Case Manual-de-Servicio-821C.pdf

Section1002 1

002

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

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

2000 Case CorporationPrinted in U.S.A.

April, 2000

FLUIDS AND LUBRICANTS

Template Name: SM_2_col Alt= to hide template information1002-2Template Date: 1994_04_05 Alt+ to display template information

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

AxlesCapacity of center bowl

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

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

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

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

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

Conversion Formulas

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

CAPACITIES AND LUBRICANTSBur 7-13071 Issued 4-00 Printed in U.S.A.

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Template Name: SM_2_colTemplate Date: 1994_04_05

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ENGINE OIL RECOMMENDATIONSEngine Oil Selection

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

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

40 20 0 20 40 60 80 100 12030 10 10 30 50 70 90 110

34 23 12 1 10 21 32 4340 29 18 7 4 16 27 38 49

292L91

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

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

MULTI-VISCOSITY OILSAE 20W - 50SAE 20W - 40

SAE 15W - 40SAE 10W - 40

SAE 10W - 30SAE 5W - 30

SAE 5W - 20SINGLE VISCOSITY OIL

SAE 40SAE 30

SAE 20W - 20SAE 10W

NOTE: Use of an engine oil pan heater or an engine coolantTemperature Celsius

Oil Viscosity / Temperature RangesTemperature Fahrenheit

A2723heater is required when operating temperatures are in theshaded area.Bur 7-13071 Issued 4-00 Printed in U.S.A.

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.

DIESEL FUEL SYSTEMUse 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 thefollowing Note.

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

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

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

Many engine problems are caused by water in the fuel.

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

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

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum .................................................................................................................................. 34Flash point, minimum ..................................................................................................................140F (60C)Cloud point (wax appearance point), maximum .................................................. -5F (-20C) See Note abovePour point, maximum ........................................................................................ -15F (-26C) See Note aboveDistillation temperature, 90% point ...................................................................... 540 to 640F (282 to 338C)

Viscosity, at 100F (38C)

Centistokes .................................................................................................................................. 2.0 to 4.3Bur 7-13071 Issued 4-00 Printed in U.S.A.

Saybolt seconds universal ............................................................................................................. 32 to 40Cetane number, minimum .................................................................. 43 (45 to 55 for winter or high altitudes)Water and sediment, by volume, maximum .................................................................................... 0.05 of 1%Sulphur, by weight, maximum ........................................................................................................... 0.5 of 1%Copper strip corrosion, maximum ........................................................................................................... No. 2Ash, by weight, maximum............................................................................................................... 0.01 of 1%

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MAINTENANCE SCHEDULEModel 821CInstructions

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

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

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

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

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

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

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

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

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

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

AS REQUIRED

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

EVERY 50 HOURS OF OPERATION





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

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

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MAINTENANCE SCHEDULEModel 821C

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

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

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

GS98J100

0000-1SECTION INDEX - ELECTRICALSection Title

Section Number450 Sherman AvenueHamilton, ON L8N 4C4 CANADA Bur 7-13121

1999 Case CorporationPrinted in U.S.A.

April, 2000Racine, WI 53404 U.S.A.

CASE CANADA CORPORATIONCASE CORPORATION700 State Street

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

Section4002 4

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CASE CORPORATION700 State StreetRacine, WI 53404 U.S.A.CASE CANADA CORPORATION3350 South Service RoadHamilton, ON L7N 3M6 CANADA Bur 7-12221

Copyright 2000 Case CorporationPrinted in U.S.A.

April, 2000

ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING, AND SCHEMATICS

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TABLE OF CONTENTSSPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7GRAPHIC SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9HOW TO USE THIS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, COLD START,

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

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

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

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

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

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

Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-4

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

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

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

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

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

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

TROUBLESHOOTING HORN, BLOWER, AIR CONDITIONING, AND CONDENSER FANS . . . . . . . . . . . . . . 43Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Seat Compressor and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Resistor Board (Blower Motor Speed Resistors with Thermal Fuse) . . . . . . . . . . . . . . . . . . . . . . . . . . 45Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Compressor Clutch Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-5

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

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

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

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

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

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

TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, EUROPEAN MODELS . . . . . . . . . . . . . . . . . . . . 62Left Front Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Right Front Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Left Rear Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Right Rear Marker Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Left Side Turn (Italy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Right Side Turn (Italy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Left Front Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Right Front Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Left Rear Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Right Rear Combination Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Left Head Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Right Head Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Rear License Lamp (European Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-6

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

CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68ELECTRICAL SCHEMATIC - SHEETS 29, 30, 31, and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83ELECTRICAL SCHEMATIC - SHEETS 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85ELECTRICAL SCHEMATIC - SHEET 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86ELECTRICAL SCHEMATIC - SHEETS 3, 4, and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-7

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

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

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

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

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

1 Bar........................................................................................................................................................ 178 ohms3 Bar.......................................................................................................................................................... 90 ohms5.2 Bar....................................................................................................................................................... 38 ohms

Fuel Solenoid Resistance (pull in) .............................................................................................................. 0.82 ohmsFuel Solenoid Resistance (hold in)............................................................................................................. 11.3 ohmsBur 7-12221 Issued 4-00 Printed in U.S.A.

4002-8

GRAPHIC SYMBOLS

GM98M003Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-9

CIRCUIT DIAGRAM LEGEND, COLOR ABBREVIATIONS, AND NOTES

GM98M001

GM98M002

NOTES:NOTE: Diagram shown with vehicle parked, power off, and controls in off or neutral position.NOTE: Sheet numbers refer to the number at the bottom center of each individual dashed block. NOTE: Machine components that are being troubleshot are represented by this symbol.NOTE: Wires that continue, uninterrupted, to the next sheet are represented by this symbol.NOTE: Wires that continue, but are interrupted by several sheets, are located by specific text references asfollows: To instrument cluster cavity 2 on sheet 11Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-10

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

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

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

The schematic poster is color coded to assist introubleshooting electrical circuits. Red denotescircuits that have constant power. Green denotescircuits that have power when the ignition switch inturned ON.Components can be located on the Electrical andHydraulic Schematic poster (rear pocket) by itemnumber using the key at the bottom right of the rearpocket. Use the following index to find the sheet(dashed block) a component is located on.

GM98M004Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-11

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

GM98M0051. BATTERIES 6. START RELAY 10. ETHER START SWITCH2. MASTER DISCONNECT SWITCH 6A. FUEL RELAY 11. NEUTRAL START RELAY #83. FUEL SHUTOFF SOLENOID 7. COLD START TEMPERATURE SWITCH 12. IGNITION SWITCH4. ALTERNATOR 8. ETHER SOLENOID 13. IGNITION RELAY #15. STARTER MOTOR 9. ETHER START RELAY #6

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

NOTE: See Section 4003 and check the batteries.

1

8 3

7

5

66A

12

10

4

2

91113Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-12

2 Master Disconnect Switch Check Points Reading Possible Cause of Bad Reading

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

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

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

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

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

3 Fuel Shutoff Solenoid Check Points Reading Possible Cause of Bad Reading

Terminal for wire 0 to ground Continuity Bad ground circuit.

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

Terminal for wire 13M to ground 24 volts Check circuit 13M, also check circuit to batteries. Bad master disconnect switch (2).NOTE: Have another person hold the ignition switch in the START position.

Terminal for wire 23F to ground 24 volts Check circuit 23F. Bad fuel relay (6A).NOTE: If the readings are good, replace the fuel shutoff valve (3).

4 Alternator Check Points Reading Possible Cause of Bad Reading

Between housing of alternator and ground Continuity Bad ground connection.


Between the negative terminal of alternator and ground 24 volts Check circuit to positive post of batteries.

NOTE: Put the ignition switch in the ON position.

Between the positive terminal of alternator and ground 24 volts Check circuit to positive post of batteries.

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

NOTE: If the readings are good, see Section 4007 to repair the alternator (4).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-13

5 Starter Motor Check Points Reading Possible Cause of Bad Reading

Between housing of starter and ground Continuity Bad ground connection.


Battery terminal to ground 24 volts Check circuit to batteries.

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

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

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

6 Start Relay Check Points Reading Possible Cause of Bad Reading



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 Check Points Reading Possible Cause of Bad Reading



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 Check Points Reading Possible Cause of Bad Reading

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

NOTE: Disconnect the wires from the cold start temperature switch (7). Make sure the engine temperature isbelow 10C (50F).Between terminals A and B Continuity Bad cold start temperature switch (7).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-14

8 Ether Solenoid Check Points Reading Possible Cause of Bad Reading

Terminal for wire 28T to ether start temperature switch Continuity Bad 28T circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Have another person push inand hold the ether start switch (10). Make sure the engine temperature is below 10C (50F).Terminal for wire 28P to ground 24 volts Check the ether start relay (9). Also check circuit 28P.NOTE: If the readings are good, replace the ether solenoid (8).

9 Ether Start Relay Check Points Reading Possible Cause of Bad Reading



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 10C (50F).Terminal for wire 28C to ground 24 volts Bad ether start switch (10), also check circuit 28C.Terminal for wire 28P to ground 24 volts Bad ether start relay (9).

10 Ether Start Switch Check Points Reading Possible Cause of Bad Reading

NOTE: Disconnect the wires from the ether start switch (10).Between terminals of switch Continuity Bad ether start switch (10).NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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

11 Neutral Start Relay Check Points Reading Possible Cause of Bad Reading


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

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

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

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

Terminal for wire 21C to ground 24 volts Bad neutral start relay (11).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-15

12 Ignition Switch Check Points Reading Possible Cause of Bad Reading


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 Check Points Reading Possible Cause of Bad Reading


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

4002-16

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

GM98M00614. IGNITION RELAY #2 16. VOLTMETER RELAY #1215. ACCESSORY RELAY #3 17. TIME DELAY MODULE

14 Ignition Relay #2 Check Points Reading Possible Cause of Bad Reading


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



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

17 141516Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-17

15 Accessory Relay #3 Check Points Reading Possible Cause of Bad Reading


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 Check Points Reading Possible Cause of Bad Reading


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 Check Points Reading Possible Cause of Bad Reading


NOTE: Put the ignition switch in the OFF position.

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

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

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

24 voltsKey ON

0 volts after 10 seconds

Bad Time Delay Module (17).

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

0 volts Bad Time Delay Module (17).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-18

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

AND BACK-UP ALARM,

GM98M00718. OUTPUT SPEED SENSOR 27. DIAGNOSTIC CONNECTOR19. ENGINE SPEED SENSOR 28. TRANSMISSION KICK-DOWN SWITCH

(LOCATED IN HYDRAULIC CONTROLLER)

20. INTERMEDIATE SPEED SENSOR

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

18

293033

252732

28

34

2120

26

31

23

24

19


4002-19

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

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

32 Back-up Alarm Relay #7 Check Points Reading Possible Cause of Bad Reading

NOTE: Remove the transmission electronic control module (25) quick disconnect.Terminal for wire 35C to terminal 7 Continuity Bad circuit 35C.

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

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

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

Terminal for wire 19H to ground 24 volts Bad fuse H, also check circuit 19H and 13R and ignition relay #2 (14).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-20

33 Back-up Alarm Disable Switch Check Points Reading Possible Cause of Bad Reading


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

Terminal for wire 35A to ground 24 volts Bad back-up alarm relay (32), also check circuit 35A.NOTE: The wire 35A jumper is connected in the North American models and open in the European models.(Back-up alarm switch enabled.)

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

34 Back-up Alarm Check Points Reading Possible Cause of Bad Reading


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

Terminal for wire 35R to ground 24 volts Bad back-up alarm disable (33), also check circuit 35R.NOTE: If the readings are good, replace the back-up alarm (34).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-21

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

CONTROL SWITCH, AND UP/DOWN COUNT SWITCH

GM98M00835. BRAKE WARNING PRESSURE SWITCH 41. AIR FILTER RESTRICTION SWITCH36. COOLANT LEVEL SENDER 42. PROGRAM RESET SWITCH37. FUEL LEVEL SENDER 43. PARK BRAKE SWITCH38. HYDRAULIC OIL TEMPERATURE SENDER 43A.INSTRUMENT CLUSTER39. HYDRAULIC FILTER RESTRICTION SWITCH 44. PILOT CONTROL SWITCH40. ENGINE COOLANT TEMPERATURE SENDER 45. UP/DOWN COUNT SWITCH

35

4243A

44

37

45

3640

4138


4002-22

35 Brake Warning Pressure Switch Check Points Reading Possible Cause of Bad Reading

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

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

Terminal A for wire 33P to ground Approximately 11.5 volts Check circuit 33P.

NOTE: Disconnect the wires from the brake warning pressure switch (35).Between terminals A and B of the switch

Continuity Bad brake warning pressure switch (35).

NOTE: Start and run the engine at idle.

Between terminals A and B of the switch

No continuity Bad brake warning pressure switch (35).

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

36 Coolant Level Sender Check Points Reading Possible Cause of Bad Reading


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

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

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

37 Fuel Level Sender Check Points Reading Possible Cause of Bad Reading



Terminal A for wire 36F to ground Approximately 5 volts Check the instrument cluster (43A).

NOTE: If the readings are correct replace the fuel level sender (37).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-23

38 Hydraulic Oil Temperature Sender Check Points Reading Possible Cause of Bad Reading



Terminal A for wire 36H to ground Approximately 5 volts Check the instrument cluster (43A).

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

39 Hydraulic Filter Restriction Switch Check Points Reading Possible Cause of Bad Reading

NOTE: Hydraulic filter restriction switch closes at 310 kPa (45 psi).Check between the housing of the hydraulic filter restriction switch (39) and the ground.

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


Terminal A for wire 31H to ground. Approximately 11.5 volts Check the instrument cluster (43A).

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

40 Engine Coolant Temperature Sender Check Points Reading Possible Cause of Bad Reading



Terminal A for wire 36C to ground Approximately 5 volts Check the instrument cluster (43A).

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

41 Air Filter Restriction Switch Check Points Reading Possible Cause of Bad Reading

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


Terminal A for wire 31F to ground Approximately 11.5 volts Check the instrument cluster (43A).

NOTE: If the readings are correct replace the air filter restriction indicator switch (41).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-24

42 Program Reset Switch Check Points Reading Possible Cause of Bad Reading


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 Check Points Reading Possible Cause of Bad Reading



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).NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher.Terminal for wire 49 to ground 24 volts Bad park brake switch (43), also check circuit 49.Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-25

43A Instrument Cluster Check Points Reading Possible Cause of Bad Reading

Connector terminal 3 to ground Continuity Bad circuit 33P, also check the brake warning pressure switch (35).Connector terminal 4 to ground Continuity Bad circuit 31D, also check the coolant level sender (36).Connector terminal 19 to ground 39 to 225 ohms Bad circuit 36F, also check the fuel level sender (37).Connector terminal 5 to ground Continuity Bad circuit 35X, also check the secondary steering switch (61).

Connector terminal 20 to ground 134 to 3521 ohmsBad circuit 36H, also check the hydraulic oil temperature sender (38).

Connector terminal 18 to ground 134 to 3521 ohmsBad circuit 36C, also check the engine coolant temperature sender (40).

Connector terminal 6 to ground Continuity Bad circuit 31F, also check the air filter restriction switch (41).Connector terminal 8 to ground Continuity Bad circuit 0 to ground.

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

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

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

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

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

Circuit 46, at terminal 13, from point to point Continuity Bad circuit 46, also check the beacon light switch (96).

Circuit 41F, at terminal 14, from point to point Continuity Bad circuit 41F, also check the rear fog lights switch (110).

Circuit 18C, at terminal 15, from point to point Continuity Bad circuit 18C, also check the high beam lights switch (111).

Connector terminal 39 to ground Continuity Bad ground circuit.

Connector terminal 9 to terminal 6 on park brake switch (43) Continuity Bad circuit 33U, also check the park brake switch (43).

Connector terminal 24 to terminal 6 on program reset switch (42) Continuity Bad circuit 37P, also check the program reset switch (42).

Connector terminal 25 to terminal 4 on program reset switch (42) Continuity Bad circuit 37R, also check the program reset switch (42).

Circuit 45R, at terminal 17, from point to point Continuity Bad circuit 45R, also check the RH turn signal (107).

Circuit 45L, at terminal 16, from point to point Continuity Bad circuit 45L, also check the LH turn signal (102).

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

Connector terminal 29 to terminal 6 on pilot control switch (44) Continuity Bad circuit 31L, also check the pilot control switch (44).

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

Connector terminal 38 to ground Continuity Bad ground circuit.Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-26

43A Instrument Cluster (Continued) Check Points Reading Possible Cause of Bad Reading

Circuit 36P, at terminal 22, from point to point Continuity Bad circuit 36P, also check the engine oil pressure sender (46).

Circuit 33R, at terminal 28, from point to point Continuity Bad circuit 33R, also check the redundant brake switches (51).

Circuit 23C, at terminal 23, from point to point Continuity

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

Circuit 53C, at terminal 36, from point to point Continuity Bad circuit 53C, also check the pilot control relay (47).

Circuit 52C, at terminal 30, from point to point Continuity Bad circuit 52C, also check the parking brake relay (48).

Circuit 44, at terminal 35, from point to point Continuity

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

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

Continuity Bad circuit 50L.

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

Continuity Bad circuit 50H.

Connector terminal 37 to ground Continuity Bad ground circuit.

Circuit 19, at terminal 2, from point to point Continuity

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

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

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

Circuit 37D, at terminal 27, from point to point Continuity Bad circuit 37D, also check the up/down count switch (45).

44 Pilot Control Switch Check Points Reading Possible Cause of Bad Reading



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

Terminal for wire 49 to ground 24 volts Bad circuit 49, also check the 5 position rotary lamp switch (112).NOTE: If the readings are correct replace the pilot control switch (44).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-27

45 Up/down Count Switch Check Points Reading Possible Cause of Bad Reading



Terminal for wire 19S to ground 24 volts Bad circuit 19S, also check instrument cluster (43A) and fuse S.Terminal for wire 37D to ground 24 volts Bad circuit 37D, also check instrument cluster (43A).Terminal for wire 37U to ground 24 volts Bad circuit 37U, also check instrument cluster (43A).NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher.Terminal for wire 49 to ground 24 volts Bad circuit 49, also check 5 position rotary lamp switch (112).NOTE: If the readings are correct replace the up/down count switch (45).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-28

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

REDUNDANT BRAKE SWITCHES

GM98M00946. ENGINE OIL PRESSURE SENDER 50. PILOT PRESSURE SOLENOID47. PILOT CONTROL RELAY #10 51. REDUNDANT BRAKE SWITCHES48. PARKING BRAKE RELAY #9 52. ENGINE AUTOMATIC SHUTDOWN RELAY #1149. PARKING BRAKE SOLENOID

46 Engine Oil Pressure Sender Check Points Reading Possible Cause of Bad Reading

Between the engine oil pressure sender (46) and ground Continuity

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


Terminal for wire 36P to ground Approximately 5 volts Bad circuit 36P, also check the instrument cluster (43A).

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

46

474852


4002-29

47 Pilot Control Relay Check Points Reading Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch(44) is OFF.Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.

Terminal for wire 53C to ground 0 volts Bad pilot control relay (47), also check circuit 53C and instrument cluster (43A).Terminal for wire 53P to ground 24 volts Bad circuit 53P.

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

48 Parking Brake Relay Check Points Reading Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the park brakeswitch (43) is OFF.Terminal for wire 19D to ground 24 volts Bad fuse D, also check circuit 19D.

Terminal for wire 52C to ground 0 volts Bad parking brake relay (48), also check circuit 52C.Terminal for wire 52P to ground 24 volts Bad circuit 52P.

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

49 Redundant Parking Brake Solenoids Check Points Reading Possible Cause of Bad Reading


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

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

50 Pilot Pressure Solenoid Check Points Reading Possible Cause of Bad Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot controlswitch (44) is OFF.Terminal A for wire 53P to ground 24 volts Bad pilot control relay (47), also check circuit 53P.NOTE: If the readings are good, replace the pilot pressure solenoid (50).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-30

51 Redundant Brake Switches Check Points Reading Possible Cause of Bad Reading

NOTE: Redundant brake switches close at 6200 kPa.



Terminal A for wire 33R to ground Approximately 11.5 volts Bad instrument cluster (43A), also check circuit 33R.

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

52 Engine Automatic Shutdown Relay Socket #11 NOTE: There are no electrical troubleshooting procedures for this relay socket.Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-31

TROUBLESHOOTING BUCKET CONTROLS

GM98M01053. DETENT SWITCH 56. RETURN TO DIG PROXIMITY SWITCH54. BUCKET CONTROL VALVES DETENT ELECTROMAGNETS 57. HEIGHT CONTROL PROXIMITY SWITCH55. RETURN TO TRAVEL/FLOAT SWITCH 58. RETURN TO TRAVEL PROXIMITY SWITCH

53 Detent Switch Check Points Reading Possible Cause of Bad Reading

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


Terminal for wire 53P to ground 24 volts Bad pilot control relay (47), also check circuit 53P.Terminal for wire 56 to ground 24 volts Bad detent switch (53), also check circuit 56.NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher.Terminal for wire 49 to ground 24 volts Bad circuit 49, also check 5 position rotary lamp switch (44).NOTE: If the readings are good, replace the detent switch (53).

54

5355

5758


4002-32

54 Bucket Control Valves Detent Electromagnets Check Points Reading Possible Cause of Bad Reading

NOTE: Disconnect the wires from the bucket control valve. Put the master disconnect switch and ignition switchin the ON position. Put the pilot control switch (44) in OFF position. Put the detent switch (53) in the ON position.Terminal for wire 56 to ground 24 volts Bad detent switch (53), also check pilot control relay (47).Circuit 53B, point to point Continuity Bad return to dig detent electromagnet.

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

Circuit 55A, point to point, to return to travel/float switch (55) Continuity Bad return to travel detent electromagnet.

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

55 Return-To-Travel/Float Switch Check Points Reading Possible Cause of Bad Reading


NOTE: Put the 5 position rotary lamp switch (112) in position 3 or higher.Terminal for wire 49 to ground 24 volts Bad circuit 49, also check 5 position rotary lamp switch (112).NOTE: Put the return to travel/float switch (55) in the FLOAT position.Terminal 5 and terminal 4 Continuity Bad return to travel/float switch (55).NOTE: Put the return to travel/float switch (55) in the TRAVEL position.Terminal 5 and terminal 6 Continuity Bad return to travel/float switch (55).

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

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

56 Return-To-Dig Proximity Switch Check Points Reading Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch(44) in the OFF position and the detent switch (53) in the ON position. Disconnect the connector from the returnto dig proximity switch (56).Terminal B for wire 0 to ground Continuity Bad ground circuit.

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

Terminal C for wire 56 to ground 24 volts Bad detent switch (53), also check circuit 56.NOTE: If the readings are good, replace the return to dig proximity switch (56).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-33

57 Height Control Proximity Switch Check Points Reading Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch(44) in the OFF position and the detent switch (53) in the ON position. Disconnect the connector from the heightcontrol proximity switch (57).Terminal B for wire 0 to ground Continuity Bad ground circuit.

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

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 height control proximity switch (57).

58 Return-To-Travel Proximity Switch Check Points Reading Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch(44) in the OFF position and the detent switch (53) in the ON position. Put the return to travel/float switch (55) inthe RETURN TO TRAVEL position. Disconnect the connector from the return to travel proximity switch (58).Terminal B for wire 0 to ground Continuity Bad ground circuit.

Terminal A for wire 55B to ground 24 volts Bad return to travel/float switch (55), also check circuit 55B.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 travel proximity switch (58).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-34

TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL

GM98M01159. SECONDARY STEERING RELAY WITH LOCKOUT 63. RIDE CONTROL SWITCH60. SECONDARY STEERING RELAY WITH LOCKOUT 64. HOIST-UP PRESSURE SWITCH61. SECONDARY STEERING SWITCH 65. RIDE CONTROL RELAY #462. SECONDARY STEERING PUMP/MOTOR 66. BUCKET DUMP PRESSURE SWITCH62A.PIN ENGAGEMENT SWITCH 67. BUCKET ROLLBACK PRESSURE SWITCH62B.PIN ENGAGE SOLENOID 68. RIDE ENGAGE SOLENOID

65 6766

62616059

6362A

64

62B


4002-35

59 Secondary Steering Relay with Lockout 60 Secondary Steering Relay with Lockout

Check Points Reading Possible Cause of Bad Reading


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

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

Continuity Bad circuit 51P.

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

Continuity Bad circuit 51.

NOTE: Start and run the engine at idle.

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

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

Terminal 6 of relay (59) to ground 24 volts Bad relay (59), also check instrument cluster (43A) and circuit 35X.Terminal 8 of relay (59) to ground 24 volts Bad relay (60).Terminal 2 of relay (60) to ground 24 volts Bad relay (59).Terminal 3 of relay (60) to ground 24 volts Bad jumper wires, also check relay (59).NOTE: Disconnect the wire from the fuel shutoff solenoid (3) to stop the engine. Keep the ignition switch in theON position.

Terminal 2 of relay (60) to ground 0 volts Bad relay (60), also check circuit 19R and 19M.Terminal 6 of relay (60) to ground 24 volts Bad relay (60), also check circuit 19R.

61 Secondary Steering Switch Check Points Reading Possible Cause of Bad Reading



Terminal for wire 35X to ground 24 volts Check the instrument cluster (43A), also check circuit 35X.NOTE: Start and run the engine at idle.

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

NOTE: If the readings are good, replace the secondary steering switch (61).Bur 7-12221 Issued 4-00 Printed in U.S.A.

4002-36

62 Secondary Steering Pump/Motor Check Points Reading Possible Cause of Bad Reading

Ground circuit to ground Continuity Bad ground circuit.

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

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

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

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

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

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

62A Pin Engagement Switch Check Points Reading Possible Cause of Bad Reading

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

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

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


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

Between terminals for wires 19P and 57

Continuity Bad pin engagement switch (62A).

62B Pin Engage Solenoid Check Points Reading Possible Cause of Bad Reading

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

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engagementswitch (62A) in the ON position.Terminal for wire 0 to ground Continuity Bad groun

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