7 12102

1002
Section
1002
FLUIDS AND LUBRICANTS
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION

© 2000 Case Corporation
450 Sherman Avenue Printed in U.S.A.
Hamilton, ON L8N 4C4 CANADA Bur 7-13071 April, 2000
Template Name: SM_2_col Alt= to hide template information
Template Date: 1994_04_05 Alt+ to display template information
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS ............................................................................................................................ 2
ENGINE OIL RECOMMENDATIONS....................................................................................................................... 3
DIESEL FUEL........................................................................................................................................................... 4
MAINTENANCE SCHEDULE ................................................................................................................................... 5
CAPACITIES AND LUBRICANTS

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

Capacity ................................................................................................................32.1 litres (34 U.S. quarts)
Type of coolant .............Ethylene glycol and water mixed for lowest ambient temperature (at least 50/50 mix)
Fuel tank
Capacity ........................................................................................................... 268 litres (70.8 U.S. gallons)
Type of fuel....................................................................................... See diesel fuel specifications on page 4
Hydraulic system
Hydraulic reservoir refill capacity ...........................................................................90 litres (95.2 U.S. quarts)
Total system .........................................................................................................174 litres (184 U.S. quarts)
Type of oil ............................................................................................................................... MS-1209 Hy-Tran Ultra®
Transmission
Refill capacity with filter change ............................................................................12.3 litres (13 U.S. quarts)
Total system capacity ............................................................................................26.5 litres (28 U.S. quarts)
Type of oil ....................................................................................................... Case No. 1 Engine Oil (15W-40)
Axles
Capacity of center bowl
Front ......................................................... 18.9 litres (20 quarts) 135H EP Plus 1.9 litres (4 pints) B91246
Rear .........................................................13.7 litres (14.5 quarts) 135H EP Plus 1.4 litres (3 pints) B91246
Capacity of planetary (each)
Front ........................................................................................................... 6.0 litres (6.5 quarts) 135H EP
Rear ................................................................................................................ 5.5 litres (6 quarts) 135H EP
Type of lubricant ........................................................................... Case (MS1316) 135H EP (SAE 85W-140)
Limited slip additive .................................................................................................................. Case B91246
Brake system
Type of fluid (same as hydraulic system) ......................................................................... MS-1209 Hy-Tran Ultra®
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged
as a result of using an alternate oil.
Conversion Formulas
Imperial quart = litres x 0.879877

Imperial gallons = litres x 0.219969
Bur 7-13071 Issued 4-00 Printed in U.S.A.

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° −20° 0° 20° 40° 60° 80° 100° 120°
−30° −10° 10° 30° 50° 70° 90° 110°
MULTI-VISCOSITY OIL
SAE 20W - 50
SAE 20W - 40
SAE 15W - 40
SAE 10W - 40
SAE 10W - 30
SAE 5W - 30
SAE 5W - 20
SINGLE VISCOSITY OIL
SAE 40
SAE 30
SAE 20W - 20
SAE 10W
−34° −23° −12° −1° 10° 21° 32° 43°
−40° −29° −18° −7° 4° 16° 27° 38° 49°
Temperature Celsius
NOTE: Use of an engine oil pan heater or an engine coolant
heater is required when operating temperatures are in the
shaded area.
1002-4
DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine
power and high fuel consumption.
In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the
following Note.
NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel
lowers below the cloud point (wax appearance point), wax crystals in the fuel will restrict the fuel filter
and cause the engine to lose power or not star t.
The diesel fuel used in this machine must meet the specifications shown below in, “Specifications for
Acceptable No. 2 Diesel Fuel”, or Specification D975-81 of the American Society for Testing and Materials.
Fuel Storage
If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank.
.
Many engine problems are caused by water in the fuel.
Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage
container at regular periods of time.
Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum .................................................................................................................................. 34
Flash point, minimum ..................................................................................................................140°F (60°C)
Cloud point (wax appearance point), maximum .................................................. -5°F (-20°C) See Note above
Pour point, maximum ........................................................................................ -15°F (-26°C) See Note above
Distillation temperature, 90% point ...................................................................... 540 to 640°F (282 to 338°C)
Viscosity, at 100°F (38°C)
Centistokes .................................................................................................................................. 2.0 to 4.3
Saybolt seconds universal ............................................................................................................. 32 to 40
Cetane number, minimum .................................................................. 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum .................................................................................... 0.05 of 1%
Sulphur, by weight, maximum ........................................................................................................... 0.5 of 1%
Copper strip corrosion, maximum ........................................................................................................... No. 2
Ash, by weight, maximum ............................................................................................................... 0.01 of 1%

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.

SECTION INDEX - ELECTRICAL 0000-1
Section Title
Section Number
Removal and Installation of Starter and Alternator ........................................................................................................ 4001
Electrical Specifications, Troubleshooting, and Schematics ............................................................................................ 4002
Batteries ................................................................................................................................................................ 4003
Starter and Starter Solenoid ....................................................................................................................................................... 4004
Information and Diagnostic Center.............................................................................................................................................. 4005
Alternator ................................................................................................................................................................................... 4007
CASE CORPORATION
700 State Street

4002
Section
4002
ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING,

AND SCHEMATICS
CASE CORPORATION
700 State Street
CASE CANADA CORPORATION Copyright © 2000 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 7-12221 April, 2000
NOTES
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GRAPHIC SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HOW TO USE THIS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, COLD START,
IGNITION SWITCH AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ignition Relay #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Accessory Relay #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Voltmeter Relay #12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,
SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Kick-down Switch (Located In Hydraulic Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Declutch Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Back-up Alarm Relay #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM RESET SWITCH, PARK BRAKE
SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH . . . 21
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4002-4
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Program Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TROUBLESHOOTING ENGINE OIL PRESSURE SENDER, PILOT CONTROL, PARKING BRAKE, ENGINE
AUTOMATIC SHUTDOWN RELAY, AND REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . 28
Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Redundant Parking Brake Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Redundant Brake Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Automatic Shutdown Relay Socket #11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TROUBLESHOOTING BUCKET CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Detent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bucket Control Valves Detent Electromagnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Height Control Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL . . . . . . . . . . . . . . . 34
Secondary Steering Relay with Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Secondary Steering Relay with Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Secondary Steering Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Secondary Steering Pump/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pin Engagement Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pin Engage Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hoist-up Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Bucket Dump Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Bucket Rollback Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ride Engage Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Rotary Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND CONDENSER FANS . . . . . . . . . . . . . . 43
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Seat Compressor and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Resistor Board (Blower Motor Speed Resistors with Thermal Fuse) . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compressor Clutch Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4002-5
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Condenser Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Not Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Condenser Fan Motor No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Condenser Fan Motor No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . 55
Left Marker/Turn Signal (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Left Drive Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Left Flood Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Right Flood Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Right Drive Lamp (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Right Marker and Turn Signal (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Left Brake, Tail, and Directional Lights (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Right Brake, Tail, and Directional Lights (North American Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
High/Low Beam Relay (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Left Front Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Left Rear Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Right Rear Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Right Front Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN MODELS . . . . . . . . . . . . . . . . . . . . 62
Left Front Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Right Front Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Left Rear Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Right Rear Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Left Side Turn (Italy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Right Side Turn (Italy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Left Front Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Right Front Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Left Rear Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Right Rear Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Left Head Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Right Head Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Rear License Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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

4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage........................................................................................................................Approximately 24 volts
Batteries
The specifications are the same for the production battery and the replacement battery.
Production Battery case P/N ............................................................................................... L51769 or BCM4DAW
Replacement Battery Case P/N ..............................................................................................L13308 or BMC4DA
Group Size ......................................................................................................................................................... 4D
Reserve Capacity ................................................................................................................................ 310 minutes
Cold Cranking Capacity:
At -17°C (0°F)................................................................................................................................800 amperes
At -29°C (-20°F) ...........................................................................................................................650 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell .....................................................................................................................................................23
Approximate weight with electrolyte ...................................................................................... 49.8 kg (110 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valves Detent Electromagnets .............................................................................................. 84 ohms
Fuel Level Sender (E-F) .........................................................................................................................240-33 ohms
Coolant and Hydraulic Temperature Sender 20°C (68°F).......................................................................... 3521ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105°C (221°F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110°C (230°F) .................................................. 133.9 ohms
Hydraulic Filter Restriction Switch closing setpoint ...........................................................................310 kPa (45 psi)
Air Filter Restriction Switch closing setpoint..................................................................................6.4 kPa (0.928 psi)
Low Brake Pressure Warning Switch opening setpoint ............................................................ 11 724 kPa (1700 psi)
A/C High Pressure Switch closing setpoint .................................................... 28 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch closing setpoint ....................................................... 0.3 Bar (4 psi) (decreasing pressure)
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

4002-8
GRAPHIC SYMBOLS
GM98M003

4002-9
CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES
GM98M001
GM98M002
NOTES:
NOTE: Diagram shown with vehicle parked, power off, and controls in off or neutral position.
NOTE: Sheet numbers refer to the number at the bottom center of each individual dashed block.
NOTE: Machine components that are being troubleshot are represented by this symbol.
NOTE: Wires that continue, uninterrupted, to the next sheet are represented by this symbol.
NOTE: Wires that continue, but are interrupted by several sheets, are located by specific text references as
follows: To instrument cluster cavity 2 on sheet 11

4002-10
HOW TO USE THIS SECTION

IMPORTANT: The troubleshooting procedures can be used with the Electrical and Hydraulic Schematic poster
(rear pocket, 7-12720, 7-12730 and 7-13450) for the 621/721/821 C-series wheel loader.
All bold item numbers, 17 , as well as The schematic poster is color coded to assist in
numbers in parenthesis,(17), found in the troubleshooting electrical circuits. Red denotes
troubleshooting procedures, correspond to circuits that have constant power. Green denotes
the circled numbers found on the Electrical and circuits that have power when the ignition switch in
Hydraulic Schematic poster (rear pocket). turned ON.
Items (90, Cigar Lighter) through (118, Cab Dome Components can be located on the Electrical and
Light), Sheets 1 through 5 and 29 through 32, only Hydraulic Schematic poster (rear pocket) by item
appear on the foldout schematics in this section (see number using the key at the bottom right of the rear
pages 67 through 97) and are not shown on the pocket. Use the following index to find the sheet
Electrical and Hydraulic Schematic poster (rear (dashed block) a component is located on.
pocket).
GM98M004

4002-11
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING,

ALTERNATOR, COLD START, IGNITION SWITCH AND RELAYS
10
12
6 9
6A 11
1 13
8 3 5
GM98M005
1. BATTERIES 6. START RELAY 10. ETHER START SWITCH
2. MASTER DISCONNECT SWITCH 6A. FUEL RELAY 11. NEUTRAL START RELAY #8
3. FUEL SHUTOFF SOLENOID 7. COLD START TEMPERATURE SWITCH 12. IGNITION SWITCH
4. ALTERNATOR 8. ETHER SOLENOID 13. IGNITION RELAY #1
5. STARTER MOTOR 9. ETHER START RELAY #6
1 – Batteries
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
NOTE: See Section 4003 and check the batteries.

4002-12
2 – Master Disconnect Switch

Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the cables from both terminals of the master disconnect switch (main contact). Put the master
disconnect switch in the ON position.
Between the terminals of the master Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.
Between the terminals of the master No continuity If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
3 – Fuel Shutoff Solenoid

Terminal for wire 0 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position.
24 volts Check circuit 13M, also check circuit to batteries. Bad master
Terminal for wire 13M to ground
disconnect switch (2).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 23F to ground 24 volts Check circuit 23F. Bad fuel relay (6A).
NOTE: If the readings are good, replace the fuel shutoff valve (3).
4 – Alternator
Between housing of alternator and

Continuity Bad ground connection.
ground
Between the negative terminal of

24 volts Check circuit to positive post of batteries.
alternator and ground
NOTE: Put the ignition switch in the ON position.
Between the positive terminal of

24 volts Check circuit to positive post of batteries.
alternator and ground
20 volts Check circuit to ignition relay #1 (13) and ignition relay #2 (14),
Terminal for wire 14 to ground
also check 75 ohm resistor.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).

4002-13
5 – Starter Motor
Between housing of starter and

Continuity Bad ground connection.
ground
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.
24 volts Bad start relay (6). Also check circuit between starter (5) and
Terminal S to ground
start relay (6).
NOTE: If the readings are not good, see Section 4004 and repair the starter (5).
6 – Start Relay
Terminal 87 for red wire to ground 24 volts Check circuit to batteries.
Terminal for wire 21C to ground 24 volts Check neutral start relay (11), also check the circuit 21C.
Terminal for wire 8 to ground 24 volts Bad start relay (6).
6A – Fuel Relay
Terminal for wire 1 to ground 24 volts Check circuit 1, also check circuit to batteries.
Terminal for wire 21C to ground 24 volts Check neutral start relay (11), also check the circuit 21C.
Terminal for wire 23F to ground 24 volts Bad fuel relay (6A).
7 – Cold Start Temperature Switch

NOTE: The cold start temperature switch opens above 10 °C (50 °F).
NOTE: Disconnect the wires from the cold start temperature switch (7). Make sure the engine temperature is
below 10 °C (50 °F).
Between terminals A and B Continuity Bad cold start temperature switch (7).

4002-14
8 – Ether Solenoid
Terminal for wire 28T to ether start

Continuity Bad 28T circuit.
temperature switch
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

Terminal for wire 19E to ground 24 volts Bad 10 ampere fuse E, also check circuit 19E.
NOTE: Put the ignition switch in the ON position. Have another person push in and hold the ether start switch
(10). Make sure the engine temperature is below 10 °C (50 °F).
Terminal for wire 28C to ground 24 volts Bad ether start switch (10), also check circuit 28C.
Terminal for wire 28P to ground 24 volts Bad ether start relay (9).
10 – Ether Start Switch

NOTE: Disconnect the wires from the ether start switch (10).
Between terminals of switch Continuity Bad ether start switch (10).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 25T to ground 24 volts Check circuit 25T.
11 – Neutral Start Relay

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the transmission is
in NEUTRAL.
Terminal for wire 21K to ground 24 volts Check circuit 21K.
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 25T to ground 24 volts Check circuit 25T.
Terminal for wire 21C to ground 24 volts Bad neutral start relay (11).

4002-15
12 – Ignition Switch
Terminal for wire 1A to ground 24 volts Check circuit 1A to Circuit Breaker A.
NOTE: Disconnect the connector from the ignition switch (12). Turn the switch to ON.
Between Bat and Ign Continuity Bad ignition switch (12).
Between Bat and Acc Continuity Bad ignition switch (12).
NOTE: Hold the ignition switch (12) in the START position.
Between Bat and Starter Continuity Bad ignition switch (12).
NOTE: Put the switch in the Acc position.
Between Bat and Acc Continuity Bad ignition switch (12).
13 – Ignition Relay #1
NOTE: Put the master disconnect switch in the ON position. Turn the ignition to the ON position.
Terminal for wire 1 to ground 24 volts Check circuit 1 to B+ stud.
Terminal for wire 13P to ground 24 volts Bad ignition relay #1 (13)

4002-16
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER

RELAY, AND TIME DELAY MODULE
17 14
15
16
GM98M006
14. IGNITION RELAY #2 16. VOLTMETER RELAY #12
15. ACCESSORY RELAY #3 17. TIME DELAY MODULE
14 – Ignition Relay #2
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 13R to ground 24 volts Bad ignition relay #2 (14).

4002-17
15 – Accessory Relay #3
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
Terminal for wire 12P to ground 24 volts Bad accessory relay (15), also check circuit 12P.
16 – Voltmeter Relay #12

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

NOTE: Put the ignition switch in the OFF position.
Terminal for wire 1A to ground 24 volts Bad circuit breaker A, also check circuit 1A to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the RESET switch (42).
Terminal for wire 37R to ground 24 volts Bad reset switch (42), also check circuit 37R.
Terminal for wire 13K to ground 24 volts Bad ignition switch (12), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
Within 10 seconds of putting the 24 volts

ignition switch in the OFF position, Key ON
0 volts after 10 Bad Time Delay Module (17).
check Terminal for wire 13D to
ground seconds
After 10 seconds of turning ignition

switch to the OFF position, check 0 volts Bad Time Delay Module (17).
Terminal for wire 13D to ground

4002-18
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND

SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR,
AND BACK-UP ALARM
,
26
31
24
23
34
28
22 25 29
27 30
19 32 33
20
21
18
GM98M007
18. OUTPUT SPEED SENSOR 27. DIAGNOSTIC CONNECTOR
19. ENGINE SPEED SENSOR 28. TRANSMISSION KICK-DOWN SWITCH
20. INTERMEDIATE SPEED SENSOR (LOCATED IN HYDRAULIC
CONTROLLER)
21. TURBINE SPEED SENSOR 29. TRANSMISSION AUTO SWITCH
22. FILTER MAINTENANCE SWITCH 30. DECLUTCH SWITCH
23. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 31. DECLUTCH BRAKE SWITCH
24. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 32. BACK-UP ALARM RELAY #7
25. TRANSMISSION ELECTRONIC CONTROL MODULE 33. BACK-UP ALARM DISABLE SWITCH
26. TRANSMISSION SHIFTER 34. BACK-UP ALARM

4002-19
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 18 through 31.
18 – Output Speed Sensor

19 – Engine Speed Sensor
20 – Intermediate Speed Sensor
21 – Turbine Speed Sensor
22 – Filter Maintenance Switch
23 – Torque Converter Output Temperature Sender
24 – Transmission Solenoid Valve and Temperature Sensors
25 – Transmission Electronic Control Module
26 – Transmission Shifter
27 – Diagnostic Connector
28 – Transmission Kick-down Switch (Located In Hydraulic Controller)
29 – Transmission Auto Switch
30 – Declutch Switch
31 – Declutch Brake Switch
32 – Back-up Alarm Relay #7

NOTE: Remove the transmission electronic control module (25) quick disconnect.
Terminal for wire 35C to terminal 7 Continuity Bad circuit 35C.
NOTE: Put the master disconnect switch in the ON position, ignition switch to the ON position and the park brake
to the OFF position. Depress brake pedal once and place gear selector in REVERSE.
Terminal for wire 35A to ground 24 volts Bad back-up alarm relay (32), also check circuit 35A.
Bad fuse A, also check circuit 19A, 13P, and ignition relay #1
Terminal for wire 19A to ground 24 volts
(13).
Bad fuse H, also check circuit 19H and 13R and ignition relay
Terminal for wire 19H to ground 24 volts
#2 (14).

4002-20
33 – Back-up Alarm Disable Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the 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.)
Bad back-up alarm disable (33), also check circuit 35R and
Terminal for wire 35R to ground 24 volts
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).

4002-21
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM

RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT CLUSTER, PILOT
CONTROL SWITCH, AND UP/DOWN COUNT SWITCH
39
41
38
40
36
42
43A
44
45
37
35
GM98M008
35. BRAKE WARNING PRESSURE SWITCH 41. AIR FILTER RESTRICTION SWITCH
36. COOLANT LEVEL SENDER 42. PROGRAM RESET SWITCH
37. FUEL LEVEL SENDER 43. PARK BRAKE SWITCH
38. HYDRAULIC OIL TEMPERATURE SENDER 43A.INSTRUMENT CLUSTER
39. HYDRAULIC FILTER RESTRICTION SWITCH 44. PILOT CONTROL SWITCH
40. ENGINE COOLANT TEMPERATURE SENDER 45. UP/DOWN COUNT SWITCH

4002-22
35 – Brake Warning Pressure Switch

NOTE: Brake pressure warning switch opens at 11 724 kPa (1700 psi).
Terminal B for wire 0 to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: Disconnect the wires from the brake warning pressure switch (35).
Between terminals A and B of the

Continuity Bad brake warning pressure switch (35).
switch
NOTE: Start and run the engine at idle.
Between terminals A and B of the

No continuity Bad brake warning pressure switch (35).
switch
NOTE: If the readings are correct see hydraulic brake troubleshooting section to check brake pressures.
36 – Coolant Level Sender

Approximately
Terminal A for wire 33P to ground 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

Approximately
Terminal A for wire 36F to ground Check the instrument cluster (43A).
5 volts
NOTE: If the readings are correct replace the fuel level sender (37).

4002-23
38 – Hydraulic Oil Temperature Sender

Approximately
Terminal A for wire 36H to ground Check the instrument cluster (43A).
5 volts
NOTE: If the readings are correct replace the hydraulic oil temperature sender (38).
39 – Hydraulic Filter Restriction Switch

NOTE: Hydraulic filter restriction switch closes at 310 kPa (45 psi).
Check between the housing of the

Bad ground connection between the hydraulic filter restriction
hydraulic filter restriction switch (39) Continuity
switch (39) and ground.
and the ground.
Approximately
Terminal A for wire 31H to ground. 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

Approximately
Terminal A for wire 36C to ground Check the instrument cluster (43A).
5 volts
NOTE: If the readings are correct replace the engine coolant temperature sender (40).
41 – Air Filter Restriction Switch

NOTE: Air filter restriction switch closes at 6.4 kPa (1 psi).
Approximately
Terminal A for wire 31F to ground Check the instrument cluster (43A).
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (41).

4002-24
42 – Program Reset Switch

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

Terminal for wire 19A to ground 24 volts Check fuse A, also check circuit 19A.
NOTE: Apply parking brake switch (43).
Terminal for wire 33U to ground 24 volts Bad park brake switch (43).
Terminal for wire 49 to ground 24 volts Bad park brake switch (43), also check circuit 49.

4002-25
43A – Instrument Cluster

Bad circuit 33P, also check the brake warning pressure switch
Connector terminal 3 to ground Continuity
(35).
Connector terminal 4 to ground Continuity Bad circuit 31D, also check the coolant level sender (36).
Connector terminal 19 to ground 39 to 225 ohms Bad circuit 36F, also check the fuel level sender (37).
Connector terminal 5 to ground Continuity Bad circuit 35X, also check the secondary steering switch (61).
134 to 3521 Bad circuit 36H, also check the hydraulic oil temperature
Connector terminal 20 to ground
ohms sender (38).
134 to 3521 Bad circuit 36C, also check the engine coolant temperature
Connector terminal 18 to ground ohms sender (40).
Connector terminal 6 to ground Continuity Bad circuit 31F, also check the air filter restriction switch (41).
Connector terminal 8 to ground Continuity Bad circuit 0 to ground.
Circuit 19V, at terminal 1 to fuse V Continuity Bad circuit 19V, also check fuse V.
Circuit 61R, at terminal 10, from Bad circuit 61R, also check the A/C - H/L pressure switches (81
Continuity
point to point and 82) and compressor clutch lockout relay (84).
Circuit 18G/42R, at terminal 12, from Continuity Bad circuit 18G/42R, also check the 5 position rotary lamp
point to point switch (112).
Circuit 46, at terminal 13, from point Continuity Bad circuit 46, also check the beacon light switch (96).
to point
Circuit 41F, at terminal 14, from

Continuity Bad circuit 41F, also check the rear fog lights switch (110).
point to point
Circuit 18C, at terminal 15, from Continuity Bad circuit 18C, also check the high beam lights switch (111).
point to point
Connector terminal 39 to ground Continuity Bad ground circuit.
Connector terminal 9 to terminal 6 Continuity Bad circuit 33U, also check the park brake switch (43).
on park brake switch (43)
Connector terminal 24 to terminal 6

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

Continuity Bad circuit 37R, also check the program reset switch (42).
on program reset switch (42)
Circuit 45R, at terminal 17, from Continuity Bad circuit 45R, also check the RH turn signal (107).
point to point
Circuit 45L, at terminal 16, from

Continuity Bad circuit 45L, also check the LH turn signal (102).
point to point
Connector terminal 21 to terminal 33 Continuity Bad circuit 50T.

Continuity Bad circuit 31L, also check the pilot control switch (44).
on pilot control switch (44)
Connector terminal 33 to terminal 21 Continuity Bad circuit 50T.

4002-26
43A – Instrument Cluster (Continued)

Circuit 36P, at terminal 22, from

Continuity Bad circuit 36P, also check the engine oil pressure sender (46).
point to point
Circuit 33R, at terminal 28, from Continuity Bad circuit 33R, also check the redundant brake switches (51).
point to point
Circuit 23C, at terminal 23, from Continuity Bad circuit 23C, also check the engine automatic shutdown
point to point relay (52).
Circuit 53C, at terminal 36, from

Continuity Bad circuit 53C, also check the pilot control relay (47).
point to point
Circuit 52C, at terminal 30, from Continuity Bad circuit 52C, also check the parking brake relay (48).
point to point
Circuit 44, at terminal 35, from point Continuity Bad circuit 44, also check the RH/LH brake lights (108 and
to point 109).
Connector terminal 31 to terminals

26 and 27 on the transmission Continuity Bad circuit 50L.
electronic control module (25)

on the transmission electronic Continuity Bad circuit 50H.
control module (25)
Circuit 19, at terminal 2, from point to Continuity Bad circuit 19S, also check the up/down count switch (45) and
point fuse S.
Circuit 37U, at terminal 26, from Bad circuit to pilot control switch (44), also check the pilot
Continuity
point to point control switch (44).
Circuit 37D, at terminal 27, from Continuity Bad circuit 37D, also check the up/down count switch (45).
point to point
44 – Pilot Control Switch

Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Terminal for wire 31L to ground 24 volts Bad pilot control switch (44).
Bad circuit 49, also check the 5 position rotary lamp switch
Terminal for wire 49 to ground 24 volts
(112).
NOTE: If the readings are correct replace the pilot control switch (44).

4002-27
45 – Up/down Count Switch

24 volts Bad circuit 19S, also check instrument cluster (43A) and fuse
Terminal for wire 19S to ground
S.
Terminal for wire 37D to ground 24 volts Bad circuit 37D, also check instrument cluster (43A).
Terminal for wire 37U to ground 24 volts Bad circuit 37U, also check instrument cluster (43A).
Terminal for wire 49 to ground 24 volts Bad circuit 49, also check 5 position rotary lamp switch (112).
NOTE: If the readings are correct replace the up/down count switch (45).

4002-28
TROUBLESHOOTING ENGINE OIL PRESSURE SENDER, PILOT CONTROL,

PARKING BRAKE, ENGINE AUTOMATIC SHUTDOWN RELAY, AND
REDUNDANT BRAKE SWITCHES
47
48
52
49
46 50
51
GM98M009
46. ENGINE OIL PRESSURE SENDER 50. PILOT PRESSURE SOLENOID
47. PILOT CONTROL RELAY #10 51. REDUNDANT BRAKE SWITCHES
48. PARKING BRAKE RELAY #9 52. ENGINE AUTOMATIC SHUTDOWN RELAY #11
49. PARKING BRAKE SOLENOID
46 – Engine Oil Pressure Sender

Between the engine oil pressure Bad ground connection between the engine oil pressure sender
Continuity
sender (46) and ground (46) and the ground.
Approximately
Terminal for wire 36P to ground Bad circuit 36P, also check the instrument cluster (43A).
5 volts
NOTE: If the readings are good, replace the oil pressure sender (46).

4002-29
47 – Pilot Control Relay

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(44) is OFF.
Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Bad pilot control relay (47), also check circuit 53C and
Terminal for wire 53C to ground 0 volts
instrument cluster (43A).
Terminal for wire 53P to ground 24 volts Bad circuit 53P.
NOTE: If the readings are good, replace the pilot control relay (47).
48 – Parking Brake Relay

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the park brake
switch (43) is OFF.
Terminal for wire 19D to ground 24 volts Bad fuse D, also check circuit 19D.
Terminal for wire 52C to ground 0 volts Bad parking brake relay (48), also check circuit 52C.
Terminal for wire 52P to ground 24 volts Bad circuit 52P.
NOTE: If the readings are good, replace the parking brake relay (48).
49 – Redundant Parking Brake Solenoids

Terminal A for wire 52P to terminal Continuity Bad circuit 52P, also check parking brake relay (48).
87 on 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).

4002-30
51 – Redundant Brake Switches

NOTE: Redundant brake switches close at 6200 kPa.
Approximately
Terminal A for wire 33R to ground Bad instrument cluster (43A), also check circuit 33R.
11.5 volts
NOTE: If the readings are good, replace the redundant brake switches (51).
52 – Engine Automatic Shutdown Relay Socket #11

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

4002-31
TROUBLESHOOTING BUCKET CONTROLS

57
58
56
54
53
55
GM98M010
53. DETENT SWITCH 56. RETURN TO DIG PROXIMITY SWITCH
54. BUCKET CONTROL VALVES DETENT ELECTROMAGNETS 57. HEIGHT CONTROL PROXIMITY SWITCH
55. RETURN TO TRAVEL/FLOAT SWITCH 58. RETURN TO TRAVEL PROXIMITY SWITCH
53 – Detent Switch
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (44) in
the OFF position.
Terminal for wire 53P to ground 24 volts Bad pilot control relay (47), also check circuit 53P.
Terminal for wire 56 to ground 24 volts Bad detent switch (53), also check circuit 56.
NOTE: If the readings are good, replace the detent switch (53).

4002-32
54 – Bucket Control Valves Detent Electromagnets

NOTE: Disconnect the wires from the bucket control valve. Put the master disconnect switch and ignition switch
in the ON position. Put the pilot control switch (44) in OFF position. Put the detent switch (53) in the ON position.
Terminal for wire 56 to ground 24 volts Bad detent switch (53), also check pilot control relay (47).
Circuit 53B, point to point Continuity Bad return to dig detent electromagnet.
Circuit 54B, point to point Continuity Bad height control detent electromagnet.
Circuit 55A, point to point, to return Continuity Bad return to travel detent electromagnet.
to travel/float switch (55)
NOTE: If the readings are good, replace the bucket control valves detent electromagnets (54).
55 – Return-To-Travel/Float Switch
NOTE: Put the return to travel/float switch (55) in the FLOAT position.
Terminal 5 and terminal 4 Continuity Bad return to travel/float switch (55).
NOTE: Put the return to travel/float switch (55) in the TRAVEL position.
Terminal 5 and terminal 6 Continuity Bad return to travel/float switch (55).
Bad circuit 55A, also check bucket control valves detent

Circuit 55A, point to point Continuity
electromagnets (54).
NOTE: If the readings are good, replace the return to travel/float switch (55).
56 – Return-To-Dig Proximity Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch
(44) in the OFF position and the detent switch (53) in the ON position. Disconnect the connector from the return
to dig proximity switch (56).
Bad bucket control valve detent electromagnets (54) or detent

Terminal A for wire 53B to ground 24 volts
switch (53), also check circuit 53B.
Terminal C for wire 56 to ground 24 volts Bad detent switch (53), also check circuit 56.
NOTE: If the readings are good, replace the return to dig proximity switch (56).

4002-33
57 – Height Control Proximity Switch

(44) in the OFF position and the detent switch (53) in the ON position. Disconnect the connector from the height
control proximity switch (57).
24 volts Bad bucket control valve detent electromagnets pressure(54)

Terminal A for wire 54B to ground
or detent switch (53), also check circuit 54B.
NOTE: If the readings are good, replace the height control proximity switch (57).
58 – Return-To-Travel Proximity Switch

(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 A for wire 55B to ground 24 volts Bad return to travel/float switch (55), also check circuit 55B.
NOTE: If the readings are good, replace the return to travel proximity switch (58).

4002-34
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE

CONTROL
63
59 62B
62A
60
61
62
64
66 68
65
67
GM98M011
59. SECONDARY STEERING RELAY WITH LOCKOUT 63. RIDE CONTROL SWITCH
60. SECONDARY STEERING RELAY WITH LOCKOUT 64. HOIST-UP PRESSURE SWITCH
61. SECONDARY STEERING SWITCH 65. RIDE CONTROL RELAY #4
62. SECONDARY STEERING PUMP/MOTOR 66. BUCKET DUMP PRESSURE SWITCH
62A.PIN ENGAGEMENT SWITCH 67. BUCKET ROLLBACK PRESSURE SWITCH
62B.PIN ENGAGE SOLENOID 68. RIDE ENGAGE SOLENOID

4002-35
59 – Secondary Steering Relay with Lockout

60 – Secondary Steering Relay with Lockout
Terminal 7 of relay (59) to ground 24 volts Check fuse M, also check circuit 19M.
Terminal 8 of relay (60) to ground 24 volts Check fuse R, also check circuit 19R.
Terminal 7 of relay (60) to ground 24 volts Bad jumper wire between terminals 7 and 8 of relay (60).
Ground wires between relays (59 Continuity Bad ground circuit.

and 60) and ground
Connector for wire 51P at secondary

steering switch (61) and terminal 3 Continuity Bad circuit 51P.
of relay (59)
Connector for wire 51 at the

secondary steering pump/motor (62) Continuity Bad circuit 51.
and terminal 6 of relay (60)
Terminal 2 of relay (59) to ground 0 volts Bad relay (59), also check secondary steering switch (61).
Bad jumper wire between terminals 2 and 3 of relay (59), also

Terminal 3 of relay (59) to ground 0 volts
check secondary steering switch (61).
24 volts Bad relay (59), also check instrument cluster (43A) and circuit
Terminal 6 of relay (59) to ground
35X.
Terminal 8 of relay (59) to ground 24 volts Bad relay (60).
Terminal 2 of relay (60) to ground 24 volts Bad relay (59).
Terminal 3 of relay (60) to ground 24 volts Bad jumper wires, also check relay (59).
NOTE: Disconnect the wire from the fuel shutoff solenoid (3) to stop the engine. Keep the ignition switch in the
ON position.
Terminal 2 of relay (60) to ground 0 volts Bad relay (60), also check circuit 19R and 19M.
Terminal 6 of relay (60) to ground 24 volts Bad relay (60), also check circuit 19R.
61 – Secondary Steering Switch

Terminal for wire 35X to ground 24 volts Check the instrument cluster (43A), also check circuit 35X.
Check the secondary steering relays (59 and 60), also check
Terminal for wire 51P to ground 0 volts
circuit 51P.
NOTE: If the readings are good, replace the secondary steering switch (61).

4002-36
62 – Secondary Steering Pump/Motor

Ground circuit to ground Continuity Bad ground circuit.
NOTE: Start and run the engine for 2 minutes. Disconnect the wire from the fuel shutoff solenoid (3) to stop the
engine. Keep the ignition switch in the ON position.
Check the secondary steering relays (59 and 60), also check
Terminal for wire 51 to ground. 24 volts
circuit 51.
Terminal for red wire to starter to 24 volts Check circuit to batteries.

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

Motor terminal of motor to ground 24 volts also check the connections between the solenoid and
pump/motor.
NOTE: If the readings are good, replace the secondary steering pump/motor (62).
62A – Pin Engagement Switch

NOTE: This switch is found only in the 621C/721C/821C and CE models with optional quick disconnect coupler.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the 5 position rotary 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).
Check the 5 position rotary lamp switch (112), also check

circuit 49.
Terminal for wire 19P to ground 24 volts Check fuse P, also check circuit 19P.
Between terminals for wires 19P and Continuity Bad pin engagement switch (62A).
57
62B – Pin Engage Solenoid

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 57 to ground 24 volts Bad pin engagement switch (62A), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (62B).

4002-37
63 – Ride Control Switch

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the 5 position rotary lamp
switch (112) in position 3 or higher and the ride control switch in the ON position.
24 volts Check the 5 position rotary lamp switch (112), also check
circuit 49.
Terminal for wire 19C to ground 24 volts Check fuse C, also check circuit 19C.
NOTE: Disconnect the connector from the ride control switch (63). Put the ride control switch (63) in the ON
position.
Between terminals for wires 19C and Continuity Bad ride control switch (63).
58S
64 – Hoist-up Pressure Switch

Circuit 58H, point to point Continuity Bad circuit 58H.
NOTE: Put the master disconnect switch and ignition switch in the ON position. Start the engine. Push the ride
control switch (63). Pull back on the loader lever until the green light under the ride control switch (63) is
illuminated.
24 volts Bad hoist-up pressure switch (64), also check the ride control
Terminal for wire 58S to ground
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 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 24 volts Bad ride control relay (65) or bad hoist-up pressure switch (64).
Terminal for wire 58D to ground 24 volts Bad bucket dump pressure switch (66).

4002-38
67 – Bucket Rollback Pressure Switch

Circuit 58, point to point Continuity Bad circuit 58.
NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Push the ride
control switch (63). The bucket rollback pressure switch (67) is normally closed and opens at 625 kPa (91 psi).
Bad bucket dump pressure switch (66), bad ride control relay
Terminal for wire 58D to ground 24 volts
(65), or bad hoist-up pressure switch (64).
Terminal for wire 58 to ground 24 volts Bad bucket rollback pressure switch (67).
68 – Ride Engage Solenoid

NOTE: Put the master disconnect switch and ignition switch to the ON position. Start the engine. Put the ride
control switch (63) and hoist-up pressure switch (64) in the ON position.
Terminal for wire 58 to ground 24 volts Bad circuit 58, also check bucket rollback pressure switch (67).
NOTE: If the readings are good, replace the ride engage solenoid (68).

4002-39
TROUBLESHOOTING WIPER/WASHER
69
74
70
71 73
72
GM98M012
69. FRONT WIPER MOTOR 72. REAR WASHER PUMP MOTOR
70. FRONT ROTARY WIPER AND WASHER SWITCH 73. REAR WIPER AND WASHER SWITCH
71. FRONT WASHER PUMP MOTOR 74. REAR WIPER MOTOR

4002-40
69 – Front Wiper Motor

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

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the rotary wiper
and washer switch (70) is in the OFF position.
Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.
NOTE: Put the rotary wiper and washer switch (70) in the LOW position.
Terminal for wire 63L to ground 24 volts Check fuse J, also check circuit 19J.
Terminal for wire 63C to ground 24 volts Bad front rotary wiper and washer switch (70)
NOTE: Put the rotary wiper and washer switch (70) in the HIGH position.
Check fuse J, also check circuit 19J. Bad front rotary wiper and
washer switch (70).
Terminal for wire 63C to ground 0 volts Bad front rotary wiper and washer switch (70).

4002-41
71 – Front Washer Pump Motor

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front rotary
wiper and washer switch (70) is in the OFF position.
NOTE: Put the front rotary wiper and washer switch (70) in the wash position.
24 volts Bad front rotary wiper and washer switch (70), also check
Terminal for wire 63W to ground
circuit 63W.
NOTE: If the readings are good, replace the rear washer pump motor (71).
72 – Rear Washer Pump Motor

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the rear wiper and
washer switch (73) is in the OFF position.
NOTE: Put the rear wiper and washer switch (73) in the wash position.
Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68W.
NOTE: If the readings are good, replace the rear washer pump motor (72).
73 – Rear Wiper and Washer Switch

Circuit 68W, point to point Continuity Bad circuit 68W.
Between terminals for wires 68C and Continuity Bad rear wiper and washer switch (73).
68L
NOTE: Put the master disconnect switch, the ignition switch, and the rotary lamp switch (112) in the ON position.
Put the rear wiper switch in the ON position.
Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.
Terminal for wire 68 L to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68L.
Terminal for wire 49 to ground 24 volts Bad rotary lamp switch (112), also check circuit 49.
NOTE: Put the rear wiper and washer switch (73) in the wash position.
Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch (73), also check circuit 68W.

4002-42
74 – Rear Wiper Motor

NOTE: Make sure the rear wiper and washer switch (73) is in the OFF position.
Between terminals for wires 68C and Continuity Bad rear wiper and washer switch (73).
68L
Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (73) in the ON position.
Terminal for wire 68L to ground 24 volts Bad rear wiper and washer switch (73).
Terminal for wire 68C to ground 0 volts Bad rear wiper and washer switch (73).
NOTE: If the readings are good, replace the rear wiper motor (74).

4002-43
TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND

CONDENSER FANS
84
86
87 81
88 77
89
82
85
75 78
83
76
79
80
GM98013
75. HORN RELAY #5 80. BLOWER MOTOR 85. COMPRESSOR CLUTCH
76. SEAT COMPRESSOR 81. LOW PRESSURE SWITCH (IN CAB) 86. CONDENSER FAN RELAY
77. HORN 82. HIGH PRESSURE SWITCH (IN REAR CHASSIS) 87. NOT USED
78. BLOWER SWITCH 83. THERMOSTAT SWITCH 88. CONDENSER FAN #1 MOTOR
79. RESISTOR BOARD 84. COMPRESSOR CLUTCH LOCKOUT RELAY 89. CONDENSER FAN #2 MOTOR
75 – Horn Relay
Terminal for wire 19U to ground 24 volts Check fuse U, also check circuit 19U.
64C to horn switch (100) Bad circuit 64C, also check horn switch (100).
NOTE: Have another person push and hold the horn switch (100).
24 volts Check horn switch (100). If the horn switch (100) is good,
replace the horn relay (75).

4002-44
76 – Seat Compressor and Switch

NOTE: This applies to models with air seat option only.
Terminal for wire 19N at seat switch 24 volts Check fuse N, also check circuit 19N.
NOTE: Put the seat compressor switch (76) in the ON position.
Terminal for wire from seat switch at 24 volts Bad seat switch, also check circuit from seat switch to
compressor compressor.
NOTE: If the readings are good replace the seat compressor.
77 – Horn
NOTE: Disconnect the wire 64 from the horn relay (75). Push and hold the horn switch (100).
Terminals for wire 64 to ground. 24 volts Check the horn relay (75), also check circuit 64.
NOTE: If the readings are good replace the horn (77).
78 – Blower Switch
Terminals for wire 19G to ground 24 volts Check fuse G, also check circuit 19G.
NOTE: Turn the blower switch to LOW.
Terminals for wire 62L to ground 24 volts Bad blower switch (78).
Terminals for wire 61T to ground 24 volts Bad blower switch (78).
NOTE: Turn the blower switch to MEDIUM.
Terminals for wire 62M to ground 24 volts Bad blower switch (78).
NOTE: Turn the blower switch to HIGH.
Terminals for wire 62H to ground 24 volts Bad blower switch (78).

4002-45
79 – Resistor Board (Blower Motor Speed Resistors with Thermal Fuse)

NOTE: Disconnect the connector from the resistor board (79).
Approximately
Between terminals 1 and 2 4.5 ohms Bad resistor board (79).
Approximately
Between terminals 2 and 3 Bad resistor board (79).
1.5 ohms
80 – Blower Motor
Terminals for wire 0 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (78) 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)

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 24 volts Check the thermostat switch (83), also check circuit 61A.
Circuit 61R, point to point Continuity Bad circuit 61R.
NOTE: Disconnect the wires from the low pressure switch (81).
Between the terminals of the low Open Bad low pressure switch (81), also check refrigerant charge
pressure switch (81) level.
82 – High Pressure Switch (In Rear Chassis)

Terminals for wire 61A to ground 24 volts Check the thermostat switch (83), also check circuit 61A.
NOTE: Disconnect the wires from the high pressure switch (82).
Between the terminals of the high Open Bad high pressure switch (82), also check for excessive
pressure switch (82) refrigerant pressure.

4002-46
83 – Thermostat Switch
HIGH.
Terminals for wire 61T to ground 24 volts Check the blower switch (78), also check circuit 61T.
NOTE: Turn the thermostat switch (83) all the way to COLD.
Terminals for wire 61A to ground 24 volts Bad thermostat switch (83).
Terminals for wire 61M to ground 24 volts Bad thermostat switch (83).
84 – Compressor Clutch Lockout Relay

Terminals for wire 61A to ground 24 volts Check thermostat switch (83), also check circuit 61A.
Terminals for wire 61R to ground 0 volts Check low pressure switch (81) and high pressure switch (82).
Terminals for wire 61C to ground 24 volts Bad compressor clutch lockout relay (84).
85 – Compressor Clutch
24 volts Check the compressor clutch lockout relay (84), also check
Terminals for wire 61C to ground
circuit 61C.
86 – Condenser Fan Relay

Terminals for wire 1 to ground 24 volts Bad circuit 1.
NOTE: Put the blower switch (78) to HIGH and the thermostat switch (83) to COLD.
Terminals for wire 61M to ground 24 volts Check the thermostat switch (83), also check circuit 61M.
Terminals for wire 12 to ground 24 volts Bad condenser fan relay (86).
87 – Not Used
NOTE: Component number 87 is not used at this time.

4002-47
88 – Condenser Fan Motor No. 1

Terminals for wire 19U to ground 24 volts Check 10 ampere circuit breaker U, also check circuit 19U.
NOTE: If readings are good, replace the condenser fan motor no. 1 (88).
89 – Condenser Fan Motor No. 2

Terminal for wire 19V to ground 24 volts Check 10 ampere circuit breaker V, also check circuit 19V.
NOTE: If readings are good, replace the condenser fan motor No. 2 (89).

4002-48
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER

OUTLET, RADIOS AND SPEAKERS
94
95
93 91
93A 92
93B
90
GM98M014
90. CIGAR LIGHTER 93. REMOTE OR 24 VOLT RADIO 94. LEFT SPEAKER
91. POWER CONVERTER 93A.12 VOLT RADIO 95. RIGHT SPEAKER
92. POWER OUTLET 93B.RADIO POWER CONVERTER
90 – Cigar Lighter
Terminal for wire 19W to ground 24 volts Check fuse W, also check circuit 19W.
NOTE: If the readings are good replace the cigar lighter (90).

4002-49
91 – Power Converter (24 volt to 12 volt)

Terminal for wire 19L to ground 24 volts Bad fuse L, also check circuit 19L.
Terminal for wire 1 to ground 24 volts Check circuit 1.
Terminal for wire 12V to ground 24 volts Bad power converter (91).
92 – Power Outlet
Terminal for wire 12V to ground 12 volts Bad power converter (91), also check circuit 12V.
NOTE: If the readings are good replace the power outlet (92).
93 – Remote Radio or 24 Volt Radio

Terminal in radio connector for wire Continuity Bad ground circuit.

0 to ground
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

12 volts Check fuse L, also check circuit 19L and 65C.
65C to ground
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 Bad circuit between the radio and the connector or bad radio
Voltage
65R to ground (93).
Terminal in radio connector for wire Bad circuit between the radio and the connector or bad radio
Voltage
65L to ground (93).

4002-50
93A – 12 Volt Radio

Terminal in radio connector for wire

Continuity Bad ground circuit.
0 to ground
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 12 volts Check fuse L, also check circuit 19L and 65C. Also check the
65C to ground 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 Voltage Bad circuit between the radio and the connector or bad radio
65R to ground (93A).
Terminal in radio connector for wire Voltage Bad circuit between the radio and the connector or bad radio
65L to ground (93A).
93B – Radio Power Converter (24 volts to 12 volts)

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the radio on.
Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (93B).
94 – Left Speaker
NOTE: Disconnect the connector from the left speaker (94). Put the master disconnect switch and the 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 Bad circuit between the left speaker (94) and the radio or a bad
Voltage
65L to ground radio (93 or 93A).
Speaker connector terminal for wire Continuity Bad circuit between the left speaker (94) and the radio (93 or
0 to ground 93A).
NOTE: If the readings are good, replace the left speaker (94).

4002-51
95 – Right Speaker
NOTE: Disconnect the connector from the right speaker (94). Put the master disconnect switch and the 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 Bad circuit between the right speaker (95) and the radio or a
Voltage
65R to ground bad radio (93 or 93A).
Speaker connector terminal for wire Continuity Bad circuit between the right speaker (95) and the radio (93 or
0 to ground 93A).
NOTE: If the readings are good, replace the right speaker (95).

4002-52
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD

SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER
MODULE
97
99
98
96 100
101
GM98M015
96. BEACON SWITCH 98. STOP LAMP SWITCH 100. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH
97. ROTATING BEACON 99. HAZARD SWITCH 101. FLASHER MODULE
96 – Beacon Switch
NOTE: Put the master disconnect switch in the ON position and the 5 position rotary lamp switch (112) in position
3 or higher.
24 volts Check the 5 position rotary lamp switch (112), also check
circuit 49.
Terminal for wire 19X to ground 24 volts Check fuse X, also check circuit 19X.
NOTE: Put the beacon switch (96) in the ON position.
Terminal for wire 46 to ground 24 volts Bad beacon switch (96).

4002-53
97 – Rotating Beacon
Bulb Continuity Bad bulb.
NOTE: Put the master disconnect switch and the beacon switch (96) in the ON position.
Bad circuit between the beacon (97) and the beacon switch
(96). Also check the beacon switch (96).
NOTE: If readings are good replace the rotating beacon (97).
98 – Stop Lamp Switch

NOTE: The stop lamp switch is located in the treadle valve below the cab. It closes with brake pedal angle.
Terminal for wire 1B to ground 24 volts Check circuit breaker B, also check circuit 1B.
NOTE: Have another person push down and hold the brake pedal.
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 1B to ground 24 volts Check Circuit Breaker B, also check circuit 1B.
NOTE: Turn the hazard switch (99) ON
Terminal for wire 45H to ground 24 volts Bad hazard switch (99).

4002-54
100 – Turn Signal, Hi/Low Beam, and Horn Switch

Terminal for wire 19B to ground 24 volts Check fuse B, also check circuit 19B.
NOTE: Move the turn signal lever for right turn.
Terminal for wire 45B to ground 24 volts Bad turn signal switch (100).
NOTE: Move the turn signal lever for left turn.
Terminal for wire 45A to ground 24 volts Bad turn signal switch (100).
NOTE: Hold Hi/Low beam lever back.
Continuity Bad turn signal switch (100), also check Hi/Low beam relay #13
(111) and circuit 64D.
NOTE: If the readings are good, replace the turn signal, Hi/Low beam, and horn switch (100).
101 – Flasher Module

NOTE: Jumper circuit 45N must be connected for North American Machines and disconnected for European
machines.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the hazard switch (99)
ON.
Terminal for wire 45H to ground 24 volts Bad circuit 45H, also check hazard switch (99).
Intermittent 24
Terminal for wire 45L to ground volts Bad flasher module (101), also check circuit 45L.
Intermittent 24
Terminal for wire 45R to ground volts Bad flasher module (101), also check circuit 45R.
NOTE: Move the turn signal lever (100) for right turn.
Terminal for wire 45B to ground 24 volts Bad circuit 45B, also check turn signal lever (100).
Intermittent 24
Terminal for wire 45R to ground volts Bad flasher module (101), also check circuit 45R.
NOTE: Move the turn signal lever (100) for left turn.
Terminal for wire 45A to ground 24 volts Bad circuit 45A, also check turn signal lever (100).
Intermittent 24
Terminal for wire 45L to ground Bad flasher module (101), also check circuit 45L.
volts
Terminal #2 to #12 wire 45N to Continuity Bad 45N circuit.

ground (North American Only).

4002-55
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP

SWITCH, AND CAB LIGHTS
118 113 102

116
103
117
114 104 110
105
111
106
115 112
107
108
109
GM98M016
102. LEFT MARKER/TURN SIGNAL 111. HIGH/LOW BEAM RELAY (ON EUROPEAN MODELS ONLY)
103. LEFT DRIVE LAMP 112. 5 POSITION ROTARY LAMP SWITCH
104. LEFT FLOOD LAMP 113. LEFT FRONT CAB LAMP
105. RIGHT FLOOD LAMP 114. LEFT REAR CAB LAMP
106. RIGHT DRIVE LAMP 115. RIGHT REAR CAB LAMP
107. RIGHT MARKER/TURN SIGNAL 116. RIGHT FRONT CAB LAMP
108. LEFT BRAKE, TAIL AND DIRECTIONAL 117. COURTESY LIGHT
109. RIGHT BRAKE, TAIL AND DIRECTIONAL 118.CAB DOME LIGHT
110. FOG LIGHT SWITCH
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.

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) Continuity Bad bulb.
Bulb (Turn signal) Continuity Bad bulb.
Intermittent 24 Check the turn signal switch (100), flasher module (101), and
volts also check circuit 45.
Terminal for wire 18F to ground 24 volts Check fuse F´, lamp switch (112), and also check circuit 18F.
103 – Left Drive Lamp (North American Models)

Put the master disconnect switch in the ON position. Put the lamp switch (112) in the drive lamp ON position.
Check fuse D´, check circuit 18D, check that jumper 41L to 41J
Terminal for wire 18D to ground 24 volts
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.
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.
Check the 5 position rotary lamp switch (112), also check

circuit 42C.

4002-57
106 – Right Drive Lamp (North American Models)

NOTE: Put the master disconnect switch in the ON position. Put the lamp switch (112) in the drive lamp ON
position.
24 volts Check fuse E´, check circuit 18E, check that jumper 41L to 41J
Terminal for wire 18E to ground
is connected, also check 5 position rotary lamp switch (112).
107 – Right Marker and Turn Signal (North American Models)

(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.
volts check circuit 45.
NOTE: Turn on the marker lights.
Check fuse G´, check the 5 position rotary lamp switch (112),
Terminal for wire 18G to ground 24 volts
and check circuit 18G.
108 – Left Brake, Tail, and Directional Lights (North American Models)
(99) is OFF. Move the turn signal lever (100) for a left turn.
Bulb (Brake and Tail) Continuity Bad bulb.
Bulb (Directional) Continuity Bad bulb.
Terminal for wire 45L to ground volts check circuit 45L.
NOTE: Turn on the tail marker lights.
Check fuse F´, check the 5 position rotary lamp switch (112),
Terminal for wire 18F to ground 24 volts
and check circuit 18F.
Terminal for wire 44 to ground 24 volts Check the stop lamp switch (98), also check circuit 44.

4002-58
109 – Right Brake, Tail, and Directional Lights (North American Models)
(99) is OFF. Move the turn signal lever (100) for a right turn.
Bulb (Brake and Tail) Continuity Bad bulb.
Bulb (Directional) Continuity Bad bulb.
Terminal for wire 45R to ground
volts check circuit 45R.
NOTE: Turn on the tail marker lights.
24 volts Check fuse G´, check the 5 position rotary lamp switch (112),
Terminal for wire 18G to ground
and check circuit 18G.
110 – Fog Light Switch

NOTE: Put the master disconnect switch and the fog light switch in the ON position. Put the 5 position rotary
lamp switch (112) in position 3 or higher.
Terminal for wire 19Y to ground 24 volts Check fuse Y, also check circuit 19Y.
Terminal for wire 41F to ground 24 volts Bad fog light switch (110).

4002-59
111 – High/Low Beam Relay (European Models)

NOTE: This relay is for use in European models only. In North American models the relay is removed. Jumper
41L and 41J is connected. Put the master disconnect switch in the ON position.
NOTE: Hold Hi/Low beam lever back.
Terminal for wire 64D to ground Continuity Check circuit 64D, also check Hi/low beam switch (100).
Put the 5 position rotary lamp switch (112) in position 3 or 4.
Terminal for wire 41J to ground 24 volts Check circuit 41J. Bad 5 position rotary lamp switch (112).
NOTE: Put the low beams ON.
24 volts Bad hi/low beam relay (111), also check that jumper 41L and
Terminal for wire 41L to ground
41J is disconnected.
NOTE: Put the high beams ON.
Terminal for wire 41H to ground 24 volts Bad high/low beam relay (111).
112 – 5 Position Rotary Lamp Switch

Terminal for wire 1 24 volts Check circuit 1.
Terminal for wire 19Z 24 volts Check fuse Z, also check circuit 19Z.
Terminal for wire 18A 24 volts Check fuse A´, also check circuit 18A.
Terminal for wire 41T 24 volts Bad 5 position rotary lamp switch (112).
Terminal for wire 49 to ground 24 volts Bad 5 position rotary lamp switch (112).
NOTE: Put the 5 position rotary lamp switch (112) in position 3 or 4.
Terminal for wire 41J 24 volts Bad 5 position rotary lamp switch (112).
NOTE: Put the 5 position rotary lamp switch (112) in position 4 or 5.
Terminal for wire 42C 24 volts Bad 5 position rotary lamp switch (112).
Terminal for wire 42R 24 volts Bad 5 position rotary lamp switch (112).

4002-60
113 – Left Front Cab Lamp

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

position 4 or 5.
24 volts Check the circuit 42R, also check 5 position rotary lamp switch
Terminal for wire 42R to ground
(112).
115 – Right Rear Cab Lamp

position 4 or 5.
Check the circuit 42R, also check 5 position rotary lamp switch
Terminal for wire 42R to ground 24 volts
(112).
116 – Right Front Cab Lamp

position 4 or 5.
Check the circuit 42C, also check 5 position rotary lamp switch
(112).

4002-61
117 – Courtesy Light

position 2 or higher.
24 volts Check the circuit 49, also check 5 position rotary lamp switch
(112).
118 – Cab Dome Light

NOTE: Put the master disconnect switch in the ON position. Put the cab dome light switch (118) in either ON
position.
Terminal for wire 19U to ground 24 volts Check the fuse U, also check the circuit 19U.
NOTE: If the readings are good, replace the cab dome light (118).

4002-62
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN

MODELS
119
123
120
125
124
129
126
130
121
131
122
127 132
128
GM98M017
119. LEFT FRONT MARKER LAMP 124. RIGHT SIDE TURN (ITALY) 129. LEFT HEAD LAMP
120. RIGHT FRONT MARKER LAMP 125. LEFT FRONT COMBINATION LAMP 130. RIGHT HEAD LAMP
121. LEFT REAR MARKER LAMP 126. RIGHT FRONT COMBINATION LAMP 131. REAR LICENSE LAMP
122. RIGHT REAR MARKER LAMP 127. LEFT REAR COMBINATION LAMP 132. ENGINE COMPARTMENT LAMP
123. LEFT SIDE TURN (ITALY) 128. RIGHT REAR COMBINATION 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.

4002-63
119 – Left Front Marker Lamp (European Models)

24 volts Check fuse F´, also check circuit 18F and 5 position rotary lamp
Terminal for wire 18F to ground
switch (112).
120 – Right Front Marker Lamp (European Models)

24 volts Check fuse G´, also check circuit 18G and 5 position rotary
lamp switch (112).
121 – Left Rear Marker Lamp (European Models)

Check fuse F´, also check circuit 18F and 5 position rotary lamp
switch (112).
122 – Right Rear Marker Lamp (European Models)

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

4002-64
123 – Left Side Turn (Italy)

is OFF. Move the turn signal lever (100) for a left turn.
Intermittent 24 Check circuits 45 and 45L, also check turn signal switch (100).
Terminal for wire 45 to ground volts Bad flasher module (101).
124 – Right Side Turn (Italy)

is OFF. Move the turn signal lever (100) for a right turn.
Intermittent 24 Check circuits 45 and 45R, also check turn signal switch (100).
Terminal for wire 45 to ground volts Bad flasher module (101).
125 – Left Front Combination Lamp (European Models)

Intermittent 24 Check circuits 45 and 45L, also check turn signal switch (100).
volts Bad flasher module (101).
Check fuse F´, also check circuit 18F. Bad 5 position rotary
lamp switch (112).

4002-65
126 – Right Front Combination Lamp (European Models)

Intermittent 24 Check circuits 45 and 45R, also check turn signal switch (100).
volts Bad flasher module (101).
24 volts Check fuse G´, also check circuit 18G. Bad 5 position rotary
lamp switch (112).
127 – Left Rear Combination Lamp (European Models)

Bulbs Continuity Bad bulb(s).
Intermittent 24 Check circuits 45 and 45L, also check turn signal switch (100)
Terminal for wire 45 to ground volts and flasher module (101).
Terminal for wire 41T and 18F to 24 volts Check fuse F´, also check circuit 41T and 18F and 5 position
ground rotary lamp switch (112).
NOTE: Put the fog lights ON.
Terminal for wire 41TF and 41F to 24 volts Check circuit 41TF and 41F, also check fog light switch (110).
ground

4002-66
128 – Right Rear Combination Lamp (European Models)

Bulbs Continuity Bad bulb(s).
Intermittent 24 Check circuits 45 and 45R, also check turn signal switch (100)
Terminal for wire 45 to ground volts and flasher module (101).
Terminal for wire 41T and 18G to 24 volts Check fuse G´, also check circuit 41T and 18G, also check 5
ground position rotary lamp switch (112).
NOTE: Put the fog lights ON.
Terminal for wire 41TF and 41F to 24 volts Check circuit 41TF and 41F, also check fog light switch (110).
ground
129 – Left Head Lamp (European Models)

NOTE: Put the master disconnect switch in the ON position. Put the low beams ON.
24 volts Check fuse D´, also check circuit 18D and hi/low beam relay
(111).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the high beams ON.
24 volts Check fuse B´, also check circuit 18B and hi/low beam relay
Terminal for wire 18B to ground
(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.
Check fuse E´, also check circuit 18E and hi/low beam relay
Terminal for wire 18E to ground 24 volts
(111).
NOTE: Put the master disconnect switch in the ON position. Put the high beams ON.
Check fuse C´, also check circuit 18C and hi/low beam relay
(111).

4002-67
131 – Rear License Lamp (European Models)

NOTE: Put the master disconnect switch in the ON position. Put the rear license lamp ON.
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.
24 volts Check fuse U, also check circuit 19F/U, and engine

Terminal for red wire to ground
compartment lamp switch (133).
133 – Engine Compartment Lamp Switch (European Models)

NOTE: Put the master disconnect switch in the ON position. Open the right side engine compartment door to
close switch. Remove both switch harness connections to check continuity.
Terminal A on connector 135 to Bad engine compartment lamp switch (133), also check circuit
Continuity
terminal a on connector 137 19F/U and fuse U.

4002-68
CONNECTORS
GM98M018

4002-69
GM98M019

4002-70
GM98M020

4002-71
GM98M021

4002-72
GM98M022

4002-73
GM98M023

4002-74
GM98M024

4002-75
GM98M025

4002-76
GM98M026

4002-77
GM98M027

4002-78
GM98M028

4002-79
GM98M029

4002-80
GM98M030

4002-81
GM98M031

4002-82
GM98M032

4002-83
ELECTRICAL SCHEMATIC - SHEETS 29, 30, 31, AND 32
1 CAB POSITIVE STUD 1
TO FUSE "W" TO FUSE "L" TO FUSE "L" TO FUSE "L" TO FUSE "L"
SHT 2 SHT 2 SHT 2 SHT 2 SHT 2
O (19L) 1.0
O (19W) 1.0
113 24 VOLT 12 VOLT

RADIO RADIO
REMOTE RADIO
O (19L) 1.0
O (19L) 1.0
93 93
O (19L) 1.0
FUSE
93A
BLOCK 14 5 11 4 9 2 1 3 6 7 8 10 12 13 TO 24V RADIO
REMOTE TO 12V RADIO
"C11"
RADIO
FUSE
R (1) 5.0
O (19L) 1.0
BLOCK
"C16"
O/W (65L) 0.8
O/W (65L) 0.8

O/W (65C) 0.8
O/W (65R) 0.8
O/W (65C) 0.8
O/W (65R) 0.8
O/W (65C) 0.8
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
FUSE
B (0) 0.8
FUSE
B (0) 0.8
FUSE
BLOCK BLOCK BLOCK
O (19W) 3.0
"C5" "C5" "C5"

91 RADIO
24V IGN
O (19L) 1.0
POWER
O (19L) 1.0
POWER JUMPER
O (19L) 1.0
JUMPER
HARN
CONVERTER
CONVERTER JUMPER HARN HARN
GND 12V 6 3 1 2 5 4 6 3 1 2 5 4
R (12V) 5.0 RADIO
RADIO HARN
RADIO
RADIO
RADIO 93B RADIO
6 3 1 2 5 4 RADIO
HARN HARN
HARNESS HARNESS HARNESS HARNESS
115 114
O/W (65L) 0.8

114
B (0) 0.8
O/W (65R) 0.8

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

A A A
O/W (65R) 0.8

FUSE A
O/W (65R) 0.8

O/W (65L) 0.8
24V 12V 114
B (0) 0.8
B (0) 0.8
B (0) 0.8
BLOCK B (0) 0.8
B (0) 0.8
B B (0) 0.8 B B B B (0) 0.8
"C6",
90 "C12",
R (12V) 3.0
CIGAR "C18" 109 109 109 110

LIGHTER
110 110
A B A B A B
116
112 112 112
92 94 A B A B A B
94 94
POWER LEFT 111
OUTLET 111 LEFT 111 LEFT
SPEAKER
SPEAKER SPEAKER
95 95 95
B (0) 3.0
B (0) 1.0
B (0) 5.0
B (0) 1.0
B (0) 1.0
B (0) 3.0
RIGHT RIGHT RIGHT

SPEAKER SPEAKER SPEAKER
4 CAB NEGATIVE STUD 4
SHEET 29 SHEET 30 SHEET 31 SHEET 32
BC00E078

4002-84
NOTES

4002-85
ELECTRICAL SCHEMATIC - SHEETS 1 AND 2
2 CAB SWITCHED POWER 2

VIA RR FOR HT. SW. ON SHEET 4
3 INSTRUMENT ILLUMINATION 3
R (1B) 0.8
O (19X) 1.0 30
TO FUSE B SPLICE WITH TIME
CIRCUIT BREAKER B O (19B) 0.8
ON SHEET 8 DELAY GROUND
12 AMP FLASHER
R (1B) 0.8
ON SHEET 10
101 MODULE
1 PED|CAB B (0) 1.0
TO SPLICE CAB|FRONT 13 B (1B) 0.8 65 R (1B) 0.8 R (1B) 0.8 1 POWER IN

#4 ON
Gy (49) 1.0
SHEET 8 R (1B) 0.8 S DBr (45N) 0.8 2 FLASHER OUT
CAB|PED B (0) 1.0 3 GROUND
Gy (49) 0.8 15 B (0) 1.0 4 GROUND
BEACON
TO BACK-UP
96 SWITCH R (1B) 0.8 5 N.C.
6 N.C.
ALARM DIS.
SWITCH ON TO BACK-UP ALARM DBr/LG (45R) 0.8 7 R. TURN LIGHT OUT
Gy (49) 0.8
SHEET 12 B (0) 1.0 DISABLE SWITCH
ON SHEET 12 DBr/Y (45L) 0.8 8 L. TURN LIGHT OUT
2
DBr/LG (45B) 0.8 9 RIGHT TURN SW.
DBr/Y (45A) 0.8 10 LEFT TURN SW.
6 2
DBr (45H) 0.8 67 DBr (45H) 0.8 11 HAZARD SW.
5 66
Gy (49) 0.8 DBr (45N) 0.8 12 OPPOSITE SIDE CONTROL
6
Gy (49) 1.0 4
TO PLOT
5 PULL CONNECTOR APART
CONT. SW. 62
P (46) 1.0
TO PILOT
ON SHEET 16 B (0) 0.8 CONT. SW. FOR EUROPEAN MACHINES
4 ON SHT 16
13 SHOWN FOR NAO
42 71 64
P (46) 0.8
2
HAZARD
TO INSTRUMENT
CLUSTER CAVITY 13 SWITCH 99 4 T (44) 1.0
ON SHEET 14 4 TO CLUSTER CAVITY 35
ON SHEET 17 1
B (0) 1.0
1
4 CAB|FRONT
CAB NC
23 CAB
3 C
ROOF T (44) 0.8 X

2 PED|CAB
NO
DBr/Y (45L) 0.8 A DBr/Y (45L) 1.0 31
B (0) 1.0 DBr/LG (45B) 0.8
TO RR WIPER
98 DBr/Y (45A) 0.8
70
69
T (44) 0.8 DBr/Y (45L) 0.8 DBr/LG (45R) 0.8 C DBr/LG (45R) 1.0
32
MOTOR GROUND B (0) 1.0 CAB|REAR REAR|REAR LIGHT
ON SHEET 25
STOP LAMP 33
B (0) 1.0
P (46) 1.0
DBr/LG (45L) 1.0 9 DBr/Y (45L) 1.0
O (19B) 0.8
10
SWITCH 13 12 DBr/LG (45R) 1.0 11 DBr/LG (45R) 1.0 34
(SWITCH IN TREADLE T (44) 0.8 8 T (44) 1.0 7 T (44) 1.0
VALVE BELOW CAB 35
CLOSES WITH BRAKE H
A B PEDAL ANGLE) 45 31 B (0) 0.8 DBr/LG (45R) 0.8 21 94
85 R
2
L
54 TO CLUSTER CAVITY 17
1 PED|CAB ON SHEET 17
B (0) 1.0
B A O/LB (64D) 0.8 55 TO CLUSTER CAVITY 16

H/L DBr/Y (45L) 0.8
42 ON SHEET 17
M 68 67
B (0) 1.0
41
O/LB (64D) 0.8
66
B (0) 0.8
B (0) 0.8 13
ROTATING
BEACON
97 O/LB (64C) 0.8
O/LB (64C) 0.8 TO HORN RELAY
#5 ON SHEET 26
CAB FLOOR
WELD STUD
36
VIA RR FOG LT. SW.
ON SHEET 1
TURN SIGNAL,
HI/LOW BEAM,
100 AND HORN
SHEET 1 SWITCH
SHEET 2
BC00E079

4002-86
ELECTRICAL SCHEMATIC - SHEET 3A
BC00E096

4002-87
ELECTRICAL SCHEMATIC - SHEETS 3, 4, AND 5
VIA SPLICE #3
2 CAB SWITCHED POWER 2
R (1) 3.0
30 O (19X) 1.0 RIGHT 113 114 115 116
TO INSTRUMENT CLUSTER
FUSES
CAVITY 15 SHEET 14 O (18C) 0.8 LEFT LEFT RIGHT RIGHT
LEFT LEFT LEFT RIGHT RIGHT FUSE X BEACON (7.5) FRONT REAR REAR FRONT
102 MARKER/TURN 103 DRIVE 104 FLOOD 105 FLOOD 106 DRIVE FUSE Y FOG LIGHTS (7.5) CAB CAB CAB CAB
SIGNAL LAMP LAMP LAMP LAMP 107 LAMP LAMP LAMP
FUSE Z FRNT. FLOOD LIGHTS AND ILLUM (10A) LAMP
DBe (42C) 1.0

FUSE A REAR FLOOD LIGHTS (10A) COURTESY
B (0) 1.0
RIGHT 117 LIGHT
B (0) 1.0
B (0) 1.0
DBe (42C) 1.0
B (0) 1.0
DBe (42R) 1.0
DBe (42R) 1.0

FUSE B HIGH BEAM LEFT (5A)
MARKER/TURN FUSE C HIGH BEAM RIGHT (5A)
SIGNAL
FUSE D LOW BEAM LEFT (5A)
O (18G) 1.0
B (0) 1.0
B (0) 1.0
O (18E) 1.0
DBr (45) 1.0

O (18F) 1.0
B (0) 1.0
DBe (42C) 1.0
B (0) 1.0
DBr (45) 1.0
O (18D) 1.0
B (0) 1.0
FUSE E LOW BEAM RIGHT (5A)
1.0
FUSE F TAIL LIGHTS LEFT (5A)
R (1) 3.0
DBe (42C)
FUSE G TAIL LIGHTS RIGHT (5A) TO ENG. COMP. LIGHT
ON PAGE 3 (EURO)
6/7/821C ONLY A B
78
18
B (0) 1.0 B (0) 1.0
B (0) 1.0
P (41T) 1.0
A B A B A B A B
DBe (42C) 1.0

B (0) 1.0
R (19Y) 1.0
O (19Z) 1.0
77
O (18G) 0.8
79 83 80
O (18F) 0.8
O (18G) 0.8
H/L RELAY REMOVED AND
O (18D) 0.8
O (18A) 2.0
Gy (49) 0.8
FRONT
P (41L) 0.8
P (41H) 2.0
P (41L) 2.0
A B C LIGHT CONNECTOR MATED FOR NAO
(H/L SHOWN FOR EURO)
8 FRONT
P (41J) 0.8
C B A A B C 9 C B A
1
B (0) 0.8
6 7
Gy (49) 0.8
B (0) 1.0 B (0) 1.0
HIGH/LOW
DBe (42C) 1.0
BEAM RELAY
111 21 DBe (42R) 1.0 DBe (42R) 1.0
FRONT|CAB
59 B (0) 1.0
O (18D) 1.0 O 30 7 DBe (42C) 1.0
8
O (18E) 1.0 P O (18E) 0.8 REAR|CAB B (0) 0.8 B (0) 0.8
O (18G) 1.0 56a
E 4
DBe (42C) 1.0

DBe (42R) 1.0
56
DBe (42C) 1.0 J 56b 1
B (0) 1.0
O (18C) 1.0 O (18C) 0.8
3 84
Q
B (0) 1.0
B (0) 1.0
6
O (18B) 1.0 G O (18B) 0.8 S O (19U) 1.0
CAB
B (0) 1.0 B (0) 1.0
O (18F) 1.0 F O (18F) 0.8 DOME 118
31 DBr/Y (45L) 1.0 P (18G) 1.0 LIGHT CAB CAB
TO R.H. RR MARK LT. NAO Y (18G/42R) 1.0 TO CAB/PED CONN.
ROOF ROOF
32 DBr/LG (45R) 1.0 CAVITY 12 ON SHEET 14
ON SHEET 1 (EURO)
CAB 23 CAB 24
DBr/Y (45L) 1.0 21
O (18F) 1.0 O (18G) 1.0 6 P (18G) 1.0 EURO P (41J) 2.0 TO FUSE U ON O (19U) 1.0
33 R (1) 3.0 SHEET 10
Gy (49) 1.0
B (0) 2.0 8 9 O (18G) 0.8 O (18G) 0.8 DBe (42R) 0.8
34 DBr/LG (45R) 1.0 O (19U) 0.8
17 P (18F) 1.0 5
T (44) 1.0 T (44) 1.0 DBe (42C) 0.8
10 P (41F) 1.0 2 P (41F) 1.0 DBe (42C) 1.0
35 B (0) 2.0
P (41J) 2.0
REAR LIGHT|REAR REAR|CAB P (41T) 1.0 DBe (42R) 0.8 B (0) 1.0
T (44) 1.0 C A B D B (0) 2.0 Gy (49) 0.8

TO CLUSTER CAVITY 14
1.0
D B A C 33
106 105 ON SHEET 14
94
B (0) 1.0
B(O) 2.0
B (0) 1.0
P (18F) 1.0
P(41F)
2
Gy (49) 1.0 LIGHTS
TO L.H. RR. 34 32 SWITCH PARK
MARK LT. ON
SHEET 3 (EURO) TO RETURN TO TRAVEL 25 POSITION AND DRIVE FLOOD ILLUMINATION
6 SWITCH, SHEET 19 TAIL F&R
Gy (49) 1.0 5 B (0) 1.0 HD TL F4 B1 IL F1 B3 F3 F2 B2

5 POSITION 3 3
1 OFF
2 4 2 4 2 3 4
4
ROTARY 1 5 1 5 1 5
108 109 43 LAMP 112 2 ON
B (0) 2.0
B (0) 1.0
TO BEACON SW.
3 ON ON ON
ON SHEET 1
FOG SWITCH
RIGHT BRAKE,
LEFT BRAKE,
TAIL, AND DIRECTIONAL TAIL, AND DIRECTIONAL
LIGHT 110 TO BEACON SWITCH
4 ON ON ON ON
36 SWITCH ON SHEET 1 5 ON ON ON
NAO
VIA GROUND
TO L.H. RR. TO R.H. RR. SPLICE
MARKS LT. ON SHEET 1 MARKS LT. ON SHEET 1
(EURO) (EURO)
SHEET 3 SHEET 4 SHEET 5
BC00E080

4002-88
NOTES

4002-89
INDEX
Symbols B
12 Volt Radio ..........................................................50 Bulb (Continued)
24 Volt Radio ..........................................................49 Right Front Cab Lamp........................................60
5 Position Rotary Lamp Switch...............................59 Right Front Combination Lamp
(European Models) ........................................65
A Right Front Marker Lamp
Accessory Relay #3................................................17 (European Models) ........................................63
Air Filter Restriction Switch.....................................23 Right Marker (North American Models)..............57
Alternator ................................................................12 Right Rear Cab Lamp ........................................60
Right Rear Combination Lamp
B (European Models) ........................................66
Back-up Alarm ........................................................20 Right Rear Marker Lamp
Back-up Alarm Disable Switch ...............................20 (European Models) ........................................63
Back-up Alarm Relay #7.........................................19 Right Side Turn Lamp (Italy) ..............................64
Batteries ................................................................. 11 Right Tail Lamp (North American Models) .........58
Beacon Switch........................................................52 Right Turn Signal (North American Models) ......57
Beacon, Rotating ....................................................53 Rotating Beacon ................................................53
Blower Motor ..........................................................45
Resistor Board with Thermal Fuse .....................45 C
Blower Switch .........................................................44 Cab Dome Light .....................................................61
Brake Warning Pressure Switch.............................22 Cigar Lighter...........................................................48
Bucket Control Valves Detent Electromagnets.......32 Circuit Diagram Legend............................................9
Bucket Dump Pressure Switch ...............................37 Cluster, Instrument ...........................................25, 26
Bucket Rollback Pressure Switch...........................38 Cold Start Temperature Switch ..............................13
Bulb Color Abbreviations ..................................................9
Cab Dome Lamp ................................................61 Compressor Clutch.................................................46
Courtesy Light ....................................................61 Compressor Clutch Lockout Relay.........................46
Engine Compartment Lamp Compressor, Seat ..................................................44
(European Models) ....................................... 67 Condenser
Left Brake Lamp (North American Models) ........57 Fan Motor No. 1 .................................................47
Left Directional Lamp Fan Motor No. 2 .................................................47
(North American Models) .............................. 57 Condenser Fan Relay ............................................46
Left Drive Lamp (North American Models) .........56 Connector, Diagnostic ............................................19
Left Flood Lamp (North American Models) ........56 Converter, Radio Power (24 volts to 12 volts) ........50
Left Front Cab Lamp ..........................................60 Coolant Level Sender.............................................22
Left Front Combination Lamp Courtesy Light ........................................................61
(European Models) ....................................... 64
Left Front Marker Lamp D
(European Models) ....................................... 63 Declutch Brake Switch ...........................................19
Left Head Lamp (European Models) ..................66 Declutch Switch......................................................19
Left Marker (North American Models) ................56 Detent Switch .........................................................31
Left Rear Cab Lamp ...........................................60 Diagnostic Connector .............................................19
Left Rear Combination Lamp
(European Models) ....................................... 65 E
Left Rear Marker Lamp Engin Speed Sensor ..............................................19
(European Models) ....................................... 63 Engine Automatic Shutdown Relay Socket #11 .....30
Left Side Turn Lamp (Italy).................................64 Engine Compartment Lamp
Left Tail Lamp (North American Models)............57 (European Models).............................................67
Left Turn Signal (North American Models) .........56 Engine Compartment Lamp Switch
Rear License Lamp (European Models) ............67 (European Models).............................................67
Right Brake Lamp (North American Models)......58 Engine Coolant Temperature Sender.....................23
Right Directional Lamp Engine Oil Pressure Sender ...................................28
(North American Models) .............................. 58 Ether Solenoid........................................................14
Right Drive Lamp (North American Models).......57 Ether Start Relay ....................................................14
Right Flood Lamp (North American Models) ......56
4002-90
E L
Ether Start Switch...................................................14 Lamp (Continued)
Left Turn Signal (North American Models).........56
F Rear License (European Models) ......................67
Filter Maintenance Switch ......................................19 Right Brake (North American Models) ...............58
Flasher Module.......................................................54 Right Directional (North American Models)........58
Fog Light Switch .....................................................58 Right Drive (North American Models) ................57
Front Rotary Wiper and Washer Switch .................40 Right Flood (North American Models)................56
Front Washer Pump Motor .....................................41 Right Front Cab..................................................60
Front Wiper Motor...................................................40 Right Front Combination (European Models) ....65
Fuel Level Sender ..................................................22 Right Front Marker (European Models) .............63
Fuel Relay ..............................................................13 Right Head (European Models) .........................66
Fuel Shutoff Solenoid .............................................12 Right Marker (North American Models) .............57
Right Rear Cab ..................................................60
G Right Rear Combination (European Models) .....66
Graphic Symbols ......................................................8 Right Rear Marker (European Models) ..............63
Right Side Turn (Italy) ........................................64
H Right Tail (North American Models) ...................58
Hazard Switch ........................................................53 Right Turn Signal (North American Models) ......57
Height Control Proximity Switch .............................33 Switch, 5 Position Rotary ...................................59
Hi/Low Beam Switch...............................................54 Left Brake Lamp (North American Models) ............57
High Pressure Switch (In Rear Chassis) ................45 Left Directional Lamp (North American Models) ....57
High/Low Beam Relay (European Models) ............59 Left Drive Lamp (North American Models) .............56
Hoist-up Pressure Switch .......................................37 Left Flood Lamp (North American Models) ............56
Horn........................................................................44 Left Front Cab Lamp ..............................................60
Horn Relay..............................................................43 Left Front Combination Lamp (European Models) .64
Horn Switch ............................................................54 Left Front Marker Lamp (European Models) ..........63
How to Use this Section .........................................10 Left Head Lamp (European Models) ......................66
Hydraulic Filter Restriction Switch ..........................23 Left Marker Lamp (North American Models) ..........56
Hydraulic Oil Temperature Sender .........................23 Left Rear Cab Lamp ...............................................60
Left Rear Combination Lamp (European Models)..65
I Left Rear Marker Lamp (European Models)...........63
Ignition Relay #1.....................................................15 Left Side Turn Lamp (Italy).....................................64
Ignition Relay #2.....................................................16 Left Speaker ...........................................................50
Ignition Switch ........................................................15 Left Tail Lamp (North American Models)................57
Instrument Cluster ............................................25, 26 Low Pressure Switch (In Cab)................................45
Intermediate Speed Sensor....................................19
M
L Master Disconnect Switch ......................................12
Lamp Module
Cab Dome ..........................................................61 Flasher ...............................................................54
Courtesy .............................................................61 Time Delay .........................................................17
Engine Compartment (European Models)..........67 Transmission Electronic Control ........................19
Left Brake (North American Models) ..................57 Motor, Starter .........................................................13
Left Directional (North American Models) ..........57
Left Drive (North American Models) ...................56 N
Left Flood (North American Models) ..................56 Neutral Start Relay .................................................14
Left Front Cab ....................................................60 Notes ........................................................................ 9
Left Front Combination (European Models) .......64
Left Front Marker (European Models) ................63 O
Left Head (European Models) ............................66 Outlet, Power..........................................................49
Left Marker (North American Models) ................56 Output Speed Sensor.............................................19
Left Rear Cab.....................................................60
Left Rear Combination (European Models)........65 P
Left Rear Marker (European Models).................63 Park Brake Switch ..................................................24
Left Side Turn (Italy)...........................................64 Parking Brake Relay...............................................29
Left Tail (North American Models) .....................57 Pilot Control Relay..................................................29
4002-91
P R
Pilot Control Switch ................................................26 Right Marker Lamp (North American Models) ........57
Pilot Pressure Solenoid ..........................................29 Right Rear Cab Lamp.............................................60
Pin Engage Solenoid ..............................................36 Right Rear Combination Lamp
Pin Engagement Switch .........................................36 (European Models).............................................66
Power Converter (24 volt to 12 volt) .......................49 Right Rear Marker Lamp (European Models) ........63
Power Outlet...........................................................49 Right Side Turn Lamp (Italy) ..................................64
Program Reset Switch............................................24 Right Speaker.........................................................51
Right Tail Lamp (North American Models) .............58
R Right Turn Signal Lamp
Radio (North American Models) ...................................57
12 volt.................................................................50 Rotating Beacon.....................................................53
24 volt.................................................................49
Power Converter (24 volts to 12 volts) ...............50 S
Remote...............................................................49 Seat Compressor and Switch.................................44
Rear License Lamp (European Models).................67 Secondary Steering Pump/Motor ...........................36
Rear Rotary Wiper and Washer Switch..................41 Secondary Steering Relay with Lockout.................35
Rear Washer Pump Motor......................................41 Secondary Steering Switch ....................................35
Rear Wiper Motor ...................................................42 Sender
Redundant Brake Switches ....................................30 Coolant Level .....................................................22
Redundant Parking Brake Solenoids......................29 Engine Coolant Temperature .............................23
Relay Engine Oil Pressure ...........................................28
Accessory, #3.....................................................17 Fuel Level ..........................................................22
Backup Alarm, #7 ...............................................19 Hydraulic Oil Temperature .................................23
Compressor Clutch Lockout ...............................46 Torque Converter Output Temperature..............19
Condenser Fan ..................................................46 Sensor
Ether Start ..........................................................14 Engine Speed ....................................................19
Fuel ....................................................................13 Intermediate Speed............................................19
High/Low Beam (European Models) ..................59 Output Speed .....................................................19
Horn ...................................................................43 Transmission Solenoid Valve and
Ignition, #1..........................................................15 Temperature ..................................................19
Ignition, #2..........................................................16 Turbine Speed ...................................................19
Neutral Start .......................................................14 Shifter, Transmission..............................................19
Parking Brake.....................................................29 Shutoff, Fuel Solenoid ............................................12
Pilot Control........................................................29 Solenoid
Ride Control .......................................................37 Ether ..................................................................14
Secondary Steering with Lockout.......................35 Fuel Shutoff........................................................12
Socket #11, Engine Automatic Shutdown ..........30 Pilot Pressure.....................................................29
Start....................................................................13 Pin Engage ........................................................36
Voltmeter, #12 ....................................................17 Redundant Parking Brake ..................................29
Remote Radio.........................................................49 Ride Engage ......................................................38
Return-To-Dig Proximity Switch .............................32 Speaker
Return-To-Travel Proximity Switch.........................33 Left .....................................................................50
Return-To-Travel/Float Switch................................32 Right...................................................................51
Ride Control Relay .................................................37 Specifications ...........................................................7
Ride Control Switch ................................................37 Start Relay..............................................................13
Ride Engage Solenoid............................................38 Starter Motor ..........................................................13
Right Brake Lamp (North American Models) ..........58 Stop Lamp Switch ..................................................53
Right Directional Lamp Switch.....................................................................46
(North American Models) ...................................58 5 Position Rotary Lamp......................................59
Right Drive Lamp (North American Models) ...........57 Air Filter Restriction............................................23
Right Flood Lamp (North American Models) ..........56 Back-up Alarm Disable.......................................20
Right Front Cab Lamp ............................................60 Beacon ...............................................................52
Right Front Combination Lamp Blower ................................................................44
(European Models).............................................65 Brake Warning Pressure ....................................22
Right Front Marker Lamp (European Models) ........63 Bucket Dump Pressure ......................................37
Right Head Lamp (European Models) ....................66 Bucket Rollback Pressure ..................................38

4002-92
S T
Switch (Continued) Thermostat .............................................................46
Cold Start Temperature......................................13 Thermostat Switch..................................................46
Declutch .............................................................19 Time Delay Module ................................................17
Declutch Brake...................................................19 Torque Converter Output Temperature Sender .....19
Detent.................................................................31 Transmission Auto Switch ......................................19
Engine Compartment Lamp Transmission Electronic Control Module................19
(European Models) ....................................... 67 Transmission Kick-down Switch.............................19
Ether Start ..........................................................14 Transmission Shifter...............................................19
Filter Maintenance..............................................19 Transmission Solenoid Valve and
Fog Light ............................................................58 Temperature Sensors ........................................19
Front Rotary Wiper and Washer ........................40 Transmission Solenoid Valve and Temperature
Hazard................................................................53 Sensors .....................................................19
Height Control Proximity ....................................33 Turbine Speed Sensor ...........................................19
Hi/Lo Beam ........................................................54 Turn Signal Lamp (North American Models) ..........56
High Pressure (In Rear Chassis) .......................45 Turn Signal Switch .................................................54
Hoist-up Pressure ..............................................37
Horn ...................................................................54 U
Hydraulic Filter Restriction .................................23 Up/down Count Switch ...........................................27
Ignition................................................................15
Low Pressure (In Cab) .......................................45 V
Master Disconnect .............................................12 Voltmeter Relay #12...............................................17
Park Brake .........................................................24
Pilot Control Switch ............................................26 W
Pin Engagement.................................................36 Wiper
Program Reset ...................................................24 Front Motor ........................................................40
Rear Rotary Wiper and Washer .........................41 Front Rotary Switch ...........................................40
Redundant Brake ...............................................30 Front Washer Pump Motor.................................41
Return-To-Dig Proximity.....................................32 Front Washer Switch..........................................40
Return-To-Travel Proximity ................................33 Rear Motor .........................................................42
Return-To-Travel/Float.......................................32 Rear Rotary Switch ............................................41
Ride Control .......................................................37 Rear Washer Pump Motor .................................41
Seat Compressor ...............................................44 Rear Washer Switch ..........................................41
Secondary Steering............................................35
Stop Lamp..........................................................53
Transmission Auto .............................................19
Transmission Kick-down ....................................19
Turn Signal.........................................................54
Up/down Count ..................................................27
Symbols, Graphic .....................................................8

Section
4005
INFORMATION AND DIAGNOSTICS CENTER
4005
CASE CORPORATION
700 State Street
NOTES
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Requested Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Actual Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission Mode (Automatic or Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SETTINGS, DIAGNOSTICS, AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Programming the Information Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manual Scrolling Gauge Displays (01, 02, or 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Automatically Scrolling Gauge Displays (03 or 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Individual Function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Testing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting Display Center Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Voltmeter at Key ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4005-4
Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Park Brake Information Center Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pilot Lockout Information Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Work Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fog Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air Conditioning Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Transmission Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Requested Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operational Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Actual Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive Line Shift Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hourmeter Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tachometer Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Movement Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Beacon Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Left Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Right Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Caution and Warning Master Indicator Lights Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diagnostic Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Park Brake Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Redundant Brake Pressure Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service Brake Foot Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pilot Lockout Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Display Location 047 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Display Location Numbers (048 and 049) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Minimum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maximum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gear Range Read Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Display Location Number 054 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reset Diagnostic Stack for Locations 071 through 090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Display Location Numbers (056 - 060) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Interval Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ZF Transmission ECM Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ZF Transmission ECM Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Information Center Software Revision Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
LED Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
LCD Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Internal Information Center Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Entry Code for Accessing Test Mode Locations 100 to 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transmission Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Display Location Numbers 104 - 113 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instrument Cluster (Information Center) Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instrument Cluster (Information Center) Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instrument Cluster (Information Center) Date Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Display Location Numbers 117 - 120 Reserved for Supplier Information . . . . . . . . . . . . . . . . . . . . . . . . . 29
Display Location Numbers 121 -129 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Display Location Numbers 131 - 139 Reserved for Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . 30
Display Location Numbers 140 - 170 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Temporary Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4005-5
Display Location Numbers 191 - 196 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Display Location Number 197 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Display Location Number 199 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4005-6

4005-7
INFORMATION AND DIAGNOSTIC CENTER

The information and diagnostic center monitors a number of functions and can be tailored to fit the operator’s
preferences, refer to Figure 1. The information center not only monitors machine functions, it warns the operator
when caution is needed due to a possible malfunction and when immediate action is needed due to a possible
critical malfunction. When the machine is started, the information and diagnostic center will perform the following
self-test:
6 7 8
5 9
4 10
3 11
12
2
1 13
20
14
19
15
18
16
17
RD98K316
1. BEACON INDICATOR 11. HYDRAULIC OIL FILTER INDICATOR
2. WORK LIGHT INDICATOR 12. AIR FILTER INDICATOR
3. PILOT CONTROL INDICATOR 13. TRANSMISSION OIL FILTER INDICATOR
4. LOW COOLANT INDICATOR 14. TRANSMISSION OIL TEMPERATURE GAUGE
5. BRAKE PRESSURE INDICATOR 15. HYDRAULIC OIL TEMPERATURE GAUGE
6. STOP MASTER INDICATOR 16. VOLTMETER GAUGE
7. CAUTION MASTER INDICATOR 17. FUEL LEVEL GAUGE
8. SECONDARY STEERING INDICATOR 18. ENGINE OIL PRESSURE
9. PARKING BRAKE INDICATOR 19. ENGINE COOLANT TEMPERATURE GAUGE
10. AIR-CONDITIONING INDICATOR 20. SERVICE INDICATOR ICON
FIGURE 1. INFORMATION CENTER
Self-Test 3. All LED’s (Light Emitting Diodes) will illuminate

for 2 - 3 seconds.
IMPORTANT: During operation, if the stop master
indicator (on the front console) flashes, and the 4. Six bar graphs will energize for 2 - 3 seconds.
warning alarm is continuous, stop the machine, stop 5. The warning alarm will sound for 2 - 3 seconds.
the engine, and find the problem.
6. If there is an open circuit between a sensor and
1. Turn the ignition (key) switch to the ON position. the information center, the LED will flash and the
2. The information center will automatically check warning alarm will sound for 5 seconds.
each monitored system.

4005-8
7. If there were no faults detected during the check, Caution Master Indicator (Yellow)
all monitored systems will return to normal
operation. When the caution master indicator illuminates:
8. If only some of the LEDs illuminate, replace the 1. The warning alarm sounds for three seconds.
information center. 2. The indicator turns yellow and one or more of the
9. If the LEDs illuminate, but the warning alarm following conditions exist:
does not sound, replace the information center. A. Parking brake engaged when shifting into
forward or reverse.
10. If the warning alarm sounds but the LEDs do not
illuminate, replace the information center. B. High engine coolant temperature.
11. If the warning alarm does not sound and the C. High hydraulic oil temperature.
LEDs do not illuminate on the information center, D. High transmission oil temperature.
do the following steps to test the power circuit: E. Low engine oil pressure.
F. High or low air conditioning pressure.
Power Circuit Test
G. Air filter restriction.
A. Check the 7.5 amp fuse V. If the fuse is bad,
replace the fuse and repeat Self-Test steps 1 H. Transmission filter restriction (not applicable
through 7. If the fuse is good, do the next step. for 621C model).
B. Check wire 19V for continuity. Repair/replace I. Hydraulic filter restriction.

the wire as required. If continuity is found do J. Alternator malfunction.
the next step. K. Low fuel.
C. Check wire 13V for continuity. Repair/replace
the wire as required. If continuity is found, do Beacon Indicator
the next step. The beacon indicator illuminates when the Beacon (if
D. Check the voltmeter relay #12 for proper equipped) is in the ON position.
operation, see Section 4002. If voltmeter Work Light Indicator
operates properly, do the next step.
The work light indicator illuminates when the work
E. If no faults are found in Power Circuit Test
lights are ON.
steps A through D, then remove and replace
the information center. Pilot Control
The Pilot Control indicator illuminates when the pilot
Indicators and Gauges lockout is actuated.
Stop Master Indicator (Red) Low Coolant Indicator
IMPORTANT: Failure to follow these procedures may The low coolant indicator illuminates when the
result in injury and/or damage to the machine. engine coolant is low.
When the stop master indicator illuminates: 1. The warning alarm sounds continuously.
1. Stop the machine immediately. 2. The stop master indicator will be red.
2. Turn OFF the engine. 3. Stop the engine and add coolant to the radiator.
3. The warning alarm sounds continuously and one
Brake Pressure Indicator
or more of the following conditions exist:
A. Low engine oil pressure. The brake pressure indicator illuminates when the
brake system pressure is too low.
B. Low brake pressure.
1. The warning alarm sounds continuously.
C. Low steering pressure.
D. Low engine coolant level. 2. The stop master indicator will be red.
E. High engine coolant temperature. 3. Stop the engine and correct the problem.
F. High hydraulic oil temperature.
G. High transmission oil temperature.

4005-9
Secondary Steering Indicator (If 2. The caution master indicator turns yellow.
equipped) 3. Replace the transmission oil filters as required.
The secondary steering indicator illuminates when Transmission Oil Temperature Gauge
the primary steering system pressure is too low. The transmission oil temperature gauge is shown as
1. The warning alarm sounds continuously. an indicator bar with a green, yellow or red zone.
2. The stop master indicator will be red. Green Zone:
3. Stop the engine and correct the problem. Indicates normal operating temperature, 20° to 120°
C (68° to 248° F).
Parking Brake Indicator
Yellow Zone:
The parking brake indicator illuminates when the
parking brake is applied. If the transmission is shifted 1. Transmission oil temperature is too low, 20° C or
into FORWARD or REVERSE when the parking below (68° F or below), or it has increased, 120°
brake is applied: to 125° C (248° to 257° F).
1. The warning alarm sounds for 3 seconds. 2. The indicator bars flash.
2. The caution master indicator turns yellow. 3. The warning alarm sounds for 3 seconds.
3. Disengage the parking brake before shifting the 4. The yellow caution master indicator turns on.
machine. Red Zone:
Air Conditioning Indicator NOTE: The machine must not be operated when the
temperature is in the red zone.
The air conditioning indicator illuminates when the air
conditioner has stopped due to refrigerant pressures 1. Transmission oil temperature continues to
that are too high or too low. increase,125° C and above (257° F and above).
1. The warning alarm sounds for 3 seconds. 2. The indicator bar flashes.
2. The caution master indicator turns yellow. 3. The warning alarm sounds continuously.
3. Service the air-conditioning system, or the 4. The red stop master indicator turns on.
outside air temperature is too cool for the system
5. Stop the machine.
to work.
6. Shift the transmission into NEUTRAL.
Air Filter Indicator
7. Run the engine at half throttle until the
The air filter indicator illuminates when the air filter is transmission cools.
restricted.
8. If the transmission oil temperature does not
1. The warning alarm sounds for 3 seconds. return to normal operating temperature, run the
2. The caution master indicator turns yellow. engine at idle speed and check the transmission
oil level.
3. Replace or clean the air filter as required.
9. Correct the problem before continuing to operate
Hydraulic Oil Filter Indicator the machine.
The hydraulic oil filter indicator illuminates when the Hydraulic Oil Temperature Gauge
hydraulic filters are restricted.
The hydraulic oil temperature gauge is shown as an
1. The warning alarm sounds for 3 seconds. indicator bar with a green, yellow, or red zone.
2. The caution master indicator turns yellow. Green Zone:
3. Replace the hydraulic oil filters as required. Indicates normal operating temperature, 20° to 105°
Transmission Oil Filter Indicator (Not C (68° to 221° F).
applicable to 621C) Yellow Zone:
The transmission oil filter indicator illuminates when 1. Hydraulic oil temperature has decreased, 20° C
the transmission filter(s) are restricted. or below (68 ° F or below), or it has increased
105° to 110° C (221° to 230° F).
1. The warning alarm sounds for 3 seconds.
4005-10
2. The indicator bars flash. 1. The indicator bars flash.
3. The warning alarm sounds for 3 seconds. 2. The warning alarm sounds for 3 seconds.
4. The yellow caution master indicator turns on. 3. The yellow caution master indicator turns on.
Red Zone: Engine Oil Pressure Gauge
NOTE: The machine must not be operated when the The engine oil pressure gauge is shown as an
temperature is in the red zone. indicator bar with a green, yellow, or red zone.
1. Hydraulic oil temperature continues to increase Green Zone:
110° C and above (230° F and above).
Indicates normal operating pressure, 140 kPa (20
2. The indicator bar flashes. psi) and above low idle.
3. The warning alarm sounds continuously. Yellow Zone:
4. The red stop master indicator turns on. 1. Engine oil pressure has decreased, 100 to 140
5. Stop the machine and correct the problem. kPa (15 to 20 psi).
2. The indicator bars flash.
Voltmeter Gauge
The voltmeter gauge is shown as an indicator bar
with a green or yellow zone. 4. The yellow caution master indicator turns on.
Green Zone: Red Zone:
Indicates normal operating range: NOTE: The machine must not be operated when the
oil pressure is in the red zone.
A. 26 to 32 volts above low idle = normal
operating range. 1. Engine oil pressure continues to decrease below
a safe operating pressure, 0 to 100 kPa (0 to 15
B. 18 to 24 volts stopped or at low idle = low to
psi).
normal battery charge.
2. The indicator bar flashes.
C. 18 to 24 volts at above low idle = problem in
charging system. 3. The warning alarm sounds continuously.
Yellow Zone: 4. The red stop master indicator turns on.
Voltage has increased or decreased: 5. Stop the machine and correct the problem.
A. 0 to 18 volts stopped or at low idle = very low Engine Coolant Temperature
battery charge.
The engine coolant temperature gauge is shown as
B. 32 volts and above = problem in charging an indicator bar with a green, yellow, or red zone.
system (overcharging).
Green Zone:
1. The indicator bars flash.
Indicates normal operating temperature, 20° to 105°
2. The warning alarm sounds for 3 seconds. C (68° to 221° F).
3. The yellow caution master indicator turns on. Yellow Zone:
4. Stop the machine and correct the problem. 1. Engine coolant temperature has decreased 20°
C or below (68° or below), or increased 105° to
Fuel Level Gauge 110° C (221° to 230° F).
The fuel level gauge is shown as an indicator bar with 2. The indicator bars flash.
a green or yellow zone.
Green Zone:
4. The yellow caution master indicator turns on.
Indicates normal operating range, 5 percent and
Red Zone:
above.
NOTE: The machine must not be operated when the
Yellow Zone:
temperature is in the red zone.
The tank is almost empty, 5 percent and below.

4005-11
1. Engine coolant temperature continues to Service Indicator Icon
increase, 110° C or above (230° F or above).
When a fault code is written, the service indicator
2. The indicator bar flashes. icon (a manual with a wrench) will be displayed on
3. The warning alarm sounds continuously. the information center.
4. The red stop master indicator turns on.

5. Stop the machine and correct the problem.

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 DESCRIPTION CORRECTIVE ACTION

1. Check low idle specifications.
ENGINE OIL Low engine oil
2. Change engine oil and filter.
PRESSURE pressure.
3. Change operating procedures.
1. Bring the machine to a safe stop and shut the engine
BRAKE PRESSURE Low brake pressure. OFF immediately.
2. Check brake system for proper charging and leaks.
STEERING OFF immediately.
Low steering pressure.
PRESSURE 2. Check the hydraulic fluid level.
3. Check hydraulic system and steering system for leaks.
OFF immediately.
COOLANT LEVEL Low coolant level.
2. Check the coolant level.
3. Check the engine cooling system for leaks.
OFF immediately.
COOLANT High engine coolant
2. Check the coolant levels after allowing the engine and
TEMPERATURE temperature.
coolant to cool down.
3. Clean the radiator.
HYDRAULIC OIL High hydraulic oil OFF immediately.
TEMPERATURE temperature. 2. Check the hydraulic fluid level.
3. Clean the cooler.
OFF immediately.
TRANSMISSION OIL High transmission oil 2. Check the transmission fluid level.
TEMPERATURE temperature. 3. Clean the cooler.
4. Check transmission for leaks.
5. Select lower gear.

4005-13
Non-Critical Warning Displays

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

Parking brake engaged and Release the parking brake and depress the
PARKING BRAKE
shifts from Forward to Reverse. service brake.
COOLANT High engine coolant 1. Idle machine and monitor temperature.
TEMPERATURE temperature. 2. Clean radiator.
HYDRAULIC 1. Idle machine and monitor temperature.
High hydraulic temperature.
TEMPERATURE 2. Clean the cooler.
1. Idle machine and monitor temperature.
TRANSMISSION
High transmission temperature. 2. Clean the cooler.
TEMPERATURE
3. Use a lower gear.
1. Check low idle specifications.
ENGINE OIL
Low engine oil pressure. 2. Change engine oil and filter.
PRESSURE
3. Change operating procedures.
1. Turn air conditioning OFF.
High or low air conditioning
AIR CONDITIONING 2. Low outside temperature.
pressure.
3. Servicing required.
1. Clean air filter.
AIR FILTER High air filter restriction.
2. Replace primary and secondary filters.
TRANSMISSION
Transmission filter restriction. Replace transmission filter.
FILTER
HYDRAULIC FILTER Hydraulic filter restriction. Replace hydraulic filter.
1. Check electrical system.
ALTERNATOR Alternator malfunction. 2. Voltages are out of range.
3. Change operating procedure.
FUEL Low fuel. Fill fuel tank within the next hour.

4005-14
INFORMATION AND DIAGNOSTIC CENTER

Many of the machine functions can be displayed on the Programmable Information Center. It can be 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
4
1
6
RD98K316
1. DIRECTION (F-N-R) 4. REQUESTED GEAR (1, 2, 3, 4)
2. TRANSMISSION DISPLAY 5. ACTUAL GEAR BARS
3. DISPLAY CENTER 6. TRANSMISSION MODE (A OR BLANK)
FIGURE 2. INFORMATION CENTER AND TRANSMISSION DISPLAY
Hourmeter Engine Coolant Temperature

The hourmeter displays the accumulated running Displays the engine coolant temperature in Celsius
time of the engine in hours and tenths of an hour with with the engine coolant temperature bar graph
an “hour glass” symbol. flashing. See page 10 for a detailed description of the
bar graph function.
Tachometer
Engine Oil Pressure
The tachometer displays the engine speed in
revolutions per minute along with a “r/min” symbol. Displays the engine oil pressure in kilopascals (kPa)
with the engine oil pressure bar graph flashing. See
Speedometer page 10 for a detailed description of the bar graph
function.
The speedometer displays the ground speed in either
kilometers per hour (km/h) or miles per hour (mph) Fuel Level
along with either a “km/h” or “mph” symbol.
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.

4005-15
Transmission Oil Temperature Transmission Display

Displays the transmission oil temperature in Celsius The Transmission Display shows the status of the
with the transmission oil temperature bar graph transmission control. The display center contains the
flashing. See page 9 for a detailed description of the following information, refer to Figure 2:
bar graph function.
Direction Selected
Hydraulic Oil Temperature Shown at the top of the display center:
Displays the hydraulic oil temperature in Celsius with F Forward

the hydraulic oil temperature bar graph flashing. See
N Neutral
page 9 for a detailed description of the bar graph
function. R Reverse
F Flashing forward not engaged.
Voltmeter
Flashing set control lever to neutral
Displays the electrical system voltage level in volts N
position.
with the voltmeter bar graph flashing. See page 10
for a detailed description of the bar graph function. R Flashing reverse not engaged.
Requested Gear
The gear position on shift lever, shown in the
center of the gear symbol:
1 1st gear
2 2nd gear
3 3rd gear
4 4th gear
Actual Gear
Shown with bars‘ to the right of the gear symbol. The
number of bars indicates the gear the transmission is
actually in.
Transmission Mode (Automatic or
Manual)
Shown in the lower left of the display center:
A Automatic Mode
No symbol will be displayed when
transmission is in Manual Mode.

4005-16
SETTINGS, DIAGNOSTICS, AND FAULT CODES
3 4 5
6
RD98K316
1. INFORMATION CENTER 3. UP COUNT 5. PROGRAM
2. DISPLAY CENTER 4. DOWN COUNT 6. RESET
FIGURE 3. INFORMATION CENTER
Programming the Information 1. Turn the machine OFF.

Center 2. Turn the key to the RUN position.
NOTE: The machine must be OFF prior to 3. Press the program/reset switch to program.
programming the information center. 4. Press the up/down count switch to up count
Two switches are used during the programming of program location 010.
the information center: the up/down count switch and 5. Center the program/reset switch to OFF.
the program/reset switch. These switches are located
on the right hand side of the information center, refer 6. Note the gauge display setting that is displayed,
to Figure 3. 01, 02, 03, 04, or 05. If the desired setting has
already been selected go to step 7.
For an up count press the left side of the up/down
count switch. For a down count press the right side of 7. Press the up/down count switch to up count to
the up/down count switch. The center position is OFF choose one of the following gauge display
or NEUTRAL. settings:
Fo r p r o g r a m m i n g p r e s s t h e l e f t s i d e o f t h e
program/reset switch. For resetting press the right
side of the program/reset switch. The center position
is OFF or NEUTRAL.
To program the information center do the following
steps:

4005-17
Individual Function Display
01 Manually scrolls through Hourmeter,
Tachometer, and Speedometer (km/h). Do the following steps to display any individual
function, at anytime, regardless of the gauge display
Manually scrolls through Hourmeter, that was programmed:
02
Tachometer, and Speedometer (mph).
1. Press the program/reset switch to program.
Automatically scrolls through Hourmeter
(at start-up), Tachometer (in 1st and 3rd 2. Press the up/down count switch to up count and
03 select one of the following individual functions:
gears), and Speedometer (km/h in 4th
gear).
000 Hourmeter
Automatically scrolls through Hourmeter 001 Tachometer
04 (at start-up), Tachometer (in 1st and 3rd
gears), and Speedometer (mph in 4th 002 Speedometer (mph)
gear).
003 Speedometer (km/h)
Manually scrolls through Hourmeter,
Tachometer, and Speedometer (mph), 004 Engine Oil Temperature
Speedometer (km/h), Engine Oil 005 Engine Oil Pressure
Temperature (Celsius), Engine Oil
05 Pressure, Fuel Level, Transmission Oil 006 Fuel Level
Temperature (Celsius), Hydraulic Oil 007 Transmission Oil Temperature
Temperature (Celsius), and Voltmeter.
008 Hydraulic Oil Temperature
NOTE: 05 is the factory installed setting.
009 Voltmeter
8. Press the program/reset switch to reset
momentarily.
3. Put the program/reset switch in the OFF (center)
9. If the Information Center does not function position.
properly, do the programming steps again.
4. If one of the individual functions (004 through
10. If the Information Center continues to 009) is selected, the corresponding bar graph will
malfunction replace the instrument panel. flash indicating that this individual function is
Manual Scrolling Gauge Displays (01, 02, being displayed.
or 05 5. The individual function selected will be shown on
the information center.
If the Information Center has been programmed to
display one of the manual scrolling displays (01, 02, Testing the Park Brake
or 05) press the up/down count switch to up count
and scroll through the gauge displays. Do the following steps to test the parking brake:
1. Press the up count switch one time to display the NOTE: The Transmission Control Module will
Tachometer. disconnect the transmission if any gear other than
3rd is used.
2. Press the up count switch again to display the
Speedometer (km/h). 1. Turn the machine ON.
3. Press the up count switch again to display the 2. Make sure the transmission is in the manual shift
Hourmeter. mode, the gear selector is in 3rd neutral gear,
and the park brake switch is ON.
Automatically Scrolling Gauge Displays
3. Set the park brake calibration as follows:
(03 or 04)
A. Press the program/reset switch to program.
If the Information Center has been programmed with
one of the automatic scrolling displays the gauge B. Press the up/down count switch to up count
display will automatically scroll through after starting until the display reads 011.
the machine. The up/down count switch has no effect
C. Put the program/reset switch in the OFF
on the display.
(center) position.

4005-18
D. Press the up/down count switch to up count If this occurs, the code in the 3rd and 4th
once, so the display reads 01. spaces will be a Clutch Calibration Main Code
09 through 14 and indicate what process the
E. Shift the transmission selector into 3rd forward
calibration was in when it was aborted
and slowly increase the engine rpm.
The 1st and 2nd spaces will produce the
F. The park brake should hold the machine at full
Clutch Calibration Sub Code, which is the
throttle.
code that informs the operator of the reason
G. To exit the test mode, press the program/reset the process was aborted.
switch to reset.
K. After completing the Clutch Calibration
Transmission Clutch Calibration procedure, turn the machine OFF for 15
Clutch Calibration ensures the most optimum shifting seconds. This sets the calibration in the
of the transmission. Before doing the following controller.
transmission clutch calibration procedures make sure
CLUTCH CALIBRATION MAIN CODES
of the following:
1. The machine is running and the transmission oil Main Code Meaning
is warm. Clutch Calibration Mode was not
2. Engine low idle speed is correct. 00 initiated because one of the
requirements was not met.
3. The transmission is in neutral.
01 Adjusting 1st gear.
4. The park brake is applied.
02 Adjusting 2nd gear.
5. If steps 1 through 4 have been accomplished,
calibrate the transmission clutches as follows: 03 Adjusting 3rd gear.
A. Put the transmission in the manual shift mode 04 Adjusting 4th gear.
and the gear selector in 3rd gear neutral.
05 Adjusting Forward gear.
B. Press the program/reset switch to program.
06 Adjusting Reverse gear.
C. Press the up/down count switch to up count
until the display reads 011. 07 Clutch Calibration Completed.
D. Put the program/reset switch in the OFF Operator aborted calibration
08
(center) position. procedure.
E. Press the up/down count switch to up count 09 Aborted while adjusting 1st gear.
twice, so the display reads 02.
10 Aborted while adjusting 2nd gear.
F. 2 00 00 will begin to flash in the display center.
11 Aborted while adjusting 3rd gear.
G. After one second, the Clutch Calibration Main
Code status will be displayed in the 3rd and 12 Aborted while adjusting 4th gear.
4th spaces (2 XX 00, the XX represents the
Aborted while adjusting Forward
3rd and 4th spaces). 13
gear.
H. The Modulation Cycle Number will be
Aborted while adjusting Reverse
displayed in the 1st and 2nd spaces (2 00 XX, 14
gear.
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 CLUTCH CALIBRATION SUB CODES
indicates that the calibration process is
Sub Code Meaning
complete and the information center will return
to normal working status. 00 Calibration in process.
J. If any of the Clutch Calibration parameters are 01 Fault present.
incorrect, the display center will stop flashing
and display a code in the 1st, 2nd, 3rd, and 02 Shift lever not in neutral.
4th spaces.

4005-19
2. Press the up/down count switch to up count until
03 Park brake not applied.
the display reads 015.
04 Output speed not 0 kph/mph. 3. The alarm will begin to sound intermittently.
05 Low transmission oil temperature. 4. Place the program/reset switch in the OFF
06 High transmission oil temperature. (center) position.
07 Low engine RPM. 5. The Information Center will display 00 and sound
the alarm, when the machine is being checked,
08 High engine RPM. while all systems are normal. If there is a fault in
the system that would cause the alarm to sound,
Setting Display Center Lighting the Information Center will display 01 while the
alarm is being checked. The alarm will sound
Do the following procedures to set the brightness intermittently.
of the display lighting:
Coolant Level Check
Do the following procedures to check the coolant
level indicator light and the coolant level switch.
the display reads 012 (for working lights OFF) or
013 (for working lights ON). 1. Press the program/reset switch to program.
3. Place the program/reset switch in the OFF 2. Press the up/down count switch to up count until
(center) position. the display reads 016.
4. Increase the brightness by pressing the up/down 3. The coolant light will flash intermittently.
count switch to the up count position.
4. Place the program/reset switch in the OFF
5. Decrease the brightness by pressing the (center) position.
up/down count switch to the down count position.
5. The Information Center will display 00, when the
NOTE: The brightness can be varied between 001 machine is being checked, if the coolant level is
and 100, with 100 being the brightest. The factory set normal. If the coolant level is low, the Information
brightness is 070 for working lights OFF and 020 for Center will display 01 while the coolant level
working lights ON. switch is being checked. The coolant light will
flash intermittently on the Information Center.
6. Press the program/reset switch to reset
(momentar ily, 0.25 s econds ) to enter the
selected brightness setting. Brake Pressure
Do the following procedures to check the brake
Voltmeter at Key ON Position pressure indicator light and the brake pressure
switch.
Do the following procedures to read the system
voltage at the key ON position. 1. Press the program/reset switch to program.
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.
(center) position.
(center) position.
4. The system voltage is displayed at the key ON
machine is being checked, if the brake pressure
position.
is normal. If the brake pressure is low, the
5. Press the program/reset switch to reset to exit Information Center will display 00 while the brake
the monitoring mode. pressure switch is being checked. The brake
pressure light will flash intermittently on the
Alarm Check Information Center.
Do the following procedures to check the audible

alarm system.
4005-20
Secondary Steering Pressure Switch 4. The Information Center will display 00, when the
Information Center is not activating the pilot
Do the following procedures to check the secondary lockout relay. The Information Center will display
steering pressure indicator light and the secondary 01 when it is activating the pilot lockout relay. The
steering switch. pilot lockout light will flash intermittently on the
5. Press the program/reset switch to program. Information Center.

Hydraulic Filter Restriction Switch Check
the display reads 018. The secondary steering
pressure light will flash intermittently. Do the following procedures to check the hydraulic
filter restriction indicator light and the hydraulic filter
restriction switch.
(center) position.
machine is being checked, if the secondary 2. Press the up/down count switch to up count until
steering switch is not activated. If the secondary the display reads 021. The hydraulic filter
steering switch is activated, the Information restriction indicator light will flash intermittently.
Center will display 00 while the secondar y
steering switch is being checked. The secondary
(center) position.
steering light will flash intermittently on the
Information Center. 4. The Information Center will display 01, when the
machine is being checked, if the hydraulic filter
Park Brake Information Center Output 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
Check hydraulic filter restriction switch is activated, the
Information Center will display 00 while the
Do the following procedures to check the park brake hyd ra ul ic fi lte r r es tr ic ti on swi tch is being
indicator light and the status of the signal that the 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
Information Center is sending to the park brake relay indicator light will flash intermittently on the
(to engage or disengage). Information Center.
Air Filter Restriction Switch Check
the display reads 019. The park brake light will Do the following procedures to check the air filter
flash intermittently. restriction indicator light and the air filter restriction
switch.
(center) position. 1. Press the program/reset switch to program.
4. The Information Center will display 00, when the 2. Press the up/down count switch to up count until
Information Center is not activating the park the display reads 022. The air filter restriction
brake relay. The Information Center will display indicator light will flash intermittently.
01 when it is activating the park brake relay. The 3. Place the program/reset switch in the OFF
park brake light will flash intermittently on the (center) position.
Information Center.
Pilot Lockout Information Output Check machine is being checked, if the air filter
restriction switch is not activated. If the air filter
Do the following procedures to check the pilot lockout restriction switch is activated, the Information
indicator light and the status of the signal that the Center will display 00 while the air filter restriction
Information Center is sending to the pilot lockout switch is being checked. The air filter restriction
relay (to engage or disengage). indicator light will flash intermittently on the
1. Press the program/reset switch to program. Information Center.
2. Press the up/down count switch to up count until Work Lights Check
the display reads 020. The pilot lockout light will
flash intermittently. Do the following procedures to check the work lights
indicator light and the work light electrical signal
3. Place the program/reset switch in the OFF coming into the Information Center.
(center) position.
4005-21
2. Press the up/down count switch to up count until Transmission Filter Restriction Switch
the display reads 023. The secondary work lights Check
indicator light will flash intermittently.
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
3. Place the program/reset switch in the OFF transmission filter restriction indicator light and the
(center) position. transmission filter restriction switch.
4. The Information Center will display 00 when the 1. Press the program/reset switch to program.
work lights are OFF and 01 when the work lights
are ON. The work lights indicator light will 2. Press the up/down count switch to up count until
continue to flash intermittently and the numbers the display reads 026. The transmission filter
on the display will change in accordance with the restriction indicator light will flash intermittently.
status of the work lights. 3. Place the program/reset switch in the OFF
(center) position.
Fog Lights Check
Do the following procedures to check the fog lights machine is being checked, if the transmission
indicator light and the fog light electrical signal filter restriction switch is not activated. If the
coming into the Information Center. transmission filter restriction switch is activated,
1. Press the program/reset switch to program. the Information Center will display 01 while the
transmission filter restriction switch is being
2. Press the up/down count switch to up count until checked. The transmission filter restriction
the display reads 024. The fog lights indicator indicator light will flash intermittently on the
light will flash intermittently. Information Center.
(center) position. Requested Gear Check
4. The Information Center will display 00 when the Do the following procedures to check that the gear
fog lights are OFF and 01 when the fog lights are being requested by the shifter is the same gear that
ON. The fog lights indicator light will continue to the Information Center is reading.
flash intermittently and the numbers on the 1. Press the program/reset switch to program.
display will change in accordance with the status
of the fog lights. 2. Press the up/down count switch to up count until
the display reads 028. The “F, N or R” indicator in
Air Conditioning Switch Check the transmission display will flash intermittently.
Do the following procedures to check the air 3. Place the program/reset switch in the OFF
conditioning indicator light and the air conditioning (center) position.
high/low pressure switch. 4. Place the gear shifter in all positions and verify
1. Press the program/reset switch to program. that the code in each position corresponds to the
codes in the table below
2. Press the up/down count switch to up count until :
the display reads 025. The air conditioning Forward 1- Neutral 1- Reverse 1-
indicator light will flash intermittently. Code 101 Code 201 Code 301
3. Place the program/reset switch in the OFF Forward 2- Neutral 2- Reverse 2-
(center) position. Code 102 Code 202 Code 302
4. The Information Center will display 00, when the Forward 3- Neutral 3- Reverse 3-
machine is being checked, if the air conditioning Code 103 Code 203 Code 303
high/low pressure switch is not activated. If the
air conditioning high/low pressure switch is Forward 4- Neutral 4-
activated, the Information Center will display 01 Code 104 Code 204
while the air conditioning high/low pressure
switch is being checked. The air conditioning Operational Indicator Status
indicator light will flash intermittently on the
Do the following procedures to check the status of
Information Center.
the operational indicator.

4005-22
2. Press the up/down count switch to up count until 7. The Information Center will read 001 when the
the display reads 029. The operational indicator shift is being made.
flashes intermittently.
8. The Information Center will read will read 010 if
3. Place the program/reset switch in the OFF the transmission does not engage the drive line.
(center) position.
9. The Information Center will read 110 if the
4. The Information Center will read 00. transmission is in Substitute Clutch Control
Mode.
Actual Gear Check 10. The Information Center will read 210 if the
Do the following procedures to check that the gear transmission is in Limp Home Mode.
engaged in the transmission is the same gear that 11. The Information Center will read 300 if the
the Information Center is reading. transmission is in Shutdown Mode.
1. With the engine running put the transmission in 12. The Information Center will read 400 if the
manual mode and release the parking brake. transmission is in T.E.C.M. Shutdown Mode.
Hourmeter Indicator Status
the display reads 030. The bars that outline the Do the following procedures to check the status of
large gear in the transmission display will flash the hourmeter indicator.
intermittently.
(center) position.
the display reads 032. The hourmeter indicator
5. Place gear that the transmission is in flashes intermittently.
corresponds to the codes in the table below.
:
(center) position.
Forward 1- Neutral 1- Reverse 1-
Code 101 Code 201 Code 301 4. The Information Center will read 00.
Code 102 Code 202 Code 302
Tachometer Indicator Status
the tachometer indicator.
Code 103 Code 203 Code 303
Forward 4- Neutral 4-
Code 104 Code 204 2. Press the up/down count switch to up count until
the display reads 033. The tachometer indicator
Limp Home Limp Home Limp Home flashes intermittently.
Mode - 115 Mode - 215 Mode - 315
(center) position.
Drive Line Shift Status
4. The Information Center will read 00.
Do the following procedures to check the drive line
shift status.
Service Indicator Status
1. With the engine running, release the parking
brake. Do the following procedures to check the status of
the service indicator.
the display reads 031. The drive line shift status 2. Press the up/down count switch to up count until
bars flash intermittently. the display reads 034. The service indicator
(center) position. 3. Place the program/reset switch in the OFF
(center) position.
5. The Information Center will read 00.
6. Shift the shift lever.
4005-23
4. The Information Center will read 00 if the service 3. Place the program/reset switch in the OFF
indicator is OFF or 01 if the service indicator is (center) position.
ON.
4. The Information Center will read 00 if the right
tur n indicator is OFF or 01 if the r ight tur n
Movement Indicator Status indicator is ON.
the movement indicator. Caution and Warning Master Indicator
1. Press the program/reset switch to program. Lights Status
2. Press the up/down count switch to up count until Do the following procedures to ensure that the
the dis play r eads 035. The K ph and Mp h caution and warning lights are working correctly.
indicators flash intermittently. 1. Press the program/reset switch to program.
(center) position. the display reads 039 (Critical Master Light Red).
4. The Information Center will read 00. 3. Place the program/reset switch in the OFF
(center) position.
Beacon Status
4. The Information Center will read 00 if the
Do the following procedures to check the status of indicator is OFF under normal operation, or 01 if
the beacon. the indicator is ON under normal operation
1. Press the program/reset switch to program. 5. Press the program/reset switch to program.
2. Press the up/down count switch to up count until 6. Press the up/down count switch to up count until
the display reads 036. The beacon indicator the display reads 041 (Caution Master Light
flashes intermittently. Yellow).
3. Place the program/reset switch in the OFF 7. Place the program/reset switch in the OFF
(center) position. (center) position.
4. The Information Center will read 00 if the beacon 8. The Information Center will read 00 if the
is OFF or 01 if the beacon is ON. indicator is OFF under normal operation, or 01 if
the indicator is ON under normal operation
Left Turn Indicator Status
Diagnostic Indicator Status
the left turn indicator. Do the following procedures to check the status of
the diagnostic indicator.
the display reads 037. The left turn indicator 2. Press the up/down count switch to up count until
flashes intermittently. the display reads 040. The diagnostic indicator
(center) position. 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 4. The Information Center will read 00.
indicator is ON.
Master Reset
Right Turn Indicator Status
Do the following procedure to reset the Information
Do the following procedures to check the status of Center to the values set at the factory for the Gauge
the right turn indicator. Display, Information Center lighting for work lights off
and on, minimum gear selection in automatic mode,
and maximum gear selection.
the display reads 038. The right turn indicator
flashes intermittently. 2. Press the up/down count switch to up count until
4005-24
(center) position. the display reads 045. The park brake light
4. Press the up/down count switch to up count twice
to change the readings from 00 to 01. 3. Place the program/reset switch in the OFF
(center) position.
5. Press the program/reset switch momentarily
(0.25 second) to reset. 4. The Information Center will read 00 when the
switch is open (service brakes are not applied)
Park Brake Switch Check and 01 when the switch is closed (service brakes
are applied).
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
Pilot Lockout Switch Check
Information Center is receiving from the park brake
switch (to engage or disengage). 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
2. Press the up/down count switch to up count until switch (to engage or disengage).
the display reads 043. The park brake light will
flash intermittently.
the display reads 046. The park brake light will
(center) position.
flash intermittently.
Information Center is not receiving a signal from
(center) position.
the park brake switch to engage the park brake.
The Information Center will display 01 when it is 4. The Information Center will display 00, when the
receiving a signal from the park brake switch to Information Center is not receiving a signal from
engage the park brake. the switch to engage the pilot lockout. The
Information Center will display 01 when it is
5. Cycle the park brake switch to ensure it is
receiving a signal from the switch to disable the
working in both directions.
loader hydraulic controls.
Redundant Brake Pressure Switch Check 5. Cycle the switch to ensure it is working in both
directions.
Do the following procedures to check the redundant
brake pressure switch.
Display Location 047
Do the following procedures to check display location
2. Press the up/down count switch to up count until 047.
the display reads 044. The brake light will flash
intermittently.
the display reads 047. The pilot lockout light
(center) position.
machine is being checked, if the brake pressure
(center) position.
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 4. The Information Center will read 00 if the circuit
Information Center will display 01 while the is closed or 01 if there is a circuit malfunction.
redundant brake pressure switch is being
checked. The brake light will flash intermittently
on the Information Center.
Service Brake Foot Switch Check

Do the following procedures to check the service
brake foot switch.

4005-25
Display Location Numbers (048 and 049) Gear Range Read Only
Reserved for Future Use Do the following procedures to read the gear range.
Minimum Gear Selection 1. Press the program/reset switch to program.
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 2. Press the up/down count switch to up count until

transmission for the lowest gear possible in the the display reads 052. The operational indicator
automatic mode. will flash intermittently.
NOTE: The 1st or 2nd gear can be selected. The 3. Place the program/reset switch in the OFF
gear that is selected will be the gear that the (center) position.
transmission is in when the machine begins to move. 4. The Information Center will read 1 or 2 (gears).
The factory minimum gear setting is 1.
2. Press the up/down count switch to up count until the display reads 053. The operational indicator
the display reads 050. will flash intermittently.
3. Place the program/reset switch in the OFF 7. Place the program/reset switch in the OFF
(center) position. (center) position.
4. Read the number (1 or 2) shown on the 8. The Information Center will read 2,3, or 4
Information Center. If this is the desired gear (gears).
selection, press the program/reset switch to
either program or reset. Display Location Number 054 Reserved
5. If you want the other minimum gear selection, for Future Use
press the up/down count switch to up count.
6. Press the program/reset switch momentarily Reset Diagnostic Stack for Locations 071
(0.25 seconds) to reset. through 090
Do the following procedure to remove all diagnostic
Maximum Gear Selection codes from field number locations 071 through 090.
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 1. Press the program/reset switch to program.
transmission for the highest gear possible in the
automatic mode. 2. Press the up/down count switch to up count until
the display reads 055. The service indicator will
NOTE: The 2nd, 3rd, or 4th gear can be selected. flash intermittently.
The gear that is selected will be the highest
attainable gear that the transmission will be able to 3. Place the program/reset switch in the OFF
reach. The factory maximum gear setting is 4. (center) position.
1. Press the program/reset switch to program. 4. Press the up/down count switch to up count until
the display reads 051. 5. Press the program/reset switch to reset. If there
are diagnostic codes in field number locations
3. Place the program/reset switch in the OFF 071 through 090 they will be removed, unless the
(center) position. condition still exists.
4. Read the number (2, 3, or 4) shown on the
Information Center. If this is the desired gear
selection, press the program/reset switch to
either program or reset.
5. If you want a different maximum gear selection,
press the up/down count switch to up count until
the desired number is displayed.
6. Press the program/reset switch momentarily
(0.25 seconds) to reset.

4005-26
Display Location Numbers (056 - 060) 1. To view the fault codes and the hours they
Reserved for Future Use occurred do the following:
Service Interval Hours
B. Press the up/down count switch to up count
Field number locations 61 through 70 are service until the display reads the desired location
interval hour settings. The service interval hours (071 - 090).
accumulate until they are reset. Once they are reset,
C. Place the program/reset switch in the OFF
they begin accumulating hours independent from the
(center) position.
machine hours until they are reset again. Do the
following procedures to view or reset the service D. Read any fault codes in the chosen location.
interval hours.
NOTE: A complete list of fault codes can be
NOTE: If the operator wanted location 061 to found in the Fault Code Table in this section.
indicate when the engine oil should be changed,
E. Press the program/reset switch to program.
location 061 would be reset to begin accumulating
hours for the next oil change. The operator could F. Press the up/down count switch to up count
then go into location 061 and monitor accumulating one time to advance to the next location.
hours. When location 061 reaches the engine oil
G. Place the program/reset switch in the OFF
change interval, the operator would change the oil
(center) position.
and reset location 061 again.
H. Read the hours that the previous fault code
1. To view the service hour interval locations do the
occurred at.
following:
NOTE: The hour location will always follow the fault
code location.
NOTE: Example: Location 072 will display the hours
until the display reads the desired location
on the machine when the fault code in location 071
(061 - 070).
was written. Location 074 will display the hours on
C. Place the program/reset switch in the OFF the machine when the fault code in location 073 was
(center) position. written.
D. Read the accumulated hours in the chosen 2. To monitor a particular location without going into
location. the programming mode do the following:
2. To reset the service interval hours do the A. Press the program/reset switch to program.
following:
A. Press the program/reset switch to program. until the location to be monitored is displayed.
B. Press the up/down count switch to up count C. Place the program/reset switch in the OFF
until the display reads the desired location (center) position.
(061 - 070).
D. Press the program/reset switch to program
C. Place the program/reset switch in the OFF and wait 5 seconds. The numbers on the
(center) position. display will change.
D. Press the up/down count switch to down count E. Place the program/reset switch in the OFF
and hold it for 3 seconds. The service interval (center) position.
hours in the chosen location will reset to 0.
F. Within 3 seconds, press the program/reset
switch to reset once.
Fault Code Status
G. With the machine is in normal operating mode
Field number locations 071 through 090 display fault press the program/reset switch to reset to
codes and the hours the faults occurred. The display the hours accumulated in the selected
Infor mation Center continuously monitors the location. (Location 000 (hour meter) is
machine’s condition and records any fault codes; programmed into the Information Center from
however, it will only record a duplicate code once the factory.
every hour. When a fault code is written, the service
indicator icon (a manual with a wrench) will be
displayed on the Information Center.

4005-27
H. To reset a programmed location back to 000 1. Press the program/reset switch to program.
(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 3. Place the program/reset switch in the OFF
operating conditions by pressing the reset (center) position.
switch.
4. The Information Center will display the LED duty
cycle in units of 0.01 percent.
ZF Transmission ECM Part Number (1st
part) LCD Duty Cycle
Do the following to display the first par t of the Do the following to display the LCD duty cycle.
transmission ECM ZF part number.
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.
(center) position.
4. The Information Center will display the LCD duty
4. The Information Center will display the first part cycle in units of 0.01 percent.
of the ZF Transmission ECM par t number
(6009#, # is a digit from 0 to 9).
Internal Information Center Temperature
ZF Transmission ECM Part Number (2nd Do the following to display the internal temperature of
part) the Information Center.
Do the following to display the second part of the 1. Press the program/reset switch to program.
transmission ECM ZF part number. 2. Press the up/down count switch to up count until
1. Press the program/reset switch to program. the display reads 096.
2. Press the up/down count switch to up count until 3. Place the program/reset switch in the OFF
the display reads 092. (center) position.
3. Place the program/reset switch in the OFF 4. The Information Center’s internal temperature
(center) position. will be displayed in degrees Celsius.
4. The Information Center will display the second Display Location Number 097 Reserved
part of the ZF Transmission ECM part number
for Future Use
(#####, # is a digit from 0 to 9).
Information Center Software Revision Entry Code for Accessing Test Mode
Number Locations 100 to 199
Do the following to access test mode locations from
Do the following to display the Information Center
100 to 199.
software revision number.
2. Press the up/down count switch to down count
until the display reads 098.
(center) position.
(center) position.
4. The Information Center will display the software
revision number.
LED Duty Cycle 6. Press the up/down count switch one time so that
Do the following to display the LED duty cycle. the display reads 099.

4005-28
7. Place the program/reset switch in the OFF 17. Press the program/reset switch to program.
(center) position.
8. Press the up/down count switch to up count until the display reads 103.
9. Press the program/reset switch to program. (center) position. When the transmission ECM
has been reprogrammed, 110 will be displayed.
10. Press the up/down count switch to up count past
location 099. 20. Press the program/reset switch to program.
NOTE: When locations 098 and 099 are reset at 21, 21. Press the up/down count switch to down count
the Information Center will scroll past location 099. until the display reads 102.
Once location 100 or higher is reached, locations 098
and 099 are automatically reset to 000. If only one of
(center) position.
the locations is set at 21, and the user leaves the
range of 098-099, locations 098 and 099 are 23. Press the up/down count switch to down count
automatically reset to 000. until the display reads 000. Location 100 and 101
are locked.
Transmission Identification Numbers 24. Press the reset button for one second.
Do the following to view and change the transmission 25. Turn off and restart the machine.
identification numbers.
1. Press the program/reset switch to program. Display Location Numbers 104 - 113
2. Press the up/down count switch to up count until Reserved for Future Use
Instrument Cluster (Information Center)
Part Number (1st part)
(center) position.
Do the following to enter the first par t of the
4. Use the up/down count switch to change the
instrument cluster (Information Center) part number.
display to read 001
2. Press the up/down count switch to down count
until the display reads 114. The service indicator
(center) position.
(center) position.
8. Use the up/down count switch to change the
4. Use the up/down count switch to enter the first
transmission identification number.
part of the instrument cluster part number from
9. Place the program/reset switch in the OFF the parts catalog.
(center) position.
10. Press the up/down count switch to down count Instrument Cluster (Information Center)
until the display reads 100. Part Number (2nd part)
11. Place the program/reset switch in the OFF Do the following to enter the second part of the
(center) position. instrument cluster (Information Center) part number.
12. Use the up/down count switch to change the 1. Press the program/reset switch to program.
transmission identification number. 2. Press the up/down count switch to down count
13. Press the program/reset switch to program. until the display reads 115. The service indicator
the display reads 102. 3. Place the program/reset switch in the OFF
(center) position.
(center) position.
4005-29
4. Use the up/down count switch to enter the
CALIBRATION NUMBER
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
TIRE REV/KM
MACHINE/TIRE
AXLE RATIO
the up/down count switch, enter the A as 0 (zero)
followed by the number, (A1 = 01, A2 = 02).
Instrument Cluster (Information Center)

Date Code
Do the following to display the instrument cluster date 621 w/ 17.5 x 25 L2 21.88 259 5667
code.
621 w/ 17.5 x 25
21.88 245 5361
1. Press the program/reset switch to program. XTLA/XHA
2. Press the up/down count switch to down count 621 w/ 20.5 x 25 L2 21.88 235 5142
until the display reads 116. The service indicator
flashes intermittently. 621 w/ 20.5 x 25
21.88 225 4923
XTLA/XHA
(center) position. 721 w/ 17.5 x 25 L2 21.37 259 5535
4. The Information center will display the date code. 721 w/ 17.5 x 25
21.37 245 5236
Read the date code as follows: the first two XTLA/XHA
numbers = year, next three numbers = day.
721 w/ 20.5 x 25 L2 21.37 235 5022
Display Location Numbers 117 - 120 721 w/ 20.5 x 25 21.37 225 4808
Reserved for Supplier Information XTLA/XHA
821 w/ 20.5 x 25 L2 23.51 220 5172
Display Location Numbers 121 -129
Reserved for Future Use 821 w/ 20.5 x 25
23.51 218 5125
XTLA/XHA
Speedometer Calibration 821 w/ 23.5 x 25 L2 23.51 208 4890
Do the following to reset the speedometer calibration. 821 w/ 23.5 x 25
23.51 207 4867
NOTE: If a dealer or customer changes tire sizes, XTLA/XHA
the speedometer calibration will have to be changed 921 w/ 26.5 x 25 L2 22.85 201 4593
to match the Information Center and transmission
ECM to the new tire size. 921 w/ 26.5 x 25 22.85 193 4410
XRD/XHA
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
(center) position.
most manufacturers).
6. Use the up/down count switch to enter the
B. If the tire revolution/km is not available,
calibration number from the table.
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.

4005-30
Display Location Numbers 131 - 139 C. Place the program/reset switch in the OFF
Reserved for Speedometer Calibration (center) position.
D. Press the program/reset switch to program
Display Location Numbers 140 - 170
and wait 5 seconds. The numbers on the
Reserved for Future Use display will change.
Temporary Fault Code Status E. Place the program/reset switch in the OFF
Field number locations 171 through 190 display (center) position.
temporar y fault codes and the hours the faults F. Within 3 seconds, press the program/reset
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 switch to reset once.
automatically be erased when the Information Center
is turned off. The Information Center monitors the G. With the machine is in normal operating mode
machine’s condition and records any fault codes into press the program/reset switch to reset to
the shor t-term resettable memory once every 3 display the hours accumulated in the selected
minutes. This will enable a technician to quickly location. (Location 000 (hour meter) is
check conditions to verify if a problem was resolved programmed into the Information Center from
or still exists after maintenance. When a fault code is the factory.
written, the service indicator icon (a manual with a H. To reset a programmed location back to 000
wrench) will be displayed on the Information Center. (hour meter - fac tor y setting), hold the
1. To view the temporary fault codes and the hours program/reset switch to reset for 5 seconds.
they occurred do the following: 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
A. Press the program/reset switch to program. operating conditions by pressing the reset
B. Press the up/down count switch to up count switch.
until the display reads the desired location Display Location Numbers 191 - 196
(171 - 190).
Reserved for Future Use
C. Place the program/reset switch in the OFF
(center) position. Display Location Number 197 Reserved
for Manufacturing Data
D. Read any fault codes in the chosen location.
Display Location Number 198 Reserved
NOTE: A complete list of fault codes can be
found in the Fault Code Table in this section. for Future Use
E. Press the program/reset switch to program. Display Location Number 199 Reserved
for Manufacturing Data
F. Press the up/down count switch to up count
one time to advance to the next location. NOTE: To exit the upper range of display location
numbers (100-199) press the program/reset switch to
G. Place the program/reset switch in the OFF
reset.
(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:
until the location to be monitored is displayed.

4005-31
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS
DISPLAY
LOCATION DEFINITION STATUS
NUMBER
000 Engine Hours
001 Engine Tachometer
002 Speedometer in Miles Per Hour
003 Speedometer in Kilometers Per Hour
004 Engine Coolant Temperature in Degrees Celsius
005 Engine Oil Pressure in Kilopascals
006 Fuel Level in Percent of Fuel in Tank
007 Transmission Oil Temperature in Degrees Celsius
008 Hydraulic Oil Temperature in Degrees Celsius
009 Voltmeter Reading (Continuous)
010 Gauge Display Selection
011 Parking Brake Test / Clutch Calibration
012 Information Center Light Setting - Work Lights Off
013 Information Center Light Setting - Work Lights On
014 Voltmeter Reading at Key-on
015 Alarm Status 00 = Off, 01 = On
00 = Normal Level
016 Coolant Level Status
01 = Low Level
00 = Switch Closed
017 Brake Pressure Status 01 = Switch Opened
(Open = Normal Pressure)
00 = Switch Closed
018 Steering Pressure Status 01 = Switch Opened
019 Present Park Brake Output from Information Center Status 00 = Off, 01 = On
Present Pilot Lockout Status Output from Information
020 00 = Off, 01 = On
Center
00 = Switch Closed
021 Hydraulic Filter Restriction Switch Status 01 = Switch Opened
(Open = Filter is OK)
00 = Switch Closed
022 Air Filter Restriction Switch Status 01 = Switch Opened
(Open = Filter is OK)
023 Present Work Lights Status 00 = Off, 01 = On
024 Present Fog Lights Status (European Only) 00 = Off, 01 = On

4005-32
DISPLAY
NUMBER
00 = Switch Open
025 Air Conditioning High/Low Pressure Switch Status 01 = Switch Closed
00 = Open
026 Transmission Filter Restriction Switch Status 01 = Closed
(Open - Filter is OK)
027 Present Status Of High Beam Lights (European Only) 00 = Off, 01 = On
101 = F1, 102 = F2, 103 = F3,
028 104 = F4, 201 = N1, 202 = N2,
Requested Gear Status
203 = N3, 204 = N4, 301 = R1,
302 = R2, 303 = R3
Status of Transmission Operation Indicator - In
029 00 = Always
Transmission Display
101 = F1, 102 = F2, 103 = F3,
104 = F4, 115 = Limp Home,
030 201 = N1, 202 = N2, 203 = N3,
Actual Gear Status
204 = N4, 215 = Limp Home,
301 = R1, 302 = R2, 303 = R3,
315 = Limp Home
Shift Status First Digit =
031 Driveline Status 000 = Shift Not In Process
Operational Mode 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 Hourmeter Status 00 - Always
033 Tachometer Status 00 - Always
034 Current Status of Service Indicator for Normal Operating

00 = Off, 01 = On
Mode (Book with the wrench)
035 Movement indicator Status 00 - Always
036 Beacon Status 00 = Off, 01 = On
037 Left Turn Indicator Status 00 = Off, 01 = On
038 Right Turn Indicator Status 00 = Off, 01 = On
039 Current Status Master Indicator (Red) 00 = Off, 01 = On
040 Current Status of Diagnostic Indicator (Book without the

00 - Always
wrench - Operators Manual)

4005-33
DISPLAY
NUMBER
041 Current Status Master Indicator (Yellow) 00 = Off, 01 = On
042 Master Reset - Reset Information Center to Factory Setting
00 = Switch Open
01 = Switch Closed
043 Park Brake Switch Status
(Closed = engaged Parking
Brake)
00 = Switch Closed
044 Redundant Brake Pressure Switch 01 = Switch Open
(Closed = Normal Operation)
00 = Switch Open
045 Service Brake Foot Switch Status 01 = Switch Closed
(Closed = Actuated)
00 = Switch Open
046 01 = Switch Closed
Pilot Lockout Switch Status
(Closed = Loader Controls
Locked)
01 = Circuit Closed
047 Seat Circuit
02 = Circuit Malfunction
050 Minimum Gear Selection Range - 1st and 2nd gear
051 Maximum Gear Selection Range - 2nd, 3rd and 4th gear
052 Minimum Gear Read Only
053 Maximum Gear Read Only
Range = 0 to 99
Default = 0
055 Reset Diagnostic Stack, 071 to 090 to zero Set to “21” and then exit this
location 055 to reset diagnostic
stack 071 -099 to zero
061 - 070 Service Hour interval Selection #1 - 10
071,073,
075,077,
079,081, Fault Code #1 Through Fault Code #10
083,085,
087, 089
072,074,076 Hour Code #1 Through Hour Code #10. Hour Codes Follow
,078,080,08 Fault Codes Respectively.
2,084,086,0
88,090 I.e.: Hour Code #1 (072) Corresponds with Fault Code #1
(071)
1st Portion Of Transmission Electronic Control Module
091 ZF part number
(ECM) Part Number (5 digits from 0-9)
2nd Portion Of Transmission ECM Part Number (5 digits
092 ZF part number
from 0-9)
093 Cluster Software Revision Number

4005-34
DISPLAY
NUMBER
094 Light Emitting Diode (LED) Duty Cycle In units of 0.01%
095 Liquid Crystal Display (LCD) Duty Cycle In units of 0.01%
096 Internal Cluster Temperature In units of deg C
098 Set to “21” to enter Test Mode

Entry Code for Accessing Test Mode Locations 100 to 199
locations (Range = 0 to 99)
Set to “21” to enter Test Mode
099 Entry Code for Accessing Test Mode Locations 100 to 199
locations (Range = 0 to 99)
100 - 103 Transmission ID Number
114 Cluster Part Number
115 Cluster Part Number
116 Cluster Date Code
130 Speedometer Calibration
171 - 190 Temporary Fault Code Status

4005-35
FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
Engine coolant short circuit measuring less

12900 than 50 ohms to the engine coolant
temperature sensor.
Engine coolant open circuit measuring greater Troubleshoot electrical circuits.
than 10,000 ohms to the engine coolant
12901
temperature sensor with hydraulic oil
temperature at 40° C (104° F) or more.
Low engine coolant level - This code will not
13000 be generated if the engine coolant
1. A critical stop function warning has occurred.
temperature is below 20° C (68° F).
2. Red stop indicator comes on and continuous
Engine oil pressure is measured below 100 buzzer sounds.
21100
kPa (14.5 PSI) 3. Stop machine and perform required service on
the critical area.
21110 Engine coolant temperature is 110° C (230° F)
or greater.
Engine oil pressure short circuit measuring
21900 less than 16 ohms to the engine oil pressure Troubleshoot electrical circuits.
sensor.
NOTE: Fault code 21900 is possible during cold
Engine oil pressure open circuit measuring engine start-up. After machine warm up, verify
21901 more than 270 ohms to the engine oil pressure proper operation.
sensor.
33900 Fuel level short circuit measuring less than 16

ohms to the fuel level sender.
Fuel level open circuit measuring more than Troubleshoot electrical circuits.
33901
270 ohms to the fuel level sender.
34000 Fuel solenoid output short circuit.
1. A caution level warning has occurred.
2. Yellow caution indicator comes on and buzzer
35000 High air filter restriction. sounds for 3 seconds.
3. Perform required service on the cautioned area.
Transmission temperature measured above buzzer sounds.
42125
125° C (257° F) 3. Stop machine and perform required service on
the critical area.
High transmission filter restriction when the 2. Yellow caution indicator comes on and buzzer
45000
transmission oil is above 20° C (68° F). sounds for 3 seconds.
1. Check the cables from TCU to shift lever.
46017 Gear range fault error 2. Check signal combinations of shift lever
positions for gear range.
1. Check the cables from TCU to shift lever.
46018 Logical error at direction select signal 2. Check signal combinations of shift lever
positions F-N-R.

4005-36
1. Check the cables from the electronic boxes to

46020 Logical fault at Park Brake Status the status switches.
2. Check signals of the status switches.
Short circuit to battery voltage or Open circuit 1. Check the connectors.
46037
at temperature sensor input 2. Check the temperature sensor.
Short circuit to ground at temperature sensor

46038
input
1. Check the cables from TCU to the sensor.
Short circuit to battery voltage or open circuit 2. Check the connectors.
46039
at converter output temperature sensor input 3. Check the temperature sensor.
46040 Short circuit to ground at converter output
temperature sensor input
Short circuit to battery voltage or Open circuit 1. Check the cables from TCU to the sensor.
46049
at engine speed input 2. Check the connectors.
46050 3. Check the speed sensor.
Short circuit to ground at engine speed input
2. Check the connectors.
3. Check the speed sensor.
46051 Logical error at engine speed input 4. Check the sensor gap.
NOTE: This fault code is reset after power up of the
TCU. It is also reset if the signal is above zero
speed threshold.
46052
at turbine speed input 2. Check the connectors.
Short circuit to ground at turbine speed input
46054 Logical error at turbine speed input 4. Check the sensor gap.
TCU.
Short circuit to battery voltage or Open circuit
46055 1. Check the cables from TCU to the sensor.
at intermediate speed input
46056 Short circuit to ground at intermediate speed 3. Check the speed sensor.
input
46057 Logical error at intermediate speed input 4. Check the sensor gap.
TCU.
46058
at output speed input 2. Check the connectors.
Short circuit to ground at output speed input

4005-37

46060 Logical error at output speed input 4. Check the sensor gap.
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the sensor gap of the output speed
Output speed zero, does not match other sensor.
46062
speeds. 3. Check the cable from the TCU to the sensor.
TCU.
1. Check the cluster controller.
46064 Invalid gear range restriction (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
46065 Invalid declutch modulation selection (CAN)
46089 Invalid test mode signal (CAN)
46090 Invalid park brake status (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
46091 Invalid shift quality selection (CAN)
46113 Short circuit to battery voltage at clutch K1
46114 Short circuit to ground at clutch K1
46115 Open circuit at clutch K1
46120 Short circuit to ground at clutch K3 1. Check the cable from the TCU to the gearbox.
46121 Open circuit at clutch K3 2. Check the connectors from the TCU to the
gearbox.
46129 Short circuit to battery voltage a clutch K4 3. Check the regulator resistance.
4. Check internal wire harness of the gearbox.
46132 Short circuit to battery voltage at clutch KV
46133 Short circuit to ground at clutch KV
46134 Open circuit at clutch KV
46135 Short circuit to battery voltage at clutch KR
46136 Short circuit to ground at clutch KR
46137 Open circuit at clutch KR

4005-38
Short circuit to ground at reverse warning

46145
alarm relay 1. Check the cable from the TCU to the gearbox.
2. Check the connectors from the backup alarm
46146 Short circuit to battery voltage at reverse device to TCU.
warning alarm relay 3. Check the resistance of backup alarm device.
46147 Open circuit at reverse warning alarm relay
1. Check pressure at clutch K1.
2. Check main pressure in the system.
3. Check sensor gap at internal speed sensor.
46177 Slippage at clutch K1 4. Check sensor gap at output speed sensor.
5. Check signal at internal speed sensor.
6. Check signal at output speed sensor.
7. Replace clutch.
7. Replace clutch.
7. Replace clutch.
7. Replace clutch.
1. Check pressure at clutch KV.
46181 Slippage at clutch KV 4. Check sensor gap at output speed sensor.
7. Replace clutch.
1. Check pressure at clutch KR.
46182 Slippage at clutch KR 4. Check sensor gap at output speed sensor.
7. Replace clutch.

4005-39
46183 Oil temperature at valve body is above limit 1. A critical stop function warning has occurred.
buzzer sounds.
3. Stop machine and perform required service on
Oil temperature at converter output is above the critical area.
46184
limit 4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
1. Check oil filter.
Differential pressure oil filter TCU measured a 2. Check wiring from TCU to differential pressure
46186 voltage at differential pressure switch out of switch.
the allowed range. 3. Check differential pressure switch (measure
resistance).
Short circuit to battery voltage at power supply 1. Check cables and connectors to sensors, which
46209
for sensors are supplied from AU1.
2. Check the power supply at the pin AU1. It
46210 Short circuit to ground at power supply for
should be approximately 5 volts.
sensors
46211 Low voltage at battery 1. Check power supply battery.
2. Check cables from batteries to TCU.
46212 High voltage at battery 3. Check connectors from batteries to TCU.
46213 Error at switch 1 for solenoid power supply 1. Check fuse
2. Check cables from gearbox to TCU.
46214 3. Check connectors from gearbox to TCU.
Error at switch 2 for solenoid power supply
4. Replace TCU.
46227 Short circuit to battery voltage at display 1. Check the cable from TCU to the display.
output 2. Check the connectors at the display.
46228 3. Change display.
Short circuit to ground at display output
46229 Error at communication on CAN 2. Check the wire of the CAN-Bus.
3. Check cable to cluster controller.
46230 Undefined VIN request via CAN.
46241 General EEPROM fault Replace the TCU.
Reprogram the correct configuration for the
46242 Current ID not set or corrupt
vehicle.
46243 Application error (ZF internal) Replace the TCU.
46245 Clutch calibration fault Check the clutch.
46246 Clutch adjustment data lost Execute AEB.
1. Clear the codes.
CAN interface failure where no signals are 2. Restart the machine.
47000
received over one second of time 3. Monitor machine operation and diagnostics.

4005-40
47001 Engine speed is missing 1. Verify corresponding function is displayed on

the information center and is working properly:
47002 Output shaft speed is missing
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
47011 Transmission oil temperature is missing 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.
Transmission filter restriction information is 2. Read filter restriction status: 00 = filter
47012
missing 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.
Current Transmission identification code is 1. Reprogram transmission ID numbers.
47013 2. Verify program count location reads 110 or 100.
outside of the range
3. Clear codes and monitor machine performance
47014 Result code (11) and continue to operate.
Low steering pressure has been detected after
51000 a normal operating pressure has been 1. A critical stop function warning has occurred.
reached since start up. 2. Red stop indicator comes on and continuous
buzzer sounds.
Low brake pressure (1700 PSI / 11721 kPa) 3. Stop machine and perform required service on
61000 has been detected after a normal operating the critical area.
pressure has been reached since start up.
1700 PSI (11,721 kPa) Brake pressure switch
61900 has not cycled within 50 hours of operation 1. Turn machine off.
time. 2. Pump service brake 30 full strokes.
3. Start machine and verify proper operation and
900 PSI (6250 kPa) Redundant brake no diagnostic codes.
61901 pressure switch has not cycled within 100 4. Operate machine and monitor performance.
hours of operation time.
64000 Park brake solenoid output short circuit. 1. Check park brake for proper operation.
2. Do park brake test, see section 7008.
3. Adjust/repair park brake as required.
66900 Park brake switch has not cycled within 50
4. Clear diagnostic codes and monitor machine
hours of operation time.
performance.

4005-41
1. Verify full pedal actuation and return, make sure

debris does not obstruct pedal travel.
Service brake foot switch has not cycled within 2. Clear codes.
66901
50 hours of operation. 3. Verify proper machine operation.
4. If code reappears, check brake light switch and
troubleshoot electrical circuits.
Hydraulic oil temperature is 110° C (230° F) or buzzer sounds.
72110
greater. 3. Stop machine and perform required service on
the critical area.
Hydraulic oil temperature short circuit
72900 measuring less than 50 ohms to the hydraulic
oil temperature sensor.
Hydraulic oil temperature open circuit
measuring greater than 10,000 ohms to the Troubleshoot electrical circuits.
72901 hydraulic oil temperature sensor with the
engine coolant temperature at 90° C (194° F)
or more.
74000 Pilot pressure solenoid output short circuit.
High hydraulic filter restriction when the
75000 1. A caution level warning has occurred.
hydraulic oil is above 20° C (68° F).
2. Yellow caution indicator comes on and buzzer
84018 System voltage is below 18 volts. sounds for 3 seconds.
84032 System voltage is above 32 volts.
86010 Corrupt engine hours, data lost 1. Operate the machine to verify all functions and
monitoring systems are working properly (no
86011 Corrupt engine hours, data suspect 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
86012 Corrupt engine hours, data suspect 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.
Corrupt tire calibration numbers, data lost – 1. Reprogram correct tire calibration number for
86020 The calibration number will default back to the the machine.
number used at cluster shipment 2. Verify proper machine operation and machine
travel speed to displayed speed.
86021 Corrupt tire calibration number, data suspect 3. Continue machine operation and monitor for
86022 Corrupt tire calibration number, data suspect recurring fault codes.

4005-42
86030 Information Center memory error

86040 Information Center program memory error
86050 Information Center RAM failure
Information Center Reset – This code is
generated if the Information Center Program
“goes astray”. The Information Center is reset.
86060 This code will also be generated if there is a
brief intermittent open between the time the
engine is shut off and the Information Center
shuts off.
86070 Open range setting
86071 Brightness setting
1. Operate the machine to verify all functions and
86072 Machine ID monitoring systems are working properly (no
yellow or red warnings, normal operation).
86073 Machine info
2. Monitor cluster performance during machine
86074 Cluster part number operational check (no new diagnostic codes, no
erratic behavior, flashing icons, etc.).
86075 Cluster date code 3. If all systems and operations are normal, clear
86076 Cluster reserved d ia gno s tic co de s an d c ont inue m ac hi ne
operation.
86077 Calibration number 4. Monitor machine for recurrence of fault codes.
86078 5. Repeated codes may be an indication of a
Shift quality
pending cluster failure.
86079 Requested Gmin
86080 Requested Gmax
86081 Declutch modulation
86082 Creep setting
86083 Service hours
86084 Diagnostics stack pointer (internal to software)
86085 Diagnostics stack contents
86086 Digital input states (internal to software)
86087 Engine hour time stamps for digital input

states (internal to software)
Air Conditioning high or low pressure 2. Yellow caution indicator comes on and buzzer
91000
indication sounds for 3 seconds.

4005-43
INDEX
A 048 and 049 ......................................................25
Actual Gear Check ................................................22 054 ....................................................................25
Air Conditioning Indicator ........................................9 056 through 060 ................................................26
Air Conditioning Switch Check ..............................21 071 through 090 ................................................25
Air Filter Indicator ....................................................9 097 ....................................................................27
Air Filter Restriction Switch Check ........................20 100 through 199 ................................................27
Alarm Check ..........................................................19 104 through 113 ................................................28
Automatic Scrolling Gauge Displays .....................17 117 through 120 ................................................29
121 through 129 ................................................29
B 131 through 139 ................................................30
Beacon Indicator ......................................................8 140 through 170 ................................................30
Beacon Status .......................................................23 191 through 196 ................................................30
Brake 197 ....................................................................30
Park, Information Center Output Check ............20 198 ....................................................................30
Park, Testing ......................................................17 199 ....................................................................30
Parking Brake Indicator .......................................9 Display Location Numbers and Descriptions .........31
Brake Pressure ......................................................19 Displays
Brake Pressure Indicator .........................................8 Gauge, Automatic Scrolling ...............................17
Gauge, Manual Scrolling ...................................17
C Individual Function ............................................17
Calibration Drive Line Shift Status ...........................................22
Transmission Clutch ..........................................18 Duty Cycle, LCD ....................................................27
Caution and Warning Master Indicator Lights .......23 Duty Cycle, LED ....................................................27
Caution Master Indicator (Yellow) ...........................8
Check E
Actual Gear .......................................................22 Engine
Air Conditioning Switch .....................................21 Coolant Temperature .........................................10
Alarm .................................................................19 Oil Pressure Gauge ...........................................10
Coolant Level ....................................................19 Engine Coolant Temperature ..........................10, 14
Fog Lights ..........................................................21 Engine Oil Pressure ..............................................14
Park Brake Switch .............................................24 Engine Oil Pressure Gauge ...................................10
Requested Gear ................................................21 Entry Code
Switch, Pilot Lockout .........................................24 Test Mode Locations 100 to 199 .......................27
Switch, Redundant Brake Pressure ..................24
Switch, Service Brake Foot ...............................24 F
Work Lights .......................................................20 Fault Code Status ..................................................26
Clutch Fault Codes ...........................................................35
Calibration, Transmission ..................................18 Filter
Codes, Fault ..........................................................35 Indicator, Air Filter ...............................................9
Control Indicator, Hydraulic Oil ........................................9
Pilot .....................................................................8 Indicator, Transmission Oil ..................................9
Coolant Restriction Switch, Air
Engine Temperature ..........................................10 Restriction Switch, Air Filter ..........................20
Indicator, Low ......................................................8 Restriction Switch, Hydraulic .............................20
Coolant Level Check .............................................19 Restriction Switch, Transmission .......................21
Critical Warning Displays .......................................12 Fog Lights Check ..................................................21
Fuel
D Gauge, Level .....................................................10
Diagnostic Center ....................................................7 Fuel Level Gauge ..................................................10
Diagnostic Indicator Status ....................................23 Fuel Lever .............................................................14
Display Center
Lighting, Setting ................................................19 G
Display Location Gauge
047 ....................................................................24 Engine Oil Pressure ..........................................10
Fuel Level ..........................................................10
4005-44
Hydraulic Oil Temperature ...................................9 Internal Information Center Temperature ..............27
Transmission Oil Temperature .............................9
Voltmeter ...........................................................10 L
Gauges and Indicators ............................................8 LCD Duty Cycle .....................................................27
Gear LED Duty Cycle .....................................................27
Check, Actual ....................................................22 Left Turn Indicator Status ......................................23
Check, Requested .............................................21 Level
Gear Range Read Only .........................................25 Coolant, Check ..................................................19
Gear Selection Lighting, Setting Display Center ............................19
Maximum ...........................................................25 Lights
Minimum ............................................................25 Fog ....................................................................21
Work ..................................................................20
H Low Coolant Indicator ..............................................8
Hourmeter ..............................................................14
Hourmeter Indicator Status ....................................22 M
Hours Manual Scrolling Gauge Displays .........................17
Service Interval .................................................26 Master Reset .........................................................23
Hydraulic Filter Restriction Switch Check ..............20 Maximum Gear Selection ......................................25
Hydraulic Oil Filter Indicator ....................................9 Minimum Gear Selection .......................................25
Hydraulic Oil Temperature .....................................15 Movement Indicator Status ....................................23
Hydraulic Oil Temperature Gauge ...........................9
N
I Non-Critical Warning Displays ...............................13
Identification Numbers
Transmission .....................................................28 O
Indicator Oil
Air Conditioning ...................................................9 Pressure Gauge, Engine ...................................10
Air Filter ...............................................................9 Operational Indicator Status ..................................21
Beacon ................................................................8
Brake Pressure ....................................................8 P
Caution and Warning Master, Status Lights ......23 Park Brake
Caution Master (Yellow) ......................................8 Information Center Output Check .....................20
Diagnostic, Status .............................................23 Testing ...............................................................17
Hourmeter, Status .............................................22 Park Brake Switch Check ......................................24
Hydraulic Oil Filter ...............................................9 Parking Brake Indicator ........................................... 9
Icon, Service .....................................................11 Pilot Control ............................................................. 8
Left Turn, Status ................................................23 Pilot Lockout
Low Coolant ........................................................8 Information Output Check .................................20
Movement, Status .............................................23 Pilot Lockout Switch Check ...................................24
Operational, Status ...........................................21 Power Circuit Test ................................................... 8
Parking Brake ......................................................9 Pressure
Right Turn, Status ..............................................23 Brake Indicator ....................................................8
Secondary Steering ............................................9 Pressure, Brake .....................................................19
Service, Status ..................................................22 Programming Information Center ..........................16
Stop Master (Red) ...............................................8 Programming, Information Center .........................16
Tachometer, Status ...........................................22
Transmission Oil Filter .........................................9 R
Indicators and Gauges ............................................8 Redundant Brake Pressure Switch Check ............24
Individual Function Display ....................................17 Requested Gear Check .........................................21
Information and Diagnostic Center ....................7, 14 Reset Diagnostic Stack for Display Locations .......25
Information Center Reset, Master ........................................................23
Internal Temperature .........................................27 Right Turn Indicator Status ....................................23
Software Revision Number ................................27
Instrument Cluster S
Date Code .........................................................29
Secondary Steering Indicator .................................. 9
Part Number (1st part) ......................................28
Secondary Steering Pressure Switch ....................20
Part Number 2nd part) ......................................28
Self-Test .................................................................. 7
4005-45
Service Brake Foot Switch Check .........................24 Transmission Oil Temperature ..............................15
Service Indicator Icon ............................................11 Transmission Oil Temperature Gauge ....................9
Service Indicator Status .........................................22
Service Interval Hours ...........................................26 V
Setting Display Center Lighting .............................19 Voltmeter ...............................................................15
Settings, Diagnostics, and Fault Codes .................16 Voltmeter Gauge ...................................................10
Software Voltmeter, Key ON ................................................19
Revision Number, Information Center ...............27
Speedometer .........................................................14 W
Speedometer Calibration .......................................29 Warning Display ....................................................12
Status Work Lights Check ................................................20
Beacon ..............................................................23
Caution and Warning Master Indicator Lights ...23 Z
Diagnostic Indicator ...........................................23 ZF Transmission
Drive Line Shift ..................................................22 See Transmission ..............................................27
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
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

4005-46
NOTES

SECTION INDEX - POWER TRAIN 0000-1
Section Title
Section Number
Transmission Specifications, Pressure Checks, and Troubleshooting ............................................................................... 6002
Transmission .......................................................................................................................................................... 6003
Front and Rear Axle ................................................................................................................................................. 6004
Drive Shaft, Center Bearing, and Universal Joints ......................................................................................................... 6005
Wheels and Tires ..................................................................................................................................................... 6006
Transmission Control Valve .................................................................................................................................... 6007
CASE CORPORATION
700 State Street

6002
Section
6002
TRANSMISSION SPECIFICATIONS, SCHEMATIC,

AND
TROUBLESHOOTING
CASE CORPORATION
700 State Street
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONSUMPTION TEST PROCEEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure 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

6002-4
4 1
3
2
5 12
9
6
8
14
11
13
7
10
GS99C607
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. FILTER RESTRICTION SWITCH (721/821C MODELS ONLY)
FIGURE 1. COMPONENT LOCATIONS SYSTEMS

6002-5
12
1
11
10 3
9
15
5
14
6
13
GS98K615
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. DRIVE SHAFT
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6
1 1
2
2
2 2
3
6 5 4
GS99C614
1. LIFTING LUGS 4. OIL DRAIN PLUG
2. TRANSMISSION SUSPENSION BORES 5. MODEL IDENTIFICATION PLATE
3. OUTPUT FLANGE CONVERTER SIDE 6. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

6002-7
1 2 3
8
7
GS99C608
1. CONVERTER BELL HOUSING 4. FILTER HEAD 7. OIL DRAIN PLUG
2. BREATHER 5. FILTER 8. OUTPUT FLANGE CONVERTER SIDE
3. TRANSMISSION CASE COVER 6. OUTPUT FLANGE REAR 9. TRANSMISSION CASE
FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

6002-8
1 2
1
7
4
6
5
5
GS98K609
1. LIFTING LUGS 5. TRANSMISSION SUSPENSION BORES
2. POWER TAKE OFF 6. OUTPUT FLANGE REAR
3. TRANSMISSION CONTROL VALVE 7. FILTER
4. OIL FILLER PIPE WITH OIL DIPSTICK 8. FILTER HEAD
FIGURE 5. COMPONENT LOCATIONS REAR VIEW

6002-9
TRANSMISSION OPERATION
General A. Determines which clutches to engage in the

transmission.
The transmissions for the C series equipment is
B. Protect the engine and transmission turbine
equipped with a Transmission ECM (Electronic
fr om overspeed conditions dur ing
Control Module). This module controls modulation
downloading.
and shifting that were normally associated with
hydraulically modulated transmissions, providing C. Receives speed information from the engine
smoother shifts and enhanced clutch life. speed sensor, the turbine speed sensor, the
intermediate clutch speed sensor and the
The Transmission ECM relies on signal from several transmission output speed sensor. These
solenoids that are incorporated into the design. speed sensors are checked to determine if
These solenoids measure the speed of several normal sensor operation is present. The data
components, as well as other sensors that measure is also used to control modulation during
temperature. These solenoids and sensors are shifting and to determine the appropriate shift
further defined in the following paragraphs. patterns.
In a ddi ti on , th e tran s mi ss i on i nc o r po rat es a D. Detects system failures and determines the
two-piece transmission case for ease of transmission appropriate alternative actions.
maintenance, helical cut gears that help reduce
E. Provides various diagnostic messages to the
noise, and all external hoses have been eliminated
Information Center.
(all oil passages are internal).
F. Provides other information to the information
Transmission ECM center, which in turn displays engine speed,
wheel speed, gear shift selection, and actual
Modulation and shifting are controlled by the gear selection.
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 G. Provides a method to calibrate the
(Transmission ECM). This module replaces the oil transmission clutch control.
and springs that are found in hydraulically modulated
transmissions. H. Establishes clutch modulation pressure during
transmission shifts.
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 Transmission Sensor Data Collection.
enhanced clutch life, whether the transmission is set The Transmission ECM collects and uses information
to the automatic or manual shift mode. from four sensors to accurately shift the transmission
The Transmission ECM also informs the Information and determine if any clutches are slipping. These
Center, by the use of diagnostic codes, of any sensors are:
transmission error and the hours of operation that the Engine (Speed) Sensor - monitors engine speed to
error occurred. determine the load on the engine for shift points and
Electrical Shift Solenoids sends the engine rpm to the Transmission ECM,
which sends the information to the tachometer in the
Electrical Shift Solenoids control the modulation of Information Center.
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining Turbine (Speed) Sensor - assists the engine speed
constant control over clutch engagement as follows: sensor in deter mining the load going into the
transmission and helps determine shift points.
A. A temperature sensor relays the oil
temperature to the Transmission ECM. Intermediate (Shaft Speed) Sensor - determines
differential gear speed in the transmission to check
B. The Transmission ECM times the rate the
for clutch slippage.
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is Output (Speed) Sensor - monitors transmission
reduced hesitation from one gear to the next. output shaft speed to help determine the load on the
transmission and to assist in determining shift points.
Transmission ECM Tasks Sends output shaft speed to Transmission ECM
which sends the information to the speedometer in
The Transmission ECM performs a variety of tasks in
the Information Center.
the overall system. The Transmission ECM:

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 If the Transmission ECM generates a code, the
infor mation from the shifter and transmission wre nch over the ser v ic e manual ic on wil l b e
solenoids to determine if there are any short circuits displayed on the Information Center.
or open circuits in the system.
Automatic Problem Modes Transmission Clutch Calibration
If the Transmission ECM detects an error condition in The Transmission ECM has the capability to find the
the transmission system, it will generate a service optimal adjustment of the clutch filling parameters for
code in the Information Center and will enter one of each individual transmission, providing the ability to
three modes: individually adjust the optimum fill time for the
individual transmission in the machine. Clutch Filling
A. Clutch Modulation Substitute Mode Parameter Calibration is performed on each machine
B. Limp-Home Mode at the plant and should be repeated at the first 250
C. Transmission/Transmission ECM Shutdown hours of use and every 1000 hours thereafter
Mode
Gear Selections
Clutch Modulation Substitute Mode
The transmission in all C Series models provides 4
In this mode, the transmission clutch modulation is
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
time dependant rather than load dependant. The
transmission ratios were designed to give optimized
transmission will go into the Clutch Modulation
speed and torque for each gear selection. The torque
Substitute Mode if any of the four speed sensors fail.
converter is a single stage torque converter (one
If the output speed sensor is working and the locking unit in the torque converter).
transmission is in gear, the shift points in Automatic
mode will be speed dependant but the modulation Automatic/Manual Modes
will be a predetermined amount of time.
The automatic/manual switch is located on the right
If the output speed sensor is not working and the control panel. The transmission is in automatic mode
transmission is in gear, the shift points will still be when the top of the automatic/manual switch is
load depen dant but the modul ation will be a depressed. The Transmission Display Center
predetermined amount of time. indicates when the machine is in the automatic
If the transmission is shifted from neutral into a mode.
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. RD98K308
FIGURE 6. AUTO/MANUAL TRANSMISSION SWITCH
Transmission/Transmission ECM Shutdown
Mode
Upshifting in Automatic Mode
In this mode, the Transmission ECM has detected a
Upshifting is determined by machine speed and the
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
torque on the transmission.
transmission. The transmission will go into Shutdown
Mode if there is a fault on more than one clutch, a The transmission will shift from first or second gear
fault on the solenoid power supply. or invalid voltage. up to the highest gear selected as the accelerator is
In this mode, the transmission ECM will shut off all depressed, machine speed increases, and required
solenoid valves and the power supply and the torque is reduced.
transmission shifts into and stays in neutral.

6002-11
If the machine speed is increasing, but the operator With the number of different ways the downshift
is not depressing the accelerator (such as when button functions, the operator can tailor the use of the
going down a hill), the transmission will not upshift. machine to the application at hand.
As the operator depresses the accelerator and the
torque on the transmission is lowered, the
transmission will upshift. 1
Downshifting in Automatic Mode
Downshifting is determined directly by machine
speed and transmission torque. The transmission will
downshift to first or second gear as machine speed
decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque
requirement incr eases, the trans mission will
downshift into third, then second, and down to first
gear, if necessary. RD98K306
1. DOWNSHIFT BUTTON/SINGLE LEVER CONFIGURATION
Upshifting in Manual Mode FIGURE 7
In the manual mode, the transmission starts out in

the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached. 1
Downshifting in Manual Mode
The transmission can be downshifted in the manual
mode without reducing engine speed or machine
RD98K273
speed. 1. DOWNSHIFT BUTTON/TWO LEVER CONFIGURATION
If 1st gear is selected from 3rd or 4th gear, the FIGURE 8

transmission will downshift into 2nd gear for 1.2 Automatic Mode
seconds and then will shift into 1st gear.
In the Automatic Mode, the downshift button only
Cold Start Protection System shifts down. The downshift button allows the operator
The transmission has a cold start protection system. to downshift through the entire range of gears. This is
When the transmission sump temperature is minus useful in long haul applications or roading.
10° C (14° F), the Transmission ECM will keep the Each time the button is pushed the transmission will
transmission in neutral. instantly downshift one gear from 4th to 3rd, then
When the transmission sump temperature warms up from 3rd to 2nd, and then from 2nd to 1st.
to minus 10° C (14°F) (within approximately one The transmission will automatically downshift and
minute), the machine will operate in all gears. then upshift, as needed, to the last gear that was
selected with the downshift button.
Downshift Button EXAMPLE: If the downshift button was used to shift
The downshift button is located on top of the joystick from 4th to 3rd gear, the transmission will
control l ever in machines with a single lever automatically shift from 3rd down and the back up to
configuration, and on top of the loader control lever in 3rd again. It will not shift into 4th until the
machines with a two lever configuration. transmission has been returned to the full range
automatic mode.

6002-12
The transmission will retur n to the full range When the brake pedal is released, the Transmission
automatic mode when: ECM gradually increases the forward or reverse
A. Another gear is selected clutch back up to system clutch pressure.
B. The shifter is moved into neutral and then into If the direction is changed while the transmission is
forward or reverse declutched, the selected forward or revers clutch will
be filled and maintain a low pressure until the brake
C. The autoshift switch is recycled.
pedal is released. Then the selected forward or
Manual Mode reverse clutch pressure will gradually increase up to
system clutch pressure.
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.

6002-13
NOTES

6002-14
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

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

6002-15
BC00E065
FIGURE 10. MEASURING POINTS AND CONNECTIONS

6002-16
CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:
TEST POINTS
Shift P V R 1 2 3 4 5 6
LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE
V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN
R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT

6002-17
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
3. Oil operating temperature high. A. Check engine and fuel system for problem.
4. Screen for suction tube plugged. B. Check that torque converter installation is
correct.
5. Suction tube or gaskets leak.
3. Engine RPM above Stall Test specified RPM.
6. Main pressure valve, springs, or valve bore.
A. Check converter pressures and flow.
7. Reduction valve, springs, or valve bore.
B. Check that torque converter installation is
8. Charge pump seals or gaskets leak. correct.
9. Charge pump worn.
Machine Stops or Hesitates While
10. Oil supply flange not sealing correctly.
Shifting - Intermittent
Some Pressures Low Possible causes include:
Possible causes include: 1. Check orifice and O-ring. (See Section 6007 for
replacing.)
1. Circuit isolation does not correct low pressure.
2. Check for foreign material plugging orifices or
A. Control valve or gasket. sticking valves.
B. Channel plate or gasket. 3. Check for reduced pressure at test pressure
points.
2. Circuit isolation corrects low pressure.
4. See Electrical Troubleshooting this section for
A. Clutch shaft or seals.
electrical system problem.
B. Clutch drum or piston.

6002-18
CONVERTER OUT PRESSURE CHECK
Test Equipment Required 2. Apply the parking brakes.
0 to 28 bar (400 psi) gauge with hose long enough to 3. Install the pressure gauge.
take readings in the cab and CAS-2324 Special 4. Heat the oil to an operating temperature of 80 to
Adapter. 100° C (176 to 212° F).
5. While in the cab, put the transmission in
Test Procedure NEUTRAL. Run the engine at full throttle. Record
1. Block the machine tires. the reading in the char t on page 6002.16.
Pressure must be 3.5 to 6.5 bar (51 to 96 psi).
LUBRICATION PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 6002.16. Pressure
must be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 4. Remove the filter and install the CAS-2702
adapter.
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter. 5. Install the flowmeter between the adapter and
the filter.
Flowmeter Test Procedure 6. While in the cab, run the engine at full throttle.
Put the transmission in NEUTRAL and record the
1. Block the machine tires. flow measurement. The correct flow for 621C
2. Apply the parking brakes. machines is 52 L/min (14 U.S. gpm) at 2000 rpm.
The correct flow for 721C and 821C machines is
3. Heat the oil to an operating temperature of 80 to 80 L/min (21 U.S. gpm) at 2000 rpm.
100° C (176 to 212° F).
CONSUMPTION TEST PROCEEDURE

1. Block the machine tires. 6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1
2. Apply the parking brakes.
L/min (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 ° F).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line L/min (2 U.S. gpm).
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).

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 operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Understanding Results to determine possible cause of any test results not within specifications.

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

Shifter Wire Shifter Tower Shifter Shroud Harness Harness
Function Shifter Trans. ECM #
Color Connector Connector Wire # ped/cab #
power B+ red/black A A 19A 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-4) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Transmission ECM Transmission Transmission Transmission Cab/eng
Clutch # Wire #
Function ECM Pin # Valve Valve Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12

6002-21
TRANSMISSION ELECTRICAL SCHEMATIC

FIGURE 11

FILTER MAINTENANCE TO FUSE A
SWITCH ON SHEET 8
2 CAB SWITCHED POWER DETENT SWITCH
2
ON SHEET 5
O (19A) 0.8
31 VIA RIDE CONTROL SWITCH
VIA BEACON SWITCH ON SHEET 22
A Y (32F) 1.0 ON SHEET 1
DIAGNOSTIC
0.8
CONNECTOR
B V (36R) 1.0
O(19A)
O (19A) 0.8 1
TORQUE CONVERTER V (37D) 0.8 2
O (19A) 0.8
OUTPUT TEMP SENDER
Gy (49) 1.0
22 B (0) 0.8 3 108
A V (36G) 1.0 V (37E) 0.8 4
OUTPUT B V (36R) 1.0
SPEED 100 31 Y (32F) 0.8 17 66 TRANSMISSION
SENSOR 142 O (19A) 1.0 29 O (19A) 0.8 45 15
AUTO SWITCH
C B (0) 1.0 28 B (0) 0.8 4 18 2
A LBe (25D) 1.0 10 LBe (25D) 0.8 62 TO PARKING BRAKE SWITCH TO PARKING BRAKE SWITCH
ON SHEET 15 ON SHEET 15
B LBe (25A) 1.0 7 LBe (25A) 0.8 19 1
ENGINE B (0) 1.0 11 B (0) 0.8 3

6
SPEED 9 O (19A) 0.8
101 LBe (25C) 1.0 LBe (25C) 0.8 42
TRANSMISSION 5
SENSOR LBe (25B) 1.0 8 LBe (25B) 0.8 41
SHIFTER
A 13 70
O (19A) 0.8
13 V (36G) 1.0 49 4
B 9
CAB|PED
B(0) 1.0
LBe (25W) 0.8 B 8

INTERMEDIATE 41
SPEED 65 LBe (25W) 0.8 48 LBe (25Z) 0.8 C 7
95
SENSOR 63 LBe (25Z) 0.8 49 LBe (25Y) 0.8 D 10
B 22 LBe (25Y) 0.8 LBe (25Y) 0.8 50
A 43 O (19A) 0.8 A 2
43 LBe (25F) 0.8 44 LBe (25F) 0.8 B 4
B(0) 1.0
TURBINE
SPEED 96 64 LBe (25R) 0.8 45 LBe (25R) 0.8 C 6
SENSOR 67 LBe (25T) 0.8 LBe (25T) 0.8 46 LBe (25T) 0.8 D 5
B TRANSMISSION
Gy (49) 1.0
LBe (25T) 0.8
A
70 KICK-DOWN
B (0) 1.0 24 SPARE SWITCH 20
B (0) 1.0 25 SPARE
TO ETHER SWITCH TO ETHER SWITCH
O (19A) 0.8
921C 1 LBe (25K) 1.0 16 LBe (25K) 0.8 56 ON SHEET 7 ON SHEET 7
LBe (25H) 0.8

2 LBe (25L) 1.0 17 LBe (25L) 0.8 10
LBe (25Y) 0.8
102 3 LBe (25M) 1.0 18 LBe (25M) 0.8 32 1 2
4 LBe (25N) 1.0 19 LBe (25N) 0.8 55
5 LBe (25P) 1.0 20 LBe (25P) 0.8 9
TO NEUTRAL START RELAY #8
6 LBe (25J) 1.0 21 LBe (25J) 0.8 51 LBe (25T) 0.8 ON SHEET 7
LOCATED IN
7 LBe (25S) 1.0 22 LBe (25S) 0.8 12 HYD. CONTROLLER LBe (25G) 0.8
8 V (36T) 1.0 5 13
9 V (36R) 1.0 12 Y (36T) 0.8 39
Y (36R) 0.8 46 29
V (36R) 1.0 ENG|CAB
TRANSMISSION SOLENOID
VALVE AND 87
O (19A) 0.8
TEMPERATURE SENSORS TO FUSE T ON SHEET 10 O (19T) 0.8
TO FUSE H
2
O (19H) 1.0
30 ON SHEET 8
1 LBe (25K) 1.0 1
6/7/821C 23 87a
2 LBe (25L) 1.0 O (19T) 0.8
TO FUSE T ON SHEET 10 68 TO FUSE A
3 LBe (25M) 1.0 Y (35C) 0.8 O (19A) 0.8 6
102A 85 86 ON SHEET 8
4 LBe (25N) 1.0 5
Gy (49) 1.0
Y (35A) 0.8
5 LBe (25P) 1.0
7 4
6 LBe (25J) 1.0
1
BACKUP ALARM
7 LBe (25S) 1.0 RELAY #7 53 DECLUTCH
TO PARKING BRAKE RELAY W (52P) 0.8 21 2
8 V (36T) 1.0 #9 ON SHEET 17
118 38 SWITCH
9 V (36R) 1.0
BACK-UP
LBe (25G) 0.8

TO RR WIPER SWITCH ALARM
Gy (49) 1.0
27 ON SHEET 25
+
G (50L) 0.5 26 2
-
Y (35R) 1.0
Y (50H) 0.5 25 B (0) 1.0 TO RR WIPER SWITCH
B (0) 1.0
ON SHEET 25
1
NC 4 1
C
B/R (50G) 0.5 6 94
B (0) 0.8
B (0) 0.8
5 1 LBe (25G) 1.0 B

NO O (19A) 1.0 D
TO MAIN CAB HARNESS Y (35R) 0.8 6 Y (35R) 1.0 4 3
ON SHEET 17 TRANSMISSION 4
ELECTRONIC 19 CAB |REAR REAR|REAR DECLUTCH FRONT|CAB
REAR
BACK-UP LIGHT BRAKE
Y (35A) 0.8
CONTROL 15 LIGHT
Y (35R) 0.8
TO MAIN CAB HARNESS

ON SHEET 17 MODULE ALARM SWITCH
B (0) 1.0
B (0) 1.0
B (0) 1.0
21 REAR
DISABLE
TO MAIN CAB HARNESS 94
B (0) 1.0
ON SHEET 17
NAO-JUMPER CONNECTED VIA DETENT SWITCH
EURO-JUMPER OPEN ON SHEET 19
SHEET 11 VIA BEACON SWITCH

ON SHEET 1 SHEET 12 SHEET 13 VIA RIDE CONTROL SWITCH
ON SHEET 19
GM99C600

Section
6003
6003
TRANSMISSION
CASE CORPORATION
700 State Street
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6003-3
SPECIAL TOOLS
Assembly car . . . . . . . . . . . . . . . . . . . . 5870 350 000 Grab sleeve . . . . . . . . . . . . . . . . . . . . .5873 002 038
Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . 5870 350 063 Grab sleeve, K3 . . . . . . . . . . . . . . . . . 5873 001 058
Support . . . . . . . . . . . . . . . . . . . . . . . . 5870 350 090 Basic set tool . . . . . . . . . . . . . . . . . . . 5873 001 000
Adjusting screws M6 . . . . . . . . . . . . . . 5870 204 031 Rolling tool . . . . . . . . . . . . . . . . . . . . . .5870 600 007
Adjusting screws, universal . . . . . . . . . 5870 204 011 Rolling tool (suction tube). . . . . . . . . . 5870 600 003
Lifting device . . . . . . . . . . . . . . . . . . . . 5870 204 002 Rolling tool (pressure oil pipes) . . . . . 5870 600 004
Internal pliers . . . . . . . . . . . . . . . . . . . . 5870 900 013 Rolling tool (Oil Pipes) . . . . . . . . . . . . 5870 600 005
Separating device size 2 . . . . . . . . . . . 5870 300 024 Assembly aid (K1, KV, KR) . . . . . . . . . 5870 345 086
Two-leg puller . . . . . . . . . . . . . . . . . . . 5870 970 004 Assembly aid (K2, K3, K4) . . . . . . . . . 5870 345 085
Handles . . . . . . . . . . . . . . . . . . . . . . . . 5870 260 010 Dial indicator. . . . . . . . . . . . . . . . . . . . .5870 600 007
Grab sleeve . . . . . . . . . . . . . . . . . . . . . 5873 001 057 Driver . . . . . . . . . . . . . . . . . . . . . . . . . 5870 057 011
Grab sleeve . . . . . . . . . . . . . . . . . . . . . 5873 001 045 Handle, Driver. . . . . . . . . . . . . . . . . . . 5870 260 002
Grab sleeve . . . . . . . . . . . . . . . . . . . . . 5873 001 059
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)

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.

6003-5
DISASSEMBLY
STEP 1 STEP 4
BK00D037 GD98M839
Fasten the transmission on an assembly stand. Remove the socket head screws, hex nuts, and
remove the duct plate from transmission housing.
STEP 2 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 GD98M851
duct plate. 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.

6003-6
STEP 7 STEP 10
GD98M853 GD98M856
Remove the socket head screws for removal of the Remove the hex head screws and remove the oil
transmission pump. feed housing. Remove the flat gasket.
STEP 8 STEP 11
GD98M854 GD98M860
Apply a bearing separator on the splines shoulder of Remove the hex head screws, cover, and flat gasket.
the stator shaft and pull the pump out of the housing
bores, using two-leg puller. STEP 12
NOTE: If traces of wear should be encountered in
the pump housing or the cam disk, the complete
pump has to be replaced.
STEP 9
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 13
GD98M855
Pry the shaft seal out of the housing bore.
Separate the transmission pump from stator.
Separate the cam plate from pump.
6003-7
STEP 14 STEP 18
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 15
BK00D029
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
GD98M862 transmission cover.
Remove the speed sensor and both inductive
transmitters. STEP 19
STEP 16
BK00D028
Separate the cover along with clutches from the

GD98M863 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.
6003-8
STEP 21 STEP 25
Remove clutch shaft retainer nuts and lift cover
free.
STEP 22
GD98M878
Squeeze the rectangular ring out and separate ball

bearing from the shaft.
NOTE: The following steps are for the disassembly
GD98M867
of the clutch KV. The disassembly of the clutch KR is
Remove the socket head screws and remove the similar.
output shaft and both oil baffle plates.
STEP 26
STEP 23
GD98M979
GD98M880
Squeeze the sealing ring out.
Pull tapered roller bearing from the shaft. Remove
the opposite tapered roller bearing.
STEP 24 STEP 27
GD98M877 GD98M881
Remove the bearing outer race and pull output shaft Separate the clutch disc carrier from the shaft.
out of the housing bore.
6003-9
STEP 28 STEP 31
GD98M882 BK00D019
Squeeze the snap ring out and remove the clutch Remove the compression spring.
disc pack.
STEP 32
STEP 29
GD98M885
Remove the O-rings.

BK00D018
STEP 33
Preload compression spring using tool. (Tool in
place.)
STEP 30
GD98M886
Squeeze the snap ring out.
BK00D020
Remove snap ring.

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 GD98M893
and K2 are similar Remove the idler gear.

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
Squeeze the snap ring out and remove the clutch Remove the compression spring.
disc pack.
STEP 44
STEP 41
BS00G001
BK00D018
Squeeze the sealing ring out. Remove bearing using
Preload compression spring using tool. (Tool in
bearing puller. Tap assembly until piston drops out of
place.)
the plate carrier.

6003-12
STEP 45 STEP 48
BK00D022 BK00D018
Remove the clutch disc carrier from the shaft. Preload compression spring using tool. (Tool in
NOTE: The following steps are for the disassembly place.
of the clutch K4.
STEP 49
STEP 46
BK00D020
GD98M800 Remove the snap ring.

Squeeze the snap ring out and separate the clutch
STEP 50
disc carrier from the shaft.
STEP 47
BK00D019
Remove the compression spring.

GD98M801
Squeeze the snap ring out and remove the clutch

disc pack.

6003-13
ASSEMBLY
NOTE: The following steps are for the reassembly of STEP 4
the oil pipes..
STEP 1
GD98M607
3
Install the screw plug with a new O-ring. Tighten the
screw plug to a torque of 140 Nm (103 lb-ft).
1
STEP 5
GD98M603
Inser t suction tube (1), pressure pipes (2), and

pressure pipe lubrication (3) into the housing.
STEP 2
Fasten suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (17 lb-ft)
STEP 3
GD98M608
Insert all bearing outer races into the housing bore.
STEP 6
GD98M605
Tilt the cover 180 degrees. Install the suction tubes

and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be GD98M609
slightly below the housing plane face. 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.
6003-14
STEP 7 STEP 10
GD98M610 BK00D019
Install the studs. Tighten the studs to a torque of 9 Preload the compression spring using tool.
Nm (6.6 lb-ft).
NOTE: The following steps are for the assembly of STEP 11
clutches KV and KR, starting with the pre-assembly
of the clutch disc carrier.
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.

6003-15
STEP 13 STEP 15
GD98M617
225A
Install the end shim and squeeze snap ring in.
1. PLATE CARRIER
2. PISTON
3. OUTER PLATE - ONE-SIDED COATED
STEP 16
4. INNER PLATES
5. OUTER PLATES - COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
8. 2.5 mm +0.2 mm
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 GD98M618
discs without oil.
Adjust the running clearance to 2.7 mm. Press the
STEP 14 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.

6003-16
STEP 17 STEP 20
GD98M619 GD98M621
Use tools to lift the end shim against snap ring Apply Loctite 243 to the stud. Tighten the stud to a
(upward) until contact is obtained and measure the torque of 17 Nm (12.5 lb-ft).
dimension from the carrier face to the end shim,
using depth gauge as shown. Example dimension STEP 21
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.
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.

6003-17
STEP 23 STEP 26
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Install gear and shaft into heated bore.
Press the idler gear against the shoulder.
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.

6003-18
STEP 30 STEP 33
GD98M630 GD98M633
Apply Loctite 243 to the stud and install the stud. Install the piston into the clutch disc carrier.
Tighten the stud to a torque of 17 Nm (12.5 lb-ft).
STEP 34
STEP 31
GD98M634
GD98M631 Install the compression spring and spring cup.

Insert the clutch disc carrier until contact is obtained. BK00D023
STEP 32 STEP 35
BK00D019
GD98M632
Preload the compression spring using tool.
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.

6003-19
STEP 36 STEP 38
BK00D018 232A
1. PLATE CARRIER
Tool in place. 2. PISTON
STEP 37 4. INNER PLATES
6. SNAP RING
7. END SHIM
8. 2.4 mm +0.2 mm
The above shows the installation position of the K1

components.
STEP 39
BK00D020

NOTE: The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3 is
identical.
232A
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
8. 1.8 mm +0.2 mm

and K3 components.

6003-20
STEP 40 STEP 42
GD98M636 GD98M638
Install the clutch disc pack. Adjust the running clearance for K1 to 2.4 mm (0.09
in). Adjust the running clearance for K2 and K3 to 1.8
STEP 41 mm (0.07 in). Press the end shim on with
approximately 10 kg (20 lb) and measure the
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
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.

6003-21
STEP 45 STEP 48
3 1
2 2
1 3
GD98M640 GD98M643
Install the running disc (1), axial needle cage (2), and Install the axial washer (3), axial needle cage (2),
axial washer (3). and running disc (1). Install the running disc (1) with
the chamfer facing the axial needle cage.
NOTE: Install the running disc (1) with the chamfer
facing the axial needle cage. 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
Heat bearing.
STEP 47
STEP 50
GD98M642
Install the idler gear until all inner discs are engaged. GD98M625
Place heated bearing on the shaft.

6003-22
STEP 51 STEP 54
Check the function of the clutch, using compressed
air.
NOTE: The following steps are for the reassemble of
clutch K4.
STEP 52
GD98M649
Install the stud. Tighten the stud to a torque of 17 Nm

(12.5 lb-ft).
STEP 55
GD98M647
Heat the gear to about 120° C (248° F) and assemble

until seated in position.
STEP 53
GD98M650
Check the function of the piston drain valve and

clean as required. Insert both O-rings into the piston
recesses and oil the O-rings.
STEP 56
GD98M648
Install the gear shaft with the snap ring.
GD98M651
Install the piston into the clutch disc carrier. Be sure

the piston bottoms out.

6003-23
STEP 57 STEP 60
BK00D019 232A
Preload the compression spring using tool. 1. PLATE CARRIER

2. PISTON
STEP 58 4. INNER PLATES
6. SNAP RING
7. END SHIM
8. 1.2 mm +0.2 mm

components..
STEP 61
BK00D018
Tool in place.
STEP 59
GD98M653
Install the clutch disc pack.
BK00D020
NOTE: The following steps are for installing the

clutch disc pack in clutch K4.

6003-24
STEP 62 STEP 64
GD98M654 GD98M656
Install the end shim and squeeze the snap ring in. Use tools to lift the end shim against snap ring
(upward) until contact is obtained and measure the
STEP 63 dimension from the carrier face to the end shim,
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
STEP 66
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.
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.

6003-25
STEP 67 STEP 70
GD98M658 GD98M661
Assemble both axial washers and the needle cage. Assemble axial washer (3), needle cage (2), and
running disc (1). Install the running disc (1) with the
NOTE: Upper and lower axial washers have the
chamfer facing the needle cage.
same thickness.
STEP 71
STEP 68
GD98M662
GD98M659
Assemble the pre-assembled clutch disc carrier until
Install both needle bearings.
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.

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. Install the snap ring into the recess of the turbine
shaft.
STEP 75
Check the function of the clutch with compressed air. STEP 79
the input shaft.
STEP 76
GD98M669
Install the turbine shaft until the snap ring snaps into
the recess of the input shaft.
GD98M666
Heat the gear to about 120° C (248° F) and assemble

until contact is obtained.

6003-27
STEP 80 STEP 83
K1 K4
AN KR
AB
K3 K2
KV
BK00D024 GD98M673
Install bearings so inner races are against shoulder. Insert all the bearing outer races into the housing
Alternate method is to heat bearing and install on cover until contact is obtained.
turbine shaft.
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
Use acceptable lifting equipment and install the

GD98M672 housing cover onto the clutches. Install clutch shaft
Insert the output shaft into the housing bore until retainer nuts.
contact is obtained.
the output shaft and clutches. All clutches have a
common installation.
6003-28
STEP 86 STEP 89
KR
KV
K4
K2
K1 K3
GD98M679 GD98M692
The above shows the position of the single clutches Insert both the O-rings into the annular groove of the
in the housing cover. oil pipes and apply grease.
STEP 87 STEP 90
AN Tilt the housing cover 180 degrees. Install the eye
KV KR
bolts for lifting.
K2 K4
STEP 91
K3 K1
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.

6003-29
STEP 93 STEP 96
GD98M685 GD98M690
Separate the housing cover from the gearbox, using Apply Loctite 243 to the socket head screws and
a lifting device. Install output gear and output gear install the screws. Tighten the screws to a torque of
cover. 23 Nm (17 lb-ft).
NOTE: The following steps are for the reassembly of STEP 97
the output shaft.
STEP 94
GD98M695
Install the housing cover with the hex head screws.

GD98M688
Tighten the screws to a torque of 46 Nm (34 lb-ft).
Position the screening plate. STEP 98
STEP 95
GD98M696
GD98M689
Install the shaft seal with the sealing lip facing the oil
chamber. Apply grease to the sealing lip.
Insert the output shaft. If bearing was removed, heat
bearing bore and install.

6003-30
STEP 99 STEP 101
GD98M697 GD98M702
Heat the output flange to about 90° C (194° F). Apply Install two alignment screws and mount the flat
Loctite 574 to the contact area and assemble the gasket.
flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (25 lb-ft). STEP 102
Apply lock plate to the hex head screws.
STEP 100
GD98M703
Install the oil feed housing with washers and hex

head screws. Screw the hex head screws in only until
BK00D034 contact is obtained, do not tighten.
Install the output flange on the converter side using a
driver tool. STEP 103
NOTE: The following steps are for the assembly of
the oil feed housing and transmission pump.
GD98M704
Install the two alignment screws and insert the stator

shaft.

6003-31
STEP 104 STEP 107
GD98M705 GD98M708
Apply oil and install the O-ring. Install the transmission pump with the socket head
screws. Tighten the screws to a torque of 46 Nm (34
STEP 105 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).
the engine connection and converter.
GD98M707
Apply grease to the new O-rings. Install the O-rings

on the socket head screws.

6003-32
STEP 109 STEP 112
GD98M712 258
Fit the flat gasket and install the cover with the hex Mount the gasket (1), intermediate plate (2), and
head screws. Tighten the screws to a torque of 23 gasket (3).
Nm (17 lb-ft).
STEP 113
STEP 110 Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (22 lb-ft).
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).
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).
the transmission control valve.
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
Install the gasket and the cover plate. Tighten to a

STEP 116 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).

6003-34
NOTES

Section
6006
WHEELS AND TIRES
6006
CASE CORPORATION
700 State Street
6006-2
TABLE OF CONTENTS
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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 IMPORTANT: When installing a Michelin tire,
rim wheels used on this machine. lubricate the tire with a tire mounting lubricant and
inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
2. The correct tire equipment, especially a tire
sure that the tire is seated on the rim. Then decrease
inflation cage, is required. Using the wrong
the pressure to the specified pressure.
procedure for a split rim wheel can result in
death.
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
1
2. Install the wheel, hardened washers and wheel 13 10
nuts. 6 8
3. Use a hand wrench (not an impact) to tighten the

11 15
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 3
4. Tighten the wheel nuts to 203 Nm (150

16 12
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
7 5
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). 9 14
2
BC00F051
FIGURE 1. TORQUE SEQUENCE FOR WHEEL NUTS
WHEEL NUTS
The wheel nuts must be tightened after every 20 Torque Specification
hours of operation until the wheel nuts stay tight:
Tighten the wheel nuts to 203 Nm (150 pound-feet) in
A. If the machine is new. the sequence shown in Figure 1. Then a final torque
B. If a wheel has been removed and installed. of 515 to 570 Nm (380 to 420 pound-feet) in the
same sequence.

6006-4
NOTES

8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS
CASE CORPORATION
700 State Street
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems in All Circuits - See the following pages for other circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test No. 1 - Primary Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test No. 2 - Secondary Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing and Adjusting the Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Testing and Adjusting the Combination Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Control Pressure at the Ends of the Spools in the Loader Control Valve . . . . . . . . . . . . . . . . . . . 11
Testing and Adjusting the Circuit Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Testing and Adjusting the Pressure for the Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
821C HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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)

8002-4
SPECIAL TOOLS
633L95 B877168V
CAS-1904 PRESSURE FITTING KIT CAS-1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS-1906 PRESSURE FITTING KIT CAS-10090 HAND PUMP
B785789M B877558M
CAS-10280 FLOWMETER CAS-1804 PRESSURE FITTING KIT

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 Fill the hydraulic reservoir with the hydraulic
No oil specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits - See the following pages for other circuits
Check and clean the one suction screen (two
if equipped with auxiliar y steering) in the
hydraulic reservoir.
Replace the two return line hydraulic filters.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for See Page 7. Do the flowmeter tests of the
No hydraulic pump.
contaminated oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 9 and check the pressure setting of
the main relief valve in the loader control No Charge the accumulator.
valve. Is the pressure setting correct?
Yes
See Page 8 and do the Secondar y Pump

Output Test.
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.

8002-6
Problem in a Single Loader Circuit

Star t and run the engine at full throttle. See Page 11. Check the pressure at both
Operate the control for the bad circuit. Does No ends of the spool in the loader control valve. Is
the cylinder move in both directions? the pressure correct at both ends?
No
The remote control valve is

damaged. See Section 8010
Yes and repair the remote control
valve.
Yes
The loader control valve is damaged. See

Section 8005 and repair the loader control
valve
See Page 10. Check the pressure setting of See Page 10 and adjust the combination
the combination valve. Is the pressure setting No valve.
correct?
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 12. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of c o n t r o l va l ve a n d c h e ck fo r wo r n o r
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 7. Do the Primary Pump Output

Test.

8002-7
Testing the Hydraulic Pump STEP 4

Slowly close the load valve on the flowmeter and
Test No. 1 - Primary Pump Output Test measure the flow at 13 790 kPa, 138 bar (2000 psi).
Make sure the engine is running at 2000 r/min with
STEP 1 the load applied. Record the flow.
Connect the flowmeter to the primary pressure hose
from the hydraulic pump located toward the engine. STEP 5
Divide the flow reading at 13 790 kPa, 138 bar (2000
STEP 2 psi) by the reading at 0 kPa, 0 bar (0 psi). The answer
Make sure the load control of the flowmeter is open. multiplied by 100 is the percent efficiency of the
Make sure the hydraulic oil is 54 to 66°C (130 to primary pump. If the efficiency is less than 75%
150°F). 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
GS98M898
1. CAS-10280 FLOWMETER 3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL)
2. HYDRAULIC RESERVOIR 4. CONNECT TO PRIMARY PRESSURE PORT HOSE

8002-8
Test No. 2 - Secondary Pump Output Test STEP 4
Slowly close the load valve on the flowmeter and
STEP 1 measure the flow at 13 790 kPa, 138 bar (2000 psi).
Connect the flowmeter to the secondary pressure Make sure the engine is running at 2000 r/min with
hose from the hydraulic pump located away from the the load applied. Record the flow.
engine.
STEP 5
STEP 2 Divide the flow reading at 13 790 kPa, 138 bar (2000
Make sure the load control of the flowmeter is open. psi) by the reading at 0 kPa, 0 bar (0 psi). The answer
Make sure the hydraulic oil is 54 to 66°C (130 to multiplied by 100 is the percent efficiency of the
150°F). 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 3. FLOWMETER OUTLET (USE WIRE TO FASTEN HOSE BELOW THE SURFACE OF THE OIL)
2. HYDRAULIC RESERVOIR 4. CONNECT TO SECONDARY PRESSURE PORT HOSE

8002-9
Testing and Adjusting the Main Adjustment

Relief Valve
STEP 1
Pressure Check
STEP 1
Engage the transport/service link.
1
STEP 2
Lower the bucket to the floor. Stop the engine.
STEP 3
Connect a 20 685 kPa, 207 bar (3000 psi) pressure
gauge to the quick disconnect fitting at Test Port 1.
This Test Port 1 is located on the opposite side of the
primary pressure port on the primary pump toward
the engine.
STEP 4
Run the engine at full throttle. Heat the hydraulic oil 2
to operating temperature.
GS98M896
STEP 5 1. LOADER CONTROL VALVE
2. MAIN RELIEF VALVE
Hold the bucket control lever in the ROLLBACK
position. Remove the cover at the front of the machine.
STEP 6 STEP 2
Read the pressure gauge. Compare the reading to
the specifications on Page 3. 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.

8002-10
Testing and Adjusting the Combination Valve

Pressure Check Adjustment
STEP 1 STEP 1
Before starting machine, pump the brakes repeatedly Remove the round plug from the regulator cartridge
to be sure the brake accumulators have no pressure. valve.
STEP 2 STEP 2
Connect a 6 895 kPa, 69 bar (1000 psi) pressure Use an Allen wrench to turn the adjusting screw
gauge to the quick disconnect fitting at the regulating clockwise to increas e the pressure or
pressure test port. counterclockwise to decrease the pressure.
1 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.

8002-11
Testing the Control Pressure at the STEP 7

Ends of the Spools in the Loader Hold the control lever in the other power position.
Read the other pressure gauge. Record the pressure
Control Valve reading.
STEP 1 STEP 8
Heat the hydraulic oil to operating temperature. The pressure at each end of the spool must be 37 to
43 bar (540 to 620 psi).
STEP 2
Lower the bucket to the floor. Stop the engine. STEP 9
If the pressure is not correct at both ends of the
STEP 3 spool, check the pressure of the combination valve. If
Remove the cover at the front of the machine. the pressure is correct at one end of the spool but not
at the other end, there is a problem in the remote
STEP 4 control valve. See Section 8010.
Connect 6 896 kPa, 69 bar (1000 psi) pressure
gauges to Test Ports 4 and 5 for the circuit which you
are testing.
1 4 5 6
GS98M897
1. LOADER CONTROL VALVE
2. TEST PORT 4 (PRESSURE GAUGE)
3. TEST PORT 5 (PRESSURE GAUGE)
4. BUCKET SPOOL
5. LIFT SPOOL
6. 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.

8002-12
Testing and Adjusting the Circuit STEP 3

Relief Valves Connect the hand pump to the disconnected line that
goes to the loader control valve.
Pressure Check
STEP 4
STEP 1 Make sure that the hand pump is full of hydraulic oil
Circuit relief valves are located as shown below. and that the temperature of the oil is approximately
21°C (70°F).
3 4
5 STEP 5
Operate the handle of the hand pump and read the
1 1 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
Loosen the lock nut. Turn the adjustment screw
clockwise to increas e the pressure or
2 counterclockwise to decrease the pressure.
1 1 STEP 2
Check the pressure again. Repeat the adjustment as
GS98M896
1. CIRCUIT RELIEF VALVE
necessary.
3. BUCKET SPOOL
4. LIFT SPOOL
5. AUXILIARY SPOOL
Remove the cover at the front of the machine.
STEP 2
Lower the bucket to the floor. Stop the engine. Find
an easy place to disconnect the line for the circuit to
be tested.

8002-13
Testing and Adjusting the Pressure Adjustment

for the Unloader Valve
STEP 1
Pressure Check If the gauge reading did not drop according to the
specifications, remove the nut and turn the adjusting
STEP 1 screw until the setting is correct
.
Engage the transport/service link.
2
STEP 2
Lower the bucket to the floor. Stop the engine. 1
3
STEP 3
Connect a 20 685 kPa, 207 bar (3000 psi) pressure
gauge to the quick disconnect fitting at Test Port 6.
This Test Port 6 is located on the face of the hydraulic
pump on the secondary pump away from the engine.
STEP 4
Start and run the engine at low idle.
STEP 5
Heat the hydraulic oil to operating temperature.
STEP 6
Put the bucket in the full ROLLBACK position.
STEP 7
Run the engine at full throttle. 1. NUT
GS98M474
2. ADJUSTING SCREW
STEP 8 3. UNLOADING VALVE
Watch the pressure gauge as you slowly move the
bucket control lever to the ROLLBACK position. STEP 2
When the gauge reading reaches 145 to 158 bar Install the nut.
(2100 to 2300 psi), the gauge reading must drop to
1 034 kPa, 10 bar (150 psi) or less.

8002-14
HYDRAULIC COMPONENT LOCATIONS
5
18
6
9 20
10
4 7
3 6
2
24
25 22
11
18
21
8
16
23
14
13 9
17
15 12
19
11
BC00D096
1. AUXILIARY STEERING PUMP 13. DUAL PRESSURE ACCUMULATOR CHARGING VALVE
2. PRIMARY/SECONDARY PUMP 14. BRAKE PUMP
3. RESERVOIR 15. PRIORITY VALVE
4. HYDRAULIC FILTERS 16. OIL COOLER
5. STEERING CONTROL VALVE 17. TRANSMISSION DECLUTCH SWITCH
6. LIFT CYLINDERS 18. FRONT BRAKE CYLINDERS
7. BRAKE VALVE 19. COMBINATION VALVE
8. LOADER CONTROL VALVES 20. BUCKET CYLINDER
9. STEERING CYLINDERS 21. COUPLER LOCKING VALVE (OPTIONAL)
10. REMOTE CONTROL VALVES 22. COUPLER LOCKING CYLINDERS (OPTIONAL)
11. REAR BRAKE CYLINDERS 23. RIDE CONTROL (OPTIONAL)
12. BRAKE ACCUMULATORS 24. OIL COOLER BYPASS VALVE
25. UNLOADING VALVE

8002-15
821C HYDRAULIC SCHEMATIC
QUICK OPTIONAL COUPLER 21 OPTIONAL

DISCONNECT LOCKING VALVE COUPLER
PARKING 22
LOCKING
BRAKE
CYLINDERS
FRONT BRAKE
BLEED SCREW
12 7 BRAKE CYLINDERS
AUXILIARY LOADER CONTROL VALVES 8
VALVE
PB T AUX PP
BRAKE
ACCUMULATOR
AUXILIARY
18 CIRCUIT
RELIEF OPTIONAL
VALVES AUXILIARY
AUXILIARY
RB
QUICK CYLINDERS
DISCONNECT 10
ACR ORIFICE
REMOTE AUXILIARY
CHECK CIRCUIT
PSIR
CONTROL VALVES RELIEF
FB
COMBINATION VALVES VALVES 6
19 VALVE ACF 11 LOADER
PSIF QUICK
LOWER & LIFT
FLOAT CYLINDERS
DISCONNECT REAR BRAKE
LOADER
CYLINDERS RAISE
BUCKET
DUMP
BUCKET
TRANS. ROLLBACK BUCKET
17 DECLUTCH CYLINDER
SWITCH
MAIN
RELIEF 20
REGENERATION MASTER VALVE
VALVE VALVE
BRAKE PRESSURE
SWITCH
UNLOADING S
25
VALVE
2
P QUICK
PRIMARY T
PRIORITY LS
BRAKE DISCONNECT
PUMP P
15 VALVE P EF
PUMP
CF
DUAL PRESSURE 14 SLAVE VALVE
13 ACCUMULATOR QUICK
SECONDARY ACCUMULATOR
CHARGING VALVE DISCONNECT
PUMP T 23 OPTIONAL
5 RIDE CONTROL
M PRESSURE BREATHER
HYDRAULIC SWITCH STEERING RIGHT
CONTROL VALVE
4 FILTERS AUXILIARY
L
1 STEERING
PUMP
P
STEERING
RESERVOIR OIL COOLER 9
LS CYLINDERS
BYPASS VALVE OIL
3
COOLER
24 R
16
LEFT
821C HYDRAULIC SCHEMATIC BC00D061

8002-16
NOTES

Section
8004
8004
HYDRAULIC PUMP
CASE CORPORATION
700 State Street
8004-2
TABLE OF CONTENTS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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)

8004-4
HYDRAULIC PUMP
Disassembly 17. Loosen and remove the screws (22) from the
pump cartridge (3).
NOTE: The hydraulic pump shown in Figure 1 is a
general cross section view. Illustration may vary from 18. Remove the plate (23) from the pump cartridge
actual component parts. (3).
1. Fasten the hydraulic pump in a vise with soft jaws 19. Loosen and remove the screws (12) from the
with the shaft extended downward. Clamp the pump cartridge (4).
vise on the shaft end cover (2), not on the 20. Remove the plate (7) from the pump cartridge
housing (8), refer to Figure 1. (4).
2. Loosen and remove the bolts (10) and the port
end cover (1). Take note of the pressure ports Inspection
position to the suction port.
1. Clean all parts in cleaning solvent and allow all
3. Remove and discard the seal (13) from the port parts to air dry or use a lint free cloth for drying
end cover (1). all parts thoroughly.
4. Firmly grasp the pump cartridge (3) and, while 2. Inspect the port end cover (1), housing (8), shaft
rotating it, pull outward and remove the pump end cover (2) and the shaft (5) for wear marks,
cartridge (3) from the housing (8). nicks and burrs. Replace the port end cover (1),
housing (8), shaft end cover (2) or shaft (5) as
5. Remove and discard the seals (14 and 15) and
required, refer to Figure 1.
backup ring (16) from the pump cartridge (3).
3. Inspect the bearing on the shaft (5) for wear and
6. Remove the hydraulic pump from the vise to
cracks. If the bearing shows signs of wear or is
reposition it with the shaft extended upward.
cracked, a new shaft (5) is required.
Clamp the vise on the housing (8), not the shaft
end cover (2). 4. Inspect the plates (7 and 23) for light scoring on
the wear surface. Replace the plate (7 or 23) with
7. Loosen and remove the bolts (11) from the
a new plate (7 or 23) if light scoring is found on
housing (8) and shaft end cover (2).
the wear surface.
8. Slowly remove the shaft end cover (2) upward
5. Inspect the pump cartridges (3 and 4). The
and away from the housing (8).
vanes must move freely in the rotor slots and not
NOTE: The shaft end cover (2) contains the pump bind or have excessive play. If the vanes do not
cartridge (4) and shaft (5). move freely in the rotor slots, or if they bind or
have excessive play, a new pump cartridge (3 or
9. Remove and discard the seal (17) from the shaft
4) is required.
end cover (2).
6. Make sure all ports in the pump cartridges (3 and
10. Remove the housing (8) from the vise.
4) are open and clean.
11. Fasten the shaft end cover (2) in the vise with the
coupling end of the shaft (5) downward.
12. Firmly grasp the pump cartridge (4) and, while
rotating it, pull outward and remove the pump
cartridge (4) from the shaft end cover (2).
13. Remove and discard the seals (19 and 20) and
backup ring (18) from the pump cartridge (4).
14. Remove the shaft end cover (2) from the vise
and remove the retaining ring (9) from the shaft
end cover (2).
15. Remove the shaft (5) from the shaft end cover (2)
by gently tapping the coupling end of the shaft
(5) with a plastic tipped hammer.
16. Remove and discard the seal (6) from the shaft
end cover (2).
8004-5
16 18 9
15 13
17
19
14
10 20
3 7
21 21 4 6
23
12 11
22
8
GS98K862
1. PORT END COVER 7. PLATE 13. SEAL 19. SEAL
2. SHAFT END COVER 8. HOUSING 14. SEAL 20. SEAL
3. PUMP CARTRIDGE 9. RETAINING RING 15. SEAL 21. GUIDE PIN
4. PUMP CARTRIDGE 10. BOLT 16. BACKUP RING 22. SCREW
5. SHAFT 11. BOLT 17. SEAL 23. PLATE
6. SEAL 12. SCREW 18. BACKUP RING
FIGURE 1. HYDRAULIC PUMP - CROSS SECTION VIEW - REFERENCE ONLY

8004-6
Assembly 12. Install the housing (8) over the pump cartridge
(4) and, while rotating it, push the housing (8)
1. Install a new backup ring (18) and new seals (19 downward until the housing (8) slips onto the
and 20) onto the pump cartridge (4), refer to guide pin (21) in the pump cartridge (4).
Figure 2.
13. Install the bolts (11) through the shaft end cover
2. If necessary, install a new plate (7) and screws (2) and into the housing (8).
(12) onto the pump cartridge (4).
14. Remove the hydraulic pump from the vise and
3. Install a new backup ring (16) and new seals (14 place it on a clean surface.
and 15) onto the pump cartridge (3).
15. Tighten the bolts (11), refer to SPECIAL
4. If necessary, install a new plate (23) and screws TORQUES for the correct torque.
(22) onto the pump cartridge (3).
16. Fasten the hydraulic pump into the vise with the
5. Install a new seal (6) into the back side of the shaft extended downward. Clamp the vise on the
shaft end cover (2) with a shaft seal driver. Make shaft end cover (2), not the housing (8).
cer tain that the open side of the seal (6) is
toward the inside of the shaft end cover (2). 17. Install the pump cartridge (3) into the housing (8)
and while rotating it, push the pump cartridge (3)
6. Lubricate the inside of the seal (6) with clean downward until the pump cartridge (3) and guide
hydraulic oil and install the shaft (5) into the shaft pin (21) slips into the housing (8).
end cover (2).
18. Lubricate the seals (14 and 15) on the pump
7. Install the retaining ring (9) to secure the shaft (5) cartridge (3) with clean hydraulic oil.
into the shaft end cover (2).
19. Lubricate and install a new seal (13) onto the
8. Fasten the shaft end cover (2) in a vise with soft port end cover (1).
jaws with the coupling end of the shaft (5)
downward. 20. Install the port end cover (1) and bolts (10) onto
the housing (8).
9. Lubricate the seals (19 and 20) on the pump
cartridge (4) with clean hydraulic oil. 21. Tighten the bolts (10), refer to SPECIAL
TORQUES for the correct torque.
10. Install the pump cartridge (4) onto the shaft (5)
and slide it down into the shaft end cover (2).
11. Lubricate and install a new seal (17) onto the
shaft end cover (2).

8004-7
16 18 9
15 13
17
19
14
10 20
3 7
21 21 4 6
23
12 11
22
8
GS98K862
1. PORT END COVER 7. PLATE 13. SEAL 19. SEAL
2. SHAFT END COVER 8. HOUSING 14. SEAL 20. SEAL
3. PUMP CARTRIDGE 9. RETAINING RING 15. SEAL 21. GUIDE PIN
4. PUMP CARTRIDGE 10. BOLT 16. BACKUP RING 22. SCREW
5. SHAFT 11. BOLT 17. SEAL 23. PLATE
6. SEAL 12. SCREW 18. BACKUP RING
FIGURE 2. HYDRAULIC PUMP - CROSS SECTION VIEW - REFERENCE ONLY

8004-8
NOTES

Section
8005
LOADER CONTROL VALVE
8005
CASE CORPORATION
700 State Street
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SEPARATING THE VALVE SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BUCKET AND AUXILIARY SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LIFT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REGENERATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CIRCUIT RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CIRCUIT RELIEF AND ANTICAVITATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8005-3
SPECIFICATIONS
Manufacturer................................................................................................................................................... Gresen
Two Spool Valve
Gresen part number ................................................................................................................................ V70-338
Case part number ................................................................................................................................... L126100
Three Spool Valve
Four Spool Valve
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)

8005-4
SEPARATING THE VALVE SECTIONS
Disassembly Assembly
NOTE: The four spool loader control valve was used 1. Install new O-rings (10 and 11) in the grooves in
for illustrating this procedure. Use this procedure as a each valve section (1, 2, 3 and 4). Apply
guide for disassembling all loader control valves. petroleum jelly to the O-rings (10 and 11) to hold
the O-rings (10 and 11) in position, refer to
1. Clean the outside of the loader control valve.
Figure 1.
Write a number on each of the valve sections for
correct assembly, 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.
2. Loosen the nuts (9) that fasten the valve sections
Install the studs (8) to align the valve sections (1,
(1, 2, 3 and 4) together.
2, 3 and 4).
3. Remove the nuts (9) and the end cover (5) from
3. Pull the valve sections (1, 2, 3 and 4) together.
the studs (8).
4. Install the end cover (5).
4. Remove the studs (8) from the inlet and outlet
section (1). 5. Install the nuts (9).
5. Separate the valve sections (1, 2, 3 and 4). 6. Tighten the nuts (9), refer to SPECIAL
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).

8005-5
7
5
10
11
11
GS98K834
1. INLET AND OUTLET SECTION 5. END COVER 9. NUT

2. BUCKET SECTION 6. PLUG 10. O-RING
3. LIFT SECTION 7. O-RING 11. O-RING
4. AUXILIARY SECTION 8. STUD
FIGURE 1 - FOUR SPOOL LOADER CONTROL VALVE ASSEMBLY - EXPLODED VIEW

8005-6
BUCKET AND AUXILIARY SECTIONS
Disassembly Inspection
NOTE: The spool ports in the valve section are 1. Clean all parts in cleaning solvent.
identified as “A” or “B”. When removing parts from
2. Inspect the spool (4) for wear and damage.
the spool ports, identify the parts according to the
port they were removed from for correct installation. 3. Inspect the inner and outer springs (7 and 8) for
damage.
1. Loosen and remove the Allen head screws (1)
and lock washers (2), refer to Figure 2. 4. Inspect the special screws (5 and 10) for damage
to the threads and inspect the threads in the
2. Remove the spring caps (3) from both ends of
ends of the spool (4) for damage.
the valve section (11).
5. Inspect the spool bores and all machined
3. Remove the spool (4).
surfaces for wear and damage.
NOTE: The spool (4), when removed from the valve
6. Inspect the poppet (16) and poppet seat for wear
section (11), contains a special screw (5), inner
and damage.
spring seat (6), inner spring (7), outer spring (8),
outer spring seat (9), and special screw (10). 7. Inspect the spring (15) for the poppet (16) for
wear and damage.
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).

8005-7
1
6
2
7
8 3
5
12
13
4
14
9 17
15
16
11
17 12
10
1
3
2
GS98K833
1. ALLEN HEAD SCREW 6. INNER SPRING SEAT 11. VALVE SECTION 16. POPPET
2. LOCK WASHER 7. INNER SPRING 12. O-RING 17. CIRCUIT RELIEF AND
3. SPRING CAP 8. OUTER SPRING 13. PLUG ANTICAVITATION VALVE
4. SPOOL 9. OUTER SPRING SEAT 14. O-RING
5. SPECIAL SCREW 10. SPECIAL SCREW 15. SPRING
FIGURE 2 - BUCKET AND AUXILIARY SECTIONS - EXPLODED VIEW

8005-8
Assembly 8. Install the poppet (16).
1. Remove any oil from the threads on both ends of 9. Install the spring (15).
the spool (4) and the threads on the special 10. Install a new O-ring (14) on the plug (13) and
screws (5 or 10), refer to Figure 2. lubricate the O-ring (14) with clean hydraulic oil.
2. Apply Loctite 271 to the threads on both ends of 11. Install and tighten the plug (13), refer to
the spool (4). SPECIAL TORQUES for the correct torque.
3. Install the special screw (10) and tighten the 12. Install a new O-ring (12). Apply petroleum jelly to
special screw (10), refer to SPECIAL TORQUES the O-ring (12) to hold the O-ring (12) in place in
for the correct torque. the valve section (11). Repeat this procedure on
4. Install the special screw (5), outer spring seat the opposite end of the valve section (11).
(9), outer spring (8), inner spring (7), and inner 13. Lubricate the spool (4) and the spool bore with
spring seat (6). clean hydraulic oil.
5. Tighten the special screw (5), refer to SPECIAL 14. Install the spool (4).
15. Install the spring caps (3), Allen head screws (1)
6. Fasten the valve section (11) in a vise with soft and lock washers (2) on each end of the valve
jaws. Lubricate the O-rings on the circuit relief section (11).
and anticavitation valve(s) (17), or the circuit
relief valve (17) with clean hydraulic oil. 16. Tighten the Allen head screws (1), refer to
SPECIAL TORQUES for the correct torque, on
7. Install and tighten the circuit relief valve or circuit both ends of the valve section (11).
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.

8005-9
3 4
5
2 2
6
8
7 7
.
GS98K835
1. ALLEN HEAD SCREW 3. PLUG 5. POPPET 7. SPRING CAP

2. CIRCUIT RELIEF AND ANTICAVITATION VALVE 4. SPRING 6. SPECIAL SCREW 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.

8005-10
LIFT SECTION
Disassembly 19. Remove the spring (28).
NOTE: The spool ports in the valve section are 20. Remove the poppet (29).
identified as “A” or “B”. When removing parts from 21. Remove and discard the O-rings (32 and 33) and
the spool ports, identify the parts according to the backup ring (31) from the plugs (30). Install new
port they were removed from for correct installation. O-rings (32 and 33) and backup rings (31).
1. Loosen and remove the Allen head screws (1)
and lock washers (2), refer to Figure 4. Inspection
2. Remove the spring caps (3) from both ends of 1. Clean all parts in cleaning solvent.
the valve section (34).
2. Inspect the spool (4) for wear and damage.
3. Loosen the special screw (5).
3. Inspect the inner and outer springs (7, 8, 22 and
4. Remove the special screw (5), outer spring seat 23) for damage.
(6), spacer (9), outer spring (8) and inner spring
4. Inspect the special screws (5 and 25) for damage
(7).
to the threads and inspect the threads in the
5. Remove the inner spring seat (12) and the large ends of the spool (4) for damage.
spacer (13).
5. Inspect the spool bores and all machined
6. Remove the sleeve (14). surfaces for wear and damage.
7. Remove the backup ring (16) and O-ring (15). 6. Inspect the poppet (29) and poppet seat for wear
and damage.
8. Remove the spool (4) from the opposite end of
the valve section (34). 7. Inspect the spring (28) for the poppet (29) for
wear and damage.
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).
large spacer (13). Install a new O-ring (11).
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).
plug (26).

8005-11
1
2
8 5 3
9 6
10
11 7
13
26
14 30
15 4
27
31
12 28 32
29 33
17
16 34
33
32 18
19
31 20
21
22
23
30
24
25
1
3
2
GS98K836
1. ALLEN HEAD SCREW 8. OUTER SPRING 15. O-RING 22. OUTER SPRING 29. POPPET
2. LOCK WASHER 9. SPACER 16. BACKUP RING 23. INNER SPRING 30. PLUG
3. SPRING CAP 10. SPOOL EXTENSION 17. O-RING 24. OUTER SPRING SEAT 31. BACKUP RING
4. SPOOL 11. O-RING 18. SMALL SPACER 25. SPECIAL SCREW 32. O-RING
5. SPECIAL SCREW 12. INNER SPRING SEAT 19. O-RING 26. PLUG 33. O-RING
6. OUTER SPRING SEAT 13. LARGE SPACER 20. INNER SPRING SEAT 27. O-RING 34. VALVE SECTION
7. INNER SPRING 14. SLEEVE 21. SPOOL EXTENSION 28. SPRING
FIGURE 4 - LIFT SECTION - EXPLODED VIEW

8005-12
Assembly 12. Install a new O-ring (17) into the valve section
(34). Apply petroleum jelly to the O-ring (17) to
1. Install the poppet (29), refer to Figure 4. hold the O-ring (17) in place in the valve section
2. Install the spring (28). (34).
3. Lubricate the O-ring (27) on the plug (26) with 13. Install the small spacer (18) on the spool (4).
clean hydraulic oil. 14. Lubricate the spool (4) and the spool bore with
4. Install and tighten the plug (26), refer to clean hydraulic oil.
SPECIAL TORQUES for the correct torque. 15. Install a new O-ring (15) and backup ring (16)
5. Lubricate the O-rings (32 and 33) and backup into the valve section (34). Apply petroleum jelly
rings (31) on the plugs (30) with clean hydraulic to the O-ring (15) to hold the O-ring (15) in place
oil. in the valve section (34).
6. Install and tighten the plug (30), refer to 16. Install the sleeve (14).
SPECIAL TORQUES for the correct torque. 17. Install the large spacer (13).
Repeat for the opposite plug (30).
18. Install the inner spring seat (12).
7. Remove any oil from the threads on both ends of
the spool (4) and the threads on the spool 19. Install the inner spring (7), outer spring (8),
extensions (10 and 21). spacer (9), outer spring seat (6) and special
screw (5).
8. Apply Loctite 271 to the threads in the spool (4).
20. Tighten the special screw (5), refer to SPECIAL
9. Install the spool extensions (10 and 21) into the TORQUES for the correct torque.
appropriate ends of the spool (4), refer to
SPECIAL TORQUES for the correct torque. 21. Install the spring cap (3) and Allen head screws
(1) and lock washers (2).
10. Install the inner spring seat (20), inner spring
(23), outer spring (22), outer spring seat (24) and 22. Tighten the Allen head screws (1), refer to
the special screw (25). SPECIAL TORQUES for the correct torque.
11. Tighten the special screw (25), refer to SPECIAL 23. Repeat procedure on opposite end of the valve
TORQUES for the correct torque. section for spring cap (3), Allen head screws (1)
and lock washers (2).

8005-13
3
4 5
2 2
1 1
6 7 6
GS98K837
1. ALLEN HEAD SCREW 3. PLUG 5. POPPET 7. SPOOL

2. PLUG 4. SPRING 6. SPRING CAP
LIFT SECTION - CROSS SECTION VIEW

8005-14
REGENERATION VALVE
Disassembly Assembly
1. Fasten the inlet and outlet section in a vise with 1. Lubricate the plunger (3) with clean hydraulic oil,
soft jaws. Loosen and remove the regeneration refer to Figure 6.
valve assembly (1), refer to Figure 6.
2. Install the plunger (3) into the body (2).
NOTE: The regeneration valve assembly (1)
3. Lubricate the valve (4) with clean hydraulic oil.
contains a body (2), plunger (3), valve (4), snap ring
(5) and an O-ring (6). 4. Install the valve (4) into the body (2).
2. Remove the snap ring (5) from the ID of the body 5. Install the snap ring (5).
(2).
6. Lubricate the O-ring (6) with clean hydraulic oil.
3. Remove the valve (4).
7. Install and tighten the regeneration valve
4. Remove the plunger (3). assembly (2).
5. Remove and discard the O-ring (6) from the body
(2). Install a new O-ring (6).
Inspection
1. Clean all parts in cleaning solvent.
2. Inspect the body (2), plunger (3), valve (4), and
snap ring (5) for wear and damage. If the body
(2) is damaged or worn, a new regeneration
valve assembly (1) must be used.

8005-15
1
3
GS98K838
1. REGENERATION VALVE ASSEMBLY 3. PLUNGER 5. SNAP RING

2. BODY 4. VALVE 6. O-RING
FIGURE 6 - REGENERATION VALVE - EXPLODED VIEW

8005-16
MAIN RELIEF VALVE
1. Fasten the inlet and outlet section in a vise with 1. Clean all parts in cleaning solvent.
soft jaws. Loosen and remove the main relief
2. Inspect the poppet (20), screen (21), sleeve (15),
valve, refer to Figure 7.
and retaining ring (22) for wear and damage.
2. Fasten the body (23) in a vise with soft jaws.
3. Inspect the plunger (6) and plunger seat (9) for
Loosen and remove the adapter (7).
wear and damage.
NOTE: The adapter (7) contains a lock nut (1),
4. Inspect the springs (5 and 13) for damage.
washer (2), adjusting screw (3), O-ring (4), spring
(5), plunger (6), O-ring (8) and plunger seat (9). 5. Inspect all machined surfaces for wear and
damage.
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).
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
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).
backup ring (10) from the adapter (7). Install new
adjusting screw (3). Install a new O-ring (4).

8005-17
12
11
10
9
8
7
6
5
4
3 26
2 25
1 24
23
22
21
20
19
18
17
16
15
14
13
GS98K839
1. LOCK NUT 7. ADAPTER 13. SPRING 19. BACKUP RING 25. O-RING
2. WASHER 8. O-RING 14. SPACER 20. POPPET 26. O-RING
3. ADJUSTING SCREW 9. PLUNGER SEAT 15. SLEEVE 21. SCREEN
4. O-RING 10. BACKUP RING 16. O-RING 22. RETAINING RING
5. SPRING 11. O-RING 17. BACKUP RING 23. BODY
6. PLUNGER 12. O-RING 18. O-RING 24. BACKUP RING
FIGURE 7 - MAIN RELIEF VALVE - EXPLODED VIEW

8005-18
Assembly 13. See Figure 8. Lubricate the O-ring on the main

relief valve (2) with clean hydraulic oil. Install and
1. Lubricate the O-ring (18) on the poppet (20) with tighten the main relief valve (2), refer to SPECIAL
clean hydraulic oil, refer to Figure 7. TORQUES for the correct torque.
2. Install the poppet (20) in the sleeve (15).
3. Lubricate the O-ring (16) and backup ring (17) on
the sleeve (15) with clean hydraulic oil. 1
4. Install the poppet (20), sleeve (15) and the
spacer (14) into the body (23). 2
5. Install the spring (13).
6. Lubricate the O-rings (11 and 12) and the
backup ring (10) on the adapter (7) with clean
hydraulic oil.
7. Install and tighten the adapter (7).
GS98K845
8. Install the plunger (6). 1. INLET AND OUTLET SECTION
10. Lubricate the O-ring (4) on the adjusting screw Figure 8. MAIN RELIEF VALVE INSTALLATION
(3) with clean hydraulic oil.
The pressure setting of the main relief valve must be
11. Turn the adjusting screw (3) into the adapter (7) checked after the loader control valve has been
to the same measurement made during installed. See Section 8002.
disassembly.
12. Prevent the adjusting screw (3) from turning and
tighten the lock nut (1).

8005-19
1 2
24
23
3
22 4
21
20
19 5
6
18
7
17
16 8
15 9
10
14
11
13
12
GS98K840
1. ADJUSTING SCREW 6. O-RING 11. O-RING 16. BACKUP RING 21. SPRING
2. WASHER 7. SLEEVE 12. SCREEN 17. O-RING 22. O-RING
3. O-RING 8. O-RING 13. RETAINING RING 18. SPACER 23. PLUNGER
4. ADAPTER 9. SPRING 14. POPPET 19. O-RING 24. LOCK NUT
5. BACKUP RING 10. BACKUP RING 15. BACKUP RING 20. ADAPTER
FIGURE 9 - MAIN RELIEF VALVE - CROSS SECTION

8005-20
CIRCUIT RELIEF VALVE
NOTE: Used on “B” port of the bucket section only. 1. Clean all parts in cleaning solvent.
1. Fasten the body (20) in a vise with soft jaws. If 2. Inspect the poppet (17) and screen (18) for wear
used, remove the cap (1) for the adjusting screw and damage.
(4), refer to Figure 10.
2. Measure the distance to the top of the adjusting wear and damage.
4. Inspect the springs (6 and 14) for damage.
5. Inspect all machined surfaces for wear and
damage.
7. Loosen and remove the adapter (8).
9. Carefully push the poppet (17) out of the body
(20).
backup ring (11) from the adapter (8). Install the
new O-rings (12 and 13) and a backup ring (11).

8005-21
13
12
11
10
9
8
7
6
5
4
3
2
1
23
18 22
21
15
20
19
17
16
14
GS98K841
1. CAP (IF USED) 6. SPRING 11. BACKUP RING 16. BACKUP RING 21. BACKUP RING
2. LOCK NUT 7. PLUNGER 12. O-RING 17. POPPET 22. O-RING
3. WASHER 8. ADAPTER 13. O-RING 18. SCREEN 23. O-RING
4. ADJUSTING SCREW 9. O-RING 14. SPRING 19. RETAINING RING
5. O-RING 10. PLUNGER SEAT 15. O-RING 20. BODY
FIGURE 10 - CIRCUIT RELIEF VALVE - EXPLODED VIEW

8005-22
Assembly 8. Lubricate the O-ring (5) on the adjusting screw

(4) with clean hydraulic oil.
1. Lubricate the O-ring (15) on the poppet (17) with
clean hydraulic oil, refer to Figure 10. 9. Turn the adjusting screw (4) into the adapter (8)
to the same measurement made during
2. Install the poppet (17) into the body (20). disassembly.
3. Fasten the body (20) in a vise with soft jaws. 10. Prevent the adjusting screw (4) from turning and
Install the spring (14). tighten the lock nut (2).
4. Lubricate the O-rings (12 and 13) and the 11. If used, install the cap (1).
hydraulic oil. The pressure setting of the circuit relief valve must be
checked with a hand pump according to instructions
5. Install and tighten the adapter (8). in Section 8002.
6. Install the plunger (7).

8005-23
1
20 2
19
18
3
17 4
5
16
15 6
14
13
12
7
11
8
10
GS98K842
1. CAP (IF USED) 5. BODY 9. SCREEN 13. O-RING 17. ADAPTER

2. LOCK NUT 6. O-RING 10. O-RING 14. POPPET 18. O-RING
3. PLUNGER 7. BACKUP RING 11. BACKUP RING 15. O-RING 19. WASHER
4. O-RING 8. RETAINING RING 12. SPRING 16. BACKUP RING 20. ADJUSTING SCREW
FIGURE 11 - CIRCUIT RELIEF VALVE - CROSS SECTION VIEW

8005-24
CIRCUIT RELIEF AND ANTICAVITATION VALVE
1. Fasten the inlet and outlet section in a vise with
1. Clean all parts in cleaning solvent.
soft jaws. Loosen and remove the circuit relief
and anticavitation valve, refer to Figure 12.
2. Inspect the poppet (21), screen (23), sleeve (16),
2. Fasten the body (25) in a vise with soft jaws. and retaining rings (15 and 24) for wear and
Loosen and remove the adapter (8). damage.
NOTE: The adapter (8) contains a lock nut (2),
washer (3), adjusting screw (4), O-ring (5), spring (6),
wear and damage.
plunger (7), O-ring (9) and plunger seat (10).
3. Remove the spring (14). 4. Inspect the springs (6 and 14) for damage.
4. Fasten the adapter (8) in a vise with soft jaws.
5. Inspect all machined surfaces for wear and
Measure the distance to the top of the adjusting
damage.
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).
ring (18) from the sleeve (16). Install a new
backup ring (11) from the adapter (8). Install new

8005-25
13
12
11
10
9
8
7
6
5
4 28
3 27
2 26
22
1
20
25
18
24
23
15
21
19
17
16
14
GS98K843
1. CAP (IF USED) 7. PLUNGER 13. O-RING 19. O-RING 25. BODY
2. LOCK NUT 8. ADAPTER 14. SPRING 20. BACKUP RING 26. BACKUP RING
3. WASHER 9. O-RING 15. RETAINING RING 21. POPPET 27. O-RING
4. ADJUSTING SCREW 10. PLUNGER SEAT 16. SLEEVE 22. ROLL PIN 28. O-RING
5. O-RING 11. BACKUP RING 17. O-RING 23. SCREEN
6. SPRING 12. O-RING 18. BACKUP RING 24. RETAINING RING
FIGURE 12 - CIRCUIT RELIEF AND ANTICAVITATION VALVE - EXPLODED VIEW

8005-26
Assembly 14. See Figure 13. Lubricate the O-ring on the circuit
relief and anticavitation valve (2) with clean
1. Lubricate the O-ring (19) on the poppet (21) with hydraulic oil. Install and tighten the circuit relief
clean hydraulic oil, refer to Figure 12. and anticavitation valve (2), refer to SPECIAL
2. Install the poppet (21) in the sleeve (16). TORQUES for the correct torque.
3. Install the retaining ring (15).

4. Lubricate the O-ring (17) and backup ring (18) on 1
the sleeve (16) with clean hydraulic oil.
5. Install the poppet (21) and sleeve (16) into the
body (25).
2
7. Lubricate the O-rings (12 and 13) and the
hydraulic oil.
8. Install and tighten the adapter (8).
GS98K845
1. INLET AND OUTLET SECTION
9. Install the plunger (7).
2. CIRCUITRELIEF AND ANTICAVITATION VALVE
10. Install the spring (6). FIGURE 13 - CIRCUIT RELIEF AND ANTICAVITATION VALVE
INSTALLATION
11. Lubricate the O-ring (5) on the adjusting screw
(4) with clean hydraulic oil. 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
12. Turn the adjusting screw (4) into the adapter (8) instructions in Section 8002.
to the same measurement made during
disassembly.
13. To prevent the adjusting screw (4) from turning,
tighten the lock nut (2).

8005-27
26
25 1 2
24
3
23
4
22
21
20 5
6
19
18 7
17 8
9
16 10
11
15
14 12
13
GS98K844
1. ADJUSTING SCREW 7. SLEEVE 13. SCREEN 19. RETAINING RING 25. LOCK NUT
2. WASHER 8. O-RING 14. RETAINING RING 20. O-RING 26. CAP (IF USED)
3. O-RING 9. SPRING 15. POPPET 21. BODY
4. ADAPTER 10. BACKUP RING 16. BACKUP RING 22. SPRING
5. BACKUP RING 11. O-RING 17. BACKUP RING 23. O-RING
6. O-RING 12. ROLL PIN 18. O-RING 24. PLUNGER
FIGURE 14 - CIRCUIT RELIEF AND ANTICAVITATION VALVE - CROSS SECTION VIEW

8005-28
NOTES

Section
8013
8013
ACCUMULATOR FOR RIDE CONTROL
CASE CORPORATION
700 State Street
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

8013-4
CHARGING THE ACCUMULATOR WITH NITROGEN
VALVE “C”
TO
NITROGEN
TANK
VALVE “D”
VALVE “B”
TO VALVE “A”
ACCUMULATOR
GS98N801
FIGURE 1. NITROGEN CHARGING KIT CAS-10899
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
! explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 450 PSI
! (31 bar). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulator
! contains nitrogen compressed to 450 PSI (31 bar). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to Figure 1.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.

8013-5
1. Close the shutoff valve A by turning it all the way 14. Back off the needle valve on the accumulator end
to the left (counterclockwise), refer to Figure 1. of the charging hose by tur ning it
counterclockwise the maximum amount. This will
2. Open valve B by turning it out all the way to the
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
left (counterclockwise).
accumulator as the hose is removed. Remove
3. Close valve C by turning it all the way to the right the charging hose from the accumulator gas
(clockwise). charging valve (11), refer to Figure 2.
4. Close the gauge valve D by turning it all the way 15. Install the valve cap (12) onto the gas charging
to the right (clockwise). valve (11) on the accumulator.
5. Connect the charging hose to the nitrogen supply 16. Install the protection bracket (13) over the gas
tank. charging valve (11) and secure it with cap screws
(14).
6. SLOWLY turn valve A clockwise while watching
the high pressure gauge. Stop turning valve A 17. Remove the charging hose from the nitrogen
when the needle on the gauge reaches 31 bar supply tank, refer to Figure 1.
(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.

8013-6
2
4
3
5
6
7
12
8
9 10
11
13 14
GS98K847
1. TUBE 6. O-RING 11. GAS CHARGING VALVE
2. WEAR RING 7. BACKUP RING 12. VALVE CAP
3. WEAR RING 8. GLAND SEAL 13. PROTECTION BRACKET
4. PISTON 9. GLAND 14. CAP SCREW
5. BACKUP RING 10. O-RING
FIGURE 2. ACCUMULATOR - EXPLODED VIEW

8013-7
ACCUMULATOR
Disassembly 5. Install the valve cap (12) on the gas charging

valve (11).
1. Use a gland wrench to slowly loosen and remove
the gland (9) from the tube (1), refer to Figure 2. 6. Install a new O-ring (10) on the gas charging
valve (11).
2. Use a punch and push the piston (4) from the
tube (1). 7. Lubricate the O-ring (10) on the gas charging
valve (11) with clean oil.
3. Remove the gland seal (8) from the gland (9).
8. Install the gas charging valve (11) in the gland
4. Fasten the gland (9) in a vise with soft jaws. Be (9). Tighten the gas charging valve (11), refer to
careful not to damage the gland (9). SPECIAL TORQUES for the correct torque.
5. Loosen and remove the gas charging valve (11) 9. Install a new gland seal (8) on the gland (9).
from the gland (9).
10. Lubricate the gland seal (8) on the gland (9) with
6. Remove and discard the O-ring (10) from the gas clean oil. Apply antisieze compound to the
charging valve (11). threads on the gland (9).
7. Remove and discard the wear rings (2 and 3) 11. Use the gland wrench to install the gland (9) in
from the piston (4). the tube (1). Tighten the gland (9), refer to
8. Remove and discard the O-ring (6) and backup SPECIAL TORQUES for the correct torque.
rings (5 and 7) from the piston (4). 12. Charge the accumulator with nitrogen according
to the instructions on page 3.
Inspection 13. Install the protection bracket (13) in place on the
1. Clean all parts in cleaning solvent. gland (9). Install the cap screws (14) that fasten
the protection bracket (13) to the gland (9).
2. Inspect the inside of the tube (1) for grooves and Tighten the cap screws (14), refer to SPECIAL
other damage. If there is damage to the tube (1), TORQUES for the correct torque.
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 O-
ring (6) on the piston (4), refer to Figure 2.
2. Install new wear rings (2 and 3) on the piston (4).
3. Lubricate the bore in the tube (1), the wear rings
(2 and 3), and the O-ring (6) on the piston (4)
with clean oil.
4. Push the piston (4) straight into the tube (1).

8013-8
NOTES

7 12102

Uploaded by

Copyright:

Available Formats

7 12102

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

7 12102

Uploaded by

Copyright:

Available Formats

1002

FLUIDS AND LUBRICANTS

CASE CANADA CORPORATION

CAPACITIES AND LUBRICANTS

Engine cooling system

Imperial quart = litres x 0.879877

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

If Case No. 1 Multi-Viscosity or Single Grade Engine

Oil Viscosity / Temperature Ranges

DIESEL FUEL SYSTEM

Specifications for Acceptable No. 2 Diesel Fuel

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

EVERY 100 HOURS OF OPERATION

EVERY 500 HOURS OF OPERATION

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

NOTE: The Case Company reserves the right to make improvements in

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

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

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

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

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

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

CASE CANADA CORPORATION

ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING,

Bur 7-12221 Issued 4-00 Printed in U.S.A.

Bur 7-12221 Issued 4-00 Printed in U.S.A.

Bur 7-12221 Issued 4-00 Printed in U.S.A.

Bur 7-12221 Issued 4-00 Printed in U.S.A.

Bur 7-12221 Issued 4-00 Printed in U.S.A.

CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES

Bur 7-12221 Issued 4-00 Printed in U.S.A.

HOW TO USE THIS SECTION

Bur 7-12221 Issued 4-00 Printed in U.S.A.

TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING,

NOTE: See Section 4003 and check the batteries.

Bur 7-12221 Issued 4-00 Printed in U.S.A.

2 – Master Disconnect Switch

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

3 – Fuel Shutoff Solenoid

Terminal for wire 0 to ground Continuity Bad ground circuit.

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

Between housing of alternator and

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

Between the negative terminal of

NOTE: Put the ignition switch in the ON position.

Between the positive terminal of

Bur 7-12221 Issued 4-00 Printed in U.S.A.

Between housing of starter and

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

Battery terminal to ground 24 volts Check circuit to batteries.

Terminal for wire 0 to ground Continuity Bad ground circuit.

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

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

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

Terminal for wire 0 to ground Continuity Bad ground circuit.

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

7 – Cold Start Temperature Switch

Terminal for wire 0 to ground Continuity Bad ground circuit.

Bur 7-12221 Issued 4-00 Printed in U.S.A.