Manual de Servicio 821C

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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
1002
Template Name: SM_2_col Template Date: 1994_04_05

1002-2
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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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1002-3
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 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120
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 29 23 18 12 7 1 4 10 16 21 27 32 38 43 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.
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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 ..................................................................................................................140F (60C) Cloud point (wax appearance point), maximum .................................................. -5F (-20C) See Note above Pour point, maximum ........................................................................................ -15F (-26C) See Note above Distillation temperature, 90% point ...................................................................... 540 to 640F (282 to 338C) Viscosity, at 100F (38C) 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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1002-5
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 JOINT (1 FITTING) ............................................... CASE MOLYDISULFIDE GREASE

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 JOINT (1 FITTING) ................................................... CASE MOLYDISULFIDE GREASE 35 LUBRICATE THE REAR DRIVE SHAFT SLIP JOINT (1) FITTING) .................................................. CASE MOLYDISULFIDE GREASE

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

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

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.

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.
Bur 7-13071
Issued 4-00
Printed in U.S.A.
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SECTION INDEX - ELECTRICAL Section Title
0000-1
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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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
4002
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 16 17 17 17 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
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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23 23 23 24 24 25 26 27 28 28 29 29 29 29 30 30 31 31 32 32 32 33 33 34 35 35 35 36 36 36 37 37 37 37 38 38 39 40 40 41 41 41 42 43 43 44 44 44 45 45 45 45 46 46
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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55 56 56 56 56 57 57 57 58 58 59 59 60 60 60 60 61 61 62 63 63 63 63 64 64 64 65 65 66 66 66 67
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 -17C (0F)................................................................................................................................800 amperes At -29C (-20F) ...........................................................................................................................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 20C (68F).......................................................................... 3521ohms Coolant and Hydraulic Temperature Sender (Yellow Line) 105C (221F) ................................................. 154 ohms Coolant and Hydraulic Temperature Sender (Red Line) 110C (230F) .................................................. 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) Contacts 2 to 3 of thermostat switch close at initial turn of the rotary switch. Contacts 1 to 2 close with thermal setting. Engine Oil Pressure Sender. Reference Resistance vs. 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). 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). 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. 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
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4002-11
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, COLD START, IGNITION SWITCH AND RELAYS
10 12
4 2
6 6A 1 8 3 7 5
9 11 13
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.
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2 Master Disconnect Switch

Check Points Reading Possible Cause of Bad Reading NOTE: Disconnect the cables from both terminals of the master disconnect switch (main contact). Put the 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 contact).
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 Terminal for wire 14 to ground 24 volts Check circuit to positive post of batteries. Check circuit to ignition relay #1 (13) and ignition relay #2 (14), also check 75 ohm resistor.
20 volts
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).
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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
NOTE: Put the master disconnect switch in the ON position. Terminal 87 for red wire 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 for wire 21C to ground Terminal for wire 8 to ground 24 volts 24 volts Check neutral start relay (11), also check the circuit 21C. Bad start relay (6).
6A Fuel Relay
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 Terminal for wire 23F to ground 24 volts 24 volts Check neutral start relay (11), also check the circuit 21C. Bad fuel relay (6A).
7 Cold Start Temperature Switch

Check Points Reading Possible Cause of Bad 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.
Copyright
4002-14
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

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 Terminal for wire 28P to ground 24 volts 24 volts Bad ether start switch (10), also check circuit 28C. Bad ether start relay (9).
10 Ether Start Switch

Check Points Reading Possible Cause of Bad 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

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 Terminal for wire 21C to ground 24 volts 24 volts Check circuit 25T. Bad neutral start relay (11).
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12 Ignition Switch
Check Points Reading Possible Cause of Bad 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 Between Bat and Acc Continuity Continuity Bad ignition switch (12). Bad ignition switch (12).
NOTE: Hold the ignition switch (12) in the START position. Between Bat and Starter Continuity Bad ignition switch (12).
NOTE: Put the switch in the Acc position. Between Bat and Acc Continuity Bad ignition switch (12).
13 Ignition Relay #1
NOTE: Put the master disconnect switch in the ON position. Turn the ignition to the ON position. Terminal for wire 1 to ground Terminal for wire 13K to ground Terminal for wire 13P to ground 24 volts 24 volts 24 volts Check circuit 1 to B+ stud. Check circuit 13K. Bad ignition relay #1 (13)
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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
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position. Terminal for wire 1 to ground Terminal for wire 13K to ground Terminal for wire 13R to ground 24 volts 24 volts 24 volts Check circuit 1 to B+ stud. Check circuit 13K. Bad ignition relay #2 (14).
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15 Accessory Relay #3
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position. Terminal for wire 1 to ground Terminal for wire 12K to ground Terminal for wire 12P to ground 24 volts 24 volts 24 volts Check circuit 1 to B+ stud. Check circuit 12K. Bad accessory relay (15), also check circuit 12P.
16 Voltmeter Relay #12

NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the ON position. Terminal for wire 1 to ground Terminal for wire 13K to ground Terminal for wire 13V to ground 24 volts 24 volts 24 volts Check circuit 1 to Relay Box Junction Block. Check circuit 13K. Bad voltmeter relay (16). Also check circuit 13V.
17 Time Delay Module

NOTE: Put the ignition switch in the OFF position. Terminal for wire 1A to ground 24 volts Bad circuit breaker A, also check circuit 1A to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the RESET switch (42). Terminal for wire 37R to ground Terminal for wire 13K to ground 24 volts 24 volts Bad reset switch (42), also check circuit 37R. 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 After 10 seconds of turning ignition switch to the OFF position, check Terminal for wire 13D to ground 24 volts Key ON 0 volts after 10 seconds
Bad Time Delay Module (17).
0 volts
Bad Time Delay Module (17).
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TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM
,
26 31 24
23 34
22 19 20 21 18
25 27 32
29 30 33
28
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
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
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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 Possible Cause of Bad 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 Terminal for wire 19A to ground 24 volts 24 volts Bad back-up alarm relay (32), also check circuit 35A. Bad fuse A, also check circuit 19A, 13P, and ignition relay #1 (13). Bad fuse H, also check circuit 19H and 13R and ignition relay #2 (14).
Terminal for wire 19H to ground
24 volts
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33 Back-up Alarm Disable Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the 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
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).
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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.
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
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35 Brake Warning Pressure Switch

Check Points Reading Possible Cause of Bad 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. Terminal B for wire 0 to ground Terminal A for wire 33P to ground Continuity Approximately 11.5 volts Bad ground circuit. Check circuit 33P.
NOTE: Disconnect the wires from the brake warning pressure switch (35). Between terminals A and B of the switch NOTE: Start and run the engine at idle. Between terminals A and B of the switch No continuity Bad brake warning pressure switch (35). Continuity Bad brake warning pressure switch (35).
NOTE: If the readings are correct see hydraulic brake troubleshooting section to check brake pressures.
36 Coolant Level Sender

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

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).
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38 Hydraulic Oil Temperature Sender

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36H to ground Approximately 5 volts Check the instrument cluster (43A).
NOTE: If the readings are correct replace the hydraulic oil temperature sender (38).
39 Hydraulic Filter Restriction Switch

Check Points Reading Possible Cause of Bad 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. Approximately 11.5 volts Check the instrument cluster (43A).
NOTE: If the readings are correct replace the hydraulic filter restriction switch (39).
40 Engine Coolant Temperature Sender

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36C to ground Approximately 5 volts Check the instrument cluster (43A).
NOTE: If the readings are correct replace the engine coolant temperature sender (40).
41 Air Filter Restriction Switch

Check Points Reading Possible Cause of Bad 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 Approximately 11.5 volts Check the instrument cluster (43A).
NOTE: If the readings are correct replace the air filter restriction indicator switch (41).
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42 Program Reset Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position with the program/reset switch (42) held in the reset position. Terminal for wire 37R to ground 24 volts Check instrument cluster (43A), also check circuit 37R.
NOTE: Put the program/reset switch (42) in the program position. Terminal for wire 37P to ground 24 volts Check instrument cluster (43A), also check circuit 37P.
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground Terminal for wire 1A to ground 24 volts 24 volts Bad program/ reset switch (42), also check circuit 49. Bad program/ reset switch (42), also check circuit 1A.
43 Park Brake Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19A to ground NOTE: Apply parking brake switch (43). Terminal for wire 33U to ground 24 volts Bad park brake switch (43). 24 volts Check fuse A, also check circuit 19A.
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground 24 volts Bad park brake switch (43), also check circuit 49.
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43A Instrument Cluster

Check Points Connector terminal 3 to ground Connector terminal 4 to ground Connector terminal 19 to ground Connector terminal 5 to ground Connector terminal 20 to ground Reading Continuity Continuity 39 to 225 ohms Continuity 134 to 3521 ohms 134 to 3521 ohms Continuity Continuity Continuity Continuity Possible Cause of Bad Reading Bad circuit 33P, also check the brake warning pressure switch (35). Bad circuit 31D, also check the coolant level sender (36). Bad circuit 36F, also check the fuel level sender (37). Bad circuit 35X, also check the secondary steering switch (61). Bad circuit 36H, also check the hydraulic oil temperature sender (38). Bad circuit 36C, also check the engine coolant temperature sender (40). Bad circuit 31F, also check the air filter restriction switch (41). Bad circuit 0 to ground. Bad circuit 19V, also check fuse V. Bad circuit 61R, also check the A/C - H/L pressure switches (81 and 82) and compressor clutch lockout relay (84). Bad circuit 18G/42R, also check the 5 position rotary lamp switch (112). Bad circuit 46, also check the beacon light switch (96).
Connector terminal 18 to ground Connector terminal 6 to ground Connector terminal 8 to ground Circuit 19V, at terminal 1 to fuse V Circuit 61R, at terminal 10, from point to point Circuit 18G/42R, at terminal 12, from point to point Circuit 46, at terminal 13, from point to point Circuit 41F, at terminal 14, from point to point Circuit 18C, at terminal 15, from point to point Connector terminal 39 to ground Connector terminal 9 to terminal 6 on park brake switch (43) Connector terminal 24 to terminal 6 on program reset switch (42) Connector terminal 25 to terminal 4 on program reset switch (42) Circuit 45R, at terminal 17, from point to point Circuit 45L, at terminal 16, from point to point Connector terminal 21 to terminal 33 Connector terminal 29 to terminal 6 on pilot control switch (44) Connector terminal 33 to terminal 21 Connector terminal 38 to ground
Continuity
Continuity
Continuity
Bad circuit 41F, also check the rear fog lights switch (110).
Continuity Continuity Continuity
Bad circuit 18C, also check the high beam lights switch (111). Bad ground circuit. Bad circuit 33U, also check the park brake switch (43).
Continuity
Bad circuit 37P, also check the 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).
Continuity Continuity Continuity Continuity Continuity
Bad circuit 45L, also check the LH turn signal (102). Bad circuit 50T. Bad circuit 31L, also check the pilot control switch (44). Bad circuit 50T. Bad ground circuit.
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43A Instrument Cluster (Continued)

Check Points Circuit 36P, at terminal 22, from point to point Circuit 33R, at terminal 28, from point to point Circuit 23C, at terminal 23, from point to point Circuit 53C, at terminal 36, from point to point Circuit 52C, at terminal 30, from point to point Circuit 44, at terminal 35, from point to point Connector terminal 31 to terminals 26 and 27 on the transmission electronic control module (25) Connector terminal 32 to terminal 25 on the transmission electronic control module (25) Connector terminal 37 to ground Circuit 19, at terminal 2, from point to point Circuit 37U, at terminal 26, from point to point Circuit 37D, at terminal 27, from point to point Reading Continuity Possible Cause of Bad Reading Bad circuit 36P, also check the engine oil pressure sender (46).
Continuity
Bad circuit 33R, also check the redundant brake switches (51). Bad circuit 23C, also check the engine automatic shutdown relay (52). Bad circuit 53C, also check the pilot control relay (47).
Continuity
Continuity
Continuity
Bad circuit 52C, also check the parking brake relay (48). Bad circuit 44, also check the RH/LH brake lights (108 and 109).
Continuity
Continuity
Bad circuit 50L.
Continuity
Bad circuit 50H.
Continuity Continuity
Bad ground circuit. Bad circuit 19S, also check the up/down count switch (45) and fuse S. Bad circuit to pilot control switch (44), also check the pilot control switch (44). Bad circuit 37D, also check the up/down count switch (45).
Continuity
Continuity
44 Pilot Control Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19C to ground Terminal for wire 31L to ground 24 volts 24 volts Bad fuse C, also check circuit 19C. Bad pilot control switch (44).
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground 24 volts Bad circuit 49, also check the 5 position rotary lamp switch (112).
NOTE: If the readings are correct replace the pilot control switch (44).
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45 Up/down Count Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19S to ground Terminal for wire 37D to ground Terminal for wire 37U to ground 24 volts 24 volts 24 volts Bad circuit 19S, also check instrument cluster (43A) and fuse S. Bad circuit 37D, also check instrument cluster (43A). Bad circuit 37U, also check instrument cluster (43A).
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground 24 volts Bad circuit 49, also check 5 position rotary lamp switch (112).
NOTE: If the readings are correct replace the up/down count switch (45).
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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 Possible Cause of Bad Reading 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 Approximately 5 volts Bad circuit 36P, also check the instrument cluster (43A).
NOTE: If the readings are good, replace the oil pressure sender (46).
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47 Pilot Control Relay

Check Points Reading Possible Cause of Bad 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 Terminal for wire 53C to ground Terminal for wire 53P to ground 24 volts 0 volts 24 volts Bad fuse C, also check circuit 19C. Bad pilot control relay (47), also check circuit 53C and instrument cluster (43A). Bad circuit 53P.
NOTE: If the readings are good, replace the pilot control relay (47).
48 Parking Brake Relay

Check Points Reading Possible Cause of Bad 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 Terminal for wire 52C to ground Terminal for wire 52P to ground 24 volts 0 volts 24 volts Bad fuse D, also check circuit 19D. Bad parking brake relay (48), also check circuit 52C. Bad circuit 52P.
NOTE: If the readings are good, replace the parking brake relay (48).
49 Redundant Parking Brake Solenoids

Check Points Terminal for wire 0 to ground Terminal A for wire 52P to terminal 87 on parking brake relay (48) Reading Continuity Continuity Possible Cause of Bad Reading Bad ground circuit. Bad circuit 52P, also check parking brake relay (48).
NOTE: If the readings are good, replace the parking brake solenoid (49).
50 Pilot Pressure Solenoid

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot 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).
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51 Redundant Brake Switches

Check Points Reading Possible Cause of Bad 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 Approximately 11.5 volts Bad instrument cluster (43A), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake switches (51).
52 Engine Automatic Shutdown Relay Socket #11

NOTE: There are no electrical troubleshooting procedures for this relay socket.
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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
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 Terminal for wire 53P to ground Terminal for wire 56 to ground Continuity 24 volts 24 volts Bad ground circuit. Bad pilot control relay (47), also check circuit 53P. Bad detent switch (53), also check circuit 56.
NOTE: If the readings are good, replace the detent switch (53).
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54 Bucket Control Valves Detent Electromagnets

Check Points Reading Possible Cause of Bad 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 Circuit 53B, point to point Circuit 54B, point to point Circuit 55A, point to point, to return to travel/float switch (55) 24 volts Continuity Continuity Continuity Bad detent switch (53), also check pilot control relay (47). Bad return to dig detent electromagnet. Bad height control detent electromagnet. Bad return to travel detent electromagnet.
NOTE: If the readings are good, replace the bucket control valves detent electromagnets (54).
55 Return-To-Travel/Float Switch
NOTE: Put the return to travel/float switch (55) in the FLOAT position. Terminal 5 and terminal 4 Continuity Bad return to travel/float switch (55).
NOTE: Put the return to travel/float switch (55) in the TRAVEL position. Terminal 5 and terminal 6 Circuit 55A, point to point Continuity Continuity Bad return to travel/float switch (55). 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 Possible Cause of Bad 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 Terminal A for wire 53B to ground Terminal C for wire 56 to ground Continuity 24 volts 24 volts Bad ground circuit. Bad bucket control valve detent electromagnets (54) or detent switch (53), also check circuit 53B. Bad detent switch (53), also check circuit 56.
NOTE: If the readings are good, replace the return to dig proximity switch (56).
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57 Height Control Proximity Switch

Check Points Reading Possible Cause of Bad 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 Terminal A for wire 54B to ground Terminal C for wire 56 to ground Continuity 24 volts 24 volts Bad ground circuit. Bad bucket control valve detent electromagnets pressure(54) or detent switch (53), also check circuit 54B. Bad detent switch (53), also check circuit 56.
NOTE: If the readings are good, replace the height control proximity switch (57).
58 Return-To-Travel Proximity Switch

Check Points Reading Possible Cause of Bad 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 Terminal A for wire 55B to ground Terminal C for wire 56 to ground Continuity 24 volts 24 volts Bad ground circuit. Bad return to travel/float switch (55), also check circuit 55B. Bad detent switch (53), also check circuit 56.
NOTE: If the readings are good, replace the return to travel proximity switch (58).
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TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL

59 60 61 62 63 62A 62B
64 66 65 67
68
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
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
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59 Secondary Steering Relay with Lockout 60 Secondary Steering Relay with Lockout
Check Points Reading Possible Cause of Bad Reading NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal 7 of relay (59) to ground Terminal 8 of relay (60) to ground Terminal 7 of relay (60) to ground Ground wires between relays (59 and 60) and ground Connector for wire 51P at secondary steering switch (61) and terminal 3 of relay (59) Connector for wire 51 at the secondary steering pump/motor (62) and terminal 6 of relay (60) NOTE: Start and run the engine at idle. Terminal 2 of relay (59) to ground Terminal 3 of relay (59) to ground 0 volts 0 volts Bad relay (59), also check secondary steering switch (61). Bad jumper wire between terminals 2 and 3 of relay (59), also check secondary steering switch (61). Bad relay (59), also check instrument cluster (43A) and circuit 35X. Bad relay (60). Bad relay (59). Bad jumper wires, also check relay (59). 24 volts 24 volts 24 volts Continuity Check fuse M, also check circuit 19M. Check fuse R, also check circuit 19R. Bad jumper wire between terminals 7 and 8 of relay (60). Bad ground circuit.
Continuity
Bad circuit 51P.
Continuity
Bad circuit 51.
Terminal 6 of relay (59) to ground Terminal 8 of relay (59) to ground Terminal 2 of relay (60) to ground Terminal 3 of relay (60) to ground
24 volts 24 volts 24 volts 24 volts
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 Terminal 6 of relay (60) to ground 0 volts 24 volts Bad relay (60), also check circuit 19R and 19M. Bad relay (60), also check circuit 19R.
61 Secondary Steering Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 35X to ground NOTE: Start and run the engine at idle. Terminal for wire 51P to ground 0 volts Check the secondary steering relays (59 and 60), also check circuit 51P. 24 volts Check the instrument cluster (43A), also check circuit 35X.
NOTE: If the readings are good, replace the secondary steering switch (61).
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62 Secondary Steering Pump/Motor

Check Points Ground circuit to ground Reading Continuity Possible Cause of Bad Reading Bad ground circuit.
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. Terminal for red wire to starter to ground Motor terminal of solenoid to ground 24 volts Check the secondary steering relays (59 and 60), also check circuit 51. Check circuit to batteries. Bad secondary steering pump/motor or solenoid (62). Check the secondary steering pump/motor or solenoid (62), also check the connections between the solenoid and pump/motor.
24 volts 24 volts
Motor terminal of motor to ground
24 volts
NOTE: If the readings are good, replace the secondary steering pump/motor (62).
62A Pin Engagement Switch

Check Points Reading Possible Cause of Bad 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 Terminal for wire 0 to ground Terminal for wire 19P to ground Between terminals for wires 19P and 57 24 volts Continuity 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 Possible Cause of Bad 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 Terminal for wire 57 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).
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63 Ride Control Switch

Check Points Reading Possible Cause of Bad 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 Terminal for wire 0 to ground Terminal for wire 19C 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).
65 Ride Control Relay

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

Circuit 58D, point to point
Continuity
Bad circuit 58D.
NOTE: Put the master disconnect switch and ignition switch to the ON position. 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 Terminal for wire 58D to ground
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24 volts 24 volts
Bad ride control relay (65) or bad hoist-up pressure switch (64). Bad bucket dump pressure switch (66).
Copyright
4002-38
67 Bucket Rollback Pressure Switch

Check Points Circuit 58, point to point Reading Continuity Bad circuit 58. Possible Cause of Bad Reading
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 Terminal for wire 58 to ground 24 volts 24 volts Bad bucket dump pressure switch (66), bad ride control relay (65), or bad hoist-up pressure switch (64). Bad bucket rollback pressure switch (67).
68 Ride Engage Solenoid

Check Points Reading Possible Cause of Bad 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 Terminal for wire 58 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).
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TROUBLESHOOTING WIPER/WASHER
69
74
70 71 72 73
GM98M012
69. FRONT WIPER MOTOR 70. FRONT ROTARY WIPER AND WASHER SWITCH 71. FRONT WASHER PUMP MOTOR
72. REAR WASHER PUMP MOTOR 73. REAR WIPER AND WASHER SWITCH 74. REAR WIPER MOTOR
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69 Front Wiper Motor

NOTE: Make sure the rotary wiper and washer switch (70) is in the OFF position. Between terminals B and D for wires 63C and 63L Continuity Bad front rotary wiper and washer switch (70).
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 Terminal for wire 63C to ground 24 volts 24 volts Check fuse J, also check circuit 19J. 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 Terminal for wire 63C to ground 24 volts 0 volts Check fuse J, also check circuit 19J. Bad front rotary wiper and washer switch (70). Bad front rotary wiper and washer switch (70).
NOTE: If the readings are good, replace the front wiper motor (69).
70 Front Rotary Wiper and Washer Switch

Check Points Reading Possible Cause of Bad 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 Terminal for wire 63C to ground 24 volts 24 volts Check fuse J, also check circuit 19J. 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 Terminal for wire 63C to ground 24 volts 0 volts Check fuse J, also check circuit 19J. Bad front rotary wiper and washer switch (70). Bad front rotary wiper and washer switch (70).
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71 Front Washer Pump Motor

Check Points Reading Possible Cause of Bad 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 Possible Cause of Bad 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 Circuit 68W, point to point Between terminals for wires 68C and 68L Reading Continuity Continuity Possible Cause of Bad Reading Bad circuit 68W. 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 Terminal for wire 68 L to ground Terminal for wire 49 to ground 24 volts 24 volts 24 volts Check fuse K, also check circuit 19K. Bad rear wiper and washer switch (73), also check circuit 68L. Bad rotary lamp switch (112), also check circuit 49.
NOTE: Put the rear wiper and washer switch (73) in the wash position. Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68W.
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74 Rear Wiper Motor

NOTE: Make sure the rear wiper and washer switch (73) is in the OFF position. Between terminals for wires 68C and 68L Continuity Bad rear wiper and washer switch (73).
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 Terminal for wire 68C to ground 24 volts 0 volts Bad rear wiper and washer switch (73). Bad rear wiper and washer switch (73).
NOTE: If the readings are good, replace the rear wiper motor (74).
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TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND CONDENSER FANS

84 86 87 88 89
81 77
82 85
75
78 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 64C to horn switch (100) Reading 24 volts 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 24 volts Check horn switch (100). If the horn switch (100) is good, replace the horn relay (75).
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76 Seat Compressor and Switch

Check Points Reading Possible Cause of Bad 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
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 Possible Cause of Bad Reading NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminals for wire 19G to ground NOTE: Turn the blower switch to LOW. Terminals for wire 62L to ground Terminals for wire 61T to ground 24 volts 24 volts Bad blower switch (78). Bad blower switch (78). 24 volts Check fuse G, also check circuit 19G.
NOTE: Turn the blower switch to MEDIUM. Terminals for wire 62M to ground Terminals for wire 61T to ground NOTE: Turn the blower switch to HIGH. Terminals for wire 62H to ground Terminals for wire 61T to ground 24 volts 24 volts Bad blower switch (78). Bad blower switch (78). 24 volts 24 volts Bad blower switch (78). Bad blower switch (78).
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79 Resistor Board (Blower Motor Speed Resistors with Thermal Fuse)

Check Points Reading Possible Cause of Bad Reading NOTE: Disconnect the connector from the resistor board (79). Between terminals 1 and 2 Approximately 4.5 ohms Approximately 1.5 ohms Bad resistor board (79).
Between terminals 2 and 3
Bad resistor board (79).
80 Blower Motor
Check Points Terminals for wire 0 to ground Reading Continuity Possible Cause of Bad Reading Bad ground circuit.
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 Possible Cause of Bad 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 Possible Cause of Bad 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) Open Bad high pressure switch (82), also check for excessive refrigerant pressure.
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83 Thermostat Switch
Check Points Reading Possible Cause of Bad 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 Terminals for wire 61M to ground 24 volts 24 volts Bad thermostat switch (83). Bad thermostat switch (83).
84 Compressor Clutch Lockout Relay

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 Terminals for wire 61R to ground Terminals for wire 61C to ground 24 volts 0 volts 24 volts Check thermostat switch (83), also check circuit 61A. Check low pressure switch (81) and high pressure switch (82). Bad compressor clutch lockout relay (84).
85 Compressor Clutch
Check Points Reading Possible Cause of Bad 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

NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminals for wire 0 to ground Terminals for wire 1 to ground Continuity 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 Terminals for wire 12 to ground 24 volts 24 volts Check the thermostat switch (83), also check circuit 61M. Bad condenser fan relay (86).
87 Not Used
NOTE: Component number 87 is not used at this time.
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88 Condenser Fan Motor No. 1

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 Possible Cause of Bad Reading Bad ground circuit.
Terminal for wire 0 to ground
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 for wire 19V to ground
24 volts
Check 10 ampere circuit breaker V, also check circuit 19V.
NOTE: If readings are good, replace the condenser fan motor No. 2 (89).
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4002-48
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET, RADIOS AND SPEAKERS
94 95
93 93A 93B
91 92
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).
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91 Power Converter (24 volt to 12 volt)

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19L to ground Terminal for wire 1 to ground Terminal for wire 12V to ground 24 volts 24 volts 24 volts Bad fuse L, also check circuit 19L. Check circuit 1. 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 Terminal in radio connector for wire 0 to ground Reading Continuity Possible Cause of Bad Reading Bad ground circuit.
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 Terminal in radio connector for wire 65L to ground Voltage Bad circuit between the radio and the connector or bad radio (93). Bad circuit between the radio and the connector or bad radio (93).
Voltage
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93A 12 Volt Radio

Check Points Terminal in radio connector for wire 0 to ground Reading Continuity Possible Cause of Bad Reading Bad ground circuit.
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 Terminal in radio connector for wire 65L to ground Voltage Bad circuit between the radio and the connector or bad radio (93A). Bad circuit between the radio and the connector or bad radio (93A).
Voltage
93B Radio Power Converter (24 volts to 12 volts)

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on. Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (93B).
94 Left Speaker
Check Points Reading Possible Cause of Bad Reading 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 Speaker connector terminal for wire 0 to ground Voltage Bad circuit between the left speaker (94) and the radio or a bad radio (93 or 93A). Bad circuit between the left speaker (94) and the radio (93 or 93A).
Continuity
NOTE: If the readings are good, replace the left speaker (94).
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95 Right Speaker
Check Points Reading Possible Cause of Bad 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 Speaker connector terminal for wire 0 to ground Voltage Bad circuit between the right speaker (95) and the radio or a bad radio (93 or 93A). Bad circuit between the right speaker (95) and the radio (93 or 93A).
Continuity
NOTE: If the readings are good, replace the right speaker (95).
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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
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 Terminal for wire 19X to ground 24 volts 24 volts Check the 5 position rotary lamp switch (112), also check circuit 49. Check fuse X, also check circuit 19X.
NOTE: Put the beacon switch (96) in the ON position. Terminal for wire 46 to ground 24 volts Bad beacon switch (96).
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97 Rotating Beacon
Check Points Bulb Terminal for wire 0 to ground Reading Continuity Continuity Bad bulb. Bad ground circuit. Possible Cause of Bad Reading
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 Possible Cause of Bad 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
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 Terminal for wire 1B to ground NOTE: Turn the hazard switch (99) ON Terminal for wire 45H to ground 24 volts Bad hazard switch (99). 24 volts 24 volts Check circuit 49. Check Circuit Breaker B, also check circuit 1B.
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100 Turn Signal, Hi/Low Beam, and Horn Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19B to ground 24 volts Check fuse B, also check circuit 19B.
NOTE: Move the turn signal lever for right turn. Terminal for wire 45B to ground 24 volts Bad turn signal switch (100).
NOTE: Move the turn signal lever for left turn. Terminal for wire 45A to ground 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. 24 volts Bad turn signal switch (100).
NOTE: If the readings are good, replace the turn signal, Hi/Low beam, and horn switch (100).
101 Flasher Module

Check Points Reading Possible Cause of Bad 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 Terminal for wire 45L to ground 24 volts Intermittent 24 volts Intermittent 24 volts Bad circuit 45H, also check hazard switch (99). Bad flasher module (101), also check circuit 45L.
Terminal for wire 45R to ground
Bad flasher module (101), also check circuit 45R.
NOTE: Move the turn signal lever (100) for right turn. Terminal for wire 45B to ground Terminal for wire 45R to ground 24 volts Intermittent 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 Terminal for wire 45L to ground Terminal #2 to #12 wire 45N to ground (North American Only). 24 volts Intermittent 24 volts Continuity Bad circuit 45A, also check turn signal lever (100). Bad flasher module (101), also check circuit 45L.
Bad 45N circuit.
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-55
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS
118 114 115 113 117 116 102 103 104 110 111 112 105 106 107
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.
Copyright
4002-56
102 Left Marker/Turn Signal (North American Models)

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard 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) Bulb (Turn signal) Terminal for wire 45 to ground Terminal for wire 18F to ground Continuity Continuity Intermittent 24 volts 24 volts Bad bulb. Bad bulb. Check the turn signal switch (100), flasher module (101), and also check circuit 45. Check fuse F, lamp switch (112), and also check circuit 18F.
103 Left Drive Lamp (North American Models)

Put the master disconnect switch in the ON position. Put the lamp switch (112) in the drive lamp ON position. Bulb Terminal for wire 18D to ground Continuity 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)

NOTE: Put the master disconnect switch in the ON position. Put the lamp switch (112) in the flood lamp ON position. Bulb Terminal for wire 42C to ground Continuity 24 volts Bad bulb. Check 5 position rotary lamp switch (112), also check circuit 42C.
105 Right Flood Lamp (North American Models)

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in the flood lamp ON position. Bulb Terminal for wire 42C to ground Continuity 24 volts Bad bulb. Check the 5 position rotary lamp switch (112), also check circuit 42C.
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-57
106 Right Drive Lamp (North American Models)

NOTE: Put the master disconnect switch in the ON position. Put the lamp switch (112) in the drive lamp ON position. Bulb Terminal for wire 18E to ground Continuity 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)

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) Bulb (Turn signal) Terminal for wire 45 to ground NOTE: Turn on the marker lights. Terminal for wire 18G to ground 24 volts Check fuse G, check the 5 position rotary lamp switch (112), and check circuit 18G. Continuity Continuity Intermittent 24 volts Bad bulb. Bad bulb. Check the turn signal switch (100), flasher module (101), and check circuit 45.
108 Left Brake, Tail, and Directional Lights (North American Models)
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch (99) is OFF. Move the turn signal lever (100) for a left turn. Bulb (Brake and Tail) Bulb (Directional) Terminal for wire 45L to ground NOTE: Turn on the tail marker lights. Terminal for wire 18F to ground 24 volts Check fuse F, check the 5 position rotary lamp switch (112), and check circuit 18F. Continuity Continuity Intermittent 24 volts Bad bulb. Bad bulb. Check the turn signal switch (100), flasher module (101), and check circuit 45L.
NOTE: Have another person push down and hold the brake pedal. Terminal for wire 44 to ground 24 volts Check the stop lamp switch (98), also check circuit 44.
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-58
109 Right Brake, Tail, and Directional Lights (North American Models)
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch (99) is OFF. Move the turn signal lever (100) for a right turn. Bulb (Brake and Tail) Bulb (Directional) Terminal for wire 45R to ground NOTE: Turn on the tail marker lights. Terminal for wire 18G to ground 24 volts Check fuse G, check the 5 position rotary lamp switch (112), and check circuit 18G. Continuity Continuity Intermittent 24 volts Bad bulb. Bad bulb. Check the turn signal switch (100), flasher module (101), and check circuit 45R.
110 Fog Light Switch

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 Terminal for wire 19Y to ground Terminal for wire 41F to ground 24 volts 24 volts 24 volts Check circuit 49. Check fuse Y, also check circuit 19Y. Bad fog light switch (110).
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-59
111 High/Low Beam Relay (European Models)

Check Points Reading Possible Cause of Bad 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 NOTE: Hold Hi/Low beam lever back. Terminal for wire 64D to ground Continuity Check circuit 64D, also check Hi/low beam switch (100). 24 volts Check circuit 1.
Put the 5 position rotary lamp switch (112) in position 3 or 4. Terminal for wire 41J to ground NOTE: Put the low beams ON. Terminal for wire 41L to ground NOTE: Put the high beams ON. Terminal for wire 41H to ground 24 volts Bad high/low beam relay (111). 24 volts Bad hi/low beam relay (111), also check that jumper 41L and 41J is disconnected. 24 volts Check circuit 41J. Bad 5 position rotary lamp switch (112).
112 5 Position Rotary Lamp Switch

Check Points Reading Possible Cause of Bad Reading NOTE: Put the master disconnect switch in the ON position. Terminal for wire 1 Terminal for wire 19Z Terminal for wire 18A 24 volts 24 volts 24 volts Check circuit 1. Check fuse Z, also check circuit 19Z. 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).
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher. Terminal for wire 49 to ground 24 volts Bad 5 position rotary lamp switch (112).
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or 4. Terminal for wire 41J 24 volts Bad 5 position rotary lamp switch (112).
NOTE: Put the 5 position rotary lamp switch (112) in position 4 or 5. Terminal for wire 42C Terminal for wire 42R 24 volts 24 volts Bad 5 position rotary lamp switch (112). Bad 5 position rotary lamp switch (112).
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-60
113 Left Front Cab Lamp

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in position 4 or 5. Bulb Terminal for wire 42C to ground Continuity 24 volts Bad bulb. Check the circuit 42C, also check 5 position rotary lamp switch (112).
114 Left Rear Cab Lamp

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 42R to ground Continuity 24 volts Bad bulb. Check the circuit 42R, also check 5 position rotary lamp switch (112).
115 Right Rear Cab Lamp

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 42R to ground Continuity 24 volts Bad bulb. Check the circuit 42R, also check 5 position rotary lamp switch (112).
116 Right Front Cab Lamp

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 Continuity 24 volts Bad bulb. Check the circuit 42C, also check 5 position rotary lamp switch (112).
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-61
117 Courtesy Light

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in position 2 or higher. Bulb Terminal for wire 49 to ground Continuity 24 volts Bad bulb. Check the circuit 49, also check 5 position rotary lamp switch (112).
118 Cab Dome Light

NOTE: Put the master disconnect switch in the ON position. Put the cab dome light switch (118) in either 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.
Copyright
4002-62
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN MODELS

119 123 125 129 120 124 126 130
121 131
122
127 128
132
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.
Copyright
4002-63
119 Left Front Marker Lamp (European Models)

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

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in position 2 or higher. Bulb Terminal for wire 18G to ground Continuity 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)

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in position 2 or higher. Bulb Terminal for wire 18G to ground Continuity 24 volts Bad bulb. Check fuse F, also check circuit 18F and 5 position rotary lamp switch (112).
122 Right Rear Marker Lamp (European Models)

NOTE: Put the master disconnect switch in the ON position. Put the 5 position rotary lamp switch (112) in position 2 or higher. Bulb Terminal for wire 18G to ground Continuity 24 volts Bad bulb. 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.
Copyright
4002-64
123 Left Side Turn (Italy)

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch is OFF. Move the turn signal lever (100) for a left turn. Bulb Terminal for wire 45 to ground Continuity Intermittent 24 volts Bad bulb. Check circuits 45 and 45L, also check turn signal switch (100). Bad flasher module (101).
124 Right Side Turn (Italy)

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the hazard switch is OFF. Move the turn signal lever (100) for a right turn. Bulb Terminal for wire 45 to ground Continuity Intermittent 24 volts Bad bulb. Check circuits 45 and 45R, also check turn signal switch (100). Bad flasher module (101).
125 Left Front Combination Lamp (European Models)

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) Bulb (Turn signal) Terminal for wire 45 to ground Continuity Continuity Intermittent 24 volts Bad bulb. 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 24 volts Check fuse F, also check circuit 18F. Bad 5 position rotary lamp switch (112).
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-65
126 Right Front Combination Lamp (European Models)

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) Bulb (Turn signal) Terminal for wire 45 to ground Continuity Continuity Intermittent 24 volts Bad bulb. 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)

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 NOTE: Put the fog lights ON. Terminal for wire 41TF and 41F to ground 24 volts Check circuit 41TF and 41F, also check fog light switch (110). 24 volts Check fuse F, also check circuit 41T and 18F and 5 position rotary lamp switch (112).
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-66
128 Right Rear Combination Lamp (European Models)

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. Bulbs Terminal for wire 45 to ground Continuity Intermittent 24 volts 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 NOTE: Put the fog lights ON. Terminal for wire 41TF and 41F to ground 24 volts Check circuit 41TF and 41F, also check fog light switch (110). 24 volts Check fuse G, also check circuit 41T and 18G, also check 5 position rotary lamp switch (112).
129 Left Head Lamp (European Models)

NOTE: Put the master disconnect switch in the ON position. Put the low beams ON. Bulb Terminal for wire 18D to ground Continuity 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)

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).
Copyright
4002-67
131 Rear License Lamp (European Models)

NOTE: Put the master disconnect switch in the ON position. Put the rear license lamp ON. Bulb Terminal for wire 18F to ground Continuity 24 volts Bad bulb. Check fuse F, also check circuit 18F and 5 position rotary lamp switch (112).
132 Engine Compartment Lamp (European Models)

NOTE: Put the master disconnect switch in the ON position. Put the engine compartment lamp ON. Bulb Terminal for red wire to ground Continuity 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 Possible Cause of Bad 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 Continuity Bad engine compartment lamp switch (133), also check circuit 19F/U and fuse U.
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-68
CONNECTORS
GM98M018
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-69
GM98M019
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-70
GM98M020
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-71
GM98M021
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-72
GM98M022
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-73
GM98M023
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-74
GM98M024
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-75
GM98M025
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-76
GM98M026
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-77
GM98M027
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-78
GM98M028
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-79
GM98M029
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-80
GM98M030
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-81
GM98M031
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-82
GM98M032
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-83
ELECTRICAL SCHEMATIC - SHEETS 29, 30, 31, AND 32
CAB POSITIVE STUD
TO FUSE "W" SHT 2
TO FUSE "L" SHT 2
TO FUSE "L" SHT 2
TO FUSE "L" SHT 2
TO FUSE "L" SHT 2
O (19W) 1.0
O (19L) 1.0
113
REMOTE RADIO FUSE BLOCK "C11"
24 VOLT RADIO
O (19L) 1.0 O (19L) 1.0
12 VOLT RADIO
O (19L) 1.0
93
REMOTE RADIO
14 5 11 4 9 2 1 3 6 7 8 10 12 13
93
TO 24V RADIO
93A
TO 12V RADIO
R (1) 5.0
O/W (65R) 0.8
O/W (65C) 0.8
O/W (65L) 0.8
O/W (65L) 0.8
O/W (65C) 0.8
O/W (65R) 0.8
"C16"
O (19L) 1.0
FUSE BLOCK
O/W (65C) 0.8
FUSE BLOCK "C5"
O (19W) 3.0
BLOCK
91
O (19L) 1.0
"C5"
BLOCK "C5"
O (19L) 1.0
POWER CONVERTER
R (12V) 5.0
O (19L) 1.0
24V
IGN
JUMPER HARN
JUMPER HARN
RADIO POWER CONVERTER

RADIO HARNESS
B (0) 0.8
FUSE
B (0) 0.8
FUSE
O/W (65R) 0.8
O/W (65L) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
B (0) 0.8
JUMPER HARN RADIO HARNESS

O/W (65R) 0.8 O/W (65L) 0.8
GND
12V
6
RADIO HARNESS
RADIO HARN
6
RADIO HARNESS
RADIO HARN
93B
24V 12V
RADIO HARN
O/W (65L) 0.8
B (0) 0.8
FUSE BLOCK "C6", "C12",

R (12V) 3.0
O/W (65R) 0.8
A B
O/W (65L) 0.8
O/W (65C) 0.8 B (0) 0.8
A B
O/W (65C) 0.8 B (0) 0.8
O/W (65R) 0.8
B (0) 0.8
115
114
114
B (0) 0.8
A B
A B
O/W (65C) 0.8 B (0) 0.8
B (0) 0.8
90
CIGAR LIGHTER
"C18"
109 110
109 110
109
110
A B
A B
A B
116
112
112
A B
112
A B
92
POWER OUTLET
B (0) 3.0 B (0) 5.0 B (0) 1.0
94
LEFT SPEAKER
B (0) 0.8
94
111
94
111
A B
B (0) 0.8
114
LEFT SPEAKER
B (0) 1.0
LEFT SPEAKER
B (0) 1.0
111
B (0) 3.0
95
RIGHT SPEAKER
CAB NEGATIVE STUD
95
RIGHT SPEAKER
95
RIGHT SPEAKER
4
SHEET 29
SHEET 30
SHEET 31
SHEET 32
BC00E078
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-84
NOTES
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-85
ELECTRICAL SCHEMATIC - SHEETS 1 AND 2
1 2
VIA RR FOR HT. SW. ON SHEET 4
CAB POSITIVE STUD CAB SWITCHED POWER INSTRUMENT ILLUMINATION

R (1B) 0.8 O (19X) 1.0 CIRCUIT BREAKER B 12 AMP TO FUSE B ON SHEET 8 R (1B) 0.8 O (19B) 0.8 SPLICE WITH TIME DELAY GROUND ON SHEET 10 PED|CAB B (0) 1.0 R (1B) 0.8 R (1B) 0.8 DBr (45N) 0.8 1 2 3 4 5 6 Gy (49) 0.8 TO BACK-UP ALARM DISABLE SWITCH ON SHEET 12 DBr/LG (45R) 0.8 DBr/Y (45L) 0.8 DBr/LG (45B) 0.8 2 DBr/Y (45A) 0.8 DBr (45H) 0.8 6 P (46) 1.0 TO PLOT CONT. SW. ON SHEET 16 5 B (0) 0.8 TO PILOT CONT. SW. ON SHT 16 67 66 DBr (45H) 0.8 DBr (45N) 0.8 7 8 9 10 11 12 POWER IN FLASHER OUT GROUND GROUND N.C. N.C. R. TURN LIGHT OUT L. TURN LIGHT OUT RIGHT TURN SW. LEFT TURN SW. HAZARD SW. OPPOSITE SIDE CONTROL
1 2 3 30
101
1
Gy (49) 1.0 TO SPLICE #4 ON SHEET 8
FLASHER MODULE
CAB|FRONT
R (1B) 0.8 S
13
CAB|PED
B (1B) 0.8
65
B (0) 1.0 B (0) 1.0
TO BACK-UP ALARM DIS. SWITCH ON SHEET 12
96
2
BEACON SWITCH
B (0) 1.0
Gy (49) 0.8 R (1B) 0.8
15
6 5 Gy (49) 1.0 4 Gy (49) 0.8
42
TO INSTRUMENT CLUSTER CAVITY 13 ON SHEET 14
P (46) 0.8
71
2
13 64
PULL CONNECTOR APART FOR EUROPEAN MACHINES SHOWN FOR NAO
62
4 23
CAB CAB ROOF
NC
HAZARD SWITCH
3 1 2
C
99
T (44) 1.0 B (0) 1.0 TO CLUSTER CAVITY 35 ON SHEET 17
4
PED|CAB DBr/LG (45B) 0.8 DBr/Y (45A) 0.8 70 69 O (19B) 0.8
1
CAB|FRONT
T (44) 0.8 X A C DBr/Y (45L) 1.0 DBr/LG (45R) 1.0 DBr/Y (45L) 0.8 DBr/LG (45R) 0.8
NO
31 32 33 34 35
B (0) 1.0 TO RR WIPER MOTOR GROUND ON SHEET 25 B (0) 1.0 P (46) 1.0 B (0) 1.0
98
STOP LAMP SWITCH
(SWITCH IN TREADLE VALVE BELOW CAB CLOSES WITH BRAKE PEDAL ANGLE)
T (44) 0.8
DBr/Y (45L) 0.8
CAB|REAR
REAR|REAR LIGHT
9 11 7 DBr/Y (45L) 1.0 DBr/LG (45R) 1.0 T (44) 1.0
13
H R L 54
10 12 T (44) 0.8 B (0) 0.8 DBr/LG (45R) 0.8 8
DBr/LG (45L) 1.0 DBr/LG (45R) 1.0 T (44) 1.0
85
A B
45 2 1
31
21
94
TO CLUSTER CAVITY 17 ON SHEET 17
PED|CAB
A
B (0) 1.0
H/L
O/LB (64D) 0.8
55 42 41
DBr/Y (45L) 0.8
B (0) 1.0
68 66
67
B (0) 0.8 O/LB (64C) 0.8
TO CLUSTER CAVITY 16 ON SHEET 17
O/LB (64D) 0.8
ROTATING BEACON
4
97
CAB FLOOR WELD STUD
13
B (0) 0.8
O/LB (64C) 0.8
TO HORN RELAY #5 ON SHEET 26
36
CAB NEGATIVE STUD

VIA RR FOG LT. SW. ON SHEET 1
100
SHEET 1
TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH
SHEET 2
BC00E079
Bur 7-12221
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Printed in U.S.A.
Copyright
4002-86
ELECTRICAL SCHEMATIC - SHEET 3A
BC00E096
Bur 7-12221
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Printed in U.S.A.
Copyright
4002-87
ELECTRICAL SCHEMATIC - SHEETS 3, 4, AND 5
VIA SPLICE #3
1 2 3 30
O (19X) 1.0
CAB POSITIVE STUD CAB SWITCHED POWER INSTRUMENT ILLUMINATION

R (1) 3.0 TO INSTRUMENT CLUSTER CAVITY 15 SHEET 14 RIGHT
1 2 3
RIGHT FUSES
O (18C) 0.8
113
FUSE X FUSE Y FUSE Z FUSE A FUSE B FUSE C FUSE D FUSE E FUSE F FUSE G BEACON (7.5) FOG LIGHTS (7.5) FRNT. FLOOD LIGHTS AND ILLUM (10A) REAR FLOOD LIGHTS (10A) HIGH BEAM LEFT (5A) HIGH BEAM RIGHT (5A) LOW BEAM LEFT (5A) LOW BEAM RIGHT (5A) R (1) 3.0 TAIL LIGHTS LEFT (5A) TAIL LIGHTS RIGHT (5A) TO ENG. COMP. LIGHT ON PAGE 3 (EURO) 6/7/821C ONLY
114
LEFT REAR CAB LAMP
DBe (42R) 1.0 B (0) 1.0 DBe (42C) 1.0 B (0) 1.0
115
RIGHT REAR CAB LAMP
DBe (42R) 1.0 B (0) 1.0
116
RIGHT FRONT CAB LAMP
DBe (42C) 1.0 B (0) 1.0
102
LEFT MARKER/TURN SIGNAL
103
LEFT DRIVE LAMP
104
LEFT FLOOD LAMP
105
RIGHT FLOOD LAMP
106
DRIVE LAMP
107
RIGHT MARKER/TURN SIGNAL
LEFT FRONT CAB LAMP
117
COURTESY LIGHT
O (18E) 1.0
O (18G) 1.0
B (0) 1.0
B (0) 1.0
DBr (45) 1.0
O (18F) 1.0
B (0) 1.0
DBe (42C) 1.0
DBr (45) 1.0
O (18D) 1.0
DBe (42C)
B (0) 1.0
B (0) 1.0
1.0
A B
P (41T) 1.0
O (19Z) 1.0
R (19Y) 1.0
O (18G) 0.8
O (18G) 0.8
O (18F) 0.8
B (0) 1.0 O (18D) 0.8
DBe (42C) 1.0
A B P (41H) 2.0 P (41L) 2.0 P (41L) 0.8

H/L RELAY REMOVED AND CONNECTOR MATED FOR NAO (H/L SHOWN FOR EURO)
A B
A B
B (0) 1.0
B (0) 1.0 FRONT A B C LIGHT FRONT
18
B (0) 1.0 O (18A) 2.0 Gy (49) 0.8
78
A B
79
P (41J) 0.8
83
B (0) 1.0
80
77
Gy (49) 0.8 B (0) 0.8
C B A
A B C DBe (42C) 1.0
C B A
1
FRONT|CAB
HIGH/LOW BEAM RELAY
111
59
30 8
B (0) 1.0 DBe (42R) 1.0 B (0) 1.0 DBe (42C) 1.0 B (0) 0.8 DBe (42R) 1.0
21
7
DBe (42R) 1.0
O (18D) 1.0 O (18E) 1.0 O (18G) 1.0 DBe (42C) 1.0 O (18C) 1.0 O (18B) 1.0 O (18F) 1.0
O P E J Q G F O (18C) 0.8 O (18B) 0.8 O (18F) 0.8 P (18G) 1.0 TO R.H. RR MARK LT. ON SHEET 1 (EURO) O (18G) 1.0 B (0) 2.0 6 8 17 10 P (18F) 1.0 P (41F) 1.0 P (18G) 1.0 9 5 2 P (41F) 1.0 O (18G) 0.8 O (18G) 0.8 O (18E) 0.8 4 3 6 56a
REAR|CAB B (0) 0.8
56 56b S
B (0) 1.0
31 32 33 34
DBr/Y (45L) 1.0 DBr/Y (45L) 1.0
B (0) 1.0 DBr/LG (45R) 1.0 O (18F) 1.0 DBr/LG (45R) 1.0
B (0) 1.0
NAO
Y (18G/42R) 1.0
TO CAB/PED CONN. CAVITY 12 ON SHEET 14 P (41J) 2.0
CAB DOME LIGHT
O (19U) 1.0
118
CAB ROOF CAB
O (19U) 1.0 O (19U) 0.8
21
EURO
DBe (42R) 0.8 DBe (42C) 0.8 P (41J) 2.0 TO CLUSTER CAVITY 14 ON SHEET 14 Gy (49) 1.0 TO RETURN TO TRAVEL SWITCH, SHEET 19 B (0) 1.0
4
23
CAB ROOF CAB

Gy (49) 1.0 B (0) 1.0 B (0) 1.0
B (0) 1.0
84
B (0) 1.0
DBe (42C) 1.0
24
R (1) 3.0
TO FUSE U ON SHEET 10
T (44) 1.0
T (44) 1.0 B (0) 2.0
35
DBe (42C) 1.0 P (41T) 1.0 DBe (42R) 0.8 Gy (49) 0.8 LIGHTS B (0) 1.0
REAR LIGHT|REAR
REAR|CAB
1.0
B(O) 2.0
106
D B A C
T (44) 1.0
105
C A B D
B (0) 2.0
P(41F)
94
TO L.H. RR. MARK LT. ON SHEET 3 (EURO)
33
P (18F) 1.0
25
HD
34
TL F4 B1 IL F1 B3 F3 F2 B2
32
SWITCH POSITION
PARK AND TAIL
DRIVE
FLOOD F&R OFF
ILLUMINATION
Gy (49) 1.0
B (0) 2.0
TO BEACON SW. ON SHEET 1
B (0) 1.0
108
36 4
LEFT BRAKE, TAIL, AND DIRECTIONAL
109
RIGHT BRAKE, TAIL, AND DIRECTIONAL
43
FOG LIGHT SWITCH
5 POSITION ROTARY LAMP SWITCH
112
2 3
1 2 3 4 ON ON ON ON ON ON
ON ON ON ON ON
110
TO BEACON SWITCH ON SHEET 1
CAB NEGATIVE STUD
NAO
TO R.H. RR. TO L.H. RR. MARKS LT. ON SHEET 1 MARKS LT. ON SHEET 1 (EURO) (EURO)
VIA GROUND SPLICE
SHEET 3
SHEET 4
SHEET 5
BC00E080
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-88
NOTES
Bur 7-12221
Issued 4-00
Printed in U.S.A.
Copyright
4002-89
INDEX
Symbols
12 Volt Radio ..........................................................50 24 Volt Radio ..........................................................49 5 Position Rotary Lamp Switch...............................59
B
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
Copyright
4002-90
E
Ether Start Switch...................................................14
L
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
M
Master Disconnect Switch ......................................12 Module Flasher ...............................................................54 Time Delay .........................................................17 Transmission Electronic Control ........................19 Motor, Starter .........................................................13
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
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
Copyright
4002-91
P
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
R
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
Copyright
4002-92
S
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
T
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
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
Bur 7-12221
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
INFORMATION AND DIAGNOSTICS CENTER
Bur 7-12251
4005
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 7-12251 Issued 4-00
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
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4005-6
Bur 7-12251
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4005-7
INFORMATION AND DIAGNOSTIC CENTER

The information and diagnostic center monitors a number of functions and can be tailored to fit the operators 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 2 1
10
11
12 13
20 19 14
15 18 17 16
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.
3. All LEDs (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.
Bur 7-12251
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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. 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:
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. C. High hydraulic oil temperature. D. High transmission oil temperature. E. Low engine oil pressure. F. High or low air conditioning pressure. G. Air filter restriction. H. Transmission filter restriction (not applicable for 621C model). I. Hydraulic filter restriction. J. Alternator malfunction. K. Low fuel.
Power Circuit Test

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

Stop Master Indicator (Red)
IMPORTANT: Failure to follow these procedures may result in injury and/or damage to the machine. When the stop master indicator illuminates: 1. Stop the machine immediately. 2. Turn OFF the engine. 3. The warning alarm sounds continuously and one or more of the following conditions exist: A. Low engine oil pressure. B. Low brake pressure. C. Low steering pressure. D. Low engine coolant level. E. High engine coolant temperature. F. High hydraulic oil temperature. G. High transmission oil temperature.
Low Coolant Indicator

The low coolant indicator illuminates when the engine coolant is low. 1. The warning alarm sounds continuously. 2. The stop master indicator will be red. 3. Stop the engine and add coolant to the radiator.
Brake Pressure Indicator

The brake pressure indicator illuminates when the brake system pressure is too low. 1. The warning alarm sounds continuously. 2. The stop master indicator will be red. 3. Stop the engine and correct the problem.
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4005-9
Secondary Steering Indicator (If equipped)

The secondary steering indicator illuminates when the primary steering system pressure is too low. 1. The warning alarm sounds continuously. 2. The stop master indicator will be red. 3. Stop the engine and correct the problem.
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: Indicates normal operating temperature, 20 to 120 C (68 to 248 F). 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). 2. The indicator bars flash. 3. The warning alarm sounds for 3 seconds. 4. The yellow caution master indicator turns on. 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. The warning alarm sounds continuously. 4. The red stop master indicator turns on. 5. Stop the machine. 6. Shift the transmission into NEUTRAL. 7. Run the engine at half throttle until 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.
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: 1. The warning alarm sounds for 3 seconds. 2. The caution master indicator turns yellow. 3. Disengage the parking brake before shifting the machine.
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. 1. The warning alarm sounds for 3 seconds. 2. The caution master indicator turns yellow. 3. Service the air-conditioning system, or the outside air temperature is too cool for the system to work.
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. 1. The warning alarm sounds for 3 seconds. 2. The caution master indicator turns yellow. 3. Replace the hydraulic oil filters as required.
Hydraulic Oil Temperature Gauge

The hydraulic oil temperature gauge is shown as an indicator bar with a green, yellow, or red zone. Green Zone: Indicates normal operating temperature, 20 to 105 C (68 to 221 F). 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).
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.
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4005-10 2. The indicator bars flash. 3. The warning alarm sounds for 3 seconds. 4. The yellow caution master indicator turns on. Red Zone: NOTE: The machine must not be operated when the temperature is in the red zone. 1. Hydraulic oil temperature continues to increase 110 C and above (230 F and above). 2. The indicator bar flashes. 3. The warning alarm sounds continuously. 4. The red stop master indicator turns on. 5. Stop the machine and correct the problem. 1. The indicator bars flash. 2. The warning alarm sounds for 3 seconds. 3. The yellow caution master indicator turns on.
Engine Oil Pressure Gauge

The engine oil pressure gauge is shown as an indicator bar with a green, yellow, or red zone. Green Zone: Indicates normal operating pressure, 140 kPa (20 psi) and above low idle. 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. Red Zone: NOTE: The machine must not be operated when the oil pressure is in the red zone. 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. 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. Green Zone: Indicates normal operating range: 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. Yellow Zone: Voltage has increased or decreased: 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. 2. The warning alarm sounds for 3 seconds. 3. The yellow caution master indicator turns on. 4. Stop the machine and correct the problem.
Engine Coolant Temperature

The engine coolant temperature gauge is shown as an indicator bar with a green, yellow, or red zone. Green Zone: Indicates normal operating temperature, 20 to 105 C (68 to 221 F). Yellow 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. Red Zone: NOTE: The machine must not be operated when the temperature is in the red zone.
Fuel Level Gauge

The fuel level gauge is shown as an indicator bar with a green or yellow zone. Green Zone: Indicates normal operating range, 5 percent and above. Yellow Zone: The tank is almost empty, 5 percent and below.
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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. 4. The red stop master indicator turns on. 5. Stop the machine and correct the problem.
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.
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4005-12
WARNING DISPLAYS Critical Warning Displays

IMPORTANT: Failure to follow these procedures may result in injury and/or damage to the machine. The following table is a listing of critical warning displays that may appear on the information center and 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 ENGINE OIL PRESSURE BRAKE PRESSURE
DESCRIPTION Low engine oil pressure. Low brake pressure.
CORRECTIVE ACTION 1. Check low idle specifications. 2. Change engine oil and filter. 3. Change operating procedures. 1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check brake system for proper charging and leaks. 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. 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. 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. 1. Bring the machine to a safe stop and shut the engine OFF immediately. 2. Check the hydraulic fluid level. 3. Clean the cooler. 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
Low steering pressure.
COOLANT LEVEL
Low coolant level.
COOLANT TEMPERATURE
High engine coolant temperature.
HYDRAULIC OIL TEMPERATURE
High hydraulic oil temperature.
TRANSMISSION OIL TEMPERATURE
High transmission oil temperature.
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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 PARKING BRAKE COOLANT TEMPERATURE HYDRAULIC TEMPERATURE TRANSMISSION TEMPERATURE ENGINE OIL PRESSURE AIR CONDITIONING AIR FILTER TRANSMISSION FILTER HYDRAULIC FILTER ALTERNATOR FUEL DESCRIPTION Parking brake engaged and shifts from Forward to Reverse. High engine coolant temperature. High hydraulic temperature. CORRECTIVE ACTION Release the parking brake and depress the service brake. 1. Idle machine and monitor temperature. 2. Clean radiator. 1. Idle machine and monitor temperature. 2. Clean the cooler. 1. Idle machine and monitor temperature. 2. Clean the cooler. 3. Use a lower gear. 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. 1. Check electrical system. 2. Voltages are out of range. 3. Change operating procedure. Fill fuel tank within the next hour.
High transmission temperature.
Low engine oil pressure. High or low air conditioning pressure. High air filter restriction. Transmission filter restriction. Hydraulic filter restriction. Alternator malfunction. Low fuel.
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4005-14
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:
2 1 4
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
The hourmeter displays the accumulated running time of the engine in hours and tenths of an hour with an hour glass symbol.
Engine Coolant Temperature

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.
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.
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.
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.
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Transmission Oil Temperature

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.
Transmission Display
The Transmission Display shows the status of the transmission control. The display center contains the following information, refer to Figure 2:
Direction Selected
Shown at the top of the display center: F N R F N R Forward Neutral Reverse Flashing forward not engaged. Flashing set control lever to neutral position. Flashing reverse not engaged.
Hydraulic Oil Temperature

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.
Voltmeter
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.
Requested Gear
The gear position on shift lever, shown in the center of the gear symbol: 1 2 3 4 1st gear 2nd gear 3rd gear 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.
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4005-16
SETTINGS, DIAGNOSTICS, AND FAULT CODES
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 to
1. Turn the machine OFF. 2. Turn the key to the RUN position. 3. Press the program/reset switch to program. 4. Press the up/down count switch to up 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:
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. 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:
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4005-17 01 02 Manually scrolls through Hourmeter, Tachometer, and Speedometer (km/h). Manually scrolls through Hourmeter, Tachometer, and Speedometer (mph). Automatically scrolls through Hourmeter (at start-up), Tachometer (in 1st and 3rd gears), and Speedometer (km/h in 4th gear). Automatically scrolls through Hourmeter (at start-up), Tachometer (in 1st and 3rd gears), and Speedometer (mph in 4th gear). 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 reset 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.
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: 000 001 002 003 004 005 006 007 008 009 Hourmeter Tachometer Speedometer (mph) Speedometer (km/h) Engine Oil Temperature Engine Oil Pressure Fuel Level Transmission Oil Temperature Hydraulic Oil Temperature Voltmeter
03
04
05
9. If the Information Center does not function properly, do the programming steps again. 10. If the Information Center continues malfunction replace the instrument panel. 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.
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.
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.
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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. 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 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Meaning Clutch Calibration Mode was not initiated because one of the requirements was not met. Adjusting 1st gear. Adjusting 2nd gear. Adjusting 3rd gear. Adjusting 4th gear. Adjusting Forward gear. Adjusting Reverse gear. Clutch Calibration Completed. Operator aborted calibration procedure. Aborted while adjusting 1st gear. Aborted while adjusting 2nd gear. Aborted while adjusting 3rd gear. Aborted while adjusting 4th gear. Aborted while adjusting Forward gear. Aborted while adjusting Reverse gear.
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. 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.
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CLUTCH CALIBRATION SUB CODES Sub Code 00 01 02 Meaning Calibration in process. Fault present. Shift lever not in neutral.
Issued 4-00
Printed in U.S.A.
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4005-19 03 04 05 06 07 08 Park brake not applied. Output speed not 0 kph/mph. Low transmission oil temperature. High transmission oil temperature. Low engine RPM. High engine RPM. 2. Press the up/down count switch to up count until the display reads 015. 3. The alarm will begin to sound intermittently. 4. Place the program/reset switch in the OFF (center) position. 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.
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). 3. Place the program/reset switch in the OFF (center) position. 4. Increase the brightness by pressing the up/down count switch to the up count position. 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.
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. 2. Press the up/down count switch to up count until the display reads 016. 3. The coolant light will flash intermittently. 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.
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
Do the following procedures to check the audible alarm system. 1. Press the program/reset switch to program.
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4005-20
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.
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.
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.
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.
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.
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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.
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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. 3. Place the program/reset switch in the OFF (center) position. 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.
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. 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. 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.
Fog Lights Check

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. 3. Place the program/reset switch in the OFF (center) position. 4. Place the gear shifter in all positions and verify that the code in each position corresponds to the codes in the table below
:
Air Conditioning Switch Check

Do the following procedures to check the air conditioning indicator light and the air conditioning high/low pressure switch. 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. 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 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 1Code 101 Forward 2Code 102 Forward 3Code 103 Forward 4Code 104
Neutral 1Code 201 Neutral 2Code 202 Neutral 3Code 203 Neutral 4Code 204
Reverse 1Code 301 Reverse 2Code 302 Reverse 3Code 303
Operational Indicator Status

Do the following procedures to check the status of the operational indicator. 1. Press the program/reset switch to program.
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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. 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.
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. 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.
:
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.
in
Forward 1Code 101 Forward 2Code 102 Forward 3Code 103 Forward 4Code 104 Limp Home Mode - 115
Neutral 1Code 201 Neutral 2Code 202 Neutral 3Code 203 Neutral 4Code 204 Limp Home Mode - 215
Reverse 1Code 301 Reverse 2Code 302 Reverse 3Code 303
Tachometer Indicator Status

Do the following procedures to check the status of the tachometer indicator. 1. Press the program/reset switch to program. 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.
Limp Home Mode - 315
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. 5. The Information Center will read 00. 6. Shift the shift lever.
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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.
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4005-23 4. The Information Center will read 00 if the service indicator is OFF or 01 if the service indicator is ON. 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.
Movement Indicator Status

Do the following procedures to check the status of the movement indicator. 1. Press the program/reset switch to program. 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. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00.
Caution and Warning Master Indicator Lights Status

Do the following procedures to ensure that the caution and warning lights are working correctly. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 039 (Critical Master Light Red). 3. Place the program/reset switch in the OFF (center) position. 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 5. Press the program/reset switch to program. 6. Press the up/down count switch to up count until the display reads 041 (Caution Master Light Yellow). 7. Place the program/reset switch in the OFF (center) position. 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
Beacon Status
Do the following procedures to check the status of the beacon. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 036. The beacon indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will read 00 if the beacon is OFF or 01 if the beacon is ON.
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.
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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.
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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. 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).
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.
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.
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.
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.
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4005-25
Display Location Numbers (048 and 049) Reserved for Future Use 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. 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. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 050. 3. Place the program/reset switch in the OFF (center) position. 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. 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.
Gear Range Read Only

Do the following procedures to read the gear range. 1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until the display reads 052. The operational indicator will flash intermittently. 3. Place the program/reset switch in the OFF (center) position. 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. 7. Place the program/reset switch in the OFF (center) position. 8. The Information Center will read 2,3, or 4 (gears).
Display Location Number 054 Reserved for Future Use Reset Diagnostic Stack for Locations 071 through 090
Do the following procedure to remove all 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.
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. 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.
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4005-26
Display Location Numbers (056 - 060) Reserved for Future Use 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). C. Place the program/reset switch in the OFF (center) position. D. Read the accumulated hours in the chosen location. 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.
1. To view the 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 (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. 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. 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. 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.
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 machines 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.
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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. 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.
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).
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. 2. Press the up/down count switch to up count until the display reads 096. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Centers internal temperature will be displayed in degrees Celsius.
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 092. 3. Place the program/reset switch in the OFF (center) position. 4. The Information Center will display the second part of the ZF Transmission ECM part number (#####, # is a digit from 0 to 9).
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.
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.
LED Duty Cycle

Do the following to display the LED duty cycle.
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6. Press the up/down count switch one time so that the display reads 099.
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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 user leaves the range of 098-099, locations 098 and 099 are automatically reset to 000. 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.
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. 10. Press the up/down count switch to down count until the display reads 100. 11. Place the program/reset switch in the OFF (center) position. 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. 16. Press the up/down count switch to up count until the display reads 010.
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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.
Instrument Cluster (Information Center) Part Number (2nd part)

Do the following to enter the second part 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 115. The service indicator flashes intermittently. 3. Place the program/reset switch in the OFF (center) position.
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4005-29 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. 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).
CALIBRATION NUMBER
TIRE REV/KM
MACHINE/TIRE
AXLE RATIO
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. 621 w/ 17.5 x 25 L2 621 w/ 17.5 x 25 XTLA/XHA 621 w/ 20.5 x 25 L2 621 w/ 20.5 x 25 XTLA/XHA 721 w/ 17.5 x 25 L2 721 w/ 17.5 x 25 XTLA/XHA 721 w/ 20.5 x 25 L2 721 w/ 20.5 x 25 XTLA/XHA 821 w/ 20.5 x 25 L2 821 w/ 20.5 x 25 XTLA/XHA 821 w/ 23.5 x 25 L2 821 w/ 23.5 x 25 XTLA/XHA 921 w/ 26.5 x 25 L2 921 w/ 26.5 x 25 XRD/XHA
21.88 21.88 21.88 21.88 21.37 21.37 21.37 21.37 23.51 23.51 23.51 23.51 22.85 22.85
259 245 235 225 259 245 235 225 220 218 208 207 201 193
5667 5361 5142 4923 5535 5236 5022 4808 5172 5125 4890 4867 4593 4410
Display Location Numbers 117 - 120 Reserved for Supplier Information Display Location Numbers 121 -129 Reserved for Future Use Speedometer Calibration
Do the following to reset the speedometer calibration. NOTE: If a dealer or customer changes tire sizes, the speedometer calibration will have to be 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. 2. Multiply the tire revolution/km by the axle ratio. The answer will be the new speedometer calibration number.
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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.
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4005-30
Display Location Numbers 131 - 139 Reserved for Speedometer Calibration Display Location Numbers 140 - 170 Reserved for Future Use Temporary Fault Code Status
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 machines 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 verify 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. 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.
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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. 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.
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4005-31
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS

DISPLAY LOCATION NUMBER 000 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 Engine Hours Engine Tachometer Speedometer in Miles Per Hour Speedometer in Kilometers Per Hour Engine Coolant Temperature in Degrees Celsius Engine Oil Pressure in Kilopascals Fuel Level in Percent of Fuel in Tank Transmission Oil Temperature in Degrees Celsius Hydraulic Oil Temperature in Degrees Celsius Voltmeter Reading (Continuous) Gauge Display Selection Parking Brake Test / Clutch Calibration Information Center Light Setting - Work Lights Off Information Center Light Setting - Work Lights On Voltmeter Reading at Key-on Alarm Status Coolant Level Status 00 = Off, 01 = On 00 = Normal Level 01 = Low Level 00 = Switch Closed 01 = Switch Opened (Open = Normal Pressure) 00 = Switch Closed 01 = Switch Opened (Open = Normal Pressure) 00 = Off, 01 = On 00 = Off, 01 = On 00 = Switch Closed 01 = Switch Opened (Open = Filter is OK) 00 = Switch Closed 01 = Switch Opened (Open = Filter is OK) 00 = Off, 01 = On 00 = Off, 01 = On DEFINITION STATUS
017
Brake Pressure Status
018 019 020
Steering Pressure Status Present Park Brake Output from Information Center Status Present Pilot Lockout Status Output from Information Center Hydraulic Filter Restriction Switch Status
021
022 023 024
Air Filter Restriction Switch Status Present Work Lights Status Present Fog Lights Status (European Only)
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4005-32 DISPLAY LOCATION NUMBER 025
DEFINITION
STATUS 00 = Switch Open 01 = Switch Closed (Open = Normal Pressure) 00 = Open 01 = Closed (Open - Filter is OK) 00 = Off, 01 = On 101 104 203 302 = = = = F1, 102 = F2, 103 = F3, F4, 201 = N1, 202 = N2, N3, 204 = N4, 301 = R1, R2, 303 = R3
Air Conditioning High/Low Pressure Switch Status
026 027
Transmission Filter Restriction Switch Status Present Status Of High Beam Lights (European Only)
028
Requested Gear Status
029
Status of Transmission Operation Indicator - In Transmission Display
00 = Always 101 104 201 204 301 315 = = = = = = 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
030
Actual Gear Status
031
Shift Status Driveline Status Operational Mode
First Digit = 000 = Shift Not In Process 001 = Shift In Process 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
032 033 034 035 036 037 038 039 040
Hourmeter Status Tachometer Status Current Status of Service Indicator for Normal Operating Mode (Book with the wrench) Movement indicator Status Beacon Status Left Turn Indicator Status Right Turn Indicator Status Current Status Master Indicator (Red) Current Status of Diagnostic Indicator (Book without the wrench - Operators Manual)
00 - Always 00 - Always 00 = Off, 01 = On 00 - Always 00 = Off, 01 = On 00 = Off, 01 = On 00 = Off, 01 = On 00 = Off, 01 = On 00 - Always
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4005-33 DISPLAY LOCATION NUMBER 041 042
DEFINITION Current Status Master Indicator (Yellow) 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) 00 = Switch Closed 01 = Switch Open (Closed = Normal Operation) 00 = Switch Open 01 = Switch Closed (Closed = Actuated) 00 = Switch Open 01 = Switch Closed (Closed = Loader Controls Locked) 01 = Circuit Closed 02 = Circuit Malfunction Range - 1st and 2nd gear Range - 2nd, 3rd and 4th gear
044
Redundant Brake Pressure Switch
045
Service Brake Foot Switch Status
046
Pilot Lockout Switch Status
047 050 051 052 053
Seat Circuit Minimum Gear Selection Maximum Gear Selection Minimum Gear Read Only Maximum Gear Read Only
055
Reset Diagnostic Stack, 071 to 090 to zero
Range = 0 to 99 Default = 0 Set to 21 and then exit this location 055 to reset diagnostic stack 071 -099 to zero
061 - 070 071,073, 075,077, 079,081, 083,085, 087, 089 072,074,076 ,078,080,08 2,084,086,0 88,090 091 092 093
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Service Hour interval Selection #1 - 10
Fault Code #1 Through Fault Code #10
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) 1st Portion Of Transmission Electronic Control Module (ECM) Part Number (5 digits from 0-9) 2nd Portion Of Transmission ECM Part Number (5 digits from 0-9) Cluster Software Revision Number
ZF part number ZF part number
Copyright
4005-34 DISPLAY LOCATION NUMBER 094 095 096 098 099 100 - 103 114 115 116 130 171 - 190
DEFINITION Light Emitting Diode (LED) Duty Cycle Liquid Crystal Display (LCD) Duty Cycle Internal Cluster Temperature Entry Code for Accessing Test Mode Locations 100 to 199 Entry Code for Accessing Test Mode Locations 100 to 199 Transmission ID Number Cluster Part Number Cluster Part Number Cluster Date Code Speedometer Calibration Temporary Fault Code Status
STATUS In units of 0.01% In units of 0.01% In units of deg C Set to 21 to enter Test Mode locations (Range = 0 to 99) Set to 21 to enter Test Mode locations (Range = 0 to 99)
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4005-35
FAULT CODES
CODE DEFINITION Engine coolant short circuit measuring less than 50 ohms to the engine coolant temperature sensor. 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. Low engine coolant level - This code will not be generated if the engine coolant temperature is below 20 C (68 F). Engine oil pressure is measured below 100 kPa (14.5 PSI) Engine coolant temperature is 110 C (230 F) or greater. Engine oil pressure short circuit measuring less than 16 ohms to the engine oil pressure sensor. Engine oil pressure open circuit measuring more than 270 ohms to the engine oil pressure sensor. Fuel level short circuit measuring less than 16 ohms to the fuel level sender. Fuel level open circuit measuring more than 270 ohms to the fuel level sender. Fuel solenoid output short circuit. 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. 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. 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. Check the cables from TCU to shift lever. 2. Check signal combinations of shift lever positions for gear range. 1. Check the cables from TCU to shift lever. 2. Check signal combinations of shift lever positions F-N-R.
POSSIBLE STEPS FOR REPAIR
12900
Troubleshoot electrical circuits.
12901
13000
21100 21110
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.
21900
Troubleshoot electrical circuits. NOTE: Fault code 21900 is possible during cold engine start-up. After machine warm up, verify proper operation.
21901
33900 33901 34000
Troubleshoot electrical circuits.
35000
High air filter restriction.
42125
Transmission temperature measured above 125 C (257 F)
45000
High transmission filter restriction when the transmission oil is above 20 C (68 F).
46017
Gear range fault error
46018
Logical error at direction select signal
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4005-36 CODE DEFINITION POSSIBLE STEPS FOR REPAIR 1. Check the cables from the electronic boxes to the status switches. 2. Check signals of the status switches. 1. Check the connectors. 2. Check the temperature sensor.
46020
Logical fault at Park Brake Status Short circuit to battery voltage or Open circuit at temperature sensor input Short circuit to ground at temperature sensor input Short circuit to battery voltage or open circuit at converter output temperature sensor input Short circuit to ground at converter output temperature sensor input Short circuit to battery voltage or Open circuit at engine speed input Short circuit to ground at engine speed input
46037 46038 46039 46040 46049 46050
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.
46051
Logical error at engine speed input
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 46053 Short circuit to battery voltage or Open circuit at turbine speed input Short circuit to ground at turbine speed input 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.
46054
Logical error at turbine speed input
NOTE: This fault code is reset after power up of the TCU. 46055 46056 Short circuit to battery voltage or Open circuit at intermediate speed input Short circuit to ground at intermediate speed input 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.
46057
Logical error at intermediate speed input
NOTE: This fault code is reset after power up of the TCU. 46058 46059 Short circuit to battery voltage or Open circuit at output speed input Short circuit to ground at output speed input 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.
Bur 7-12251
Issued 4-00
Printed in U.S.A.
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4005-37 CODE DEFINITION 1. 2. 3. 4. POSSIBLE STEPS FOR REPAIR Check the cables from TCU to the sensor. Check the connectors. Check the speed sensor. Check the sensor gap.
46060
Logical error at output speed input
NOTE: This fault code is reset after power up of the TCU. 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 46065 46089 46090 46091 46113 46114 46115 46116 46117 46118 46119 46120 46121 46129 46130 46131 46132 46133 46134 46135 46136 46137 Invalid gear range restriction (CAN) Invalid declutch modulation selection (CAN) Invalid test mode signal (CAN) Invalid park brake status (CAN) Invalid shift quality selection (CAN) Short circuit to battery voltage at clutch K1 Short circuit to ground at clutch K1 Open circuit at clutch K1 Short circuit to battery voltage at clutch K2 Short circuit to ground at clutch K2 Open circuit at clutch K2 Short circuit to battery voltage at clutch K3 Short circuit to ground at clutch K3 Open circuit at clutch K3 Short circuit to battery voltage a clutch K4 Short circuit to ground at clutch K4 Open circuit at clutch K4 Short circuit to battery voltage at clutch KV Short circuit to ground at clutch KV Open circuit at clutch KV Short circuit to battery voltage at clutch KR Short circuit to ground at clutch KR Open circuit at clutch KR 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. 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.
46062
Output speed zero, does not match other speeds.
Bur 7-12251
Issued 4-00
Printed in U.S.A.
Copyright
4005-38 CODE 46145 46146 46147 DEFINITION Short circuit to ground at reverse warning alarm relay Short circuit to battery voltage at reverse warning alarm relay Open circuit at reverse warning alarm relay 1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. 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. Check pressure at clutch K2. 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. Check pressure at clutch K3. 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. Check pressure at clutch K4. 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. 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. 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. POSSIBLE STEPS FOR REPAIR
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.
46177
Slippage at clutch K1
46178
46179
46180
46181
Slippage at clutch KV
46182
Slippage at clutch KR
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4005-39 CODE 46183 DEFINITION Oil temperature at valve body is above limit 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.
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. Short circuit to battery voltage at power supply for sensors Short circuit to ground at power supply for sensors Low voltage at battery High voltage at battery Error at switch 1 for solenoid power supply Error at switch 2 for solenoid power supply Short circuit to battery voltage at display output Short circuit to ground at display output Error at communication on CAN Undefined VIN request via CAN. General EEPROM fault Current ID not set or corrupt Application error (ZF internal) Clutch calibration fault Clutch adjustment data lost CAN interface failure where no signals are received over one second of time
46209 46210 46211 46212 46213 46214 46227 46228 46229 46230 46241 46242 46243 46245 46246 47000
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.
Replace the TCU. Reprogram the correct configuration for the vehicle. Replace the TCU. Check the clutch. Execute AEB. 1. Clear the codes. 2. Restart the machine. 3. Monitor machine operation and diagnostics.
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4005-40 CODE 47001 47002 DEFINITION Engine speed is missing Output shaft speed is missing POSSIBLE STEPS FOR REPAIR 1. Verify corresponding function is displayed on the information center and is working properly: A. Engine rpm - run engine LI to HI and verify display shows rpm. B. Output shaft speed - drive unit with mph/kph dis played and ver ify that it is wor king properly. 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. Verify 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.
47011
Transmission oil temperature is missing
47012
Transmission filter restriction information is missing
47013 47014 51000
Current Transmission identification code is outside of the range Result code (11) Low steering pressure has been detected after a normal operating pressure has been reached since start up. Low brake pressure (1700 PSI / 11721 kPa) has been detected after a normal operating pressure has been reached since start up. 1700 PSI (11,721 kPa) Brake pressure switch has not cycled within 50 hours of operation time. 900 PSI (6250 kPa) Redundant brake pressure switch has not cycled within 100 hours of operation time. Park brake solenoid output short circuit. Park brake switch has not cycled within 50 hours of operation time.
61000
61900
61901 64000 66900
1. Turn machine off. 2. Pump service brake 30 full strokes. 3. Start machine and verify proper operation and no diagnostic codes. 4. Operate machine and monitor performance. 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.
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Printed in U.S.A.
Copyright
4005-41 CODE DEFINITION POSSIBLE STEPS FOR REPAIR 1. Verify full pedal actuation and return, make sure debris does not obstruct pedal travel. 2. Clear codes. 3. Verify proper machine operation. 4. If code reappears, check brake light switch and troubleshoot electrical circuits. 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.
66901
Service brake foot switch has not cycled within 50 hours of operation.
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. 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. Pilot pressure solenoid output short circuit. High hydraulic filter restriction when the hydraulic oil is above 20 C (68 F). System voltage is below 18 volts. System voltage is above 32 volts. Corrupt engine hours, data lost Corrupt engine hours, data suspect 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 verify 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. Verify proper machine operation and machine travel speed to displayed speed. 3. Continue machine operation and monitor for recurring fault codes. Troubleshoot electrical circuits.
72901
74000 75000 84018 84032 86010 86011
86012
Corrupt engine hours, data suspect
86020 86021 86022
Corrupt tire calibration numbers, data lost The calibration number will default back to the number used at cluster shipment Corrupt tire calibration number, data suspect Corrupt tire calibration number, data suspect
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4005-42 CODE 86030 86040 86050 DEFINITION Information Center memory error Information Center program memory error Information Center RAM failure 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. Open range setting Brightness setting Machine ID Machine info Cluster part number Cluster date code Cluster reserved Calibration number Shift quality Requested Gmin Requested Gmax Declutch modulation Creep setting Service hours Diagnostics stack pointer (internal to software) Diagnostics stack contents Digital input states (internal to software) Engine hour time stamps for digital input states (internal to software) Air Conditioning high or low pressure indication 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 verify 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. POSSIBLE STEPS FOR REPAIR
86060
86070 86071 86072 86073 86074 86075 86076 86077 86078 86079 86080 86081 86082 86083 86084 86085 86086 86087
91000
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4005-43
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 .....................17 048 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
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
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
D
Diagnostic Center ....................................................7 Diagnostic Indicator Status ....................................23 Display Center Lighting, Setting ................................................19 Display Location 047 ....................................................................24
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G
Gauge Engine Oil Pressure ..........................................10 Fuel Level ..........................................................10
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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 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
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
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
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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
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
Copyright
4005-46
NOTES
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Printed in U.S.A.
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SECTION INDEX - POWER TRAIN Section Title
0000-1
Section Number
Transmission Specifications, Pressure Checks, and Troubleshooting ............................................................................... 6002 Transmission .......................................................................................................................................................... 6003 Front and Rear Axle ................................................................................................................................................. 6004 Drive Shaft, Center Bearing, and Universal Joints ......................................................................................................... 6005 Wheels and Tires ..................................................................................................................................................... 6006 Transmission Control Valve .................................................................................................................................... 6007
Bur 7-13231
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Copyright
Section 6002
TRANSMISSION SPECIFICATIONS, SCHEMATIC, AND TROUBLESHOOTING
Bur 7-12391
6002
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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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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6002-4
4 5
3 2
12
9 8 14 11
13 10 7
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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6002-5
12 1
11
10
15
9 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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6002-6
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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6002-7
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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6002-8
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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6002-9
TRANSMISSION OPERATION General

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 passages are internal). A. Determines which clutches to engage in the transmission. B. Protect the engine and transmission turbine fr om overspeed conditions dur ing downloading. 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
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.
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.
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:
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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. 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.
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. 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.
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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 panel. 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.
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
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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. As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will 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.
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 FIGURE 7
Upshifting in Manual Mode

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.
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.
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.
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 (14F) (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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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. 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.
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 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.
Copyright
6002-13
NOTES
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6002-14
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

No. IDENTIFICATION/LOCATION Measuring Points for Pressure Oil and Temperature 51 52 53 55 56 57 58 60 63 65 15 16 21 34 47 48 49 68 69 Before the Converter - Opening Pressure 9 bar Behind the Converter - Opening Pressure 3.5 bar Clutch Forward 16+2 bar Clutch Reverse 16+2 bar Clutch 16+2 bar Clutch 16+2 bar Clutch 16+2 bar Clutch 16+2 bar Behind the Converter Temperature 100 C, Short Time 120 C System Pressure 16+2 bar Measuring Points for Delivery Rates Connection to the Heat Exchanger Connection from the Heat Exchanger Inductive Transmitter and Speed Sensor Inductive Transmitter n Turbine Speed Sensor n Output and Speedometer Inductive Transmitter n Central Gear Train Inductive Transmitter n Engine Connections Plug Connection on the Hydraulic Control Unit System Pressure Pilot Pressure M16x1.5 M16x1.5 G J M18x1.5 M18x1.5 M18x1.5 1 5/16 - 12 UNF-2B 1 5/16 - 12 UNF-2B M10x1 M14x1.5 KV M10x1 KR M10x1 K1 M10x1 K2 M10x1 K3 M10x1 K4 M10x1 M14x1/5 M10x1 K B E D A C F H CONNECTION DESIGNATION ON VALVE BLOCK
NOTE: See Figure 10 for Measuring Point, Transmitter, Sensor and Connection locations.
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6002-15
FIGURE 10. MEASURING POINTS AND CONNECTIONS
BC00E065
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CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings. P.I.N. Number: TEST POINTS Shift Speed 1st F 2nd F 3rd F 4th F 1st R 2nd R 3rd R Neut
P= MAIN PRESSURE V= FORWARD CLUTCH R= REVERSE CLUTCH 1= FIRST GEAR CLUTCH 2= SECOND GEAR CLUTCH 3= THIRD GEAR CLUTCH 4= FOURTH GEAR CLUTCH 5= CONVERTER IN 6= CONVERTER OUT LP= LUBE PRESSURE
Date:
P 65
V 53
R 55
1 56
2 57
3 58
4 60
5 51
6 52
LP
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6002-17
PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low
Possible causes include: 1. Oil level not correct. 2. Oil type and grade not correct. 3. Oil operating temperature high. 4. Screen for suction tube plugged. 5. Suction tube or gaskets leak. 6. Main pressure valve, springs, or valve bore. 7. Reduction valve, springs, or valve bore. 8. Charge pump seals or gaskets leak. 9. Charge pump worn. 10. Oil supply flange not sealing correctly.
Not Enough Power

Possible causes include: 1. Check Electrical Troubleshooting in this Section to verify actual gear selected. 2. Engine RPM below Stall Test specified RPM. A. Check engine and fuel system for problem. B. Check that torque converter installation is correct. 3. Engine RPM above Stall Test specified RPM. A. Check converter pressures and flow. B. Check that torque converter installation is correct.
Machine Stops or Hesitates While Shifting - Intermittent

Possible causes include: 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.
Some Pressures Low

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. B. Clutch drum or piston.
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CONVERTER OUT PRESSURE CHECK Test Equipment Required

0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and CAS-2324 Special Adapter. 2. Apply the parking brakes. 3. Install the pressure gauge. 4. Heat the oil to an operating temperature of 80 to 100 C (176 to 212 F). 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).
Test Procedure
1. Block the machine tires.
LUBRICATION PRESSURE CHECK Test Equipment Required

0 to 7 bar (100 psi) gauge. 3. Install the pressure gauge in the cooler return line at the transmission. 4. Heat the oil to an operating temperature of 80 to 100 C (176 to 212 F). 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).
Test Procedure
1. Block the machine tires. 2. Apply the parking brakes.
FLOWMETER TEST Test Equipment Required

CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter Adapter. 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.
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).
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. 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). 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).
Bur 7-12391
Issued 4-00
Printed in U.S.A.
Copyright
6002-19
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe: A. Verify actual oil temperature at test point. Normal operating temperature can be 56 degrees C (100 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 operators 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.
Copyright
6002-20
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 power forward reverse neutral gear2(3-4) gear1(1-4) downshift Shifter B+ V R N B2 B1 DS Shifter Wire Color red/black yellow pink gray green blue purple Shifter Tower Connector A B C D Shifter Shroud Connector A B C D Harness Wire # 19A 25F 25R 25T 25W 25Z 25Y Harness ped/cab # 43 44 45 46 48 49 50 Trans. ECM # 45 43 64 67 65 63 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 A1P1 A1P2 A1P3 A1P4 A1P5 A1P6 VPSI TEMP TEMP Transmission ECM Pin # 56 10 32 55 9 51 12,13 39 46 Transmission Valve Y1 Y2 Y3 Y4 Y5 Y6 all Y TEMP TEMP Clutch # K4 KR K1 K3 KV K2 all K none none Transmission Valve Pin # 1 2 3 4 5 6 7 8 9 Wire # 25K 25L 25M 25N 25P 25J 25S 36T 36R Cab/eng Pin # 16 17 18 19 20 21 22 5 12
Bur 7-12391
Issued 4-00
Printed in U.S.A.
Copyright
6002-21
TRANSMISSION ELECTRICAL SCHEMATIC

FIGURE 11
1 2 3
O (19A) 0.8
FILTER MAINTENANCE SWITCH
CAB POSITIVE STUD

TO FUSE A ON SHEET 8
1 2 3
CAB SWITCHED POWER INSTRUMENT ILLUMINATION
DETENT SWITCH ON SHEET 5 VIA RIDE CONTROL SWITCH ON SHEET 22
31
O(19A) B V (36R) 1.0 0.8 A Y (32F) 1.0
VIA BEACON SWITCH ON SHEET 1
DIAGNOSTIC CONNECTOR
O (19A) 0.8 V (37D) 0.8 B (0) 0.8 V (37E) 0.8 1 O (19A) 0.8 3 4 Gy (49) 1.0 2
TORQUE CONVERTER OUTPUT TEMP SENDER

A V (36G) 1.0 V (36R) 1.0
22
31 Y (32F) 0.8 O (19A) 0.8 B (0) 0.8 LBe (25D) 0.8 LBe (25A) 0.8 B (0) 0.8 LBe (25C) 0.8 LBe (25B) 0.8 V (36G) 1.0 17 45 4 62 19 3 42 41 49 O (19A) 0.8 66 15 18 TO PARKING BRAKE SWITCH ON SHEET 15 TO PARKING BRAKE SWITCH ON SHEET 15 29 28 10 7 11 9 8 13
108
OUTPUT SPEED 100 SENSOR

C A B
142
O (19A) 1.0 B (0) 1.0 LBe (25D) 1.0 LBe (25A) 1.0 B (0) 1.0
TRANSMISSION AUTO SWITCH

2 1 6
ENGINE SPEED SENSOR

A B
101
LBe (25C) 1.0 LBe (25B) 1.0
O (19A) 0.8
13
CAB|PED
65 63 22 LBe (25W) 0.8 LBe (25Z) 0.8 LBe (25Y) 0.8 LBe (25F) 0.8 LBe (25R) 0.8 LBe (25T) 0.8 LBe (25T) 0.8 LBe (25Y) 0.8 48 49 50 43 O (19A) 0.8 LBe (25F) 0.8 LBe (25R) 0.8 LBe (25T) 0.8 LBe (25W) 0.8 LBe (25Z) 0.8 LBe (25Y) 0.8
70
B C D A B C D
TRANSMISSION SHIFTER
9 8 7 10 2 4 6 5
5 4
INTERMEDIATE SPEED 95 SENSOR

B A
B(0) 1.0
41
TURBINE SPEED SENSOR
96
B A
B(0) 1.0
43 64 67
44 45 46
LBe (25T) 0.8 B (0) 1.0 B (0) 1.0 24 25 16 17 18 19 20 21 22 5 12 Y (36T) 0.8 Y (36R) 0.8 SPARE SPARE LBe (25K) 0.8 LBe (25L) 0.8 LBe (25M) 0.8 LBe (25N) 0.8 LBe (25P) 0.8 LBe (25J) 0.8 LBe (25S) 0.8 56 10 32 55 9 51 12 13 39 46 29
LBe (25T) 0.8
70
TO ETHER SWITCH ON SHEET 7 LBe (25Y) 0.8
LBe (25L) 1.0 LBe (25M) 1.0 LBe (25N) 1.0 LBe (25P) 1.0 LBe (25J) 1.0 LBe (25S) 1.0 V (36T) 1.0 V (36R) 1.0 V (36R) 1.0
102
3 4 5 6 7 8 9
TO NEUTRAL START RELAY #8 ON SHEET 7
LOCATED IN HYD. CONTROLLER
LBe (25G) 0.8
ENG|CAB
TO FUSE T ON SHEET 10
O (19T) 0.8 30 O (19H) 1.0
O (19A) 0.8
TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS

6/7/821C 102A
1 2 3 4 5 6 7 8 9
87 TO FUSE H ON SHEET 8
2 1 6 5 4
LBe (25K) 1.0 LBe (25L) 1.0 LBe (25M) 1.0 LBe (25N) 1.0 LBe (25P) 1.0 LBe (25J) 1.0 LBe (25S) 1.0 V (36T) 1.0 V (36R) 1.0 TO PARKING BRAKE RELAY #9 ON SHEET 17 W (52P) 0.8 TO FUSE T ON SHEET 10 O (19T) 0.8
23 68 Y (35C) 0.8 Gy (49) 1.0 Y (35A) 0.8
87a 85 86 O (19A) 0.8 TO FUSE A ON SHEET 8
7 1 21 2
BACKUP ALARM RELAY #7
53
BACK-UP ALARM
+ B (0) 1.0 C NC
27 G (50L) 0.5 Y (50H) 0.5 26 25 1 B/R (50G) 0.5 TO MAIN CAB HARNESS ON SHEET 17 TO MAIN CAB HARNESS ON SHEET 17 TO MAIN CAB HARNESS ON SHEET 17 6 B (0) 0.8 B (0) 0.8 5 4 Y (35A) 0.8 2
Gy (49) 1.0
TO RR WIPER SWITCH ON SHEET 25 Y (35R) 1.0
B (0) 1.0
TO RR WIPER SWITCH ON SHEET 25
4
1 LBe (25G) 1.0 O (19A) 1.0
1
B D
94
Y (35R) 0.8
B (0) 1.0
B (0) 1.0
21 94
NAO-JUMPER CONNECTED EURO-JUMPER OPEN
B (0) 1.0
VIA DETENT SWITCH ON SHEET 19
CAB NEGATIVE STUD
B (0) 1.0
TRANSMISSION ELECTRONIC 19 CONTROL MODULE
Y (35R) 0.8
Y (35R) 1.0
NO
CAB |REAR
BACK-UP ALARM DISABLE
REAR|REAR LIGHT
REAR 15 LIGHT REAR
DECLUTCH BRAKE SWITCH
FRONT|CAB
LBe (25G) 0.8
118
38
DECLUTCH SWITCH
LBe (25H) 0.8
921C
LBe (25K) 1.0
O (19A) 0.8
TO ETHER SWITCH ON SHEET 7
Gy (49) 1.0
TRANSMISSION KICK-DOWN SWITCH 20
SHEET 11
VIA BEACON SWITCH ON SHEET 1
SHEET 12
SHEET 13
VIA RIDE CONTROL SWITCH ON SHEET 19
GM99C600
Copyright
Copyright
TRANSMISSION
Bur 7-13271
6003
Section 6003
Copyright
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 4 5 16
Bur 7-13271
Issued 4-00
Printed in U.S.A.
Copyright
6003-3
SPECIAL TOOLS
Assembly car . . . . . . . . . . . . . . . . . . . . Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . Support . . . . . . . . . . . . . . . . . . . . . . . . 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
GD98M839
Fasten the transmission on an assembly stand.
STEP 2
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.
GD98M851
Remove the inductive transmitter.
STEP 3
STEP 6
GD98M838
GD98M852
Remove both gaskets and the intermediate plate.
Remove the hex head screws and remove the converter housing.
Bur 7-13271
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. NOTE: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced.
Remove the hex head screws, cover, and flat gasket.
STEP 12
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.
Copyright
6003-7
STEP 14
Turn the transmission 180 degrees and remove the rear output flange.
STEP 18
STEP 15
BK00D029
GD98M862
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.
Remove the speed sensor and both inductive transmitters.
STEP 19
STEP 16
BK00D028
GD98M863
Separate the cover along with clutches from the transmission housing, using lifting device.
Remove the hex nuts and the two covers..
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.
Copyright
6003-8
STEP 21
Remove clutch shaft retainer nuts and lift cover free.
STEP 25
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 23
STEP 26
GD98M979 GD98M880
Pull tapered roller bearing from the shaft. Remove the opposite tapered roller bearing.
Squeeze the sealing ring out.
STEP 24
STEP 27
GD98M877
GD98M881
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
BK00D019
Squeeze the snap ring out and remove the clutch disc pack.
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.
Copyright
6003-10
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
GD98M893
Remove the idler gear.
Bur 7-13271
Issued 4-00
Printed in U.S.A.
Copyright
6003-11
STEP 39
STEP 42
GD98M894
BKOOD020
Remove the needle bearings and axial bearing.
Remove the snap ring.
STEP 40
STEP 43
GD98M895
BK00D019
STEP 41
STEP 44
BS00G001 BK00D018
Preload compression spring using tool. (Tool in place.)
Squeeze the sealing ring out. Remove bearing using bearing puller. Tap assembly until piston drops out of the plate carrier.
Bur 7-13271
Issued 4-00
Printed in U.S.A.
Copyright
6003-12
STEP 45
STEP 48
BK00D022
BK00D018
Remove the clutch disc carrier from the shaft. NOTE: The following steps are for the disassembly of the clutch K4.
Preload compression spring using tool. (Tool in place.
STEP 49
STEP 46
BK00D020 GD98M800
Remove the snap ring.
Squeeze the snap ring out and separate the clutch disc carrier from the shaft.
STEP 50
STEP 47
BK00D019

GD98M801
Bur 7-13271
Issued 4-00
Printed in U.S.A.
Copyright
6003-13
ASSEMBLY
NOTE: The following steps are for the reassembly of the oil pipes..
STEP 4
STEP 1
2 3 1
GD98M607
Install the screw plug with a new O-ring. Tighten the screw plug to a torque of 140 Nm (103 lb-ft).
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.
Copyright
6003-14
STEP 7
STEP 10
GD98M610
BK00D019
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.
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.

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6003-15
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.
GD98M618
STEP 14
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.
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Issued 4-00
Printed in U.S.A.
Copyright
6003-16
STEP 17
STEP 20
GD98M619
GD98M621
Use tools to lift the end shim against snap ring (upward) until contact 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. NOTE: In case of deviations from the required end shim clearance, use snap ring(s) of different thickness for correct measurement.
Apply Loctite 243 to the stud. Tighten the stud to a torque of 17 Nm (12.5 lb-ft).
STEP 21
STEP 18
Remove the clutch disc pack, oil and reinstall the clutch disc pack.
STEP 19
GD98M622
Insert ball bearing until contact 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.
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Issued 4-00
Printed in U.S.A.
Copyright
6003-17
STEP 23
STEP 26
GD98M624
BP00G020
Support the idler gear on the bearing inner race. Press the idler gear against the shoulder.
Install gear and shaft into heated bore.
STEP 27
STEP 24
BK00D024 GD98M625
Heat bearing.
Attach the idler gear axially with a snap ring.
STEP 28
STEP 25
GD98M625 BK00D023
Place heated bearing on the shaft.
Use heat gun to heat clutch disc carrier.
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.
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Issued 4-00
Printed in U.S.A.
Copyright
6003-18
STEP 30
STEP 33
GD98M630
GD98M633
Apply Loctite 243 to the stud and install the stud. Tighten the stud to a torque of 17 Nm (12.5 lb-ft).
Install the piston into the clutch disc carrier.
STEP 34
STEP 31
GD98M634 GD98M631
Install the compression spring and spring cup.

BK00D023
Insert the clutch disc carrier until contact is obtained.
STEP 32
STEP 35
GD98M632
BK00D019
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.
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Issued 4-00
Printed in U.S.A.
Copyright
6003-19
STEP 36
STEP 38
BK00D018
232A
Tool in place.
STEP 37
1. 2. 3. 4. 5. 6. 7. 8.
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.
Copyright
6003-20
STEP 40
STEP 42
GD98M636
GD98M638
STEP 41
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). 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 contact 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.
Copyright
6003-21
STEP 45 3 2 1
STEP 48 1 2 3
GD98M640
GD98M643
Install the running disc (1), axial needle cage (2), and axial washer (3). NOTE: Install the running disc (1) with the chamfer facing the axial needle cage.
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: Ensure the running disc is overlapping with the chaff collar to accommodate all the inner discs.
STEP 46
STEP 49
GD98M641
Install both the needle bearings.
BK00D024
STEP 47
Heat bearing.
STEP 50
GD98M642
Install the idler gear until all inner discs are engaged. Place heated bearing on the shaft.
GD98M625
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6003-22
STEP 51
Check the function of the clutch, using compressed air. NOTE: The following steps are for the reassemble of clutch K4.
STEP 54
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.
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6003-23
STEP 57
STEP 60
BK00D019
232A
STEP 58
1. 2. 3. 4. 5. 6. 7. 8.
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.
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6003-24
STEP 62
STEP 64
GD98M654
GD98M656
Install the end shim and squeeze the snap ring in.
STEP 63
Use tools to lift the end shim against snap ring (upward) until contact 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). 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.
STEP 66
GD98M657
Install the idler gear until all inner discs are engaged, then remove idler gear.
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6003-25
STEP 67
STEP 70 1 2 3
GD98M658
GD98M661
Assemble both axial washers and the needle cage. NOTE: Upper and lower axial washers have the same thickness.
Assemble axial washer (3), needle cage (2), and running disc (1). Install the running disc (1) with the chamfer facing the needle cage.
STEP 68
STEP 71
GD98M662 GD98M659
Install both needle bearings.
Assemble the pre-assembled clutch disc carrier until all the inner discs are engaged.
STEP 69
STEP 72
GD98M660 GD98M663
Install the idler gear.
Attach the clutch disc carrier with a snap ring.
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6003-26
STEP 73
STEP 77
BK00D024
GD98M667
Heat bearing.
Install the gear with the snap ring.
STEP 74
STEP 78
GD98M625
GD98M668
Place heated bearing on the shaft.
STEP 75
Check the function of the clutch with compressed air. NOTE: The following steps are for the reassembly of the input shaft.
Install the snap ring into the recess of the turbine shaft.
STEP 79
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 contact is obtained.
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6003-27
STEP 80
STEP 83 K1 AB K3 K4 K2 KV AN KR
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 contact is obtained.
STEP 84
STEP 81
BK00F003 GD98M671
Install the clutches onto the nesting table.
Squeeze the rectangular ring and hook the ring on the output shaft.
STEP 85
STEP 82
BK00D029
GD98M672
Insert the output shaft into the housing bore until contact is obtained. NOTE: The following steps are for the reassembly of the output shaft and clutches. All clutches have a common installation.
Bur 7-13271
Use acceptable lifting equipment and install the housing cover onto the clutches. Install clutch shaft retainer nuts.
Issued 4-00
Printed in U.S.A.
Copyright
6003-28
STEP 86 KR KV K4 K2
STEP 89
K1
K3
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 KV K2 K3 AN KR K4 K1
STEP 90
Tilt the housing cover 180 degrees. Install the eye bolts for lifting.
STEP 91
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.
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6003-29
STEP 93
STEP 96
GD98M685
GD98M690
Separate the housing cover from the gearbox, using a lifting device. Install output gear and output gear cover. NOTE: The following steps are for the reassembly of the output shaft.
Apply Loctite 243 to the socket head screws and install the screws. Tighten the screws to a torque of 23 Nm (17 lb-ft).
STEP 97
STEP 94
GD98M695
GD98M688
Install the housing cover with the hex head screws. Tighten the screws to a torque of 46 Nm (34 lb-ft).
Position the screening plate.
STEP 98
STEP 95
GD98M696 GD98M689
Insert the output shaft. If bearing was removed, heat bearing bore and install.
Install the shaft seal with the sealing lip facing the oil chamber. Apply grease to the sealing lip.
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6003-30
STEP 99
STEP 101
GD98M697
GD98M702
Heat the output flange to about 90 C (194 F). Apply Loctite 574 to the contact 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 oil feed housing with washers and hex head screws. Screw the hex head screws in only until contact is obtained, do not tighten.
Install the output flange on the converter side using a driver tool. NOTE: The following steps are for the assembly of the oil feed housing and transmission pump.
STEP 103
GD98M704
Install the two alignment screws and insert the stator shaft.
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6003-31
STEP 104
STEP 107
GD98M705
GD98M708
Apply oil and install the O-ring.
STEP 105
Install the transmission pump with the socket head screws. Tighten the screws to a torque of 46 Nm (34 lb-ft).
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.
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6003-32
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 113
Install the screw plug with new O-ring. Tighten the plug to a torque of 30 Nm (22 lb-ft).
STEP 110
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.
Copyright
6003-33
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
STEP 116
Install the gasket and the cover plate. Tighten to a torque of 23 Nm (17 lb-ft).
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).
Copyright
6003-34
NOTES
Bur 7-13271
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Section 6006
WHEELS AND TIRES
Bur 7-13301
6006
Copyright
6006-2
TABLE OF CONTENTS
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3 3 3
Bur 7-13301
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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. 2. Install the wheel, hardened washers and wheel nuts. 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. 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).
11 4 13 6 1 10 8 15
16 7 9 2 14 5
12
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.
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.
Bur 7-13301
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Printed in U.S.A.
Copyright
6006-4
NOTES
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Section 8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS
Bur 7-13371
8002
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Bur 7-13371
Issued 4-00
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
633L95
B877168V
CAS-1904 PRESSURE FITTING KIT
CAS-1808 FLOWMETER FITTING KIT
632L95
B877895M
CAS-10090 HAND PUMP
B785789M
B877558M
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?. Yes Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems. No Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.
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? Yes See Section 8003 and clean or replace the oil. No See Page 7. Do the flowmeter tests of the hydraulic pump.
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. No Charge the accumulator.
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 The remote control valve is damaged. See Section 8010 and repair the remote control valve.
Yes 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? 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.
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.
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. No Repair the component as necessary.
Bur 7-13371
Issued 4-00
Printed in U.S.A.
Copyright
8002-7
Testing the Hydraulic Pump

Test No. 1 - Primary Pump Output Test STEP 1
Connect the flowmeter to the primary pressure hose from the hydraulic pump located toward 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
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 2
Make sure the load control of the flowmeter is open. Make sure the hydraulic oil is 54 to 66C (130 to 150F).
STEP 3
Start and run the engine at 2000 r/min. Measure the flow at 0 kPa, 0 bar (0 psi). Record the flow.
GS98M898
1. CAS-10280 FLOWMETER 2. HYDRAULIC RESERVOIR
3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL) 4. CONNECT TO PRIMARY PRESSURE PORT HOSE
Bur 7-13371
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 66C (130 to 150F). 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.
2 1
GS98M99
1. CAS-10280 FLOWMETER 2. HYDRAULIC RESERVOIR
3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL) 4. CONNECT TO SECONDARY PRESSURE PORT HOSE
Bur 7-13371
Issued 4-00
Printed in U.S.A.
Copyright
8002-9
Testing and Adjusting the Main Relief Valve

Pressure Check STEP 1
Engage the transport/service link.
Adjustment STEP 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.
1. LOADER CONTROL VALVE 2. MAIN RELIEF VALVE
Remove the cover at the front of the machine.
STEP 6
Read the pressure gauge. Compare the reading to the specifications on Page 3.
STEP 2
Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure.
STEP 7
If the pressure is not correct, adjust the main relief valve.
STEP 3
Check the pressure again. Repeat the adjustment as necessary.
Bur 7-13371
Issued 4-00
Printed in U.S.A.
Copyright
8002-10
Testing and Adjusting the Combination Valve

Before starting machine, pump the brakes repeatedly to be sure the brake accumulators have no pressure.
Adjustment STEP 1
Remove the round plug from the regulator cartridge valve.
STEP 2
Connect a 6 895 kPa, 69 bar (1000 psi) pressure gauge to the quick disconnect fitting at the regulating pressure test port.
STEP 2
Use an Allen wrench to turn the adjusting screw clockwise to increas e the pressure or counterclockwise to decrease the pressure.
STEP 3
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.
Copyright
8002-11
Testing the Control Pressure at the Ends of the Spools in the Loader Control Valve
STEP 1
Heat the hydraulic oil to operating temperature.
STEP 7
Hold the control lever in the other power position. Read the other pressure gauge. Record the pressure reading.
STEP 8
The pressure at each end of the spool must be 37 to 43 bar (540 to 620 psi).
STEP 2
STEP 9
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
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.
1
1. 2. 3. 4. 5. 6.
6
GS98M897
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.
Copyright
8002-12
Testing and Adjusting the Circuit Relief Valves

Pressure Check
STEP 3
Connect the hand pump to the disconnected line that goes to the loader control valve.
STEP 4 STEP 1
Circuit relief valves are located as shown below. Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21C (70F).
3 1
5 1
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.
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 2 1
1. 2. 3. 4. 5. CIRCUIT RELIEF VALVE MAIN RELIEF VALVE BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL
Loosen the lock nut. Turn the adjustment screw clockwise to increas e the pressure or counterclockwise to decrease the pressure.
1
GS98M896
STEP 2
Check the pressure again. Repeat the adjustment as necessary.
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.
Copyright
8002-13
Testing and Adjusting the Pressure for the Unloader Valve

Engage the transport/service link.
Adjustment STEP 1
If the gauge reading did not drop according to the specifications, remove the nut and turn the adjusting screw until the setting is correct
.
2 STEP 2
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.
GS98M474
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.
1. NUT 2. ADJUSTING SCREW 3. UNLOADING VALVE
STEP 2
Install the nut.
Bur 7-13371
Issued 4-00
Printed in U.S.A.
Copyright
8002-14
HYDRAULIC COMPONENT LOCATIONS

5 18 6 9 10 4 3 24 25 11 2 22 7 6 20
1 18 21 8 16 14 13 15 12 11
BC00D096
23 9 17 19
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
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 BYPASS VALVE UNLOADING VALVE
Bur 7-13371
Issued 4-00
Printed in U.S.A.
Copyright
8002-15
821C HYDRAULIC SCHEMATIC

QUICK DISCONNECT PARKING BRAKE
OPTIONAL COUPLER 21 LOCKING VALVE
OPTIONAL COUPLER 22 LOCKING CYLINDERS LOADER CONTROL VALVES 8
BLEED SCREW
PB T AUX PP
12 BRAKE ACCUMULATOR
7 BRAKE VALVE
FRONT BRAKE CYLINDERS 18
AUXILIARY
AUXILIARY CIRCUIT RELIEF VALVES
AUXILIARY
RB ACR PSIR FB
QUICK DISCONNECT
10 REMOTE CONTROL VALVES

AUXILIARY ORIFICE CHECK VALVES CIRCUIT RELIEF VALVES
OPTIONAL AUXILIARY CYLINDERS
19
COMBINATION VALVE
ACF PSIF
11
QUICK DISCONNECT
REAR BRAKE CYLINDERS
LOADER LOWER & FLOAT LOADER RAISE BUCKET DUMP BUCKET ROLLBACK MAIN RELIEF VALVE
6 LIFT CYLINDERS
17
TRANS. DECLUTCH SWITCH
BUCKET CYLINDER
REGENERATION VALVE
20
MASTER VALVE
BRAKE PRESSURE SWITCH
25 2
P
UNLOADING VALVE
QUICK DISCONNECT
P
BRAKE PUMP DUAL PRESSURE 13 ACCUMULATOR CHARGING VALVE 14
PRIMARY PUMP
PRIORITY 15 VALVE P
LS EF CF
SLAVE VALVE ACCUMULATOR
SECONDARY PUMP M
QUICK DISCONNECT
T
HYDRAULIC 4 FILTERS
PRESSURE SWITCH
5 STEERING CONTROL VALVE

L
BREATHER
OPTIONAL 23 RIDE CONTROL

RIGHT
AUXILIARY 1 STEERING PUMP

P
RESERVOIR 3
OIL COOLER BYPASS VALVE 24
OIL COOLER 16
LS
STEERING CYLINDERS
R
LEFT 821C HYDRAULIC SCHEMATIC Bur 7-13371 Issued 4-00 Printed in U.S.A.
BC00D061
Copyright
8002-16
NOTES
Bur 7-13371
Issued 4-00
Printed in U.S.A.
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Section 8004
HYDRAULIC PUMP
Bur 7-13381
8004
Copyright
8004-2
TABLE OF CONTENTS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 4 4 4 6
Bur 7-13381
Issued 4-00
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

NOTE: The hydraulic pump shown in Figure 1 is a general cross section view. Illustration may vary from actual component parts. 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. 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).
17. Loosen and remove the screws (22) from the pump cartridge (3). 18. Remove the plate (23) from the pump cartridge (3). 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.
Copyright
8004-5
15 14
16
13
18 17 19
1 5
10
20 7 23 21 21 4 6
22 8
12
11
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. 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).
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.
Bur 7-13381
Issued 4-00
Printed in U.S.A.
Copyright
8004-7
15 14
16
13
18 17 19
1 5
10
20 7 23 21 21 4 6
22 8
12
11
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
LOADER CONTROL VALVE
Bur 7-13391
8005
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Bur 7-13391
Issued 4-00
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).
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. SPECIAL
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-5
2 3
4 4
6 7
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). 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).
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.
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-7
6 7 8 12 5 3
1 2
13 4 14 9 15 16 17
11
17 10 1 2
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
12
3
GS98K833
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
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. 2. Apply Loctite 271 to the threads on both ends of the spool (4). 3. Install the special screw (10) and tighten the special screw (10), refer to SPECIAL TORQUES for the correct torque. 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. 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.
8. Install the poppet (16). 9. Install the spring (15). 10. Install a new O-ring (14) on the plug (13) and lubricate the O-ring (14) with clean hydraulic oil. 11. Install and tighten the plug (13), 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). 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).
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-9
3 2
4 5 2
6 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.
Copyright
8005-10
LIFT SECTION 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 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). 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).
19. Remove the spring (28). 20. Remove the poppet (29). 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.
Copyright
8005-11
1 2 8 9 11 13 15 14 27 12 28 29 33 17 16 34 32 31 10 7 26 30 4 6 5 3
33 32 31 22 23 30 25 1 2
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
18 21 20 19
24
3
GS98K836
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.
Copyright
8005-12
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. 10. Install the inner spring seat (20), inner spring (23), outer spring (22), outer spring seat (24) and the special screw (25). 11. Tighten the special screw (25), 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). 22. Tighten the Allen head screws (1), 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.
Copyright
8005-13
3 4 2 1 5 2
7
1. ALLEN HEAD SCREW 2. PLUG 3. PLUG 4. SPRING 5. POPPET 6. SPRING CAP 7. SPOOL
6
GS98K837
LIFT SECTION - CROSS SECTION VIEW
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-14
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). 5. Remove and discard the O-ring (6) from the body (2). Install a new O-ring (6).
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
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.
Copyright
8005-15
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.
Copyright
8005-16
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). 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).
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.
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-17
12 11 10 9 8 7 6 4 3 2 1 23 22 21 20 18 17 15 13
1. 2. 3. 4. 5. 6. LOCK NUT WASHER ADJUSTING SCREW O-RING SPRING PLUNGER
5 25 24 26
19
16
14
GS98K839
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.
Copyright
8005-18
Assembly
1. Lubricate the O-ring (18) on the poppet (20) with clean hydraulic oil, refer to Figure 7. 2. Install the poppet (20) in the sleeve (15). 3. Lubricate the O-ring (16) and backup ring (17) on the sleeve (15) with clean hydraulic oil. 4. Install the poppet (20), sleeve (15) and the spacer (14) into the body (23). 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. 12. Prevent the adjusting screw (3) from turning and tighten the lock nut (1).
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.
1 2
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.
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-19
1 24 23 22
3 4
21 20 19 18 17 16 15 14 7 8 9 10 11 13 12
GS98K840
5 6
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.
Copyright
8005-20
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). 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).
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.
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-21
13 12 11 10 9 8
7 5 4 2 1 3 6
23 18 15 19 17 16 14 22 21 20
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.
Copyright
8005-22
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). 3. Fasten the body (20) in a vise with soft jaws. Install the spring (14). 4. Lubricate the O-rings (12 and 13) and the backup ring (11) on the adapter (8) with clean hydraulic oil. 5. Install and tighten the adapter (8). 6. Install the plunger (7). 7. Install the spring (6).
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. 10. Prevent the adjusting screw (4) from turning and tighten the lock nut (2). 11. If used, install the cap (1). The pressure setting of the circuit relief valve must be checked with a hand pump according to instructions in Section 8002.
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-23
20 19 18
1 2
3 17 4
5 16 15 14 13 12 11 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.
Copyright
8005-24
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. 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).
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.
Bur 7-13391
Issued 4-00
Printed in U.S.A.
Copyright
8005-25
13 12 11 10 9 8 7 5 4 2 1 18 23 15 19 17 16 14
GS98K843
6 27 28
3 22 20 24 21 25
26
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
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8005-26
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). 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). 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. 13. To prevent the adjusting screw (4) from turning, tighten the lock nut (2).
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.
1 2
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.
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26 25 24 3 4 22 21 20 5 19 18 17 8 9 16 15 14 13 12 10 11 6 7 1 2
23
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
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8005-28
NOTES
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ACCUMULATOR FOR RIDE CONTROL
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8013
Section 8013
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8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3 4 7 7 7 7
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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
B786441M
CAS-10899 NITROGEN ACCUMULATOR CHARGING KIT
CAS-1456 GLAND WRENCH
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8013-4
CHARGING THE ACCUMULATOR WITH NITROGEN
VALVE C
TO NITROGEN TANK
VALVE D
TO ACCUMULATOR
VALVE B VALVE A FIGURE 1. NITROGEN CHARGING KIT CAS-10899

GS98N801
! !
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 120F (49C). 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.
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Copyright
8013-5 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). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 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). 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. 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. 15. Install the valve cap (12) onto the gas charging valve (11) on the accumulator. 16. Install the protection bracket (13) over the gas charging valve (11) and secure it with cap screws (14). 17. Remove the charging hose from the nitrogen supply tank, refer to Figure 1.
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8013-6
2 4 5 6 7 8 9 10 11 13 14
GS98K847
12
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
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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). 4. Fasten the gland (9) in a vise with soft jaws. Be careful not to damage the gland (9). 5. Loosen and remove the gas charging valve (11) from the gland (9). 6. Remove and discard the O-ring (10) from the 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). 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. 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. 9. Install a new gland seal (8) on the gland (9). 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.
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. 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
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8013-8
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Manual de Servicio 821C

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

Template Name: SM_2_col Template Date: 1994_04_05

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CAPACITIES AND LUBRICANTS

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ENGINE OIL RECOMMENDATIONS Engine Oil Selection

Oil Viscosity / Temperature Ranges

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DIESEL FUEL SYSTEM

Specifications for Acceptable No. 2 Diesel Fuel

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MAINTENANCE SCHEDULE Model 821C

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

EVERY 50 HOURS OF OPERATION

EVERY 100 HOURS OF OPERATION

EVERY 250 HOURS OF OPERATION

EVERY 500 HOURS OF OPERATION

EVERY 1000 HOURS OF OPERATION

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

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MAINTENANCE SCHEDULE Model 821C

SECTION INDEX - ELECTRICAL Section Title

1999 Case Corporation Printed in U.S.A. April, 2000

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

CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES

HOW TO USE THIS SECTION

10. 11. 12. 13.

2 Master Disconnect Switch

3 Fuel Shutoff Solenoid

7 Cold Start Temperature Switch

Bad cold start temperature switch (7).

9 Ether Start Relay

10 Ether Start Switch

11 Neutral Start Relay

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

16. VOLTMETER RELAY #12 17. TIME DELAY MODULE

16 Voltmeter Relay #12

17 Time Delay Module

Bad Time Delay Module (17).

Bad Time Delay Module (17).

Terminal for wire 19H to ground

33 Back-up Alarm Disable Switch

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

35 Brake Warning Pressure Switch

36 Coolant Level Sender

37 Fuel Level Sender

38 Hydraulic Oil Temperature Sender

39 Hydraulic Filter Restriction Switch

40 Engine Coolant Temperature Sender

41 Air Filter Restriction Switch

42 Program Reset Switch