean hydraulic oil.

11. If used, install the cap (1).

5. Install and tighten the adapter (8).

The pressure setting of the circuit relief valve must be checked with a hand pump according to instructions in Section 8002.

6. Install the plunger (7). 7. Install the spring (6).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


1

20

2

19 18 3 17

4

5 16 15

6

14 13 12

7

11 8

10 9

GS98K842

1. 2. 3. 4.

CAP (IF USED) LOCK NUT PLUNGER O-RING

5. 6. 7. 8.

BODY O-RING BACKUP RING RETAINING RING

9. 10. 11. 12.

SCREEN O-RING BACKUP RING SPRING

13. 14. 15. 16.

O-RING POPPET O-RING BACKUP RING

17. 18. 19. 20.

ADAPTER O-RING WASHER ADJUSTING SCREW

FIGURE 11 - CIRCUIT RELIEF VALVE - CROSS SECTION VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


CIRCUIT RELIEF AND ANTICAVITATION VALVE Disassembly 1. Fasten the inlet and outlet section in a vise with soft jaws. Loosen and remove the circuit relief and 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). 3. Remove the spring (14). 4. Fasten the adapter (8) in a vise with soft jaws. Measure the distance to the top of the adjusting screw (4). Make a record of the measurement for use during assembly.

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 and damage. 3. Inspect the plunger (7) and plunger seat (10) for wear and damage. 4. Inspect the springs (6 and 14) for damage. 5. Inspect all machined surfaces for wear and damage.

5. Loosen the lock nut (2). 6. Remove the adjusting screw (4). 7. Remove the spring (6). 8. Remove the plunger (7). 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 backup ring (18) from the sleeve (16). Install a new O-ring (17) and backup ring (18). 13. Remove and discard the O-ring (19) and backup ring (20) from the poppet (21). Install a new O-ring (19) and backup ring (20). 14. If necessary, remove the retaining ring (24) and screen (23) from the poppet (21). Discard the screen (23). Install a new screen (23) and install the retaining ring (24). 15. Remove and discard the O-rings (27 and 28) and backup ring (26) from the body (25). Install new O-rings (27 and 28) and a backup ring (26). 16. Remove and discard the O-rings (12 and 13) and backup ring (11) from the adapter (8). Install new O-rings (12 and 13) and a backup ring (11). 17. Remove and discard the O-ring (5) from the adjusting screw (4). Install a new O-ring (5).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


13 12 11 10 9 8 7 6

5 4 2

3

26

22

1

20

27

28

25

18

24 23

15

21 19 17 16 14 GS98K843

1. 2. 3. 4. 5. 6.

CAP (IF USED) 7. PLUNGER LOCK NUT 8. ADAPTER WASHER 9. O-RING ADJUSTING SCREW 10. PLUNGER SEAT O-RING 11. BACKUP RING SPRING 12. O-RING

13. 14. 15. 16. 17. 18.

O-RING SPRING RETAINING RING SLEEVE O-RING BACKUP RING

19. 20. 21. 22. 23. 24.

O-RING BACKUP RING POPPET ROLL PIN SCREEN RETAINING RING

25. 26. 27. 28.

BODY BACKUP RING O-RING O-RING

FIGURE 12 - CIRCUIT RELIEF AND ANTICAVITATION VALVE - EXPLODED VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


Assembly 1. Lubricate the O-ring (19) on the poppet (21) with clean hydraulic oil, refer to Figure 12. 2. Install the poppet (21) in the sleeve (16).

14. See Figure 13. Lubricate the O-ring on the circuit relief and anticavitation valve (2) with clean hydraulic oil. Install and tighten the circuit relief and anticavitation valve (2), refer to SPECIAL TORQUES for the correct torque.

3. Install the retaining ring (15). 4. Lubricate the O-ring (17) and backup ring (18) on the sleeve (16) with clean hydraulic oil. 5. Install the poppet (21) and sleeve (16) into the body (25).

1 2

6. Install the spring (14). 7. Lubricate the O-rings (12 and 13) and the backup ring (11) on the adapter (8) with clean hydraulic oil. 8. Install and tighten the adapter (8). 9. Install the plunger (7). 10. Install the spring (6). 11. Lubricate the O-ring (5) on the adjusting screw (4) with clean hydraulic oil. 12. Turn the adjusting screw (4) into the adapter (8) to the same measurement made during disassembly.

GS98K845

1. INLET AND OUTLET SECTION 2. CIRCUITRELIEF AND ANTICAVITATION VALVE FIGURE 13 - CIRCUIT RELIEF AND ANTICAVITATION VALVE INSTALLATION

The pressure setting of the main relief valve must be c he cke d wi t h a h an d p um p a c c o r di ng to th e instructions in Section 8002.

13. To prevent the adjusting screw (4) from turning, tighten the lock nut (2).

Bur 7-13391

Issued 4-00

Printed in U.S.A.


26 1

25

2

24 3

23

4 22 21 20

5 6

19

7

18 17

8 9

16

10 11

15 12

14 13

GS98K844

1. 2. 3. 4. 5. 6.

ADJUSTING SCREW 7. SLEEVE WASHER 8. O-RING O-RING 9. SPRING ADAPTER 10. BACKUP RING BACKUP RING 11. O-RING O-RING 12. ROLL PIN

13. 14. 15. 16. 17. 18.

SCREEN RETAINING RING POPPET BACKUP RING BACKUP RING O-RING

19. 20. 21. 22. 23. 24.

RETAINING RING O-RING BODY SPRING O-RING PLUNGER

25. LOCK NUT 26. CAP (IF USED)

FIGURE 14 - CIRCUIT RELIEF AND ANTICAVITATION VALVE - CROSS SECTION VIEW

Bur 7-13391

Issued 4-00

Printed in U.S.A.


NOTES

Bur 7-13391

Issued 4-00

Printed in U.S.A.

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8013

Section 8013 ACCUMULATOR FOR RIDE CONTROL


Bur 7-13471


Copyright © 8013-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-13471

Issued 4-00

3 3 3 4 7 7 7 7

Printed in U.S.A.

Copyright © 8013-3

SPECIFICATIONS Accumulator 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 TORQUES Accumulator 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 KIT

Bur 7-13471

B786441M

CAS-1456 GLAND WRENCH

Issued 4-00

Printed in U.S.A.

Copyright © 8013-4

CHARGING THE ACCUMULATOR WITH NITROGEN

VALVE “C”

TO NITROGEN TANK

VALVE “D”

TO ACCUMULATOR

VALVE “B” VALVE “A” GS98N801

FIGURE 1. NITROGEN CHARGING KIT CAS-10899

!

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. M253A

!

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 the accumulator at a dangerous rate of speed. M406

!

WARNING: Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulator contains nitrogen compressed to 450 PSI (31 bar). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator 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 during high pressure (10 bar/150 psi and above) applications.

Bur 7-13471

Issued 4-00

Printed in U.S.A.

Copyright © 8013-5

3. Close valve C by turning it all the way to the right (clockwise).

14. Back off the needle valve on the accumulator end of the charging hose by tur ning it counterclockwise the maximum amount. This will p r eve nt ni t r og e n f r om es c a p i ng fr o m t h e accumulator as the hose is removed. Remove the charging hose from the accumulator gas charging valve (11), refer to Figure 2.

4. Close the gauge valve D by turning it all the way to the right (clockwise).

15. Install the valve cap (12) onto the gas charging valve (11) on the accumulator.

5. Connect the charging hose to the nitrogen supply tank.

16. Install the protection bracket (13) over the gas charging valve (11) and secure it with cap screws (14).

1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to Figure 1. 2. Open valve B by turning it out all the way to the left (counterclockwise).

6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi).

17. Remove the charging hose from the nitrogen supply tank, refer to Figure 1.

NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the two cap screws (14) and the protection bracket (13) from the gas charging valve (11) on the accumulator, refer to Figure 2. 8. Remove the valve cap (12) from the gas charging valve (11) on the accumulator. 9. Back off the needle valve on the accumulator end of the charging hose by tur ning it counterclockwise to the maximum amount. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve, refer to Figure 1. 10. Install the charging hose fitting onto the accumulator gas charging valve (11), refer to Figure 2. 11. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator, refer to Figure 1. 12. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, s l i g h t l y o p e n t h e n e e d l e v a l ve o n t h e accumulator charge hose. By regulating the needle valve, fill the accumulator to 31 bar (450 psi). Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. 13. Close valve B by turning to the right (clockwise). After a few minutes, check the accumulator for leakage.

Bur 7-13471

Issued 4-00

Printed in U.S.A.

Copyright © 8013-6

1

2 4

3 5 6 7 12

8 9

10 11 13

14 GS98K847

1. 2. 3. 4. 5.

TUBE WEAR RING WEAR RING PISTON BACKUP RING

6. 7. 8. 9. 10.

O-RING BACKUP RING GLAND SEAL GLAND O-RING

11. 12. 13. 14.

GAS CHARGING VALVE VALVE CAP PROTECTION BRACKET CAP SCREW

FIGURE 2. ACCUMULATOR - EXPLODED VIEW

Bur 7-13471

Issued 4-00

Printed in U.S.A.

Copyright © 8013-7

ACCUMULATOR Disassembly 1. 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 the tube (1). 3. Remove the gland seal (8) from the gland (9).

5. Install the valve cap (12) on the gas charging valve (11). 6. Install a new O-ring (10) on the gas charging valve (11). 7. Lubricate the O-ring (10) on the gas charging valve (11) with clean oil.

4. Fasten the gland (9) in a vise with soft jaws. Be careful not to damage the gland (9).

8. Install the gas charging valve (11) in the gland (9). Tighten the gas charging valve (11), refer to SPECIAL TORQUES for the correct torque.

5. Loosen and remove the gas charging valve (11) from the gland (9).

9. Install a new gland seal (8) on the gland (9).

6. Remove and discard the O-ring (10) from the gas charging 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 backup rings (5 and 7) from the piston (4).

Inspection 1. Clean all parts in cleaning solvent. 2. Inspect the inside of the tube (1) for grooves and other damage. If there is damage to the tube (1), a new tube (1) must be used.

10. Lubricate the gland seal (8) on the gland (9) with clean oil. Apply antisieze compound to the threads on the gland (9). 11. Use the gland wrench to install the gland (9) in the tube (1). Tighten the gland (9), refer to SPECIAL TORQUES for the correct torque. 12. Charge the accumulator with nitrogen according to the instructions on page 3. 13. Install the protection bracket (13) in place on the gland (9). Install the cap screws (14) that fasten the protection bracket (13) to the gland (9). Tighten the cap screws (14), refer to SPECIAL TORQUES for the correct torque.

3. Remove small scratches inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion. 4. Inspect the piston (4) for wear or damage that can cause nitrogen or oil leakage. Use a new piston (4) as required. 5. Inspect the gland (9) for wear or damage that can cause nitrogen leakage. Use a new gland (9) as required. 6. Inspect the gas charging valve (11) for wear or damage that can cause nitrogen leakage. Use a new gas charging valve (11) as required.

Assembly 1. Install new backup rings (5 and 7) and a new Oring (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).

Bur 7-13471

Issued 4-00

Printed in U.S.A.

Copyright © 8013-8

NOTES

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